SPTRS4257
SPTRS4257
SPTRS4257
Thermoforming
Contents
Eastar™ 6763 copolyester—Thermoforming 3
Film properties 3
Benefits 6
Film yield 7
Applications 7
Medical packaging 7
Sterilization 7
Thermoforming 8
Heating 8
Sealing 9
Radio frequency sealing 9
Heated bar sealing 9
Impulse sealing 10
Cutting 10
Cutting with steel rule dies 10
Matched metal dies 11
Reclaiming scrap 12
Regulatory status 12
Quality manufacturing 12
Summary checklist 12
Eastar™ 6763 copolyester
Thermoforming
3
Table 1. Physical properties of film extruded in Eastman’s laboratories from Eastar™ 6763 copolyester
Test method
Property, units
a
Typical value ASTM ISO
Inherent viscosity 0.70 — b
—b
Microns 250
D374 —
Mils 10
Transparency, % 85 D1746 —
Transmittance, %
Regular (specular) 89
D1003
modified
—
Total 91
g/m2·24 h 6
F372 —
g/100 in. 2·24 h 0.4
M.D. 93 (21)
D2582 —
T.D. 93 (21)
4
Table 1 Physical properties of film extruded in Eastman’s laboratories from Eastar™ 6763 copolyester (continued)
Test method
Property, units
a
Typical value ASTM ISO
Tear resistance, trouser @ 200 mm/min speed, N/mm (lbf/in.)
M.D. 36 (205)
— 6383-1
T.D. 36 (205)
M.D. 52 (7,500)
D882 527-3/2/50
T.D. 52 (7,500)
M.D. 59 (8.600)
D882 527-3/2/50
T.D. 59 (8.600)
Elongation @ yield, %
M.D. 4
D882 527-3/2/50
T.D. 4
Elongation @ break, %
M.D. 400
D882 527-3/2/50
T.D. 400
Dart impact, 12.7-mm (1/2-in.) dia. head, 127-mm (5-in.) dia. clamp,
660-mm (26-in.) drop, g
a
Unless noted otherwise, all tests were run @ 23°C (73°F) and 50% relative humidity.
b
Inherent viscosity was determined using test method ECC-A-AC-G-V-1. Values determined from 100% virgin pellets with no regrind, edge trim, or recycled materials.
When sheet is extruded with regrind, edge trim, or recycled material, lower values should be expected.
c
Test conducted @ 38°C (100°F) and 100% relative humidity.
Some variation is inherent in all plastics testing, and Eastman makes no representation that the material
the foregoing data are considered to be representative in any particular shipment will conform exactly to the
of average properties for 250-micron (10-mil) film. values given.
5
Benefits
Thermoforming sheet made of Eastar™ 6763 copolyester • A
llows reduced energy consumption compared with PVC
offers many benefits. (low forming temperature and no need for refrigerated
• Is lawful for use in a variety of food contact and medical molds)
applications • D
oes not stress-whiten
• Has sparkling clarity • A
dapts to conventional forming and sealing equipment
• Is tough—even at temperatures as low as –29°C (–20°F) • H
eat-seals to most standard multipurpose coated blister
• Has a yield 4% greater than PVC board that is used for PVC and cellulosic films
• M
ay be successfully sterilized with ethylene oxide, gamma
radiation, and electron beam In Table 2, the optical and impact properties of film made of
• O
ffers fast forming cycles—can be formed at faster cycles Eastar 6763 are compared with those of films made of
than materials such as PVC when heater capacity is the polyvinyl chloride and acrylic multipolymer.
limiting factor
Dart impact, 12.7-mm (1/2-in.) dia. head, 127-mm (5-in.) dia. clamp,
660-mm (26-in.) drop, g
a Blisters formed from 250-micron (10-mil) films were exposed for 30 minutes to various temperatures and compared to a control blister. After 30 minutes @ 71°C (160°F),
blisters of Eastar™ copolyester and PVC exhibited slight distortion.
b
Run by ASTM D3763.
6
Table 3. Eastar™ 6763 copolyester vs. other polymers
7
Thermoforming Mold design for thermoforming
Heating Aluminum, or aluminum oxide powder, is the material of
choice for the construction of molds, although other
A uniform temperature across the film must be materials such as wood and epoxy can also be used.
maintained in the forming operation; therefore, air currents Aluminum provides good heat transfer and is cost-effective
near the forming machine should be minimized. because of its good machinability and wear properties. For
Contact heating (direct conduction) is used in form, fill, and the production of quality parts at minimum cycles, molds
seal lines; however, Teflon™-coated aluminum or hard-coated should be cored for temperature control and, when
metal heating plates are required because Eastar 6763 tends appropriate, add cooling channels. Anodized hard coats can
to adhere to hot metal. Convection heating, which is about be applied to mold surfaces to extend life.
