Processing Fluoroelastomers
Processing Fluoroelastomers
Processing Fluoroelastomers
qxd
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5:45 PM
Page 1
Processing Information
Dyneon
Fluoroelastomers
Processing Fluoroelastomers
Mill Mixing
Internal Mixing
Calendering
Extruding
Barwell Preforming of Fluoroelastomers
Injection Molding
Mixing Equipment Sizes, Capacities, Power Requirements
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. . . . . . . . 100
. . . . . . . . 30
........3
........6
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Batch weights will vary for different size mills depending on the type and level of filler(s) but the suggested weights, based
on 1.04 and 1.84 specific gravity stock, are shown as follows.
Mill Size (inches)
Total Compound
25 to 35
35 to 70
75 to 125
150 to 250
44 to 62
62 to 121
134 to 223
268 to 447
36
48
60
84
Fluorocarbon elastomers typically have a specific gravity of 1.80 to 1.86 in standard compounds but can exceed a specific
gravity of 2.0 with certain fillers.
Due to differences in mills, it is recommended to start with the low compound weights and increase quantities until a satisfactory dispersion of filler is obtained.
Internal Mixing
Internal (or Banbury) mixing can be successfully accomplished with a variety of compounds that includes various filler systems and blends of gum viscosities (even high viscosity stocks) containing the commercially available crosslinker systems
for fluoroelastomers (diamines, dihydroxies and peroxides). Special care must be exercised with amines. Most fluoroelastomer compounds can be mixed in "one-pass" in an internal mixer if the proper steps are followed. This one pass technique
for fluoroelastomers can generally be completed in a 3 to 5 minute cycle.
Mixing Procedure
To insure a proper mix the internal mixer must be clean and free of any contamination from prior batches; such as other synthetic compounds, condensation on rotors and chamber, oil and grease, or residual sulfur. The drop pan, conveyor system,
take-off, and two roll rubber mill must also be free of such contamination. It is advisable to run a cleanout batch with raw
gum (without accelerators or curatives) like EPDM prior to mixing.
Turn full cooling water on the rotors and chamber. Set ram pressure at 60-80 psi, rotor speed slow (30-40 RPM). Premix
fillers in a clean polyethylene bag or suitable container before addition. Add the pre-weighed fluoroelastomer to the internal
mixer, lower ram and run polymer breakdown for 30 to 60 seconds or until temperature reaches 49 to 54C (120 to 130F).
Raise ram and add the premixed fillers. Lower ram and continue mixing until temperature reaches 75 5C (166 10F).
Check to insure ram height gauge indicates proper chamber volume, since at a proper charge volume indicator will oscillate.
Raise ram and sweep ram and throat. Lower ram and continue to mix until temperature reaches 88 to 93C (190 to 200F).
Raise ram and sweep ram and throat. Continue to mix until temperature reaches 104 to 113C (220 to 235F) or until audible
indication (sucking sound) that the batch is together. Dump batch onto mill and mix to a uniform smoothness before batching off (for refinement to obtain ultimate dispersion, physical and rheological properties).
Comments
Internal mixing can be successfully accomplished with a variety of conditions and compounds (viscosity + filler loading). The
internal mixer must be clean and have no condensation on the rotor or chamber. Residual sulfur or sulfur compounds, some
talcs, oil, grease, or condensation may have significant adverse effects on the fluoroelastomer cure system. Overloading or
underloading the internal mixer will result in a poorly dispersed batch. Care must be taken to avoid a batch temperature
exceeding 121C (250F) which may result in a scorched stock. In general the internal temperature thermocouple (recorder)
will indicate a temperature which is lower than the actual stock temperature, defined as thermal lag. To correlate for thermal
lag, determine the actual stock temperature with pyrometer at drop and correlate this to the recorder reading.
Care must be taken when calculating the batch size for internal mixers. The calculation involves:
Chamber Volume X Specific Gravity X Load Factor = Batch Size
(____in.3 X 16.39 cc/in.3) X (____g/cc) X (.67 to .70) = ____g
(____g) X (1 Ib/454 g) = ____Ibs
Typical batch weights for fluoroelastomers are:
Banbury Size
Volume in3
No. 3
No. 9
4,300
11,400
190 to 220
545 to 585
Adjustments in batch size may have to be increased to accommodate for increased chamber volume due to wear and for
compound specific gravity.
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Compound Storage
Compounded stock should be thoroughly cooled and dry before storing. Stock may be stored under ambient conditions in
most cases although climate controlled areas are preferred.
If the stock is to be kept in a refrigerated environment, it is advisable to have the compound sealed in plastic before storing.
Upon removal from cold storage, the stock should be allowed to come to room temperature while still sealed in plastic to
prevent condensation formation on the compounded stock. If stock is not sealed with plastic, all condensation must be
allowed to evaporate prior to milling, preforming or molding.
Note: Inclusion of surface moisture will cause scorch.
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The most important temperature is that of the extrudate itself. The stock temperature should be in the range of 88 to 116C
(190 to 240F) for best surface appearance and rate of extrusion. This temperature must be monitored and extruder conditions may have to be optimized to maintain proper extrudate temperature. Failure to control the heat history on the polymer
can lead to scorched material due to heat caused by internal shearing that takes place in the extruder.
