Isoplast - Processing Guidelines
Isoplast - Processing Guidelines
Isoplast - Processing Guidelines
Processing Guidelines
1 Plastic Drying Fundamentals
Physical nature of water in plastics
Process of drying
1 Drying
Dryer requirements
Managing residual moisture content
2 Dryer Technology
Principle of dehumidifying/desiccant dryers
Regeneration
Single/multiple dehumidifying/desiccant bed dryers
Return air cooling
Dew point meters and calibration
The efficiency of a dehumidifying/desiccant bed
Options
4 Screw Design
4 Injection Molding
Troubleshooting
Weld line strength
Tool balancing
Regrind
Annealing
7 Extrusion
8 Blow Molding
8 Coloring
Plastic Drying
Fundamentals
Drying
ISOPLAST resins are thermoplastic polyurethane polymers and are
hygroscopic. Because polyurethane polymers absorb moisture, and
react with it at processing temperatures, it is very important to remove
the moisture prior to processing.
ISOPLAST resins that are put into drying hoppers directly from the
sealed shipping containers should typically dry in four to six hours hours
under optimal drying conditions (see dryer requirements). If the seals
on the containers have been broken, or if the resin or regrind has
been exposed to the atmosphere for any reason, the necessary drying
time will be 10 to 12 hours. A moisture level at or below 200 ppm
is necessary for successful processing.
Once dry, keeping the resin dry is critical. The ambient air dew point
will have a great effect on how fast ISOPLAST resins pick up moisture
when exposed to the environment. During the summer, when ambient
temperatures and humidity are both high, ISOPLAST resins that have
been properly dried can pick up enough moisture to begin to cause
splay (bubbles and streaking) in as little as 15 minutes!
Process of drying
The effective drying of a resin involves two distinct processes:
The diffusion of moisture from within the pellet to the pellet surface
The removal of water from the pellet surface
The dew point of the air used to dry ISOPLAST resins must be at or below
-40C (-40F). If the dryer regenerates based on time rather than dew
point, you must be sure that the dew point does not rise above -40C
(-40F) before the dehumidifying/desiccant beds switch for regeneration.
If the dew point does rise above -30C (-20F),
the dryer will add moisture to the resin.
Dryer Technology
Drying (cont.)
Dryer requirements
Not every dryer is capable of reducing the moisture level in ISOPLAST
resins to an acceptable level. In general, dehumidifying/desiccant
dryers are suitable for drying ISOPLAST resins, provided they
can produce:
an air flow minimum of 2.5 m 3/ hr/kg (40 ft3/hr/lb) of material
a drying temperature between 85C (185F) and 138C (280F)
dependant on the ISOPLAST resin
a continuous dry air flow with a dew point of -40C (-40F)
which corresponds to 0.008 weight percent moisture in the
dehumidified air
Regeneration
The process of drying a moisture saturated dehumidifying/desiccant
bed is achieved by passing heated ambient air over the bed. The higher
temperature (>200C [>392F]) makes the bed release the absorbed
moisture. When the bed is sufficiently dry, it is cooled down and can be
switched back into the closed loop when the alternate bed becomes
saturated with moisture.
With return air above 65C (150F), there will be no drying at all.
Most dryer manufacturers can supply an after-cooler for their drying units
that will cool the return air below the 55C (130F) maximum allowable
temperature. As the required drying temperature increases, the need
for an after-cooler also increases.
Once dry, it is critical to retain low resin moisture levels during processing.
This can be accomplished by mounting the dryer hopper directly on the
in feed of the processing equipment. Alternatively, a small shot hopper
can be used fed by a closed loop, dry-air conveying system from the large
dryer hopper.
Single/multiple dehumidifying/desiccant
bed dryers
If the dryer has only one dehumidifying/desiccant bed, the material will not
dry during the regenerating of the moisture saturated bed. To overcome
this time loss, multiple dehumidifying/ desiccant bed dryers were developed.
While the saturated dehumidifying/desiccant bed is regenerating, another
dry dehumidifying/desiccant bed is switched into the closed loop and
is able to continue drying the material.
