PLASTISTRENGTH

TECHNICAL BROCHURE

ACRYLIC PROCESS AIDS FOR PVC APPLICATIONS

ARKEMA Plastic Additives A worldwide leader for your PVC formulation and processing needs

ARKEMA PLASTIC ADDITIVES

FROM RESEARCH TO CUSTOMER SATISFACTION A leading position, with a worldwide presence: Production sites in Europe, USA, Asia Full integration in major raw materials Large expertise consolidated through backward integration Continuous policy of investment in R&D and new facilities to better serve customer needs A full range of PVC additives A strong focus on rigid PVC applications A sales network covering more than 100 countries

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TABLE of CONTENTS
1. 2. 3. ARKEMA: a partner focused on customer satisfaction........................ 4 Range of high performance Process Aids for PVC applications ......... 6 General Performances of Plastistrength Process Aids .................... 7
3.1 3.2 3.3 3.4 Formulation ................................................................................................. 7 Effects on fusion, gelation, processability in the extruders.......................... 8 Role of Process Aids on mechanical properties of PVC melts .................... 10 Antisticking Process Aids (Metal release technology) ................................. 12

4.

Application examples of Plastistrength in PVC ................................ 15

4.1 4.2 4.3 4.4 Calendering ................................................................................................. 15 Thermoforming ............................................................................................ 16 Extrusion ..................................................................................................... 19 Extrusion of rigid PVC foam ........................................................................ 21

4.4.1 4.4.2
4.5 4.6

Foam Profile................................................................................................21 Foam Core Pipe...........................................................................................22

Injection Moulding ....................................................................................... 24 Bottle Blow Moulding ................................................................................... 26

5.

ARKEMA Plastic Additives Locations .................................................. 28

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1 ARKEMA: a partner focused on customer satisfaction

With over 40 years experience, and production sites in Europe, the USA and Asia, ARKEMA stands as a worldwide leader in PVC additives. We develop, manufacture and market an extensive range of PVC additives, which can satisfy the strictest requirements in terms of stabilisation, processing and end-use properties for all rigid PVC applications.

Ribcourt Blooming Prairie Mobile Carrollton Brignoud Pierre-Bnite

Vlissingen

Beijing

Tokyo

Impact Modifiers Process Aids Stabilisers Co-stabilisers

ARKEMAs very wide range of PVC additives can satisfy the strictest requirements in terms of stabilisation, costabilisation, impact modification and process aids. ARKEMAs extensive knowledge of the PVC industry (Lacovyl PVC resins) allows it to offer users first-class technical service (SaintFons Technical Centre, France and King of Prussia Technical Centre, USA) with every PVC transformation technique and additive technology expertise. ARKEMAs range of additives is available throughout the world with widely spread production facilities.
Tin stabilisers

Epoxidised oils Ecepox

Thermolite Stavinor

Metallic soaps

Phosphites

Stavinor S

Clearstrength C&W

MB S Impact Modif ers

Acryperl Mattingagent Durastrength

Plastistrength P&L Processing aids Process Aids

Acrylic impact modif ier

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ARKEMAs research facility is very active in many fields of expertise in which the company holds a leading position among which tin stabilisers; acrylic and MBS impact modifiers and acrylic process aids. Plastistrength range of process aids was designed for all PVC applications in packaging (films and bottles) as well as in construction (profiles, pipes, sheets, including rigid foams). Our experts, located in ARKEMAs Technical Center in St Fons, France, are able to offer very comprehensive technical support, and to provide creative solutions for all your vinyl formulation and processing needs. They prepared this brochure to illustrate the main performance characteristic of our process aids and to give you basic recommendations for your specific applications and needs.

Plastistrength s operations benefit fully from their integration within ARKEMA, one of the largest chemical groups worldwide: Expertise in vinyl technology, consolidated through an ongoing policy of investment in R&D Full integration in major raw materials A sales network covering more than 100 countries.

ARKEMA offers also a broad range of other plastic additives which, in many cases, may be used in combination with PLASTISTRENGTH Process Aids, such as CLEARSTRENGTH MBS modifiers, THERMOLITE tin stabilizers, STAVINOR lubricants and phosphites, ECEPOX epoxidised soyabean oil, AZOBUL blowing agents, DURASTRENGTH acrylic weatherable impact modifiers for opaque applications

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2 Range of high performance Process Aids for PVC applications

Plastistrength 5XX series: these products have excellent compatibility with PVC. They are
used to achieve better PVC melt homogeneity, improve its mechanical properties (more elasticity, higher strength to prevent tearing) and in some cases speed up the PVC gelation times. The efficiency regarding the mechanical properties is generally related to the molecular weight, which is increasing from P550/P501, P551, P555 and finally P530.

