Introduction To PolymersAnd Compounds

In TPE’s

PolymersPolymers

• If we think of If we think of atomsatoms, for example Carbon (C) , for example Carbon (C) and Hydrogen (H) as and Hydrogen (H) as building blocksbuilding blocks we can we can make many different structures by piecing make many different structures by piecing different blocks (atoms) together. different blocks (atoms) together.

• Not all atoms go together but if we can build a Not all atoms go together but if we can build a stable structure we can make stable structure we can make bigger building bigger building blocksblocks called called MonomersMonomers. .

PolymersPolymers

• So if we take Carbon (C) and Hydrogen (H) So if we take Carbon (C) and Hydrogen (H) we can make the simple we can make the simple monomer Ethylenemonomer Ethylene..

PolymersPolymers• If we join lots of these “If we join lots of these “monomermonomer” building ” building

blocks together we then make a “blocks together we then make a “polymerpolymer”, ”, this word comes from this word comes from PolyPoly meaning meaning manymany and and mer mer which meanswhich means unit unit as in as in Monomer Monomer (One Unit) (One Unit) , hence “, hence “many Monomersmany Monomers” (or ” (or many units).many units).

PolymersPolymers

• If we think of a polymer as a If we think of a polymer as a chainchain we can think of we can think of each each monomermonomer as a as a linklink in that chain. The more links in that chain. The more links we have the longer the chain is, this is known as the we have the longer the chain is, this is known as the molecular weight (Mw)molecular weight (Mw) of the polymer and can greatly of the polymer and can greatly affect properties such as strength, recovery and melt affect properties such as strength, recovery and melt flow.flow.

(e.g. Kraton 1651 has a higher Mw than Kraton 1654)(e.g. Kraton 1651 has a higher Mw than Kraton 1654)

Low Mw

High Mw

PolymersPolymers

• The polymer chains form The polymer chains form entanglementsentanglements between between each other and this influences propertieseach other and this influences properties

• The The longerlonger the the chainschains the the more entanglementsmore entanglements, this , this increasesincreases properties such as properties such as strengthstrength and and recoveryrecovery but but decreasesdecreases properties like the properties like the melt flow ratemelt flow rate. .

PolymersPolymers• Different Monomers can be produced and attached Different Monomers can be produced and attached

together to make different polymers, but also we can together to make different polymers, but also we can start to combine start to combine moremore than one Monomerthan one Monomer to form to form more more complicated polymerscomplicated polymers. These are known as . These are known as Block CopolymersBlock Copolymers

• SBS (Calprene 419) is a Block Copolymer made from SBS (Calprene 419) is a Block Copolymer made from Styrene Monomer and Butadiene MonomerStyrene Monomer and Butadiene Monomer

FormulationsFormulations

• Our formulations at VTP are based upon Our formulations at VTP are based upon combinations of polymerscombinations of polymers

• Although we add other Although we add other non-polymer ingredientsnon-polymer ingredients it is it is the the polymerspolymers that that influenceinfluence the the main propertiesmain properties of the of the compound compound

• Typically we would combine at least Typically we would combine at least one “rubbery”one “rubbery” materialmaterial with at least with at least one “plastic” materialone “plastic” material

• The benefit of this is that we have a material that The benefit of this is that we have a material that shows shows properties of rubber at room temperaturesproperties of rubber at room temperatures but but can moulded or extruded like a plasticcan moulded or extruded like a plastic

SBSSBS[[Styrene] – [Butadiene] – [Styrene]Styrene] – [Butadiene] – [Styrene]

• ““Rubbery” MaterialRubbery” Material

• Fina 409, Calprene 419, Calprene 411, Kraton D-1101 are all Fina 409, Calprene 419, Calprene 411, Kraton D-1101 are all SBS.SBS.

• Used in lower cost compounds but has lower performance.Used in lower cost compounds but has lower performance.

• Degrades quite easily above 200Degrades quite easily above 200°°C, especially if left at this C, especially if left at this temperature.temperature.

