PVC Window Profile

7/14/2019 PVC Window Profile

http://slidepdf.com/reader/full/pvc-window-profile 1/32

PVC Window ProfilePVC Window ProfileFormulating for Formulating for

Export to North AmericaExport to North America

Henry WiebkingHenry Wiebking

Senior Scientist, Plastics Technology

Grace LiGrace LiBusiness Manager, China



TopicsTopics

North American ProfilesNorth American Profiles

How They Compare with Chinese ProfilesHow They Compare with Chinese Profiles

IngredientsIngredients

ChangesChanges

Use of TorqueUse of Torque RheometerRheometer The Importance of Calcium Carbonate The Importance of Calcium Carbonate

Tuffgard Tuffgard®®

PCC for Window ProfilesPCC for Window Profiles Hints for Successful Plant TrialsHints for Successful Plant Trials

SummarySummary

DiscussionDiscussion



North American Profiles areNorth American Profiles are

Not the Same as Chinese ProfilesNot the Same as Chinese Profiles

Physical PropertiesPhysical Properties

Thin and LightThin and Light High PerformanceHigh Performance

CompoundsCompounds

High Quality IngredientsHigh Quality Ingredients



North American Profiles areNorth American Profiles are

Not the Same as Chinese ProfilesNot the Same as Chinese Profiles

LeadLead--FreeFree

Can not use lead stabilizersCan not use lead stabilizers

Must change stabilizer and add lubricantsMust change stabilizer and add lubricants

High DurabilityHigh Durability – – WeatherabilityWeatherability Must hold color and impact strengthMust hold color and impact strength

Impact test as per ASTM D 4726Impact test as per ASTM D 4726 Should have AAMA CertificationShould have AAMA Certification

American Architectural Manufacturers Assoc. American Architectural Manufacturers Assoc. Standards for Window ProfilesStandards for Window Profiles



North American and ChineseNorth American and Chinese

Profiles Contain the SameProfiles Contain the SameBasic IngredientsBasic Ingredients

ResinResin

StabilizerStabilizer LubricantsLubricants

Impact ModifierImpact Modifier

Titanium Dioxide Titanium Dioxide

Calcium CarbonateCalcium Carbonate



IngredientIngredient China USAChina USA

ResinResin Extrusion Grade PVC ResinExtrusion Grade PVC Resin

StabilizerStabilizer NonNon--LeadLeadLeadLead

CompoundsCompounds

LubricantsLubricants

CalciumCalcium StearateStearateplus Waxplus Wax

CalciumCalcium StearateStearate

plus Wax and/orplus Wax and/or

Ester LubricantsEster Lubricants

ImpactImpact

ModifierModifier

StandardStandard

CPECPE

Acrylic and/orAcrylic and/or

High Performance CPEHigh Performance CPE

Titanium Titanium

DioxideDioxide

Lower DurabilityLower Durability

Coarser GradesCoarser Grades

Low Levels (~5phr)Low Levels (~5phr)

High DurabilityHigh Durability

Finer GradesFiner Grades

Higher Levels (~10phr)Higher Levels (~10phr)

CalciumCalcium

CarbonateCarbonate22--6 Micron Active6 Micron Active

~5phr~5phr<1 Micron Active<1 Micron Active

5 to 85 to 8 phrphr

But Differ in Specifics and Levels



Must RemoveMust Remove

Lead Based StabilizersLead Based Stabilizers

Lead Compounds Stabilize and LubricateLead Compounds Stabilize and Lubricate Are an important lubricant in local formulasAre an important lubricant in local formulas

NonNon--Lead Stabilizers Types IncludeLead Stabilizers Types Include DibutyltinDibutyltin

Barium cadmiumBarium cadmium Barium zincBarium zinc



Issue With Switching toIssue With Switching to

LeadLead--Free StabilizerFree Stabilizer

Lead Alternatives Do Not Lubricate as WellLead Alternatives Do Not Lubricate as Well

Higher Levels of Additional Lubricants NeededHigher Levels of Additional Lubricants Needed

Internal lubricants to adjust viscosityInternal lubricants to adjust viscosity External lubricants for metal releaseExternal lubricants for metal release

