Injection Molding of Rubber

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Belgian Plastics and Rubber Institute

Additives and Processing Aids forPolymers


Conference in cooperation with BPG
Oktober 22th 2008, Auberge du Pecheur , Sint Martens-Latem (Gent)

Struktol Process Additives


Injection Moulding of rubber compounds Improvments by using additives
PROCESSING AIDS FOR POLYMERS
Schill + Seilacher Struktol Aktiengesellschaft
Peter Kosczinsky 644

Contents
1. Production Processes Compounds and Requirements 2. Processing Additives Introduction + Function
3. How to choose the right Process Additive 4. Example Case Studies problems and their solution 5. Conclusion

Injection Moulding Compounds

Requirements
Must have high level of dispersion Need to have excellent flow properties A fast cure rate is required Must release easily from the mould Should be low in mould fouling

Injection Moulding
High precision components
Seals, O rings, Gaskets and bellows, Metal bonded parts Rubber compounds must be well mixed

Injection Moulding
Highly automated process
Short production cycles are used Robotised demoulding High uniformity of produced parts

2. Production Process in the Rubber Industry


What can be influenced by process additives?

Raw Materials

Compounding

Rubber Compound

Processing

Final rubber article

2.1 Function of Process Additives


Compounding stage
Raw Materials
Compounding

Rubber Compound

Processing

Final rubber article

Viscosity reduction Easier mixing release Better batch homogenity Shorter cycles, more efficient mixing Better filler dispersion
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2.2 Function of Process Additives


Processing stage

Raw Materials

Compounding

Rubber Compound

Processing

Final rubber article

Improved compound flow Reduced compound stickiness Better demoulding / Less fouling Improved article appearance Higher productivity 9 Less scrap rate

3. The Choice of Additive


What production process ? Other details: Mooney viscosity, ShA, rubber-metal bonding, automotive? etc

Problem Details?

Problem?!

Appearance of rubber part ?

Type of polymer used / blend ?

Formulation analysis: filler dosage? curing system? plasticiser type? stearic acid level? etc.

Know-How Experience
Suited, most efficient process additive is choosen
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4. Example Case Studies


4.1 Injection Moulding of EPDM
Formulation : 3907.5

Compound 1
175 95 10 10 1 1

Compound 2
175 95 10 10 1 1 2 8 2,5 304,5

Process Additive Struktol WS 180 - Process lubricant (organosilicone based) - efficient at low dosage 0,5 - 2 phr - well compatible with EPDM (low peroxide demand) - pelletised product

Vistalon 3666 N-550 Statex Sunpar 2280 ZnO Vulkanox HS/LG Vulkanox MB2/MG-C Struktol WS 180 (flakes) Perkadox 14-40 Sartomer 206 Sum :

8 2,5 302,5

Occuring Problems: a) insufficient compound flow b) stickiness of parts to mould surface c) quick mould fouling

- suited for automotive sector

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4.1 Injection moulding of EPDM


(Compound1 + Compound 2)

a) Influence of compound flow


Trial procedure

Injection Spider Mould Arburg Injection Machine

Compound 1 (control) and Compound 2 (Struktol WS 180) injected 30 cycles


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4.1 Injection moulding of EPDM


(Compound1 + Compound 2)

a) Influence of compound flow


The Result

Compound 1: Control spider

Compound 2: Spider incl. Struktol WS 180


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4.1 Injection moulding of EPDM


(Compound1 + Compound 2)

c) Reduction of mould fouling level


Trial Procedure

Compound 1 + Compound 2: injected 30 cycles each

Mould cleaning: Struktol MC-I mould cleaning compound injected after Compound 1 and Compound 2 cycles

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4.1 Injection moulding of EPDM


(Compound1 + Compound 2)

c) Reduction of mould fouling level


A Rating Scheme how to judge dirt level in the mould

Areas A E are rated with notes


(front- and backside):

Dirt Level Note

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4.1 Injection moulding of EPDM


(Compound1 + Compound 2)

c) Reduction of mould fouling level


The Result

Note: 8

Note: 6

Dirt Level caused by Compound 1 (control)

Dirt Level caused by Compound 2 (Struktol WS 180)


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5. Example Case Studies


5.2 Injection of AEM (Vamac)
Mischung 3828.4 Vamac HGV Vamac G Russ N-772 Struktol KW 759 Naugard 445 Armeen 18D Stearinsure Struktol WB 222 Vulcofac HDC Ekaland DPG Summe

Process Additive
50 50 70 5 2 0,5 2

Compound 1
50 50 70 5 2 0,5 2

Compound 2

Struktol WB 222
Process lubricant

(fattyacid / ester based) - Dosage 1,0 - 3,0 phr 1

1,25 4 184,75

1,25 4 184,25

- well compatible with AEM - Mikro Beads

Occuring Problems: a) insufficient compound flow b) stickiness of parts to mould surface c) mould fouling

- suited for automotive sector

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5.1 Injection moulding of AEM


(Compound 1 + Compound 2)

a) Influence of compound flow


The Result

Compound 1 Armeen 18D + Stearic Acid

Mischung 2 Armeen 18D + WB 222

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5.2 Injection moulding of AEM


(Compound 1 + Compound 2)

a) Influence of mould fouling


Trial procedure

Compound 1 + Compound 2 Injection with 40 cycles each

Mould cleaning: Struktol MC-I mould cleaning compound injected after compound 1 + compound 2 cycles

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5.2 Injection moulding of AEM


(Compound 1 + Compound 2)

a) Influence of mould fouling


The result

Dirt level caused by compound 1 - control (Armeen 18D + Stearic Acid)