Plastistrength 770: the presence of styrene in these process aids brings some lubrication effect. The release from hot metal parts such as dies, calender rolls, injection moulds, is improved without the disadvantage of plate-out brought by many external lubricants.
All Plastistrength Process Aid grades are copolymers of MMA with other acrylics and in some cases styrene like for Plastistrength 770. The choice of the monomers, the polymerisation sequence, and the molecular weight of the final copolymer are the main factors influencing the performance: improvement of the mechanical properties of the melt, acceleration of the gelation times, lubrication and other key rheological criteria critical to most PVC processes.

Molecular weight (melt strength )

P530 P555* P551 P550, P501*

Control of fusion and melt strength

Metal release effect P700 P710 * P770

Anti-sticking efficiency
P501* Molecular weight Glass Trans. Temp. (Tg) Antisticking Efficiency Low Low P550 Low High P551 Medium High Low P555* High Medium P530 Very High Medium P770 Very Low Medium & High High

* Produced only in USA

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3 General Performances of Plastistrength Process Aids

3.1 Formulation
In order to illustrate the main performances characterising process aids and the general trends, a simplified formulation was used where the nature and the content of the process aids was varied. Due to the strong effect of MBS modifiers (and particularly Clearstrength 320) as gelation promoter, it was withdrawn in some formulations to emphasize the role of the process aid.

FORMULATION PVC, Kw 57 (Lacovyl SO71S) Octyl tin mercaptide (Thermolite T892) Epoxidised soyabean oil (Ecepox PB3) Hydrogenated Castor oil Oxidised PE wax Process Aid (Plastistrength) P5XX Antisticking Process Aid (Plastistrength) P770 Impact modifier (Clearstrength 320) Blue pigment Products in bold characters are available from ARKEMA. The various technical data that were used in this brochure were obtained using process aids at various levels and in various combinations of conventional high molecular weight process aid with antisticking process aid. The technical performances illustrated in this document were sometimes obtained in more specific formulations characteristic of the application. In this case the formulation will be displayed. 100 1.5 1 0.6 0.1 0.5-1.5 0.5-1.0 8 0.1

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3.2 Effects on fusion, gelation, processability in the extruders.

Due to their high compatibility with PVC and high molecular weight, standard process aids have the possibility to entangle short PVC chains, transfer the shear generated by the processing devices and promote fusion. The performances are controlled by two main factors:

Process Aid

The molecular weight of the process aid: high Mw = high shear transfer. The Tg (glass transition temperature) of the process aid: low Tg = ability to entangle PVC chains at low temperature.

PVC

Entanglements

High molecular weights PA are also increasing the viscosity of the PVC melt, as evidenced by higher torques and pressures during extrusions, higher torques in plastograph (see picture below). PLASTOGRAPH

Torque Rheometer Graph

Torque / Viscosity Melt Temperature Maximum

Torque Rheometer graph

Equilibrium

Time Gelation Time

The maximum torque point is often taken to monitor PVC gelation time, although at this stage the compound is not completely fused yet. PVC is considered completely fused when the melt temperature reaches equilibrium. Maximum torque is simply an easy point to monitor formulation behavior comparatively.

The table below illustrates the tendencies. Plastograph tests are run without MBS in the formulation while the single screw extrusion was made on 8 phr MBS based formulation (Clearstrength 320).

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Plastograph (170C) Fusion time (s) No PA Standard PA P501 P550 P551 P555 P530 Antisticking PA P770 210 18.8 15.2 3.70 65 85 70 72 75 21.8 21.5 21.3 23.0 23.9 15.1 15.3 15.5 16.1 16.5 3.60 3.75 4.21 4.42 4.62 58 59 63 67 71 75.5 76.9 77.3 78.6 79.5 225 Peak torque (N.m) 18 Equilib. torque (N.m) 15 Melt viscosity
(x103 Pa.s)

Single screw extrusion

Die pressure, bars 61 torque (N.m) 76

3.60

General trends:
The overall results lead to the following conclusions:

Gelation promotion: P501 > P551 P555 P530 > P550 >> P770 Torques and melt pressures: P530 P555 > P551 > P550 ~ P501 >> P770
The process aid molecular weight has a direct role on the PVC gelation speed linked to the shear transfer effect described above, but our experience has demonstrated that the glass transition temperature Tg has even a stronger effect. The higher mobility of a low Tg copolymer allows the PA to entangle PVC chains sooner in the process and more efficiently. Plastistrength 770 has fewer incidences on the properties of the melt (lower molecular weight and higher Tg copolymers). It can be used to fine tune PVC melt rheology and particularly to reduce the sticking behaviour of the melt on the metal part like it will be discussed later.

