TPV - ELASTRON P.V101.A80.N

1 of 126 products in this brand
A soft, colorable thermoplastic vulcanizate, TPV (EPDM/PP) in the thermoplastic elastomer family designed for use in medical applications.

Polymer Name: Thermoplastic Vulcanizate (TPV)

Processing Methods: Extrusion, Injection Molding

Density: 910.0 - 910.0 kg/m³

Tear Strength: 50.0 - 50.0 kN/m

Compression Set (70 °C): 42.0 - 42.0 %

Technical Data Sheet

Knowde Enhanced TDS

Identification & Functionality

Technologies

Features & Benefits

Materials Features
Advantages of Elastron V
  • Service temperature -40˚C to 140˚C
  • Wide hardness range (30 ShA- 65 ShD)
  • Lower density (Density changes between 0,89 and 1,05 g/cm³)
  • Design flexibility
  • Good resistance to acids and bases as well as oils (ex: IRM 903 , IRM 901)
  • UV and ozone resistance
  • Recyclable
  • Easy processing with shorter cycle time
  • Provides quite higher saving on the processing cost (less scrap)
  • Low flex fatigue
  • Flame retardant grades available
  • Low compression set
  • Weathering resistance
ELASTRON Products Features at a Glance

• Excellent UV and ozone resistance
• Abrasion resistance
• Available products for adhesion to PP,PE, etc and engineering plastics. (ABS,PC,PA, etc.)
• High temperature resistance
• OEM approved grades
• Excellent compression set
• Low temperature resistance
• %100 recyclable

Key Benefits of Weatherseals
  • Long term durability
  • Excellent Weathering Resistance
  • Excellent Sealing Performance
  • Elasticity 
  • Low Weight
  • Fast Production, Reduced Lobor Cost
  • Process Advantages
  • Recyclable
Key Benefits of Under the Hood & Chasis

• Long term durability
• Eliminates the clamp need with system component welding
• Excellent fluid resistance
• Reduced leakage risk
• Low weight
• Fast production, reduced labor cost
• Process advantages
• Vibration dampering
• Elasticity
• Recyclable

Features For Electrical & Cables

• Excellent surface appearance
• Resistance to high temperatures
• UL 94 HB / V0 / V1 listed products
• Halogen Free Flame Retardant
(HFFR)
• 100% recyclable
• Copper stabilized grades
• Low dielectric constant and high oxygen index
• High dielectric strength, surface and volume resistivity
• Ease of extrusion
• Excellent low temperature properties
• Excellent compression set properties
• Low smoke density
• RoHS, ELV and WEEE compliance
• Non-toxic
• Resistant to oil, chemicals, acids&bases
• Easy to color with masterbatch
• Excellent UV resistance
• Colored compounds available

Key Benefits of Exterior

• Long term UV and ozone resistance
• Colorable
• Tear and abrasion resistance
• Impact resistance at low and high temperatures
• Low weight
• Flexible at low temperatures Easy processing and good flow property
• Bondability to various plastics (PP, ABS, PA, PC, PE)
• Low labor cost
• Recyclable

Features For White Goods & Appliances

• Resistant to detergents, acids, bases, etc.
• Good weathering resistance
• Excellent UV resistance
• Colored compounds
• Excellent compression set
• Resistant to high temperatures
• Excellent low temperature resistance
• Co-extrusion with many plastics
• Excellent surface appearance
• 100% recyclable

Key Benefits of Interior

• UV Resistance
• Colorable
• Soft Touch, antislip
• Scratch and abrasion resistance
• Low emission
• Low weight
• Low odor behavior
• Easy process and good flow property
• Recyclable

Features of Medical

Features
• Excellent bonding to many thermoplastics
• Easy to color
• Excellent surface appearance
• Antistatic compounds available
• Soſt touch compounds
• Availability of transparent grades
• 100% recyclable
Other Features
Elastron medical TPE compounds are tested according to USP ‘88’ for their in vivo biocompatibility and ISO 10993-5, USP ‘87’ for their in vitro cytotoxicity. Tested compounds all have USP Class VI approvals. Elastron medical TPE compounds also meet requirements of European Pharmacopeia monographs 3.2.8 sterile single-use plastic syringes and 3.2.9 rubber closures for containers for aqueous parenteral preparations for powders and for freeze-dried powders. Elastron medical TPE compounds are sterilizable with gamma irradiation, ethylene oxide (EtO) and steam.

