DuPont Engineering Polymers for High Performance Extrusion Solutions October, 2005
2 Legal Disclaimer The information and suggestions provided in this presentation are based on data believed to be reliable, but the DuPont Company makes no warranties express or implied as to their accuracy and assumes no responsibility or liability arising out of its use by others. The disclosure of information herein is not a license to operate under, or a recommendation to infringe, any patents. The data listed here fall within the normal range of properties, but they should not be used to establish specification limits nor used alone as the basis of design. Further, the information and suggestions are not intended to substitute for any testing you may need to conduct to determine for yourself the suitability of a particular material for a particular purpose. DuPont makes no guarantee of results and assumes no obligation or liability in connection with the use of the information or suggestions provided in this presentation. Copyright 2005 E.I. du Pont de Nemours and Company. All rights reserved. The DuPont Oval, DuPont and The miracles of science and products denoted with a are registered trademarks or trademarks of DuPont or its affiliates.
Extrusion A technology in which we can help you to grow 3 DuPont Engineering Polymer Materials are already well introduced in the extrusion sector for high performance finished products. We have an excellent portfolio of Performance materials for extruded applications where we can offer benefits both in terms of performance & productivity (m/min). There is strong commitment from DuPont Engineering Polymers to support our customer business thanks to our broad range of Performance materials. We have an extrusion team that can help Companies along the Extrusion value chain with success assessment, material selection, processing, etc.
4 Objectives Show the benefits of DuPont EP products for the Extrusion sector Provide extrusion technologies & solutions in DuPont Engineering Polymers Share the DuPont offering (specific features and benefits) Demonstrate materials use inspecific application sectors Compare DuPont TPEs vs. Vulcanized rubber (material advantages & advantages for extrusion Companies) Discuss opportunities Share real product development initiatives
5 The combination of EP Products & the benefits of the extrusion process Engineering Polymer Performance High temperature capability High strength Range of flexibility, hardness & chemistries (polyamide,polyester,etpv) Fatigue resistance Chemical resistance V A L U E Extrusion process Continuous process with high O/P rates Unlimited lengths & very large widths Flexibility of thickness using same equipment Multi layer capability Opportunity to post form parts Leads to creation of Value
6 The Value that EP extruded products can bring to end users & processors OEM s Processors Components with enhanced performance & reliability EP Extruded Products Opportunity to enter new markets by replacement of traditional materials Possibility of new innovative product designs Potential to produce higher performance versions of existing designs extended capability & markets Cost, performance & weight benefits by replacing materials such as Metal or rubbers Creation of new differentiated product offerings
R e in f o r c em e n t We are the leaders in semi crystalline Engineering Polymers for Extrusion Extrusion solutions Hoses Tubing Oil/Gas Piping Monofil Profiles Cables 7 Mandrels F L E X I B L E M A N D R E L M a n d r e l R u b b e r R u b b e r L e a d o r b a n d a g e Delrin Crastin DuPont ETPV Hytrel Pipelon Zytel 6 (modified) Zytel 66 Zytel 612 & 610
Extrusion 8 A comprehensive range of options in flexibility Product Modulus (Mpa) 500 1000 1500 2000 2500 3000 DuPont ETPV Hytrel Zytel 610 & 612 Zytel 6 (ST811) & 66 Crastin PBT Delrin
Major resin properties influencing Extrusion 9 Key factors Melt Viscosity [Kpa.s]@1s Influence/Comments - Low = 0.7 to < 2. For Wire Coating & monofilament - Intermediate = 2 to < 4. For tubing & rodstock - High = 3 to < 6. For blown film, rods and profiles Consistent viscosity - Extrusion is a continuous process and requires high stability Moisture control - Moisture control /drying is critical for Nylon, but also important for all other EP resins - Plasticiser effect + Hydrolysis + Molecular weight changes + Surface defects Melting Point - Low melting Point = less mechanical and electrical energy needed Crystallisation rate - Determined by Polymer type,composition & quenching equipment - Affects surface appearance, mechanical properties, chemical resistance, tolerance, shrinkage, war page.