Role of other additives in PVC gelation:

The effect of process aid on PVC gelation can be significantly altered by other additives in the formulation. Outside conventional lubrication systems, which certainly can enhance or cancel the effect of PA, other additives like impact modifiers (acrylic or MBS), present in large amount in many formulations, have also strong gelation promotion effects that lessen the incidence of the process aid:
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100 90 80 70 Time (s) 60 50 40 30 20 10 0

No MBS

8 phr C320

NoNo PA P.A.

1.5 phr P551 1.5 phr

P551SD

No No P.A. PA

1.5 phr 1.5 phr P551 P551SD

It is generally advised not to use process aids to control the fusion behaviour of PVC. Other additives specifically delay or accelerate PVC gelation. The main function of process aid is to control and confer the appropriate melt strength and elasticity of PVC necessary for each process.

3.3 Role of Process Aids on mechanical properties of PVC melts

The ability of process aids to increase the mechanical resistance, the elasticity and consequently the strain before initiation of cracks of the melts, is the main reason for their broad introduction in many PVC applications: Reduction of tearing during blow moulding, during deep thermoforming Disappearance of shark skins in extrusion Smooth banks in rigid or flexible calendering Regular flows in injection moulds Retention of gas bubbles in the melt to achieve light cellular PVC, etc... Mechanical properties of the melts increase with the molecular weight of the process aids and their use levels in the formulation:

Mechanical properties of PVC melts: P530 > P555 > P551> P550 P550 > P770
Illustration of melt strength:
The strength of a melt could be measured with the Rheotens equipment: a 2 mm rod is extruded and introduced between two rotating wheels whose speed is linearly increased. The melt is more and more elongated until it breaks. The force applied on the wheels and the speed at break allow the calculation of the melt strength and melt strain.
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The graph below confirms the expectations, and shows that several combinations of P770 with P551 or P550 could lead to comparable melt strengths.

350 Load at break (g) 300 250 200 150 100 650 750 850 Elongation at break (%) 950 1050 No P.A. P550/P501 P770 P530

P555
P551

P770 with 0.5 phr P550 and 8 phr MBS. P5XX: tested in formulations with 0.7 phr P770 and 8 phr MBS.

Another way to assess melt strengths is the measurement of the elongations of parisons due to their own weight. A blow moulding extruder whose die is at a height of approximately 1.2 m is used, and the necessary time for the parison to reach the floor is measured. Elongations of parison, without process aid (left) and with Plastistrength 550 (right)

When the strength is high, the elongation of the parison due to gravity is limited, and more time is needed to reach the floor:
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30

Flow time (s)

Melt strength: flow times of parisons due to gravity along 1.2 m.

20

10

No P.A.

P770

P550

P551

P530

Illustration of melt elasticity:

The best-known consequence of the elasticity brought by high molecular weight polymers is the die swell phenomenon. When the melt exits the die, the shear stress is released and the molecules lose their orientation to return to more random arrangement. This results in an expansion of the melt in directions perpendicular to the extrusion. Die swell increases when high molecular weight process aids are used:

40

Die swell (%)

30 20 10 0

Melt elasticity: die swell of extruded rods (same extrusions as Rheotens tests, 180C, die = 2 mm)

No P.A.

P770

P550

P551

P530

3.4 Antisticking Process Aids (Metal release technology)

Antisticking process aids have been developed to minimize the sticking of PVC melt on hot metal surface (calender rolls or extruder screws and dies), in other word to improve the metal release performance without providing the typical drawbacks of other additives such as external lubricants. ARKEMA has supplied the PVC market with Plastistrength 700 for decades and recently has developed a new very high performance additive: Plastistrength 770.

Illustration of antisticking effect:

While processing, PVC melt tends to stick to hot metal surface, phenomenon particularly critical on a calender. High sticking generally leads to PVC burning, plate-out, flow marks and loss of
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transparency. Plastistrength 770 is new generation version of Plastistrength 700, developed to enhance drastically the antisticking performance of the formulation.
100 90 80 70 60 50 40 30 20 10 0 w/o PA P700 P770

Two-roll mill sticking test

Sticking Time measured on 100% recycled compound (200C)

When sticking becomes critical and external lubricant cannot be added to the formulation, Plastistrength 770 could be used. Plastistrength 770 is a complex low molecular weight acrylic/styrene copolymer process aid that is extremely efficient at levels as low as 0.5 to 1.0 phr.