one-half as efficient as contact heating, is generally used Sometimes when thermoforming on large flat surfaces, the
only in sheetfed thermoforming systems. plastic sheet/film does not come in contact with the mold
For continuous roll-fed systems, combinations of radiant and because of air entrapment. When there are problems with air
convection heating are used when sheeting made of Eastar entrapment, more vacuum holes can be put in the surface of
6763 is being thermoformed. Radiant heaters that use the mold. Sandblasting or vapor-honing the mold can help
ceramic elements or quartz lamps generate infrared energy with air entrapment. However, sandblasting and vapor-
that heats the center of the sheet more efficiently. honing will change the thermoformed part from shiny/glossy
to a matte surface and the amount of matte will change as
A common method to uniformly heat most thicknesses of the mold wears.
sheet made of Eastar 6763 employs quartz panels with
embedded heating elements that are equipped with Vacuum holes should be drilled through the mold surface with
thermocouples for temperature control. The sheet performs a #78 drill. Each hole should be back-drilled oversize to within
well with ovens that use quartz panels on top and calrod, 1.6 mm (0.0625 in.) of the surface to permit rapid evacuation.
ceramic, or black iron strip heaters on the bottom. They should be located in an inside radius. Vacuum slots
should be no wider than 50–75 micron (2–3 mil).
When heating continuous sheet, it is often possible to utilize
only the last two indexes before the mold. To prevent When designing the mold, the distance between individual
excessive sag of the sheet, the heating cycle should be as short cavities should be the same as the depth of the cavities.
as possible, provided the proper sheet temperature is reached. Female molds with generous draft angles provide better
flanges and easier removal with fewer problems from
Sheet made of Eastar 6763 ranging in thickness from 500 to bridging; however, thin bottoms can be a problem. Severe
1,000 micron (20 to 40 mil) will run with about the same heat undercuts must be avoided, and radii should be as generous
profile in the oven. Time to heat the sheet normally controls as possible.
the machine cycle if temperature-controlled molds are used.
Pressure boxes have two advantages: they improve cycles
To prevent “cold-forming,” it is essential that a temperature- and provide better definition and uniformity. In addition,
sensing device be used to monitor the sheet temperature as it they can provide a coining action that will greatly simplify
enters the mold. Optical pyrometers are excellent for this use. the cutting operation.
Film extruded from Eastar 6763 can be thermoformed with A plug-assist is suggested for parts with deep draws. Plug
fast cycle times using conventional forming equipment. Tests dimensions, depths, and clearances commonly used in the
in Eastman’s laboratory indicate that the surface thermoforming industry can be used to ensure rapid mold
temperature of the film prior to forming should range conformation and uniform wall thickness. Plug-assist is
from 140° to 163°C (280° to 325°F). helpful if the objective is to get orientation in the part.
There are many types of materials available for construction
of assist plugs, including 3M’s syntactic foam, which provides
good release and does not have to be temperature-controlled.
Once on cycle, it will not add or take away heat from the
sheet. Watch for plug wear and replace when necessary.
8
Forming Sealing pressure—Sufficient force must be applied to
provide the cutting action on tear-seal or seal-and-cut
Many options exist for the forming operation. For example,
operations.
male or female molds can be used; plug-assist can be used
for female cavities; cutting can be either in place, at the Preheat time—The time needed to push the tool into
next index, or in an extra step; and a pressure box can be intimate contact with the upper film before the RF power
incorporated to provide pressure for forming as well as is applied. A time of 0.75 to 1.0 seconds is generally used.
coining to aid in cutting.
Sealing time—The time during which the RF energy is
The following will provide a good starting point for forming applied. The energy softens Eastar 6763. The clamping
sheet made of Eastar™ 6763 copolyester, particularly if the pressure then forces the tool into the copolyester, sealing
sheet thickness is 1,250 micron (50 mil) or less: and, if desired, cutting through the copolyester. A typical
sealing time for a 10-kW machine is 1.0 to 1.5 seconds.
Mold temperature, °C (°F) 40–60 (100–140)
Cooling time—The time that is used to hold the seal in place
Sheet temperature, °C (°F) 140–163 (280–325) until the bond solidifies. This typically requires 0.5 seconds.
Plug temperature, °C (°F) 120–135 (250–275)
Power setting—The power setting depends on the machine
Cycle, s 3–10 and power available. A 10-kW machine would typically be
run at 75% power to seal and cut two 10-mil films in 1.0 to
Forming pressure, MPa (psi) 0.21–0.28 (30–40)
1.5 seconds. Typical plate current and grid current meter
Vacuum, mm (in.) of mercury 508–660 (20–26) readings are 0.5 amps and 0.4 amps respectively.
9
Impulse sealing
Variables in the impulse sealing process:
• Power setting
• Sealing pressure (air pressure)
• Dwell or seal time
• Cooling time
Cooling time 1s 1s Minimum clamp force = (total rule length) (sheet thickness)
Air pressure 0.41 MPa (60 psi) 0.41 MPa (60 psi) × (cutting force)
Cutting = 24,000 lb
Materials such as PVC and HIPS fracture after being cut only
The preferred material for the backing plate is either mild
approximately 75% through the thickness, but sheet made of
or stainless steel with a hardness less than that of the die;
Eastar must be cut completely through to cleanly separate
in this way, the backing plate will suffer the wear and dulling
the parts. Although there are many ways to cut thermoformed
of the die will be avoided. Aluminum is not recommended
sheet, this brochure covers only steel rule and matched
for the backing plate because it tends to splinter, which will
metal dies.
contaminate the parts, and have a short life.