• Sometimes difficult to disperse (i.e. nibs – Europrene)Sometimes difficult to disperse (i.e. nibs – Europrene)

• Poor resistance to UV.Poor resistance to UV.

• Medium capacity for retaining oil Medium capacity for retaining oil

SBSSBS[[Styrene] – [Butadiene] – [Styrene]Styrene] – [Butadiene] – [Styrene]

Different SBS grades are made by:Different SBS grades are made by:

• Using different ratio’s of [Styrene] to Using different ratio’s of [Styrene] to [Butadiene][Butadiene]

• Making the chains longer or shorter (Mw)Making the chains longer or shorter (Mw)

• Altering the structure of the chainsAltering the structure of the chains

• Extending with different amounts of oilExtending with different amounts of oil

SEBSSEBS[Styrene] – [Ethylene] – [Butylene] – [Styrene][Styrene] – [Ethylene] – [Butylene] – [Styrene] • Rubbery MaterialRubbery Material

• Kraton 1650, Kraton 1651, Kraton 1654, Calprene C6174S, Kraton 1650, Kraton 1651, Kraton 1654, Calprene C6174S, Septon 4055Septon 4055

• More expensive material than SBS but has superior propertiesMore expensive material than SBS but has superior properties

• Stable over 230Stable over 230°C and can remain at high temperatures for °C and can remain at high temperatures for reasonable periods of time without any or much degredationreasonable periods of time without any or much degredation

• Can be difficult to disperse but easier than some SBSCan be difficult to disperse but easier than some SBS

• Very Good resistance to UVVery Good resistance to UV

• Extremely high capacity for retaining oil Extremely high capacity for retaining oil

SEBSSEBS[Styrene] – [Ethylene] – [Butylene] – [Styrene][Styrene] – [Ethylene] – [Butylene] – [Styrene]

Different grades of SEBS are made by:Different grades of SEBS are made by:

• Using different ratios of the monomer blocksUsing different ratios of the monomer blocks

• Mw (Chain Length) is usually the biggest Mw (Chain Length) is usually the biggest difference between grades difference between grades

EPDMEPDM[Ethylene] - [Propylene] - [Diene] Modified[Ethylene] - [Propylene] - [Diene] Modified

• EPDM is a synthetic rubberEPDM is a synthetic rubber

• Nordel IP3745, Royalene 694 and Royalene 539 are EPDM Nordel IP3745, Royalene 694 and Royalene 539 are EPDM rubbersrubbers

• EPDM is slightly more expensive than SBS but not as EPDM is slightly more expensive than SBS but not as expensive as SEBSexpensive as SEBS

• EPDM is stable up to around 230EPDM is stable up to around 230°C but if left at temperatures °C but if left at temperatures above 200°C for any length of time can begin to degradeabove 200°C for any length of time can begin to degrade

• Fairly easy to disperse in normal TPE style compounds. More Fairly easy to disperse in normal TPE style compounds. More complicated in TPV (XL) compoundscomplicated in TPV (XL) compounds

• Very good resistance to UVVery good resistance to UV

EPDMEPDM[Ethylene] [Propylene] [Diene] Modified[Ethylene] [Propylene] [Diene] Modified

Different grades of EPDM are made by:Different grades of EPDM are made by:

• Using different Ethylene to Propylene ratio’sUsing different Ethylene to Propylene ratio’s

• Using different Diene’s for modificationUsing different Diene’s for modification

• Extending with different oil amountsExtending with different oil amounts

Polypropylene (PP)Polypropylene (PP)[Propylene][Propylene]nn

• Plastic materialPlastic material

• Novolen 1100N, BP 100GA12, Moplen HP500N are all grades Novolen 1100N, BP 100GA12, Moplen HP500N are all grades of PPof PP

• Plastics we use at VTP tend to be more economical than Plastics we use at VTP tend to be more economical than “rubbery” materials“rubbery” materials