220 200
Time to critical sticking (min)

P700 Competitor A P770 P770 and wax (0.4 to 0.2)

180 160 140 120 100 80 60 40 20 0

Sticking Time (s)

wax: 0.4phr

wax: 0.3phr

wax: 0.2phr

0,7

0,8

0,9

Loading Antisticking PA (phr)

The new generation antisticking process aid offers about 20 to 30% higher efficiency than the current market references as far as antisticking behavior of the PVC melt. It is also interesting to observe the effect of external lubricant on the sticking behavior. Indeed, by reducing the wax content, sticking time decreases drastically, which is a true roadblock for formulators who want to decrease the external lubricant content to improve plate-out or transparency. Another aspect of the strength of this new generation antisticking process aid is to be able to maintain acceptable sticking behavior of the PVC formulation with lower external lubricant contents. Plastistrength 770 has demonstrated excellent results in extrusion allowing significant reduction in die plate-out and increase of extrusion throughput. The performance results displayed below were achieved by replacing conventional external lubricants.
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No Process Aid 1.0 phr of Plastistrength P770

No Process Aid

1.0 phr of Plastistrength 770

Current melt antisticking technologies such as non-polar external lubricant or oxidized polyethylene wax are efficient to improve the metal release but are also known to decrease finished PVC articles (such as films) transparency. Plastistrength technologies are based on very compatible acrylic chemistry and consequently remains in the PVC matrix, offering optimum transparency performances.
21 20 19
P770 External lubricant (Wax)

Haze (%)

18 17 16 15 14 13 0 0,2 0,4 0,6 0,8 1 1,2

Antisticking additive loading (phr)

When increasing P770 loading, the outstanding antisticking efficiency allows the PVC specimen to be extruded or calendered with a smoother surface and consequently lower haze (higher transparency). When the surface smoothness is optimal, increasing loading of P770 does not alter the transparency due to very high solubility of the process aid in the PVC matrix in contrary to conventional external lubricants.
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4 Application examples of Plastistrength in PVC

4.1 Calendering
Calendering of soft or rigid PVC is a high output process that requires very good melt homogeneity (no fish-eyes), smooth surfaces, regular rolling banks. Plate-out problems are often critical, as very large surfaces of hot metal are in contact with the melt. Process aids are usually introduced, often as combinations of high molecular weight process aids and lubricating grades.

Benefits of Plastistrength Process Aids:

The melt elasticity provided by the process aids leads to smooth rolling banks (P5xx grades):

No process Aid

1.5 phr of P551

High molecular weight process aids allow all additives to be perfectly dispersed in the PVC melt. Less fish eyes - During fusion, high molecular weight process aids, along with an increase of the melt viscosity, will force PVC (particularly all potential residual high molecular weight fragments) as well as all other additives (impact modifiers, lubricants, fillers) to melt homogeneously via shear transfer. Fish eyes, as called unfused particles, will break down in the PVC melt. Consequently, Plastistrength Process Aids often lead to an improvement of the film transparency. Gelation is promoted as discussed earlier.
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Flow Marks and air bubbles Flow marks and air bubbles are often the consequence of inappropriate melt viscoelasticity and consequently can be minimized with the right choice of process aids or combination of process aids. Flow marks can be reduced by decreasing the melt viscoelasticity (lower loading of PA or lower Mw) while air bubbles is opposite. One defect is often the drawback of resolving the other one and consequently the solution comes with an optimum composition of PA. When Plastistrength 770 is used, antisticking is improved and plate out is reduced. Plastistrength Process Aids can improve the mechanical properties of the hot film for processes such as embossing, stretching, winding following calendering.

Selection of the right Process Aids:

One of the major defect in rigid PVC calendered films is the presence of so called "flow marks" on the films. If the elasticity of the melt is too high, a wave appears in the rolling banks, which pattern is still visible on the film. To avoid flow marks, either the molecular weight of the process aid or its use level have to be reduced. P770 Film smoothness : excellent ; : good ; : acceptable ; : poor. P550 P551 P530

Recommendations:
Multipurpose Process Aids Metal release Process Aid

Application Calendered thick rigid film Calendered thin rigid film Extruded rigid film Flexible film Stretched film

P550

P551

P530

Use level
0.5-1.5 0.5-1.5 0.5-2 0.5-2 0.5-2

P770

Use level
0.5-1.5 0.5-1.5 0.5-1.5 0.5-1.5 0.5-1.5

: most suitable ;

: possible alternative

In most cases, the combination of P5XX grades with P770 will allow to achieve the best performances.

4.2 Thermoforming
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Thermoforming is a process where finished PVC films or sheet are post heated and stretched. This process involves heating of this material at a temperature where process aids allow the control of melt mechanical properties.