Features of Food

The monomers and additives used in manufacturing food contact TPE grades should be listed in the Union List of Authorized Substances of Regulation 10/2011/EC on plastic materials and articles intended to come into contact with food. Ingredients used in manufacturing these products are subject to a specific migration limit (SML).
Elastron provides the quality and conditions of above mentioned regulation and limits.
• Excellent bonding to many thermoplastics
• Easy to color
• Excellent surface appearance
• Soſt touch compounds
• Availability of transparent grades
• 100% recyclable
• NSF 51/61 Compliant Grades

Applications & Uses

Plastics & Elastomers Processing Methods
Processing Information
Injection MoldingTypical Value (English)Typical Value (SI)
Rear311 to 347 °F155 to 175 °C
Center329 to 365 °F165 to 185 °C
Front347 to 383 °F175 to 195 °C
Nozzle383 to 437 °F195 to 225 °C
Mold77 to 122 °F25 to 50 °C
Recommended Predrying2 hours at 194 °F2 hours at 90°C

Extrusion MoldingTypical Value (English)Typical Value (SI)
Feed320 to 356 °F160 to 180 °C
Rear329 to 365 °F165 to 185 °C
Center338 to 374 °F170 to 190 °C
Front365 to 401 °F185 to 205 °C
Head374 to 428 °F190 to 220 °C
Die383 to 437 °F195 to 225 °C
Recommended Predrying2 hours at 194 °F2 hours at 90°C
Electrical & Cables Applications

Elastron provides flexible and high performance TPE solutions for electric and cable applications.
Applications
• Wire & Cables
> Primary Insulation
> Cable Jacketing
> Welding Cables
> Coaxial Cables
> Mechanical Tool Cables
> Instrumentation Cables
• Cable Multigates And Grommets
• Industrial Plugs And Switches
• Electrical Seals And Other Accessories
Halogen Free Flame Retardant (HFFR) Compounds for Eelectrical
Applications

Elastron Halogen Free Flame Retardant (HFFR) grades also offer great advantages for electrical applications. TPE grades for both injection and extrusion processes are available.
• Excellent long term electrical
properties
• Halogen free
• Excellent bonding to many plastics
• UL V0, V1, V2 and HB listed
• RoHS, ELV and WEEE compliant
• Colored compounds available
• Non-toxic
• Copper stabilized grades
• Oil & chemical resistance
• Low smoke density
• Suitable for dry & wet applications
• Excellent UV and ozone resistance
• 100% recyclable
• Easy to color with masterbatch

White Goods & Appliances Applications

Elastron offers low and high temperature resistant, RoHS compliant, detergent, acid&base resistant grades with excellent compression set values.
• Washing Machine Applications
• Dishwasher Applications
• Dryer Applications
• Refrigerator Applications

Medical Applications

Elastron medical TPE compounds are tested according to USP ‘88’ for their in vivo biocompatibility and ISO 10993-5, USP ‘87’ for their in vitro cytotoxicity.
• Syringe tips
• Infusion bottle caps
• Clogs (Antistatic and steam
sterilizible for medical applications)
• Sterilizible for medical applications

Food Applications

With the help of the experiences gained from manufacturing of medical TPE compounds, Elastron offers high quality food contact TPE compounds.
• Food Packing
• Food Box Seals
• Grips for Kitchen Equipments
• Water Pump Seals

