The DuPont Performance Polymers Laboratory (Elastomers ) DPP Lab.pdf · The DuPont Performance Polymers Laboratory (Elastomers ) 2 2 ... Vamac®, Viton®, Kalrez®, Viton® Free Flow,

DuPont Performance Polymers ConferenceDuPont Performance Polymers Conference

May 20May 20th,th, 20102010

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Patrick Patrick PagliaPaglia

The DuPont Performance The DuPont Performance PolymersPolymers LaboratoryLaboratory((ElastomersElastomers))

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� Outskirt of Geneva

� 250 people

� DPP - Elastomers lab : 22 people

� Technical Support to customers located in Europe & abroad

� Vamac®, Viton®, Kalrez®, Viton® Free Flow, Neoprene

� ISO/TS 16949:2009 (Viton®) & ISO 9001:2008 (all products)

� Yearly Compounder Course – next June 2010

European Technical Center

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What’s unique to ETC

� Many professionals with multiproduct experience

� Broadest range of diversity and language skills

� Central geographical location / time zone

� Well integrated with the business

� Well integrated & synergies with DuPont labs

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� A TS&D LAB with unique or clearly differentiated capabilities within DPE, serving a strategic technology segment

� Critical mass (staffing, investment, competencies) to provide full service for that technology or market segment world wide

� Close links and exchanges with other leading, non-competing players active in the same value chain for the technology (for example, mould manufacturers)

� Ideally geographically close to the main markets

� Provides support to the other regions

DPP definition of TS&D Lead Center

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� Several mills – four (0.5 kg to 15 kg)

� Internal mixer – two (1.6 liter & 9 liter)

� Presses for slabs

� Mooney, MDR, RPA, MTS, Goettfert, Rosand capillary

� + standard testing equipment (Tensile, TR 10, etc.)

� Injection moulding machines – three

� 2K injection moulding machine

� Oven for post-cure & aging

� Explosive Decompression Unit

� Strong analytical capabilities

Elastomers lab of the Europen Technical Center

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Injection moulding capability

� MIR, 135 tons

� 38 mm barrel

� Reciprocating screw

� Essentially o-ring moulds of various part dimension s & surface finishes

� One vertical & two horizontal injection moulding mac hines

� Product development beyond conventional rubber lab equipments (RPA, capillary rheometer, etc…)

0123456789

10

60 65 70 75 80 85 90 95 100 105 110

Injection Pressure (bar)

Inje

ctio

n T

ime

(s)

Viton GBL-S

Viton GBL

� Optimisation of custom compounds – flow & release

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Injection moulding capability

� To cope with broader DPP portfolio

� Maplan, 300 tons

� 27 mm barrel, L/D 13

� Ideal for low volume compounds, e.g. evaluation of experimental polymers

� Quick cleaning for transitions

� New entry :

� O-ring moulds

� Diversification of mould estate :

� Multiple cavity moulds for broad processing assessments in one go : flow, release, scorch

� Special projects : brush for long runs

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Injection moulding capability

� Vertical injection noulding machine

� REP, 70 tons

� Bonded parts

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Peel sample

Zytel ® FE 270056Vamac® Ultra IP

Optimum process parameters

Vamac® cavity: 190°C

Curing time: 45 sec

Post cure: 40min @ 190ºC

Total cycle time: 70 sec

Hardness, Shore A: 60

Compression set: ~20 %

Peel adhesion: >2.5 N/mm

2K injection moulding capability

Rotary table

1010

Compression moulding capability

� Characterisation of new product

� Determination of best releasing aid package

� Optimisation of custom compound with emphasis on release performance

� Complementary to the injection moulding assets

0

10

20

30

40

50

60

70

80

90

100

0 10 20 30 40 50 60

Molding Cycle #

% S

tic

kin

g C

av

itie

s

Viton GLT-S (1% average sticking)Viton GLT (47% average sticking)Viton GLT-505 (37% average sticking)

1111

ED testing equipment

To be compressed(larger piece)

Uncompressed(smaller piece)

A program developed internally ensures constant data acquisition and optimum pressure release

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ED testing equipment

� 100 % CO2

� 24 hour exposure

� Temperature : Room Temperature, 100 °C, 150 °C, 200 °C

� Pressure : 5 MPa, 10 MPa, 15 MPa

� Decompression rate : 2 to 12 MPa/min

� One decompression cycle

� Uncompressed and compressed K-325 o-rings (37.47 mm x 5.33 mm, 3 specimen per condition)

� Samples analyzed based on Norsok M-710a visual inspection method

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� THERMAL ANALYSIS

� Differential Scanning Calorimeter (D.S.C.)� Thermo Gravimetric Analyzer (T.G.A.)� Thermo Mechanical Analyzer (T.M.A.)

Analytical laboratory

Heat absorptionEndotherm (fusion)

Heat absorptionExotherm (cristallization)

Glass transition (Tg)

D.S.C T.G.A

1414

� SPECTROMETRIC ANALYSIS� Fourier Transformed Infra-Red Spectrometer (F.T.I.R.)

� X-Ray Fluorescence Spectrometer (X.R.F.)

Analytical laboratory

101520253035404550556065707580859095

100.0

%T

4000.03600 3200 2800 2400 2000 1800 1600 1400 1200 1000 800 650.0

FKM > Viton®FFKM > Kalrez®

IR enables a quick and easy differentiation between

fluoroelastomers (FKM) and perfluoroelastomers (FFKM)

Ca KA1-HS-Min

0

0.1

1

2

3

5.56 5.6

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� OPTICAL BINOCULAR & IMAGING

� ANALYTICAL FACILITIES FROM OTHER DUPONT DIVISIONS

� COMPLEMENTARY SUPPORT FROM RESEARCH INSTITUTE

Analytical laboratory

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Akron extrusion layout

Barrier SectionFKM VTR-7551

Cover SectionTie Layer

Reinforcement Cover

� Product / compound development

� VTR-7551 for thin veneers

� Bonding evaluation of Viton-silicone hoses for turbo charger & industrial applications

Barrier screw used for optimal FKM extrusion

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Extruder 1 - FKM

Extruder 2 - tie layer

mandrel

Mandrelon reel

puller

Coextruded hose

Tandem Extruded hoseExtruder 1 - FKM Extruder 2 - tie layer

mandrel

Mandrelon reel

puller

55.0°

Akron multi-extrusion layout

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The information set forth herein is furnished free of charge and is based on technical data that DuPont believes to be reliable and falls within the normal range of properties. It is intended for use by persons having technical skill, at their own discretion and risk. This data should not be used to establish specification limits nor used alone as the basis of design. Handling precaution information is given with the understanding that those using it will satisfy themselves that their particular conditions of use present no health or safety hazards. Since conditions of product use and disposal are outside our control, we make no warranties, express or implied, and assume no liability in connection with any use of this information. As with any product, evaluation under end-use conditions prior to specification is essential. Nothing herein is to be taken as a license to operate or a recommendation to infringe on patents.

Caution: Do not use in medical applications involving permanent implantation in the human body. For other medical applications, discuss with your DuPont customer service representative and read Medical Caution Statement H-50103-3.

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