• PP is very stable and would not degrade until well above SBS PP is very stable and would not degrade until well above SBS and SEBS degradation temps, even after prolonged periodsand SEBS degradation temps, even after prolonged periods

• Dispersion is not usually an issue with plasticsDispersion is not usually an issue with plastics

• We have to make sure PP melts though, this happens at 160 - We have to make sure PP melts though, this happens at 160 - 165165°C but we usually need to go higher than this to ensure that °C but we usually need to go higher than this to ensure that all of the material gets to this temperatureall of the material gets to this temperature

• PP has no real issues with UV attackPP has no real issues with UV attack

Polypropylene (PP)Polypropylene (PP)[Propylene][Propylene]nn

Different PP grades are usually made by:Different PP grades are usually made by:

• Using different structures Using different structures

• Different MwDifferent Mw

• Provide different melt flow materialsProvide different melt flow materials

Polyethylene (PE)Polyethylene (PE)[Ethylene][Ethylene]nn

• Plastic materialPlastic material

• Flexirene CM50, Flexirene MR50 and Eraclene MP94 Flexirene CM50, Flexirene MR50 and Eraclene MP94 are all types of PEare all types of PE

• Again PE is more Economical than the “Rubbery” Again PE is more Economical than the “Rubbery” materials we usematerials we use

• As with PP, PE is very stable from degradationAs with PP, PE is very stable from degradation

• Dispersion is not really an issue as long as we melt Dispersion is not really an issue as long as we melt the PE. The melt temp of PE is around 135 to 145the PE. The melt temp of PE is around 135 to 145°C °C (this varies depending on type of PE)(this varies depending on type of PE)

• PE has no real issues with UVPE has no real issues with UV

Polyethylene (PE)Polyethylene (PE)[Ethylene][Ethylene]nn

Polyethylene's are a bit more complicated in the Polyethylene's are a bit more complicated in the types available, typical variants are:types available, typical variants are:

• Based on densities (due to varying amounts Based on densities (due to varying amounts of crystallisation) this can give quite different of crystallisation) this can give quite different materialsmaterials

• Different Mw materialsDifferent Mw materials

• Different melt flow materialsDifferent melt flow materials

Polystyrene (PS)Polystyrene (PS)[Styrene][Styrene]nn

• Plastic MaterialPlastic Material

• Empera 116 is a PS materialEmpera 116 is a PS material

• PS is more economical than “rubbery” materials but is more PS is more economical than “rubbery” materials but is more expensive than PP or PEexpensive than PP or PE

• PS is quite stable but is more prone to problems than PP or PEPS is quite stable but is more prone to problems than PP or PE

• Dispersion again is not much of an issue but we have to soften Dispersion again is not much of an issue but we have to soften material enough to compound in properly. PS doesn’t actually material enough to compound in properly. PS doesn’t actually melt like PP or PE but softens enough around 145 - 155melt like PP or PE but softens enough around 145 - 155°C°C

• PS can have some issues with UVPS can have some issues with UV

Polystyrene (PS)Polystyrene (PS)[Styrene][Styrene]nn

Different grades of PS are made by:Different grades of PS are made by:

• The amount of styrene in the polymer chainThe amount of styrene in the polymer chain

• The Mw of the gradeThe Mw of the grade

• Different rubber types and amounts added to Different rubber types and amounts added to improve impact resistance (HIPS)improve impact resistance (HIPS)

CompoundsCompounds400 Series (SBS)400 Series (SBS)

• Example “Dryflex 400601”Example “Dryflex 400601”

• Based on SBS (Kraton D-1101C)Based on SBS (Kraton D-1101C)

• Can be used for Injection Moulding and Can be used for Injection Moulding and ExtrusionExtrusion

• Would be used for general purpose low cost Would be used for general purpose low cost mouldings typicallymouldings typically

CompoundsCompounds400 Series (SBS)400 Series (SBS)

Dryflex 400601 Formulation:Dryflex 400601 Formulation:

• SBSSBS – Main Polymer Base – Main Influence on compound – Main Polymer Base – Main Influence on compound propertiesproperties