Properties

Color
Physical Form
Appearance
Colorable
Incompatible with
PVC, Acetal
Physical Properties
ValueUnitsTest Method / Conditions
Compression Set (at 100°C for 22 hr)55%ASTM D 395
Compression Set (at 23°C for 22 hr)25%ASTM D 395
Compression Set (at 70°C for 22 hr)42%ASTM D 395
Density0.91g/cm³ASTM D 792
Durometer Hardness80Shore AASTM D 2240
Elongation at Break550%ASTM D 412
Modulus of Elasticity (100%)4.3MPaASTM D 412
Modulus of Elasticity (300%)6.2MPaASTM D 412
Tear Resistance50N/mmASTM D 624
Tensile Strength at Break8MPaASTM D 412
Aging Test
ValueUnitsTest Method / Conditions
Ozone Resistance StressedNo Cracks
Shrinkage
ValueUnitsTest Method / Conditions
Across Flow1.17%ASTM D 955
Flow2.25%ASTM D 955
Overview of the Chemical Resistance
Chemical Resistance
Acid
Bases
Salts
Good
Good
Good
Aqeous Solutions
Organic Solvents
Good
Variable
Oils
Automotive Oils
Swells
Swells
Other Automotive Fluids Variable
  Temp,°C 45 shA 75 shA 40 shD
    TS E H W V TS E H W V TS E H W V
ACIDS AND
ALKALIS
98% Sulphuric Acid 23 A C A A A B B A A A A A A A A
10% Hydrochloric Acid 23 A B A A A A A A A A A A A A A
50% Sodium Hydroxide 23 A C A A A A A A A A A A A A A
10% Potassium Hydroxide 23 A C A A A A A A A A A A A A A
AQUEOUS SOLUTIONS Water 80 A B A A A A A A A A A A A A A
10% Zinc Chloride 23 A A A A A A A A A A A A A A A
15% Sodium Chloride 23 A A A A A A A A A A A A A A A
18% Calcium Chloride 23 A B A A A A A A A A A A A A A
%2.5 Detergent* 23 A B A A A A A A A A A A A A A
80 A B A A A A A A A A A A A A A
%2.5 Rinse Aid 80 A A A A A A A A A A A A A A A
Special detergent test** 80 A B A A A A A A A A A A A A A
ORGANIC SOLVENTS Dimethlyformamide 23 A A A A A A A A A A A A A A A
Aniline 23 A B A A A A A A A A A A A A A
Acetic acid 23 A A A A A A A A A A A A A A A
Ethanol 23 B A A A A A A A A A A A A A A
Glycerol 23 A A A A A A A A A A A A A A A
Cyclohexane 23 B A A B C B A A B B A A A A A
Diethyl Ether 23 C A A B B B A A B B D B A A A
Methylethylketone 23 F B A B B D A A A A A A A A A
Bromobenzene 23 E A A C C C A A B B A A A A A
n-butyl acetate 23 F C A B C D A A B B A A A A A
n-hexane 23 F E A B B F C A B B D A A A A
Xylene 23 C A A C C D A A B B A A A A A
Dioctyl phthalate 23 B A A A A B B A A A A A A A A
1,4-dioxane 23 F B A B B C A A A A A A A A A
OILS AND FUELS IRM 901 100 C D A D C C C A C B B B A A A
125 D D B E D C C B D C C C A B B
  IRM 902 100 C C A E D C C A C C B B A B A
125 D E B F E C C B D D C C A C B
  IRM 903 100 D D C D D D C B E D C C A C B
125 D D C F E D D B E E C C B D C
AUTOMOTIVE
FLUIDS
Automatic transmission fluid 125 D D B F F D D B E D C C B C C
23 A B A A A A A A A A A A A A A
100 A A A A A A A A A A A A A A A
Hydolic Brake Fluid 23 B A A A A A A A A A A A A A A
Grease 100 B A A C C C A A C B B A B A A
Power Steering Fluid 125 D C B E E D D B D C C C B C B
Antifreeze 125 A A A A A A A A A A A A A A A

*Dishwasher detergent, calgonit
** These test is composed of the cycle: 4 hours detergent 2,5% , 4 hours rinse aid 2,5% and 16 hours water. Total test duration is 240 hours.

