Processing
Extrusion
Machine Design
Diagrammatic view of a three-section screw
Metering zone Compression zone Feeding zone
0,3 L 0,4 L 0,3 L
L = 25–30 D
Fig. 16
Single-screw extruders with a com- Barrels with a grooved feeding zone
pression ratio of 1:2 to 1:3, preferably have proven successful in practice,
1:2.5, are recommended for and provide the following benefits:
processing of Elastollan.
• constant feeding characteristics
Our experience shows that three • increased pressure
improved build-up
section screws with a L/D ratio of
25 to 30 are most suitable.
• output
If grooved feeding zones are used,
Three-section screws should have a cooling is necessary. It is also
continuous, constant pitch of 1D. advisable to use a screw with a
mixing section, in order to improve
The radial clearance between screw homogeneity of the melt. Such
and barrel should be 0.1 to 0.2 mm. mixing sections should, however,
be designed to avoid shear
For processing of Elastollan multi- degradation.
zone screws, e.g. barrier screws
(undercuts >1.2
_ mm) have also proven
suitable. Short screws with a high
compression ratio are unsuitable.
Relation: screw diameter – flight depth (feeding zone)
14
Flight depth (feeding zone) [mm]
12
10
4
30 40 50 60 70 80 90 100 110 120
Screw diameter [mm]
Fig. 17
16
Processing
Extrusion
Machine Design
Use of breaker plates and screen Extrusion of thermoplastic poly-
packs is recommended. Good urethane requires a more powerful
results have been obtained from a motor than for other thermoplastics.
combination of two screens of 400 Power consumption is between 0.3
mesh/cm2 as backing plates and two and 1 kWh per kg output, depending
fine screens of 900 mesh/cm2. Finer on screw design.
screens may be necessary for certain
applications (e.g. film production). Melt pumps have proved successful
for continuous melt flow.
Depending on screw diameter and
type of die, breaker plates should
have holes of 1.5 to 5 mm in diameter.
Processing Parameters
Processing Temperature Screw Speed
The following temperature ranges, Since thermoplastic polyurethanes
which are dependent on the hard- are shear-sensitive, excessively high
ness of the Elastollan grades are screw speeds may lead to a reduc-
recommended: tion in product properties.
Fig. 18 shows the relation of max.
screw speed to screw diameter.
Recommended temperatures for processing in °C
Shore Heating zones
hardness Cylinder Adapter Die head Nozzle
60 to70 A 140–175 160–175 165–170 160–165
75 to 85 A 160–200 175–200 175–205 170–205
90 to 98 A 170–210 200–220 195–215 190–210
Table 6
Relation: max. screw speed – screw diameter
100
Screw speed [rpm]
80
max. circumferential speed 0,15 m/s
60
40
20
30 40 50 60 70 80 90 100 110 120
Screw diameter [mm]
Fig. 18
17
Processing
Extrusion
Processing Parameters
Melt Pressure Cleaning of the Extruder
Melt pressure is dependent on the When changing grade or after several
head-design and the die gap, and on days of continuous operation, clean-
melt temperature. Normally the ing of the extruder is recommended.
maximum pressure at the adapter is
300 bar, however, peaks of up to Polypropylene or HDPE, which
1.000 bar can occur at start-up. require higher processing tempera-
Thus, for safety at start-up, a variable tures, are suitable for this purpose.
screw drive is recommended. If In addition, it is sometimes neces-
needed, starve feeding is possible. sary to use a purging compound.
Die Design
To ensure a constant melt flow, it is In all other respects, guidelines for
important to operate with narrow head design are the same as for the
cross-sections and to avoid dead extrusion of other thermoplastics.
spots in the die. This will cause
automatic self-cleaning of the die. Fig. 19 shows examples of typical
dies:
Wire and cable sheathing dies
Pressure die Tube die
Fig. 19
18
Processing
Extrusion
Die Design
For extrusion of tubes and profiles, constant discharge. Land length
dies with a relatively long land are should be two to four times nozzle
recommended. This reduces the diameter.
shear stresses, thus permitting a
Tube extrusion die
Entry bush Body Spider Torpedo Pin Die support Die
Fig. 20 Breaker plate
Cooling and Calibration
Freshly extruded thermoplastic Calibration devices as shown in
polyurethanes have a relatively low diagrammatic view in Fig. 21 are
melt strength and are therefore prone suitable to support the extrudate.
to distortion. This necessitates effec-
tive cooling. The water bath should It is essential to provide a lubricating
be close up to the extruder head. film of water between the surface of
Chilled water is preferred. Instead of the extrudate and the calibrating die.
cooling baths a cooling line with This can be achieved by a water
spray nozzles is also suitable. spray ring located before the entry
into the cooling bath.