Benefits of Plastistrength Process Aids:

Process aids help to thermoform PVC films to very deep shapes: high molecular weight characteristics allow improving strain at break and tensile strength of preheated films.

Lower viscosity grade P550 allows very high elongations. It is recommended when low viscosities are required, for example for PVC/vinyl acetate copolymers, or for vacuum forming.

9 8 7 6 5 4 3 2 1 0 8 10

(low radius = good thermoformability)

Bottom radius (mm)

Vacuum forming : bottom radius of a 70 mm deep thermoformed cup (400 m thick film) Low radius indicate that the final shape is closer to the mould geometry

P530 P551 P550 12 Preheating time, s 14 16

Higher molecular weight grades like P551 and to some extent P530 improve both strain and strength. They are recommended in the case of pressure forming, where tensile resistance is critical

No process Aid

2 phr of P530

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Selection of the right Process Aids:

The major difficulty in the case of thermoforming is to select the process aid with the most suitable combination of melt resistance and elongation properties with respect to the thermoforming conditions. At low temperature, a grade with high strength (P530, P551), will lead to difficulties to stretch the film and poor thermoformed shape. At high temperature, a film prepared with grades of process aids allowing high strain but low melt viscosities might not resist to the tensile stress and tear. This compromise is illustrated in the previous page and below.
1000 750 500 250 0 70 90 110 130 150 170

Elongation at break (%)

No PA P550 P551 P530

Formulation : PVC Kw58 Thermolite 490 Clearstrength 320 GMS Ester wax Process Aid

100 2.0 5.0 0.6 0.4 3.0

Temperature of tensile test (C)

Recommendations:
Multipurpose Process Aids Application Vacuum forming, or low Temperature process Pressure forming, or high temperature process : most suitable ; : possible alternative P550 P551 P530 Use level 0.5-2.5 0.5-2.5

Antisticking process aids, such as Plastistrength 770, might be used in the formulation to help the former steps of calendering or extrusion processes. P770 will also provide excellent metal release performance, allowing good transparency retention. P530 could be recommended for the high temperatures thermoforming, provided that the calendering step can be run without defects.

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4.3 Extrusion
Extrusion is the most widely used PVC processing route to make windows, shutters, rain gutters, pipes, cables, transparent and opaque sheets (sometimes foamed). A wide range of extrusion machines are used, single screw, parallel or conical twin screws, sometimes at the same location for the same type of applications. Hence, formulations with wide processing windows are developed. Addition of Plastistrength Process Aids to the PVC formulations allow to achieve this flexibility of use, and control the physical properties of end products.

Benefits of Plastistrength Process Aids:

Elasticity of the melt and die-swell increase with the molecular weight of the process aids. It allows the melt to better fill the calibrator to achieve the right geometrical dimensions and achieve smooth surface for optimum gloss performance. Extrusion:
120 100 Die swell (%) 80 60 40 20 0 0 1 2 3 4 5 6 Process Aid loading (phr)

P530 P551 P550 P770 DOP

30 mm screw, L/D = 20, 30 rpm, 160/180/200C Formulation: PVC, Kw58 Thermolite 490 Clearstrength 320 GMS Plastistrength 770 Plastistrength P or DOP 100 2.0 5.0 0.6 0.6 0 - 5.0

Shark skin are reduced and can even completely disappear due to the combination of faster gelation and higher elasticity of the melt

No process Aid

1.5 phr of P551

Gloss is improved, particularly when antisticking process aid grades like Plastistrength 770 is used in combination with other high molecular weight grades
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44 42 % Gloss 40 38 36 34 32 P550 P551 P530

60 gloss measured on L shape window profiles

Fish eyes in transparent PVC can be reduced owing to the high shear transfer brought by high molecular weight Process Aids

Selection of the right Process Aids:

As process aids chains tend to be oriented in the die and in the calibrator during the cooling stage, further heating of the material will cause the so-called "reversion" or shrinkage of the profiles : long chains return from a stretched orientation to more random organization. As a consequence, reversion increases with process aids molecular weight. Intermediate molecular weight grades are recommended in the case of applications demanding very low reversions.