Regulatory & Compliance

Quality Standards

Technical Details & Test Data

Additional Information
ELASTRON products are not compatible with PVC and Acetal. Regrinding level up to 20% is recommended with minimum property loss.
Processing information for Extrusion

Profile Extrusion
TPV - ELASTRON P.V101.A80.N - Processing Information For Extrusion
Typical thermoplastic Extruder

The selection of extruder barrel diameter depends on the dimension of the profile being produced. As throughput needing increases, diameter must be increased. A length to diameter ratio (L/D) of 24:1 are recommended. If higher capacity needed, L/D ratios of 30:1 preferred as they deliver a higher output capability, more uniform output rate and better melt quality with the proper screw design.
TPV - ELASTRON P.V101.A80.N - Processing Information For Extrusion - 1
Extrusion of Elastron TPE product requires medium to high shear to properly plasticize (high shear for Elastron V products) and ensure properly processing at recommended temperatures. General purpose three zone screw design (feed, transition/compression, metering), having a compression ratio of 2.5 to 3.5 with an L/D of 18:1 to 24:1 is recommended. Barrier screws especially for Elastron V products are used successfully and are recommended.
In order to be changed the melt flow from rotational to uniform laminar flow, there are some relaxation zone after the extruder barrel. During extrusion, melt being inside the barrel are compressed and stressed and it needs uniform flow before profiling.
Also breaker plate must be used for screening. Special screens must be installed on the breaker plate to catch the foreign or burned particles coming from the screw or barrel inside. Depending on the extruder size and capacity breaker plates having holes from 2mm to 4mm can be used, and 20 or 40 mesh screens are recommended.
The advantages of using screens:

  • Homogenize melting due to pressure,
  • Catchting the burned particles coming from the screw,
  • Catching the unmelted particles due to ununiform screw design,
  • Increasing the shear,
  • Increasing the surface quality,
  • eIncreasing back pressure to better melt quality.
     

Melting in the Screw

TPV - ELASTRON P.V101.A80.N - Processing Information For Extrusion - 2


From left to right, during processing, melting takes places. The material being melted remains behind the solid material. That’s why if we don’t use enough compression ratio and the length of compression zone, there would be some unmelted material in the metering zone and we could see the rough surface on the profile. We have to ensure that the material coming to the metering zone have to be melted completely.
Melting in the Conventional Screw

 

TPV - ELASTRON P.V101.A80.N - Processing Information For Extrusion - 3

How to Guarantee Melting (Barrier Screw)

TPV - ELASTRON P.V101.A80.N - Processing Information For Extrusion - 4


Extra barrier flights let us extra compression during melt transition from filling to metering zone. This compression provides extra melting due to shear increasing.

 

 

Processing information for Injection

Injection Molding
TPV - ELASTRON P.V101.A80.N - Processing Information For Injection
Injection molding machine is consist of two side, a clamping side and an injection side. The main purpose of the clamping side to open and close the mold, and the ejection of products. The purpose of the injection unit are to melt the material by heat being specified and then to inject molten material into a mold. The screw is rotated with the rpm being specified on the screen to melt material introduced from the hopper and to accumulate molten material in front of the screw. After the required amount of molten material is accumulated with screw retraction, injection phases are stared. As molten material is introducing in a mold, the injection machine controls the ram speed of the screw, or injection speed (speed profile). In addition to this, it controls molding pressure after molten material fills out cavities.


Injection Molding Cycle
TPV - ELASTRON P.V101.A80.N - Processing Information For Injection - 1
TPV - ELASTRON P.V101.A80.N - Processing Information For Injection - 2

 