• PPPP – Plastic Phase – Influences compound properties and helps – Plastic Phase – Influences compound properties and helps to process efficientlyto process efficiently

• OilOil (Edelex) – This oil suits SBS the best. Used to soften the (Edelex) – This oil suits SBS the best. Used to soften the material and improve flow and process efficiencymaterial and improve flow and process efficiency

• FillerFiller – Calcium Carbonate (e.g. Calmote UF) – Main use is to – Calcium Carbonate (e.g. Calmote UF) – Main use is to extend the compound and hence “cheapen” it as this material is extend the compound and hence “cheapen” it as this material is significantly lower in cost than polymersignificantly lower in cost than polymer

CompoundsCompounds500 Series (SEBS)500 Series (SEBS)

• Example “Dryflex 500600”Example “Dryflex 500600”

• These grades are unfilledThese grades are unfilled

• Based on SEBS (Kraton G1651)Based on SEBS (Kraton G1651)

• Can be used for Injection Moulding and ExtrusionCan be used for Injection Moulding and Extrusion

• Would be typically used for general purpose more Would be typically used for general purpose more demanding mouldings that require very easy demanding mouldings that require very easy colouring or a clean/transparent appearancecolouring or a clean/transparent appearance

• These would be used over the 400 Series if the These would be used over the 400 Series if the application is for outdoorsapplication is for outdoors

CompoundsCompounds500 Series (SEBS)500 Series (SEBS)

Dryflex 500600 Formulation:Dryflex 500600 Formulation:

• SEBSSEBS – Main Polymer Base – Main Influence on compound – Main Polymer Base – Main Influence on compound propertiesproperties

• PPPP – Plastic Phase – Influences compound properties and helps – Plastic Phase – Influences compound properties and helps to process efficientlyto process efficiently

• OilOil (Primol) – This oil suits SEBS the best and is medically (Primol) – This oil suits SEBS the best and is medically approved (also suitable for food contact materials). Used to approved (also suitable for food contact materials). Used to soften the material and improve flow and process efficiencysoften the material and improve flow and process efficiency

• StabilisersStabilisers – Antioxidants and UV stabilisers (e.g. – Antioxidants and UV stabilisers (e.g. Irganox/Tinuvin or Polyad which is a pre-blend) – The use of Irganox/Tinuvin or Polyad which is a pre-blend) – The use of these is to prevent or slow down the degradation from heat and these is to prevent or slow down the degradation from heat and oxygen when processing and UV rays during service.oxygen when processing and UV rays during service.

CompoundsCompounds600 and 660 Series (SEBS)600 and 660 Series (SEBS)

• Example “Dryflex 600600 or 660600”Example “Dryflex 600600 or 660600”

• These grades are filled and semi-filled respectivelyThese grades are filled and semi-filled respectively

• Based on SEBS (Kraton G1651)Based on SEBS (Kraton G1651)

• Can be used for Injection Moulding and ExtrusionCan be used for Injection Moulding and Extrusion

• Would be typically used for general purpose more demanding Would be typically used for general purpose more demanding mouldingsmouldings

• These would be used over the 400 Series if the application is for These would be used over the 400 Series if the application is for outdoors and the 500 series if a higher density is required or if outdoors and the 500 series if a higher density is required or if the clean/transparent nature of the 500 series is not required the clean/transparent nature of the 500 series is not required and for cost purposes these grades are suitable and for cost purposes these grades are suitable

CompoundsCompounds600 and 660 Series600 and 660 Series

Dryflex 600600 or 660600 Formulation:Dryflex 600600 or 660600 Formulation:

• SEBSSEBS – Main Polymer Base – Main Influence on compound properties – Main Polymer Base – Main Influence on compound properties

• PPPP – Plastic Phase – Influences compound properties and helps to – Plastic Phase – Influences compound properties and helps to process efficientlyprocess efficiently