Example (standard lead stabilized window profiles formulation, extruded at 195C on conical twin screw machine, 6.5 phr of acrylic impact modifier Durastrength 320 and 1.5 phr of Process Aid): No process aid Shrinkage, % 1.45 P550 1.57 P551 1.68 P530 1.83

Recommendations :
Multipurpose Process Aids Application Windows, shutters Pipes Bioriented pipes Foam pipes, (core) Cables, flexible Blown films Compact sheets : most suitable ; : possible alternative P550 P551 P530 Use level 0.5-2.0 0.5-2.0 0.5-2.0 1.5-3 1.5-3 0.5-1.5 0.5-2.0 0.5-1.5 0.5-1.5 Metal release Process Aid P770 Use level 0.5-1.5 0.5-1.5

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4.4 Extrusion of rigid PVC foam

Extrusion of rigid PVC foam is a very demanding process in terms of mechanical properties of the melt : if the melt is not resistant enough, gas bubbles will collapse or move to the surface, leading to high densities, irregular cell structures (poor mechanical properties of finished PVC article) and uneven surface (loss of gloss). Thus, this application requires the highest levels of process aids in the formulations. To prevent foam extrusion defects, ARKEMA has developed Plastistrength 530. Owing to its very high molecular weight, P530 has demonstrated outstanding performance in foam making, allowing low density (cost saving), high throughput and high quality surface finish of PVC articles. 4.4.1

Foam Profile
Tin stabilized Formulation CaZn stabilized Formulation PVC, Kw 57 CaZn one pack* Loxiol G60 AC680A Calcium carbonate TiO2 Formulated ADCA Plastistrength 530 100 3.5 1.0 0.2 4.0 3.0 0.6 7.0

Lead stabilized Formulation

PVC, Kw 57 100 PVC, Kw 57 100 Tribas. lead sulfate 2.0 Thermolite 490 1.7 Dibas. lead stearate 2.0 Loxiol G60 1.0 Lead stearate 0.5 AC316A 0.2 Calcium stearate 1.0 Calcium stearate 0.6 AC316A 0.2 ESBO 1.0 Calcium carbonate 5 Calcium carbonate 4.0 TiO2 3 TiO2 3.0 ADCA (Azobul F) 0 - 0.6 Formulated ADCA 0.6 Plastistrength 530 6.0 Plastistrength 530 7.0 * CaZn one pack are generally made of various Calcium and costabilizers

Zinc salts formulated with multiple

Benefits of Plastistrength Process Aids:

In the presence of P530, melt strength is greatly improved: gas bubbles are retained into the melt P530 is the best process aid for low foam density owing to it super high molecular weight With Plastistrength 530, cells do not collapse, and a fine, regular structure is obtained Since the gas does not escape from the melt, the surface aspect of the finished pieces (mat to glossy) is better controlled. This will be particularly critical in the case of freefoamed sheets for display signs Plastistrength 530 offers the highest elasticities of the melt and highest die-swells: as a consequence, it is the only grade allowing to fill very thick shapes and reduce the voids at the center of Celuka foamed profiles (inward foaming).
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No process Aid

6 phr of P530

Low molecular weight PVC grades (Kw 57 to 60) are usually used for this application: Plastistrength 530 acts has a powerful shear transfer capability allowing homogeneous distribution of all the additives, including the blowing agents. Large foam sheets require a regular distribution of the PVC melt through the coat hanger shape die. Plastistrength 770 may also be added to the formulation to prevent die plate out and allow better melt flow.

4.4.2 Foam Core Pipe

P530 is particularly efficient in the foam recipe of foam core pipes. It is probably the most efficient process aid available on the market for this application. Its ability to control foam structure and to reduce foam density is illustrated in the figure below. Such results have been confirmed at industrial scale, allowing pipe producers to reduce process aid use level by 5 to 20 wt% in their foam recipe.

Compact PVC inner layer

Cellular PVC core layer

Compact PVC outer layer

Schema of a typical Foam core pipe section Skins recipe PVC K66-K68 PVC K57-K58 CaCO3 Thermolite 8000 (organotin one pack) Plastistrength 530 AZOBUL F (ADCA blowing agent) 100 10 - 18 1.8-2.5 Foam recipe 100 10 - 30 2.2-2.5 1,5 - 6 0,2 - 0,5

Typical foam core pipe formulations __________________________________________ 22 ___________________________________________

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0,72 0,71 0,70 Foam density 0,69 0,68 0,67 0,66 0,65 0,64 0,63 0,62 0,61 3,0 3,5 4,0 4,5 5,0 Process Aid content (phr)
P530

Comp. C
Comp. A
Comp. B

P530 ability to reduce foam density versus standard process aid grades (lab scale free foaming twin conical screw extrusion: 5 mm rod die) For more details on foam pipe additives, please, ask for our specific Pipe & Fittings technical brochure.

Selection of the right Process Aids:

Only process aids with very high molecular weights like P530 or in some special cases P551 can be used in rigid foam formulation.