To dry ISOPLAST resins sufficiently, multiple dehumidifying/desiccant bed
dryers are preferred because a continuous flow of dry air with sufficiently
low dew point is required. Single dehumidifying/desiccant beds tend to
give a larger fluctuation in moisture content in the air. This is not ideal
for drying ISOPLAST resins.
If the dryer has been in use continuously for more than three years, or an
equivalent period intermittently, some degradation of the molecularsieve
in the dehumidifying/desiccant beds may have taken place. The dryer may
no longer be able to reach the initial specified dew point. The best way
of establishing whether there has been a serious deterioration of the
moisture absorption capacity of the dehumidifying/desiccant beds,
is to calibrate the dryer on a regular basis with an external calibrated
dew point meter.
Options
ISOPLAST resins have also been dried in vacuum ovens and in microwave
dryers. The drying temperature table still applies, as do the drying times.
ISOPLAST resins will not dry in dryers that use ambient air, whether it is
heated or not.
Screw Design
Injection Molding
A properly designed screw will melt the resin and yield a uniform melt
temperature in the proper temperature range, without over shearing
the resin and causing it to degrade. Every resin family has different
requirements for the screws that can be used to process it.
Barrier and mixing screws have been used successfully, but due
to the large number of potential designs, no specific details can be
recommended. Please refer to your technical service and development
representative for assistance. In general, barrier and mixing screws
should be low shear or gentle in nature. In some cases, screws
designed for rigid PVC have worked well for ISOPLAST resins.
Barrel capacity should be no more than six times the shot size (shot
size should not be less than 15 percent nor greater than 85 percent
of barrel capacity). If the shot size is too large for the machine, the
melt temperature will not be uniform. If the shot size is too small for
the machine, ISOPLAST resins are more likely to degrade. Degradation
will start to show up as a yellow color shift and move to splay and
gassing in more extreme cases.
Injection molding machine clamping capability should allow for 0.3 to 0.7
metric tones/square centimeter ( 2 to 5 tons/square inch) of clamping
force based on the projected area of the part to be molded. General
purpose nozzles are recommended, rather than nylon type. The orifice
in the nozzle tip should be as big a diameter as possible, based on
the sprue diameter. Variac temperature control is not recommended.
A thermocouple and temperature controller should be used on the
nozzle and tip. ISOPLAST resins tend to freeze off easily at the nozzle
tip, therefore, good temperature control is necessary. It may also be
necessary to insulate the nozzle tip from the sprue bushing. Cardboard
can be used to do this. Sprue break, or pulling the nozzle tip away
from the mold after the screw has returned (recovered) can allow
the nozzle temperature to recover between shots.
Vented barrels are not recommended for the ISOPLAST resins because
it is difficult to keep the ISOPLAST resins from foaming out of the vent.
Vented barrels are NOT a substitute for drying ISOPLAST resins. By the
time the melt reaches the vent, damage to the molecular weight has
already occurred.
It is a good practice to use position transfer, or changing from first stage
injection pressure to second stage injection pressure by screw position
rather than time. This ensures that the injection stroke does not bottom
out and over fill the cavity before packing or the second stage takes place.
To determine the proper position for switch over, short shoot the mold using
only the first stage, filling pressure, and no second stage packing. Gradually
change the switch over position until the cavity is 95 99% full on first
stage, this will be the proper switch over position.
Over packing the cavity on first stage pressure can cause clear Isoplast
resins to become brittle. To determine whether brittleness was caused
by over packing or by moisture, anneal the parts for 2 4 hours at the
appropriate temperatures shown in Table 1. If they were over packed, the
parts will become ductile after annealing. If the material was process wet,
the parts will remain brittle.
Temperature C
81-89
124-135
101-109
124-135
81-89
124-135
81-89
81-89
101-109
81-89
81-89
Range F
178-192
255-275
214-225
255-275
178-192
255-275
178-192
178-192
214-225
178-192
178-192
With the long glass fiber filled resins, early position transfer will
cause an artificial weld line. The interrupted flow will result in an area
in the part that is low in glass fiber, creating a weak spot. Position transfer
is still a good idea, but make sure the part is 95 percent full before this
takes place. Generally, with long glass fiber filled resins, faster filling will
give stronger weld lines and better surface finish, but excessive speed
will cause jetting into the cavity and may contribute to brittleness.