Once the temperatures of the extruder are set and extrudate is at proper temperature, screw speed can be adjusted to
obtain desired production needs. This can normally be done without dramatically changing surface appearance of the
extrusion. At this point the pressure build-up at the die should be monitored, since as the RPM is increased, higher
pressures will be apparent. The pressure generally is to be kept below 7000 psig or below blow out plug or shear pin rating.
Hot Feed
The procedure for hot feed process differs from cold feed only in regard to how the stock is handled prior to contact with
the extruder.
Although equipment (i.e. warm-up and feed mills) will vary at different production facilities, typical conditions of mill and
stock temperatures are:
Warm-up and Feed Mill Conditions
Full cooling water on both rolls
Stock Temperatures
Warm-up mill
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 to 82C (140 to 180F)
Feed mill
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 to 93C (160 to 200F)
Hopper/Extruder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 to 77C (140 to 170F)
Comments
As mentioned before, polymer choice, filler types and levels and also the process aids utilized, all play an important role in
the extrudability and overall processing characteristics of a given compound. The suggested conditions are starting points to
be considered and final adjustments should be made as experience on the particular compound and equipment is obtained.
During start-up the extrudate should be carefully watched since too much heat or too little heat or temperature will result in
a rough finish on the extrudate. There is a temperature region, or transition zone usually 5 to 11C (20 to 11F) where the
extrudate will be smooth, which above or below (outside of this region) the extrudate will not exhibit a smooth finish.
Cure system type and level will affect the extrudability of the compound. In order of scorch resistance,the dihydroxy or
incorporated cure is the best, followed by peroxides and finally diamines.
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O-Ring Formulation
Molded Goods
100
25
3
6
0.5 to 0.75
100
25
3
6
0.5 to 0.75
Dyneon FE 5620
Dyneon FC 2122, FC 2123 or FE 5622Q
MT Black
MgO
Ca (OH)2
Carnauba Wax
Due to the many variables encountered in equipment and equipment design of injection molding equipment, the following
guidelines will only provide an initial starting point. Modification of conditions may be required on specific equipment being
utilized.
Machine Condition Guidelines
Critical Machine Variables
Screw-Barrel Temperature
Injection Barrel Temperature
Injection Pressure
After Injection Pressure
After Injection Pressure Time
Injection Rate
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Mixing Equipment
Sizes, Capacities, Power Requirements
Open Roll Mills
Approximate
Batch Capacity
(Lbs.)
Roll Size
6" x 13"
8" x 16"
10" x 20"
12" x 24"
14" x 30"
16" x 42"
18" x 48"
22" x 60"
24" x 72"
26" x 84"
28" x 84"
1.25
2.5
5
10
20
30
45
75
125
150
175
to
to
to
to
to
to
to
to
to
to
to
Motor
2
4
8
18
30
50
70
125
200
250
300
HP
RPM
7.5
10-15
15-20
30-40
40-50
60-75
75-100
125-150
150-200
150-200
200-250
190
190
190
190
600-720
600-720
600-720
600-720
600-720
600-720
600-720
"Banbury" Mixers
Size of
Machine
Net Volume
of Chamber
(Cu. in.)
B
00
1A
3A
9
11
27
103
263
1193
4315
11443
14940
37709
Approximate Batch
Capacity ( Lbs.)
Specific Gravity
1.25
1.50
2.0
3
5
27-33
100-115
250-300
340-410
700-800
4
6
32-40
120-140
310-360
400-500
850-1000
Motor Horsepower
Std.
Double
Speed
Speed
5
8
44-52
160-180
410-500
550-650
1000-1500
8.5
15
50
150
200
300
1250 or 1500
17
30
100
300
400
600
Cooling
Water
(Gal /min.)
Compressed
Air on Ram
(Cu. Ft./Cycle)
25
75
150
150
200
4
10
18
20
16
Physical Properties
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ISO 9001/QS-9000
All Dyneon fluoroelastomers are manufactured at ISO 9001 registered facilities.
Dyneon fluoroelastomers produced in North America are manufactured at
QS-9000 registered facilities.
Important Notice:
Because conditions of product use are
outside Dyneons control and vary widely,
user must evaluate and determine whether
a Dyneon product will be suitable for users
intended application before using it.
The following is made in lieu of all
express and implied warranties
(including warranties of merchantability and fitness for a particular purpose):
If a Dyneon product is proved to be
defective, Dyneons only obligation,
and users only remedy, will be, at
Dyneons option, to replace the quantity
of product shown to be defective
when user received it or to refund
users purchase price. In no event will
Dyneon be liable for any direct, indirect,
special, incidental, or consequential
loss or damage, regardless of legal
theory, such as breach of warranty or
contract, negligence, or strict liability.
Dyneon 2001
Issued: 01/01
Printed in USA
98-0504-1325-5
All Rights Reserved
Dyneon LLC
6744 33rd Street North
Oakdale, MN 55128
Phone:+1 800 723 9127
+1 651 733 5353
Fax:+1 651 737 7686
www.dyneon.com
Dyneon is a trademark of Dyneon