Positioning of main EP extrusion products (50%RH/23 deg C) 10 Product MPt ºC Moisture absorption % (equilibrium) Tensile modulus(mpa) Crastin PBT 225 0.5 1600 to 2700 DuPont ETPV Hytrel TPC-ET 156-223 to 225 0.8 1.2 to 45 28 to 1150 Zytel PA 6 222 2.8 500 to 1400 Zytel PA66 260 2.5 900 to 1200 Zytel PA610/612 218 1.2 1500 to 1700 Delrin 178 0.22-0.35 3200
11 Positioning of main EP extrusion products (50%RH/23 deg C) Product Hardness Shore D (* = ETPV Shore A) (# = Rockwell) Tensile strength @ yield (Mpa) Elongation at break (%) Crastin PBT 108# 35 to 58 3.6 to 7 DuPont ETPV Hytrel TPC-ET 60 to 90* 35-82 5 to 9 10 to 53 185 to 200 200 to550 Zytel PA 6 108#? 29 to 55 >50 Zytel PA66 108# 40 to 53 >50 Zytel PA610/612 108#? to 54 >50 Delrin 92/R120# 72 40 Note: Zytel, quoted at 50%RH
Key extrusion per application area Application Crastin DuPont ETPV Hytrel Delrin Zytel 6 & 66 12 Zytel 610 & 612 Profiles Various with different viscosities & toughness Various with different hardnesses Wide range of materials available High viscosity acetal homopolymer Various including toughened ones Medium & high viscosity Mandrels Specially developed according to hose dimensions Hose & tubing Various with different viscosities & toughness Various with different hardnesses Grades with different hardnesses & performance available High viscosity acetal homopolyme r Various including toughened ones Medium & high viscosity including toughened ones
Key extrusion per application area 13 Application Crastin DuPont ETPV Hytrel Delrin Zytel 6 & 66 Zytel 610 & 612 Monofilament Medium viscosity Various when elasticity is required High viscosity &/or heat stabilized Medium & high viscosity Wire & cable Medium viscosity & hydrolysis resistant Various with different hardnesses Wide range of materials also with flame retardancy As wire sliding cover Medium & high viscosity, some toughened Medium & high viscosity, some toughened Conveyor belting Low hardness materials with high temperature resistance Various when flex fatigue is required. Some with food compliance
DuPont EP extrusion portfolio : Positioning vs Rubber 14 Hytrel & DuPont ETPV vs Cross linked Rubber EP Product portfolio Advantages Uses standard thermoplastic processing techniques Fast thermoplastic processing Supplied in ready to use compounded form Long term material shelf life No post mould curing of parts No plasticisers Lower density Often lower material price vs. performance rubbers Recyclable Customer Benefits Allows thermoplastic processors to enter a new market Higher productivity & lower manufacturing costs Takes out premixing & compounding stage leading to lower cost & part consistency No risk of material losses due to shelf life issues Higher productivity & lower part cost Part performance not changed by plasticiser migration + no contamination Lighter components & volume cost benefits Reduced part cost Meets environmental requirements & allows some use of regrind
Key areas of opportunity: Hose and tube 15 Co-extruded barrier Zytel inside PE tube for fuel handling High pressure hose Hytrel Fuel Resistance Complete body with PE outer cover High temperature Resistance Flexibility Dimensional stability Chemical resistance Clutch pipe & hose - Hytrel Pressure resistance Over wide temp range. From -40 to 110 deg C Long working life - Up to 500,000 KM Cost efficient Fuel vent tube DuPont ETPV Suitable strength, Toughness & flexibility Between -40 and 125ºC Resistance to Automotive fluids & Greases Low part cost thanks To thermoplastic Processing Page 13
Key areas of opportunity: Hoses, Tubes and Wire & Cables Servo Brake Vacuum tube - Hytrel Over 10 years Experience in use Air brake tubes - Pressures 10 & 12.5 Bar -comply with ISO 7628 Oil cooler hoses - DuPont ETPV High temperature Resistance Dimensional stability 16 Outperforms PA12 in temperature resistance Chemical resistance Automotive Degass Tube - Hytrel Retractable Coiled Truck Cable Hytrel Chemical Resistance High & Low temperature resistance Flexibility Absence of plasticizer Outstanding Elastic Memory Low temperature flexibility Absence of plasticizer
Key areas of opportunity: Hoses, Tubes & Monofilaments 17 3D Truck Pipe Hytrel Corrosion Resistance Coiled Truck Air Brake Tubes - Hytrel Hytrel Metal Lower cost vs. previous solution Low weight Easy handling & assembly Outstanding Elastic Memory Low temperature flexibility Absence of plasticizer Working temp: -40 to 130ºC Have ISO compliance High tech. fabrics Monofilaments Hytrel Zytel (6/12, 6/10) Breathable fabric Shape recovery & draping Higher Flexibility & Chemical Resistance than Conventional Nylon products Easy maintenance & cleaning
18 Key areas of opportunity: Conveyor Belts, Mandrels, Wires & Cables Conveyor Belts Hytrel Flexible Mandrels Hytrel Flex fatigue High & low temp. Resistance FLEXIBLE MANDREL Reinforcement Dimensional stability Flexibility Weld ability Chemical & Abrasion Resistance Hot plate weld ability Mandrel Rubber Rubber Lead or bandage Easy release or Removal Chemical resistance Encapsulated Conveyor Belt Cable Hytrel Automotive Primary Wire Hytrel Flex & tear Resistance even at low temperatures Low toxicity & corrosion in case of fire Abrasion resistance Grease Resistance Flexibility at low temperatures Comply with glow Wire test Page16
19 New Product development initiatives New Grades Under Development For Launch before end 2005: Improved hydrolysis resistant : - Hytrel End fitting suitability: - Hytrel Better scratch resistance: - Hytrel (Masterbatch) Improved processing: - Mandrels: Hytrel
20 So what s next? Hopefully you now have a better idea of our materials offering for extruded performance parts. In a way that it might lead you to explore some possible new opportunities &/or improved applications. So that you might enter into new markets or offer better solutions for your existing products. Contact us now at: plastics.dupont.com. Our extrusion team is ready to collaborate with you. In consequence, let s have a first discussion on the subjects of your particular interest. Would you like to join us for a DuPont Engineering Polymers Extrusion Web Seminar? If so, please let us know through plastics.dupont.com. And, we would be glad to be part of this journey.