1. Filling Phase: Melt must be filled to the mold as fast as possible according to the part geometry. If there are any restricted area having affected to the filling properties, proper speed profile must be determined. Flow characteristics are determined by melt temperature, speed, and shear rate. Too high injection speed can create excessive shear and result in issue such as splay and jetting. High speed filling is terminated at Switchover point and low speed packing phase commences.
1.1. Switchover Point: It’s a transition point from filling to packing and plays a crucial role in the quality of the molded parts. Late switchover can cause building up of excessive cavity pressure and it leads to flash and mold opening. Early switchover is also leads to short shot and longer cycle times.
2. Packing Phase: As soon as the material gets into the cavity, cooling starts and it induces shrinkage. That’s why, there is a need to inject more material in, in order to prevent this shrinkage. After being loaded %98 volume of cavity, injection speed and pressure must be reduced during this phase. Due to the fact that packing pressure determines part weight and part dimensions, it is important to completely fill the mold avoiding over packing 3"! or under packing Blow!
3. Holding Phase: By reducing the pressure and speed being applied, certain amount of pressure must be applied until gate completely freezing off. Gate freezing is the solidification of material around the gate area and prevents melt backflows out of the mold and let us keep the dimension and weight values stable.
4. Gate Sealing Point: The plastic enters the cavity through the gate. As long as the gate is not frozen, new material comes in to the mold replacing unoccupied free spaces left from shrinking material. At the end of the solidification, gate is completely blocked due to cooled down and no any material can get to flow path back.
5. Cooling Phase: To ensure optimum molding cycles while maintaining part surface requirements and mold filling capability, a stable mold temperature should be determined and maintained. The cooling time takes about 80% of injection molding cycle, so a well-designed cooling system can shorten the molding time and improve the productivity.


Material Moving in The Runner
TPV - ELASTRON P.V101.A80.N - Processing Information For Injection - 3

TPV - ELASTRON P.V101.A80.N - Processing Information For Injection - 4
During injection, injection speed and material viscosity are two of the most important factors to effect the molding quality. If your material is low viscous material do not use excessive injection speed because high speed generates high shear rates and material gets warmed on the way of runner and it’s temperatures exceed the degradation level. In that case your material would get sticked to the cavity wall after injection. If your material is sticking to the mold, reduce your injection speed gradually.


Material Molding in The Mold
TPV - ELASTRON P.V101.A80.N - Processing Information For Injection - 5
Case 1: Thanks to optimum melt speed, two opposite flow channel meet seamlessly without any weak areas.
Case 2: The same material with low melt speed causes weak mixing. Cold Weld Line
Case 3: The same material with very low melt speed causes empty area due to not facing together. Short Shot.


Why Melt Speed is Low

  • Low injection speed:

During filling phase, while injection to the cavity through flowpath, melt gets cooled over the time, that’s why we
must inject the material as fast as possible, otherwise melt would get cooled on the way and there would not be
homogenous mixing at the intersection line of two separate flow.

  • High viscous material:

Material viscosity might be higher than normal. In this case, material runs slowly in the flow path despite the
injection speed being increased.

  • Low mold temperature

If mold temperatures are lower than normal, material cannot move in the mold by its natural flow properties, it’s also tend to make wavely surface on the part.

  • Unproper gate location Gate
  • Low gate diameter:

Means pressure loss for injection speed in the cavity

  • Insufficient melt temperature:

Lower melt temp means higer viscosity.
TPV - ELASTRON P.V101.A80.N - Processing Information For Injection - 6
 

Why Gate Diameter is Important During Gate Sealing
We have to hold the material after packing phase until gate is completely freezing off. Otherwise our liquid material goes back to runner inside over the gate. That’s why, gate diameter is so important, because we have to freeze that area. Larger gate diameter increases the holding time, lower gate diameter takes place a premature freezing.
TPV - ELASTRON P.V101.A80.N - Processing Information For Injection - 7
Gater diameter is lower than normal. That means our material is still enough hot even if we have completely sealed the gate. Because due to lower diameter, our gate had frozen earlier than normal but we need to push some material when hot material cools down. In that case, after injecttion, there would be some voids inside at the same time some areas would collapse.
TPV - ELASTRON P.V101.A80.N - Processing Information For Injection - 8
Gater diameter is still not enough diameter beacuse there are some areas need to be cooled. We must increase the diameter gradually.
TPV - ELASTRON P.V101.A80.N - Processing Information For Injection - 9
We have reached the best diameter. Due to this we would not see any warpage because after gate sealing there are no any hot areas containing high risk
TPV - ELASTRON P.V101.A80.N - Processing Information For Injection - 10
Higher gate diameter increases gate sealing time so our cycle time would be greater.
 