Recommendations:
Multipurpose Process Aids Metal release Process Aid

Application All applications Foam pipes, (core)

P550

P551

P530

Use level
5 -8 1.5-4

P770

Use level
0.5-2.0

: most suitable ;

: possible alternative

In some cases, it is possible to combine P530 with P551 in order to retain enough melt strength but adjust the die swell to existing die + calibrators assortments. Addition of Plastistrength 770 will improve the surface aspect.

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4.5 Injection Moulding

Injection moulding is probably the most demanding PVC process in terms of melt viscosities. Fluidity has to be increased when the thickness of the walls decreases or the dimensions of the parts increase. Furthermore, the injection screws bring less shear than conventional extruders, hence short PVC gelation times are necessary especially when a dry blend is used. Mould release ability is also of the primary importance to achieve fast injection cycles, and high outputs.

Benefits of Plastistrength Process Aids:

Reduction of jetting: when PVC melt viscosity is low, the moulds might be filled with a jet of material lacing into the cavity. Upon cooling, the pattern of this jet may still appear inside the material and cause residual stress and heterogeneous aspect. Due to their elasticity, process aids help to fill regularly the moulds:

No process Aid

1.2 phr of P551

High gloss: better elasticity of the melt means better contacts to the walls (moulds) and smoother glossy surface. Combinations of Plastistrength 5XX grades with P770 are recommended to achieve high gloss and efficient mould release.

No process Aid Fast fusions as needed like discussed earlier.

1.2 phr of P551

Reduction of "gate blush": cooling of the material starts from the walls of the moulds considering that the hottest part is the injection gate. If the melt has a poor elasticity, microcracks may appear near to the gate. These cracks, via light scattering, will make the PVC part hazy (white appearance). This phenomenon, known as gate blush is due to the

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stress field from hot to cooler areas. These cracks disappear when process aids are introduced to improve the elasticity. Improvement of weld strengths: the smoother tips of the flowing melt in the presence of Plastistrength process aid leads to stronger welds:
700 Tensile strength (kg/cm) 600 500 400 300 200 100 0 0 1 2 3 4 5 Plastistrength 551 loading (phr) 6
Tin stabilised Lead stabilised

5 Elongation (%) 4 3 2 1 0

Tensile bar:
Gate Weld line Gate

Formulations: lead
PVC, Kw 57

tin

100 PVC, Kw 57 100 Tribas. lead sulfate 3 Dioctyl tin mercapt. 2.5 Dibas. lead stear. 1.2 Montan wax 0.5 Lead stearate 1 P551 0-5 Ca stearate 2 P551 0-5

Selection of the right process aids:

Process aids tend to increase the PVC melt viscosities, and thus reduce the melt flow. This is particularly true at low temperatures. To fill complicated mould shapes, low molecular weight grade are recommended. Plastistrength 770 is recommended to improve the sticking behaviour while maintaining a low viscosity The spiral mould test indicates the variation of melt flow with temperature

Spiral flow length (cm)

80 70 60 50 40 30 20 10 0 140
No process aid P550 P551 P530

160 180 200 Cylinder head temperature (C)

220

Recommendations:
Multipurpose Process Aids Metal release Process Aid

Application Thin parts Thick parts (fittings,...) Soft PVC

P550

P551

P530

Use level
0.5-1.5 0.5-2.0 0.5-5.0

P770

Use level
0.5-1.5 0.5-1.5

: most suitable ;

: possible alternative

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4.6 Bottle Blow Moulding

Blow moulding is the general process to prepare all kinds of bottles, from small cosmetic bottles to 5 gallons water bottles. The output in this process is very high, generally several thousands bottles per hour. As a consequence, excellent metal release ability is of the utmost importance. Regarding the end users, the visual aspect of the bottle is critical : absence of fish eyes, absence of flow lines, high transparency.

Benefits of Plastistrength Process Aids:

Gelation is promoted. Although the presence, in most cases, of MBS moderates the influence of the process aid on PVC fusion, this effect will remain particularly appreciated in the case of calcium/zinc stabilized formulations, where PVC gelation is known to be slower than with tin stabilizers. Along the extruder, more shear is transferred to the melt and fish-eyes are reduced. Melt strength is improved: parison draw down is reduced, and thus a consistent thickness from the bottom to the top of the mould is achieved. Elongations of parison, without process aid (left) and with Plastistrength 550 (right)

The melt with more elasticity can allow parison to fill the mould (even complex shape and dimension) and respect the bottle design In the presence of Plastistrength 770, die deposits are reduced and releasability from the mould is excellent.