The length of cooling bath required
for Elastollan grades generally Fig. 22 describes the layout of a tube
exceeds the requirement for other extrusion line for Elastollan.
thermoplastics. The length depends
on the grade of material, extrudate
shape and section, and haul-off
speed.
Due to high coefficient of friction,
compared to general thermoplastics,
active calibration of thermoplastic
polyurethane is not possible.
Calibration die
Fig. 21
19
Processing
Extrusion
Cooling and Calibration
Cooling bath for tube extrusion
Cooling water tank Vacuum tank Calibration
Water pump Heat exchanger Vacuum pump
Fig. 22
Extrusion techniques
Tubes and Profiles Sheathing
Tubes and profiles are mostly Sheathing of cables, hoses, etc. is
extruded horizontally. However, thin- carried out by using a crosshead (see
walled tubes, e.g. fire-hose linings, Fig. 23), equipped with a pressure or
are generally extruded vertically. tube die (see Fig. 19). The inner-core
which is to be sheathed must be dry
It is necessary to supply supporting and free from grease, in order to
air to prevent collapsing of the tubes. avoid blistering after extrusion and to
ensure good bonding.
To assist shape stability for hollow
shapes it is recommended to use
vacuum.
The guide rollers in the cooling bath
should be matched to the shape of
the extrudate.
Diagrammatic view of a crosshead
Body Torpedo Die
Wire guide
Breaker plate
Entry bush Die support Pin
Fig. 23
20
Processing
Extrusion
Extrusion Techniques
Film Blow moulding
Special Elastollan grades are suit- Blow moulded articles can be man-
able for the manufacture of blown ufactured from selected Elastollan
film. grades using conventional blow
moulding machines.
Fig. 24 shows, in diagrammatic form,
a film blowing head. To improve ease of demoulding,
the use of a mould with roughened
Diagrammatic view surface (approx. 35 µm) is recom-
of a film blowing head mended. Wall thickness control is
necessary to compensate for elonga-
Mandrel
tion of the parison. Fig. 26 shows a
Die torpedo head for blow moulding.
Diagrammatic view
of a torpedo head
Spiral
mandrel
Drive
Barrel Extruder
Torpedo
Barrel
Mandrel
Deflector piece Die
Fig. 24 Parison
Films of greater wall thickness can be Fig. 26
produced by the flat film extrusion
process using a sheet die (see
Fig. 25); normal extrusion grades are
suitable.
Diagrammatic view
of a sheet die
Fig. 25
21
Processing
Extrusion
Special Processing Methods
Following special methods are suita- Thermoplastic Foam Extrusion
ble for Elastollan: for weight reduction and to achieve
special properties.
Coextrusion
to achieve a combination of proper- Two methods are applicable:
ties of different thermoplastics in one
processing step. • Chemical expanding
of the melt by addition of expand-
For bonding reasons materials have ing agent with conventional
to be compatible. Compatibility can extruders; foam density between
0.4 and 1.0 g/cm³ is attainable.
differ between Elastollan ether and
ester types. • Physical expanding
of melt by injection of gas into the
extruder. Foam density below
0.4 g/cm³ is attainable. The
structure of foam is controlled by
a nucleating agent.
Trouble Shooting Guidelines
Trouble shooting guidelines
Melt/ Die Die Screw Land Homo- Moisture Material Cooling Lubricant
Cylinder tempera- pressure speed/ length genisation content contami- feeding
tempera- ture Output nation zone
ture
Pulsation
Rough surface
Surface streaks
Bubbles/Blisters
Flow lines/
Spider lines
Excssive blocking
Unmelted particles
Dimensional variations
Unsufficient dimensional
stability
Melt fracture
Material degradation
Increase to solve problem
Reduce to solve problem
Increase or reduce to solve problems
Table 7
22