• OilOil (Primol) – This oil suits SEBS the best and is medically approved (Primol) – This oil suits SEBS the best and is medically approved (also suitable for food contact materials). Used to soften the material (also suitable for food contact materials). Used to soften the material and improve flow and process efficiencyand improve flow and process efficiency

• StabilisersStabilisers – Antioxidants and UV stabilisers (e.g. Irganox/Tinuvin or – Antioxidants and UV stabilisers (e.g. Irganox/Tinuvin or Polyad which is a pre-blend) – The use of these is to prevent or slow Polyad which is a pre-blend) – The use of these is to prevent or slow down the degradation from heat and oxygen when processing and UV down the degradation from heat and oxygen when processing and UV rays during service.rays during service.

• FillerFiller – Calcium Carbonate (e.g. Calmote UF) – Main use is to extend – Calcium Carbonate (e.g. Calmote UF) – Main use is to extend the compound and hence “cheapen” it as this material is significantly the compound and hence “cheapen” it as this material is significantly lower in cost than polymerlower in cost than polymer

CompoundsCompounds9000 Series (TPO)9000 Series (TPO)

• Example “Dryflex 9012-001”Example “Dryflex 9012-001”

• These grades are based on EPDM Rubber mixed These grades are based on EPDM Rubber mixed with a PP plasticwith a PP plastic

• These grades can be filled or unfilledThese grades can be filled or unfilled

• These can be used for injection moulding or extrusionThese can be used for injection moulding or extrusion

• Usually used for economical injection moulding, Usually used for economical injection moulding, especially in automotive. Car bumpers are the especially in automotive. Car bumpers are the biggest usage for this material (not from VTP biggest usage for this material (not from VTP material) material)

CompoundsCompounds9000 Series (TPO)9000 Series (TPO)

• EPDMEPDM – One of the main polymer bases – Big influence on – One of the main polymer bases – Big influence on product propertiesproduct properties

• PPPP – Plastic phase and one of the main polymer bases – Big – Plastic phase and one of the main polymer bases – Big influence on product properties and processinginfluence on product properties and processing

• Calcium StearateCalcium Stearate – Process Aid – Acts an internal lubricant to – Process Aid – Acts an internal lubricant to aid processing both when compounding and moulding/extrudingaid processing both when compounding and moulding/extruding

• StabilisersStabilisers – Antioxidants and UV stabilisers (e.g. – Antioxidants and UV stabilisers (e.g. Irganox/Tinuvin or Polyad which is a pre-blend) – The use of Irganox/Tinuvin or Polyad which is a pre-blend) – The use of these is to prevent or slow down the degradation from heat and these is to prevent or slow down the degradation from heat and oxygen when processing and UV rays during service.oxygen when processing and UV rays during service.

CompoundsCompoundsXL Series (TPV)XL Series (TPV)

• Example “Dryflex XL60100-001”Example “Dryflex XL60100-001”

• These grades are based on EPDM Rubber mixed with a PP These grades are based on EPDM Rubber mixed with a PP plastic like a TPO, but the Rubber phase is vulcanised.plastic like a TPO, but the Rubber phase is vulcanised.

• These grades can be filled or unfilled but usually conatin a small These grades can be filled or unfilled but usually conatin a small amount of filleramount of filler

• These can be used for injection moulding or extrusion These can be used for injection moulding or extrusion depending on the actual gradedepending on the actual grade

• Usually used for higher end mouldings or extrusions that require Usually used for higher end mouldings or extrusions that require better temperature resistance or better aggressive fluid better temperature resistance or better aggressive fluid resistance (Automotive under bonnet)resistance (Automotive under bonnet)

CompoundsCompoundsXL Series (TPV) XL Series (TPV)

• EPDMEPDM – One of the main polymer bases – Big influence on product properties – One of the main polymer bases – Big influence on product properties

• PPPP – Plastic phase and one of the main polymer bases – Big influence on product – Plastic phase and one of the main polymer bases – Big influence on product properties and processingproperties and processing