Vent Design
TPV - ELASTRON P.V101.A80.N - Processing Information For Injection - 11

 

Why Back Pressure is Important
TPV - ELASTRON P.V101.A80.N - Processing Information For Injection - 12
Back pressure is the pressure when taking place on front of the screw during screw retraction to prepare the next shot. Increasing it’s values, collects more material on front of the screw, that’s why if you don’t change the injection speed strokes, your part weight would be heavier than before because of higher density taking place of the same volume in front of the screw.
 

Screw
TPV - ELASTRON P.V101.A80.N - Processing Information For Injection - 13
Compression ratio = H1/H2
L/D = Flighted Length / Screw Diameter

TPV - ELASTRON P.V101.A80.N - Processing Information For Injection - 14
Reciprocating screw injection molding machines equipped with a general purpose screw design are adequate for processing the material.
This screw design, should have 50% of its length as the feed zone, 25% as the compression zone, and 25% as the metering zone. A screw L/D (length to diameter) ratio between 18:1 and 24:1 and a screw compression ratio between 2:1 and 3:1 are recommended. A floating check ring, rather than a ball check, is also recommended. Nozzles should be of the free-flow design and as short as possible.
 

Cooling
TPV - ELASTRON P.V101.A80.N - Processing Information For Injection - 15
Cooling channels must be installed correctly, if there are any voids between them, cooling effecting the part would not be balanced. That’s why warpage issue risk takes place.
TPV - ELASTRON P.V101.A80.N - Processing Information For Injection - 16

Troubleshooting for Injection

1. Short Shot
TPV - ELASTRON P.V101.A80.N - Troubleshooting For Injection

  • Restricted flow areas, such as wrong type of gates, wrong dimesion of runners, and thin walls.
  • Low melt or mold temperatures.
  • Due to insufficient ventillation, trapped air inside the cavity.
  • Insufficient machine injection pressure, low injection speed.
  • Machine mulfunctioning such as blocked feed throat, or a worn non-return valve that causes loss of injection pressure or there could be some pressure loss on the flowpath.
  • Premature solidification of the material melt, poor injection speed profile, or prolonged injection time.

 

2. Flash

TPV - ELASTRON P.V101.A80.N - Troubleshooting For Injection - 1

  • Low clamp force: Clamping force must be higher than injeciton pressure. If the clamping force is too weak to hold the mold plates together during the injection process, flash takes place.
  • Gap within the mold: Flash will occur if the parting surface does not contact completely, due to a deformed mold structure, parting surface defect, improper machine and mold set up, or flash or foreign material stuck on the parting surface.
  • Injection parameters: High melt temperature (lowered the viscosity of the material) or high injection pressure win the calmping force and flash takes place.
  • Nonconforming venting: Due to venting design and a very poor venting system, or venting dimension is not properly.

 

3. Sink Marks

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  • After injection, holding must be applied until gate completely freezing off, otherwise melt goes back to runner inside and sink marks takes place.
  • Short cooling time, because after stress relaxation in cooling, new material loaded to the cavity replacing the voids.
  • High melt temperature or mold temperature
  •  Due io mold design, there might be some pressure loss in order to hold the material after injection.

 

4. Splay Marks

TPV - ELASTRON P.V101.A80.N - Troubleshooting For Injection - 3

If material are used without predrying, the moisture inside the material can cause this marks. Also high rpm during screw retraction, generates gas and this gas are injected the parts with melted material.

  • Dryplastic according to our suggestion.
  • Reduce injection speed, because high speed generates due to friction.
  • Reduce melt temperatures by reducing the barrel temepratures.
  • Reduce screw rpm, high rpm generates gas.
  • Increase back pressure, increasing the back pressure discharge the gas through the hooper.
  • Increase mold temperatures
  • Increase venting
  • Increase gate diameters, because tight diameter generates gas due to high shear rates.

 

5. Warpage

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A differential cooling rate of the melt in two sections of the molded product.