Selection of the right process aids:

A consequence of the higher melt elasticity in the presence of process aids is a higher die swell of the parison, higher thickness of the bottle walls and consequently heavier bottles. Weight is always carefully controlled, as it is a compromise between cost and mechanical

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properties. Too high molecular weights or too high process aids loading in the formulation will dramatically increase the bottles weight. Variation of weight with PA composition (1.5l bottle)

90 80 70
Bottle weight (g)

60 50 40 30 20 10 0
No P.A P700/P550 1.2/0.5 P700/P550 0.7/1.5 P700/P551 0.7/1.5 P700/P530 0.7/1.5

To achieve a given weight of the bottles, Plastistrength 551 could be used at a lower level than P550 due to its higher molecular weight. However, the bottle weight will be more sensitive to any fluctuation in the dosage of P551 in the dry blend. Low molecular weight P770 will have less impact on bottle weight.

Recommendations:
Multipurpose Process Aids Metal release Process Aid

Application All bottles Bioriented bottles

P550

P551

P530

Use level
0.5-1.7 0.5-1.7

P770

Use level
0.5-1.5 0.5-1.0

: most suitable ;

: possible alternative

When the formulation is based on combinations of Plastistrength 550 or P551 with a lubricating process aid, P770 is recommended: P770 allows to control the mechanical properties of the melt and the weight of the bottles along with an outstanding metal release effect. If the formulation contains only one process aid, then Plastistrength 770 should offer the best compromise between melt strength and metal release ability.

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5 ARKEMA Plastic Additives Locations

FRANCE ARKEMA (European Headquarter) Ceca, Immeuble Iris - La Dfense 2 F-92062 Paris la Dfense Cedex, France tel : (33) 01.47.96.93.78 - (33) 01.47.96.93.70 fax : (33) 01.47.96.93.64 Technical service: ARKEMA Quai Louis Aulagne, B.P.35 69191 Saint-Fons Cedex, France tel : (+33) (0) 4 72 89 91 49 fax : (+33) (0) 4 72 89 93 01 EUROPE Austria See Dsseldorf Office Belgium See The Netherlands Office Scandinavia ARKEMA NORDEN Herlev Hovedgade 195 2730 HERLEV tel : (+45) (0) 44 50 3939 fax : (+45) (0) 44 50 3940 The Netherlands: ARKEMA NEDERLAND BV Ottho Heldringstrass 41 1066 XT Amsterdam tel : (+31) (0) 20 408 94 00 fax : (+31) (0) 20 669 19 09 Spain & Portugal ARKEMA ESPANA Polgono Industrial Pratense Calle 100, s/n - Acceso A08006 08820 EL PRAT DE LLOBREGAT tel : (+34) (0) 93 403 95 00 fax : (+34) (0) 93 403 95 12 Internet Addresses www.arkemagroup.com www.specialchem.com USA ARKEMA North America 2000 Market Street Philadelphia, PA 19103-3222, USA tel : + 1 (215) 419.7000 Customer Service : 1800.225.7788 fax : + 1 (215) 419.7591 Technical service: ARKEMA North America King of Prussia Technical Center 900, First Avenue King of Prussia, PA 19406 tel : + 1 (610) 848.6385 fax : + 1 (610) 848.6261

Germany ARKEMA Deutschland GmbH Tersteegenstrasse 28 D-40474 Dsseldorf tel : + 49 (0) (211) 4552.0 fax : + 49 (0) (211) 4552.112 Poland ARKEMA POLSKA UL-Marynarska 19 A 02-672 Warsawa tel : +48 (0) 22 640 49 00 fax : +48 (0) 22 640 29 20 Turkey ARKEMA TRKIYE Ihlamur, Yildiz Cadessi Kessaf Sokak N 4 Besiktas 80700 ISTANBUL tel : (+90) (0) 212 227 63 84 fax : (+90) (0) 212 227 63 85

Italy ARKEMA ITALIA Srl Via Degli Artigianelli 10 I-20159 Milano tel : (+39) (0) 2 668 111 fax : (+39) (0) 2 668 03607 Switzerland See Dsseldorf Office

United Kingdom ARKEMA UK 1 focus park Ashbourne way Shirley Solihul B90 4QU tel : (+44) (0) 121 746 5500 fax : (+44) (0) 121 744 6407

The information contained in this document is based on trials carried out by our Research Centres and data selected from the literature, but shall not in no event be held to constitute or imply any warranty, undertaking express or implied commitment from our part. Our formal specifications define the limit of our commitment. No liability whatsoever can be accepted by ARKEMA with regards to the handing, processing or the use of the product or products concerned which must in all cases be employed in accordance with all relevant laws and/or regulations in force in the country or countries concerned.

11/04 PA 03
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