When the screw stalls (turns, but does not retract), melted resin pumps
out of the screw faster than the unmelted pellets can be conveyed forward.
This creates a void in the screw and the next shot will be gassy. Rather
than using temperatures, a second method of correcting this problem is
to use a more restrictive check valve. It will need to be streamlined, but
the flow path must be more restrictive to reduce the pumping rate of the
melted polymer.
Cooling time will run between 10-40 seconds for parts with wall
thicknesses of 1.3-3.2 m (0.051-0.126 in). Thicker parts will
require longer cooling times. The long glass fiber filled ISOPLAST
composites must be cooled until a rigid skin has formed on the outside
of the part. If these composites are removed from the mold too quickly,
they will post mold blow (i.e., they will puff up and warp as the hot
plastic allows the long glass fibers to try to straighten out). The only
cure is more cooling, with either more time, a colder mold, or both.
Weld lines, the hair lines formed by two or more flow fronts coming
together, always form behind holes in parts. This often occurs around any
obstruction or easy flow channel in the flow path. Weld lines can be strong
with ISOPLAST resins. The melt temperature must be kept high until the
two flow fronts meet. There can be no gas trapping at the flow fronts. If
there are problems, changing the injection speed up or down will usually
move the point at which the flow fronts meet, allowing better ventilation.
Troubleshooting
If the location of the weld line is constantly moving from part to part, it
is a good indication that the melt temperature is not uniform from shot
to shot. Slow the screw speed down as much as possible and raise the
back pressure to help make the melt temperature more uniform. Minor
melt temperature changes will cause significant viscosity changes in
ISOPLAST resins.
Extrusion
Regrind
Up to 25 percent of reground ISOPLAST resin can be used. Care must be
taken to keep out contamination and to keep the regrind dry. Wet regrind
can cause the same problems as wet virgin ISOPLAST resin. It does not
matter where the moisture came from, the resulting parts will be brittle
with splay and there will be nozzle drool.
If the resin is exposed to too much shear, the melt temperature will be
higher than desired. This will result in very low melt strength and may
also result in foaming, die build up, surface splay, and discoloration
of the extrudate.
If the screw cannot be changed to a low shear profile, pre-heating
the resin will usually help. Also, do not use cooling water on the feed
throat. Instead, run the dryer at the upper limit of the recommended
drying temperature range, being careful not to cake the material and
starve feed the extruder. Slowing down the screw rpm may also help.
Annealing
The recommended annealing temperatures for ISOPLAST resins are
shown in Table 2. Parts can be annealed in any air oven that gives uniform
heat and can support the part. Heavy parts should be annealed on the
lower side of the temperature range for a longer period of time. Small
or thin parts that can support themselves may be annealed at a higher
temperature for a shorter period of time. There may be some yellowing
of the surface, but it will not have an adverse effect on the physical
properties of the final parts.
Screws designed for rigid PVC have performed well with ISOPLAST resins
in some cases.
The resin should be below its glass transition temperature before it
is exposed to water. See Table 2 for the glass transition temperatures
of ISOPLAST resins. ISOPLAST resins can react with water at elevated
temperatures (above glass transition temperature) and will lower
the molecular weight of the resin and the physical properties of the
resulting product.
Temperature C
81-89
124-135
101-109
124-135
81-89
124-135
81-89
81-89
101-109
81-89
81-89
Range F
178-192
255-275
214-225
255-275
178-192
255-275
178-192
178-192
214-225
178-192
178-192
Blow Molding
Pellets or beads may present a slipping hazard. Slight itching and irritation may result from skin
contact. Repeated exposure to particles generated by grinding glass fiber-reinforced materials may
result in implantation of particles in the skin.
Good general ventilation of the polymer processing area is recommended.
Processing may release fumes which may include polymer fragments and other decomposition
products. Fumes can be irritating. At temperatures exceeding melt temperature, polymer fragments
can occur. Good general ventilation should be sufficient for most conditions. Local exhaust ventilation
may be necessary for some operations.
Use safety glasses. If there is a potential for exposure to particles which could cause mechanical
injury to the eye, wear chemical goggles. If vapor exposure causes eye discomfort, use a full-face
respirator. No other precautions other than clean body-covering clothing should be needed for
handling ISOPLAST engineering thermoplastic polyurethane resins. Use gloves with insulation for
thermal protection, when needed.