  • Reduce melt temperature to reduce the cooling time.
  • Reduce the mold temperature to reasonable level according to our requirements
  • Increase pack and hold pressures, if any pressure loss.
  • Increase pack and hold times,
  • Due to unsufficeient cooling time warpage takes place after ejection. That’s why increase the cooling time to cool the part to suffient level.

 

6. Burn Marks

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Material degradation
Burn marks can result from the degraded materials and then appears on the surface of the molded part or near the venting areas. Material degradation is caused by:

  • High melt temperature: Excessive melt temperature can be caused by higher barrel temperature setting, or malfunctioning in the temperature controller.
  • High screw rotation speed: If the screw rpm is too high during the plasticization time during screw retraction, that will create too much frictional heat, which could degrade the material.
  • Restrictive flow path: When the melt flows through the flowpath which icludes restrictive nozzle, runner, gate, or part sections, shear rates gets incresedheat, which could degrade the material.
  • High speed injection: Creates extra ternperatures due to frictional heat in the runner.

 

7. Voids

TPV - ELASTRON P.V101.A80.N - Troubleshooting For Injection - 6

Occurs when the parts thickness is high. If the mold temperature is higher than normal during cooling, the plastic melt shrinks towards the wall and therefore sucks a vacuum void on the inside of the part

  • Reduce melt temperature: Cooling after high temperature might cause the voids.
  • Reduce mold temperature: High mold temperatures keeps the melt temperatures high, that’s why thiskind of voids occur.
  • Reduce injection speed: High speed injection creates high frictional shear and melt cooling would be hard.
  • Increase pack and hold pressures: Packing and holding pressures send the gas or airs to out through the ventilation channels.
  • Increase pack and hold times

 

8. Bubbles

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Moisture or gase coming from the product gets injected in the mold cavity this moisture or gas if embedded inside the melt can show up as bubbles.

  • Dry material to suggested moisture levels:
  • Increase back pressure: Back pressure let us send the gas to outside of the mold
  • Reduce melt temperature

 

9. Gate Vestige

TPV - ELASTRON P.V101.A80.N - Troubleshooting For Injection - 8

  • When holding phase, reduce the injection speed and pressure
  • Arrange the injection speed profile properly,
  • Increase the melt temperature by using the barrel temperatures gradually

 

10. Jetting

TPV - ELASTRON P.V101.A80.N - Troubleshooting For Injection - 9

 

TPV - ELASTRON P.V101.A80.N - Troubleshooting For Injection - 10

  • Place the gate to against to metal surface.
  • Use an overlap gate or a submarine gate
  • Slow down the melt with a gradually divergent flow area.
  • Reduce injection speed
  • Increase melt temperature

 

11. Weld Lines

TPV - ELASTRON P.V101.A80.N - Troubleshooting For Injection - 11

  • Increase melt temperature: If two different flow meets together as colder than normal, such king of traces would be coming out.
  • Increase mold temperatures: Cold mold wall prevents the material flow.
  • Increase injection speeds: Lower injection speed causes premature cooling.
  • Increase venting: Ventilation supply us better flowing in the mold.
Troubleshooting for Extrusion

1. Interrupted melt output: Unbalaced barrel temperatures.

  • Reduce the feed zone temperature to feed the material to transition zone properly.
  • Checked the temperature resistance and cooling sysytem.
  • Checked the screen to catch the degraded, burned particles.
     

2. Surging: Due to contaminated material or wrong temeprature seetings unbalanced die exit.

  • Increase the barrel temperatures gradually for each zone equally.
  • Check the screen, clean if it is blocked.
  • Check for the blockage in the hooper.
  • Check the screw configuration.
  • Clean the screw before production.
     

3. No Output: Die blocked due to solidification.

  • Check the material enterence from hooper to barrel inside.
  • There might be blockage in the hooper inside.
  • Increase the die temperature to dissolve the blockage.
  • Change the screen.

     

4. Rough Surface due to unmelted particles:

  • Check the screen if there is any tears.
  • Increase the temperatures especially in the compression zone.
  • Check the zone temperature resistance.
  • If there are any crosslinked particles on the surface, reduce the screw rpm and the zone temperatures in order to
  • prevent the degradation.
     