Cutting with steel rule dies Heating the steel rule knife and/or the backing plate to
50°–70°C may improve cutting Eastar™ 6763 copolyester
Steel rule dies offer the least expensive option for small-
and reduce blade wear. Higher temperatures may cause
volume cutting. These dies are usually mounted in a 15- to
the plastic to rejoin or stick to the blade.
20-mm (0.62- to 0.75-in.) thick wood chase by the die maker.
Although it is best to accurately measure shrinkage from an Since the dies must contact the backing plate to get
actual cavity, 0.005 mm per mm (0.005 in. per in.) is a good complete cut-through, great care must be taken during
rule of thumb to use with sheet made of Eastar™ 6763 “make-ready” to ensure the dies are not damaged. Use
copolyester. For cutting simple shapes, use a long center the following make-ready procedure:
bevel or a double, double bevel die shape with a hardness of
10
Die
1. L ocate the position of the cutting die in the press
by taping a make-ready sheet of 0.15- to 0.20-mm
(0.006- to 0.008-in.) kraft wrapping paper to the
cutting surface of the backing plate.
2. P lace carbon paper face down on the kraft paper and
carefully bring the die down to kiss against the paper
so that the location of the die is marked.
3. M
ark the location of the paper on the cutting plate so
that it can be placed under the plate in the same location
Punch
as it was on top.
4. P lace the make-ready paper under the plate and a sheet
of Eastar 6763 in position to be cut. Be sure the press is too strongly that zero clearance must be maintained to
backed off so as not to cut too deeply on the first hit. ensure clean cutting of sheet made of Eastar 6763.
5. B
y repeated and careful adjustment, bring the press Matched dies can be designed so that all cutting edges are
down until 75%–80% of the sheet is cut through. parallel and all cutting begins at the same instant. A useful
6. R
emove the make-ready paper and place 0.8- to option to extend die life is to use shear-point cutting, wherein
0.15-mm (0.003- to 0.006-in.) make-ready tape on the die is crowned by slightly raising the center line of the die.
areas that are not cutting. Do not overlap the tape. This permits the punch to contact the higher center line first.
As the punch moves into the die, it does so with a shearing
7. P lace the make-ready paper under the cutting plate
action as the cutting progresses to the die edges.
again and carefully take another hit.
8. R
epeat this buildup procedure until the entire die is If provision can be made during thermoforming, coining
fully cutting. should also be used; this reduction in thickness will
substantially increase die life. Part shrinkage must be
Die life can be extended if bearers are placed outside the considered to properly match the location of coining to the
sheet area to provide a positive stop for the platens. They are cutting die.
particularly recommended on punch presses and two-post
presses to ensure the platens are always in the same relative Denesting thermoformed parts
position when fully closed. They also help prevent die
Eastar™ 6763 copolyester has a high gloss and will often block,
damage during make-ready.
making it difficult to denest the formed parts. In this event, an
Eastman denesting concentrate can be added during sheet
Matched metal dies
extrusion. This, combined with denest lugs, should provide
A matched metal die, also referred to as a punch and die, is satisfactory part separation; the concentrate will, however,
recommended for high-volume applications. It is mounted in produce a slight haze in the sheet and formed part.
a separate cutting press through which the continuously
formed sheet passes. It is designed so that the parts nest as
they are punched through the die. The figure below
illustrates a punch and die.
11
Silicone coatings can be used as a denesting aid when applied Quality manufacturing
either to thermoformed parts or to one side of the sheet
Eastar 6763 is manufactured under a quality system that is
during the extrusion process. Coating both sides of the sheet
BSI-registered (Certificate No. FM 14068), conforming to the
is generally unnecessary because the silicone will transfer
requirements of ISO 9001:2008.
to the uncoated side after winding. Silicone coatings should
always be applied in the least amount and lowest
Summary checklist
concentration practical. Crazing or stress-cracking caused
by a silicone emulsion can be minimized by uniformly The following checklist summarizes processing steps that are
applying a well-mixed emulsion at the lowest practical level. important for the successful production of blister packages
Never heat the silicone solution. Use moderately heated air using Eastar 6763.
(<50°C [<120°F]) to dry and remove carrier solvent (usually 1. Use nip-polished film
water) prior to winding.
2. U
se sheet-forming temperatures of 140° to 163°C
Silicone coatings provide better clarity than an internal (280° to 325°F)
denest concentrate, such as 6763 C0030 at 1–2 wt%
addition, and will provide a degree of slip during forming that 3. Prevent webbing by
can improve material distribution. A silicone coating cannot – Not overheating the film
be used in some applications because it may affect certain
secondary operations such as printing and sealing. – Keeping the film properly tensioned
Contact Eastman to obtain a list of silicone emulsions – Using correct mold spacing
approved for use on sheet of Eastar™ 6763 copolyester. – Using plug-assist on deep-draw molds
Although the information and recommendations set forth herein are presented in good faith, Eastman Chemical
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SP-TRS-4257 6/17