Combustibility
Coloring
ISOPLAST engineering thermoplastic polyurethane resins will burn and, once ignited, may burn rapidly
under the right conditions of heat and oxygen supply. Do not permit dust to accumulate. Dust layers
can be ignited by spontaneous combustion or other ignition sources. When suspended in air, dust
can pose an explosion hazard. Dense black smoke is produced when product burns. Toxic fumes are
released in fire situations.
Fire fighters should wear positive-pressure, self contained breathing apparatus and full protective
equipment. Water or water fog are the preferred extinguishing media. Foam, alcohol resistant foam, carbon
dioxide, or dry chemicals may also be used. Soak thoroughly with water to cool and prevent re-ignition.
Please check with your Lubrizol Sales or TS&D contact for details
of suitable masterbatches and where they can be obtained.
Disposal
DO NOT DUMP INTO ANY SEWERS, ON THE GROUND, OR INTO ANY BODY OF WATER. For unused or
uncontaminated material, the preferred options include sending to a licensed recycler, reclaimer,
incinerator, or other thermal destruction device. For used or contaminated material, the disposal
options remain the same although additional evaluation is required (see, for example, in the U.S.A.,
40 CFR, Part 261, Identification and Listing of Hazardous Waste). All disposal methods must be in
compliance with Federal, State/Provincial, and local laws and regulations.
As a service to its customers, Lubrizol can provide lists of companies which recycle, reprocess, or
manage chemicals or plastics, and companies that manage used drums. Contact the nearest Lubrizol
Customer Service Center for further details.
Handling Considerations
Environment
Material Safety Data (MSD) sheets for ISOPLAST* engineering thermoplastic polyurethane resins are
available from Lubrizol, a business group of Lubrizol Advanced Materials, Inc. and its subsidiaries.
MSD sheets are provided to help customers satisfy their own handling, safety, and disposal needs,
and those that may be required by locally applicable health and safety regulations, such as OSHA
(U.S.A.), MAK (Germany), or WHMIS (Canada). MSD sheets are updated regularly, therefore, please
request and review the most current MSD sheet before handling or using any product.
Generally speaking, in the environment lost pellets are not a problem except under unusual circumstances when they enter the marine environment. They are inert and benign in terms of their
physical environmental impact, but if ingested by waterfowl or aquatic life, they may mechanically
cause adverse effects. Spills should be minimized and they should be cleaned up when they happen.
Plastics should not be discarded into the ocean or any other body of water.
The following comments are general and apply only to ISOPLAST engineering thermoplastic
polyurethane resins as supplied.
Product Stewardship
Various additives and processing aids used in fabrication and other materials used in finishing steps
have their own safe use profile and must be investigated separately.
Lubrizol Advanced Materials, Inc. has a fundamental concern for all who make, distribute, and use
its products, and for the environment in which we live. This concern is the basis of our Product
Stewardship philosophy, by which we assess the health and environmental information on our
products and then take appropriate steps to protect employee and public health and the environment.
Our Product Stewardship program rests with every individual involved with Lubrizol products from
initial concept and research to the manufacture, sale, distribution, and disposal of each product.
Customer Notice
Lubrizol encourages its customers and potential users of Lubrizol products to review their applications
for such products from the standpoint of human health and environmental quality. To help ensure
that Lubrizol products are not used in ways for which they were not intended or tested, Lubrizol
personnel will assist customers in dealing with ecological and product safety considerations. Your
Lubrizol sales representative can arrange the proper contacts. Lubrizol literature, including Material
Safety Data sheets, should be consulted prior to the use of Lubrizol products. These are available
from the nearest Lubrizol Customer Service Center.
Handling and fabrication of plastic resins can result in the generation of vapors and dusts
including small particles of glass fibers. Dusts resulting from sawing, filing, and sanding of plastic
parts in post-molding operations may cause irritation to eyes and the upper respiratory tract. In dusty
atmospheres, use an approved dust respirator.
Processing Guidelines
Lubrizol Advanced Materials, Inc. / 9911 Brecksville Road, Cleveland, Ohio 44141-3201 / 1.216.447.5000 / www.estane.com
Printed in U.S.A.
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