5. Burned and discolored extrudate:

  • Reduce the screw rpm.
  • Reduce barrel temeperatures gradually until getting the right color.
  • Select the extruder having lower L/D ratio for production.
     

6. Die lines:

  • Select the material having lower viscosity.
  • Increase the die temperatures.
     

7. Melt Fracture:

  • Reduce the barrel temperatures.
  • Change the material with in accordance with the die design.
     

8. Shark Skin:

  • Reduce rpm.
  • Change the screen.
  • Increase the melt temperature.

     

9. Fish eyes:

  • Check the material and screen for contamination.
  • Material must be dried properly before using.
  • Reduce the temperatures to prevent material degredation.
     

10. Bubbles on the profile surface:

  • Be sure to dry the material properly.
  • Reduce the melt temperature.
  • Reduce screw rpm.

11. Warpage: Insufficient cooling

  • Increase the cooling bath lenght, reduce the water temperature.
  • Balance the die according the part wall thickness.
     

12. Orange Peel surface:

  • Die temperaure is too low, increase the die temperature.
  • Increase the temperature of the zones which is close to die.
     
Physical and Chemical Effects of Fluids on Elastomers

Elastomers that are in contact with fluids are subject to chemical and physical effects.
Chemical Effects
Some base fluids and additives react chemically with elastomers, particularly at elevated temperatures, resulting in additional crosslinking or scission of the polymer chains. In addition, the action of a liquid on elastomers can be markedly affected by the presence of atmospheric oxygen. For some elastomers the effect of aeration is considerable and for others, insignificant.
A chemical reaction between fluid and elastomer can lead to serious changes in the physical properties of the elastomer. When the attack is severe, the elastomer loses its elasticity and becomes hard and brittle or soſt and tacky.
A shrinkage normally causes a reduction in flexibility and increase in hardness, modulus and tensile strength.
If the test fluid is nonvolatile, the swell will remain permanent. If the fluid is volatile, shrinkage can occur if the elastomer is allowed to dry out. Drying out does not occur as long as the elastomeric part is continuously in contact with the fluid or its vapor [1].
Physical Effects
Changes in the physical properties of elastomers that are in contact with fluids may result from two simultaneous actions:
(a) Absorption of the liquid by the elastomer and
(b) Extraction of soluble constituents such as plasticizers and antioxidants from the elastomer
The result is a change in volume (i.e. swelling if a is greater than b or shrinkage if b is greater than a).
Swell increases from time of immersion up to a point where no more fluid will be absorbed and the volumetric expansion remains constant. The time taken to reach this state of equilibrium is largely dependent on the temperature, shape and thickness of the part.
The change in volume can alter such physical properties of the elastomer as hardness, modulus, tensile strength and elongation. A swell has the same effect as adding plasticizer to the elastomer by making it more flexible with decrease in hardness, modulus and tensile strength. Such changes are more or less proportional to the percentage of volume increase.
Test Methods
Injection molded test plaques were prepared. The dimension of the plaques is 125 x 65 x 2mm. Test specimens were cut from these plaques
to measure the effect of fluid immersion upon tensile properties, hardness and weight change, using ASTM procedures.

Property ASTM Procedure Abb.
Elongation at break D412; die c E
Tensile Strength D412; die c TS
Hardness D2240 (3 sec. delay ) H
Weight change D471 W
Volume change D471 V

Rating of Tests Results
All test results of properties are classified by using the table indicating in below:

Rating Percent Change Meaning Description
A |<20| Good Very good suitability
Elastomer shows little or no effect from exposure.
Little effect on performance and physical properties.
Very good resistance
B |20 - 39| Fair Good suitability
Some effects from exposure with some loss of physical properties
Some chemical swelling
C |40 - 59| Not recom. Limited suitability
Significantly swell and loss of physical properties aſter exposure
D
E
F
|60 - 79|
|80 - 100|
|>100|
Not recom.
Not recom.
Not recom.
The elastomer is unsuitable for application in this media
The elastomer is unsuitable for application in this media
The elastomer is unsuitable for application in this media