Dirt level caused by Compound 2 (Armeen 18D + WB 222)


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Semi-permanent Release Agents


Struktol Permalease 90
Instant curing Can be used at low mould temperatures (130C) Water based Reduction of mould fouling Good surface finish

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Mould Surface Modification

uncoated

Permalease coated

Friction Modus AFM microscope view of coated steel plate in friction mode
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Influence of mould fouling


(Injection moulding of AEM compounds) Compound1 + Compound 2
Trial procedure

Spider Mould Arburg Injection moulding

Mould coating with Struktol Permalease 90


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Influence of mould fouling


Result: Injection moulding of AEM coated + uncoated mould.
Compound 1 (Armeen 18D / Stearinsure)

Dirt level after 40 cycles with a uncoated mould

Dirt level after 40 cycles with a coated mould


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Influence of mould fouling


Result: Injection moulding of AEM coated + uncoated mould
Compound 2 (Armeen 18D / WB222)

Dirt level after 40 cycles with a uncoated mould

Dirt level after 40 cycles with Permalease 90 coated mould


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5. Conclusion
It is important to choose the best suited process additive for concerned process / occured problem
Use of little process additive helps to solve production problems in an easy way Injection moulding problems can be resolved by using e.g. Struktol WS 180 or Struktol WB 222 (better flow, lower mould fouling, improved article appearance)

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Struktol HT Products
A new range of products developed to offer added advantages
Several products have improved dispersing nature Easier dispersibility at lower temperatures Can be mixed into soft compounds or at end of mixing
HT Product HT 202 HT 204 HT 266 HT 105 Standard Product A 50P WB 16 EF 44 A86
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HT Product offers improved safety for use in soft compounds or low viscosity compounds when added at the end of mixing or in mill mixing. HT product will disperse at temperatures above 60 C 60C

Better / faster dispersion of HT variant compared to standard process additive grades

Result Improved flexibility Improved safety Improved performance


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Ingredient CR (Type W) ODPA AFD N-990 Struktol KW 400 Struktol Zimag 29/43 Struktol WB 16 Flake Struktol WB 16 Microb. Struktol HT 204
DOTG CBS Sulphur

Control

WB 16 Fl

WB 16 Beads

HT 204

100 2 1 35 30 8

100 2 1 35 30 8
3

100 2 1 35 30 8
3

100 2 1 35 30 8

3 1 1 1 1 1 1 1 1 0.5

Single stage mixing 0.5 in laboratory 0.5Banbury.0.5

Process additives added late after 2 45 together with curatives Dump at 3 30


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7 6

power (kW)

Mixing energy is reduced due to presence of WB 16 types. Rotor slippage occurs due to insufficient WB 16 dispersion. Low temperature generation

5 4 3 2 1 0 0 60 120 180

time ( sec )

Control WB 16 Fl WB 16 HT 204 -MDR 2000 180 C


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torque (dNm)

Cure curves show reduced max torque with WB 16 variants. Probably this is due to rotor slippage as undispersed WB 16 melts at 180C during curing

6 5 4 3 2 1 0

10

15

20

25

30

time (min)

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Rheological behaviour:
Control dump temperature (C) energy consumption (kj) Sample temperature (C) 59 478 73 WB 16 Fl 53 339 56 WB 16 Beads 51 339 55 HT 204 53 408 65

Mooney viscosity (1+4) Rheometer MDR 2000


torque ML (d/Nm) torque MH (d/N/m) tc 10% tc 90% tan delta (MH)

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180/30 0,2 6,1 1,3 7,6 0,03

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180C/30 0,2 5,5 1,4 8,9 0,04

10
180C/30 0,2 5,5 1,4 8 0,04

12
180C/30 0,2 6 1,3 7,8 0,03

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Physical properties:
Control Cure time for 2 mm (min) 180C cure time for 6 mm (min) 180C 30 30 31 WB 16 Fl 30 30 31 WB 16 Beads 30 30 31 HT 204 30 30 31

Shore hardness Tensile test


tensile strength (MPa) elongation at break (%) Modulus 100 % (MPa) Modulus 300% (MPa)

12,7 759 0,6 2,2

7,3 588 0,6 2,5

10,5 669 0,6 2,3

12,3 745 0,6 2,2

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Control

WB 16 Microbead

WB16 Flakes

HT 204 (Microbead)
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Microscope images of cut surfaces of vulcanisates

Tensile Strength
MPa 14 12 10 8 6 4 2 0 Control WB 16 Flake WB 16 Microbead HT 204
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Conclusion
In a soft / low temperature mixing compound for injection moulding Struktol WB 16 flake did not disperse Struktol WB 16 microbead was borderline Struktol HT 204 was fully OK

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Ingredient CR (Type W) ODPA AFD N-220 Silica (VN3) Struktol KW 400 Struktol Zimag 29/43 Struktol HT 204 (added early) Struktol HT 204 (added late)
DOTG CBS Sulphur

Control

HT 204 early

HT 204 late

100 2 1 30 10 10 8

100 2 1 30 10 10 8
3

100 2 1 30 10 10 8
3

1 1 0.5

1 1 0.5

1 1 0.5

Single stage mixing in laboratory Banbury. HT 204 added early after 30 seconds together with silica HT 204 added late after 2 30 - together with curatives Dump at 3 30
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Spider Mouldings

Control

Struktol HT 204 added early

Struktol HT 204 added late

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Conclusion
The point of addition has an influence

Late addition resulted in increased flow properties for the same loading Struktol HT 204 dispersed OK when added late in mixing
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Thank you for your attention For more info: www.struktol.de

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