• OilOil (Primol) – This oil suits EPDM the best and is medically approved (also suitable (Primol) – This oil suits EPDM the best and is medically approved (also suitable for food contact materials). Used to soften the material and improve flow and for food contact materials). Used to soften the material and improve flow and process efficiencyprocess efficiency

• Cure PackageCure Package – Provides the chemical reaction that vulcanises the EPDM rubber – Provides the chemical reaction that vulcanises the EPDM rubber

• StabilisersStabilisers – Antioxidants and UV stabilisers (e.g. Irganox/Tinuvin or Polyad which is – Antioxidants and UV stabilisers (e.g. Irganox/Tinuvin or Polyad which is a pre-blend) – The use of these is to prevent or slow down the degradation from a pre-blend) – The use of these is to prevent or slow down the degradation from heat and oxygen when processing and UV rays during serviceheat and oxygen when processing and UV rays during service

• Process AidProcess Aid – Fatty Acid (e.g. Crodamide E) – Works as an internal lubricant when – Fatty Acid (e.g. Crodamide E) – Works as an internal lubricant when compounding and moulding/extruding. Also migrates to the surface to form a greasy compounding and moulding/extruding. Also migrates to the surface to form a greasy layer that helps with de-moulding and helps material flow through the die when layer that helps with de-moulding and helps material flow through the die when extrudingextruding

CompoundsCompounds4000 Series (Glazing)4000 Series (Glazing)

• Example “Vitaprene 4058-101”Example “Vitaprene 4058-101”

• These grades are based on SBS mixed with a PE These grades are based on SBS mixed with a PE plastic (LLDPE) (Also other polymers incorporated)plastic (LLDPE) (Also other polymers incorporated)

• These grades are usually reasonably well filled to These grades are usually reasonably well filled to reduce raw material costsreduce raw material costs

• These grades are predominantly for extrusionThese grades are predominantly for extrusion

• Usually used for glazing gaskets and sealsUsually used for glazing gaskets and seals

CompoundsCompounds4000 Series (Glazing)4000 Series (Glazing)

• SBSSBS – The main base polymer – used for cost purposes – The main base polymer – used for cost purposes

• EPDMEPDM – Also used in relatively high amount, improves properties such as UV resistance – Also used in relatively high amount, improves properties such as UV resistance without using lots of expensive SEBSwithout using lots of expensive SEBS

• PEPE – The main plastic component for processing and properties – The main plastic component for processing and properties

• SEBSSEBS – Used in small amount to improve some of the poorer properties of the other – Used in small amount to improve some of the poorer properties of the other polymerspolymers

• PPPP – Used in small amounts to influence specific properties and processing – Used in small amounts to influence specific properties and processing

• OilOil (Combination) – Used for softening, cost reduction and property/processing influence (Combination) – Used for softening, cost reduction and property/processing influence

• StabilisersStabilisers – Essential with these grades due to nature of SBS for heat and UV and the fact – Essential with these grades due to nature of SBS for heat and UV and the fact that service of these materials is typically outdoors in the direct view of the sunthat service of these materials is typically outdoors in the direct view of the sun

• FillersFillers – Essential for lowering raw material costs due to competitive market and low – Essential for lowering raw material costs due to competitive market and low marginsmargins

• Black M/BBlack M/B – Contains Carbon Black which is used to provide the black colouration – Contains Carbon Black which is used to provide the black colouration

• Process aidProcess aid – Fatty Acid – Essential to help flow through the die and help prevent build up – Fatty Acid – Essential to help flow through the die and help prevent build up of die dross or shark-skin effectsof die dross or shark-skin effects

CompoundsCompounds

Obviously there are many more polymers and Obviously there are many more polymers and additives we use, but what we have covered is additives we use, but what we have covered is the main bread and butter of VTP compounds the main bread and butter of VTP compounds and raw materials.and raw materials.

We have only covered very basics of polymers We have only covered very basics of polymers as well but the concepts we have looked at as well but the concepts we have looked at should help to show why we use the different should help to show why we use the different materials and how to some degree the materials and how to some degree the formulations are developedformulations are developed