Different Types of Lubricant Systems AvailableDifferent Types of Lubricant Systems Available

CalciumCalcium stearatestearate with paraffin waxwith paraffin wax

Ester lubricant packagesEster lubricant packages



Changing the Lubricant PackageChanging the Lubricant Package

Lubricant Types and Levels Determine aLubricant Types and Levels Determine a

CompoundCompound’’s Fusion Characteristicss Fusion Characteristics

Fusion TimeFusion Time

ViscosityViscosity

Fusion Characteristics are Adjusted to Match:Fusion Characteristics are Adjusted to Match:

A compound that runs wellA compound that runs well

The requirements of the processing equipment The requirements of the processing equipment A TorqueA Torque RheometerRheometer ((BrabenderBrabender,, HaakeHaake) is) is

Used to Measure Fusion CharacteristicsUsed to Measure Fusion Characteristics





TorqueTorque RheometerRheometer CurveCurve

TORQUELOADING PEAK

FUSION PEAK

DEGRADATION

EQUILIBRIUM

TIME





Torque Torque RheometerRheometer Testing Testing

A Trial and Error ProcessA Trial and Error Process Continue adjusting as needed.Continue adjusting as needed.

Experience plays an important role.Experience plays an important role. When the goal is achieved moveWhen the goal is achieved move

on to a plant trial.on to a plant trial.



Adjusting Formulations Adjusting Formulations

Using the TorqueUsing the Torque RheometerRheometer

PropertyProperty

Fusion TimeFusion Time

Fusion TorqueFusion Torque

Equilibrium TorqueEquilibrium Torque

Stability TimeStability Time

Adjust With Adjust With

External Lube LevelExternal Lube Level

LubricantsLubricants

Internal Lube LevelInternal Lube Level

Stabilizer level/typeStabilizer level/type



Torque Torque RheometerRheometer::

Key to Successful Formulation DevelopmentKey to Successful Formulation Development

IngredientSelection





IngredientSelection

StartingFormulation





IngredientSelection

StartingFormulation

Torque RheometerTesting





IngredientSelection

StartingFormulation


FormulationModification

h





IngredientSelection

StartingFormulation



ProductionTrial





IngredientSelection

StartingFormulation



ProductionTrial

ProductTesting



Impact ModifierImpact Modifier

One of the More Expensive IngredientsOne of the More Expensive Ingredients

AcrylicsAcrylics

Main type used in North AmericaMain type used in North America

OffenOffen used aloneused alone

Suppliers:Suppliers:

ArkemaArkema

, Rohm & Haas, Kaneka,.., Rohm & Haas, Kaneka,..

Chlorinated Polyethylene (CPE)Chlorinated Polyethylene (CPE)

Used alone or in combination with acrylicsUsed alone or in combination with acrylics

High quality product requiredHigh quality product required Suppliers: Dow, Bayer, Solvay,Suppliers: Dow, Bayer, Solvay,……..

Choice of calcium carbonate may allow reduction in impact modifier level.



Key Change: Type and AmountKey Change: Type and Amount

of Titanium Dioxideof Titanium Dioxide Provides colorProvides color

Retards weatheringRetards weathering Color changeColor change

Loss of physical propertiesLoss of physical properties

Need Durable,Need Durable, DispersableDispersable, Plastics Grade, Plastics Grade Use at high levels: 8Use at high levels: 8--12phr12phr

Suppliers and GradesSuppliers and Grades

KronosKronos:: KronosKronos 2220, 22222220, 2222 DupontDupont:: TiPureTiPure®® R R --102, R 102, R --105105



Calcium CarbonateCalcium Carbonate

Not Just a Cheap FillerNot Just a Cheap Filler Does Lower Formulation CostDoes Lower Formulation Cost

As a Filler As a Filler -- replacing resinreplacing resin

As a Modifier As a Modifier – – can improve impact strengthcan improve impact strength

Provides ColorProvides Color

Aids Processing Aids Processing

Die scrubDie scrub

Speeds meltingSpeeds melting

Retards Degradation:Retards Degradation: HClHCl ScavengerScavenger



Most Important CaCO3 Properties in ProfilesMost Important CaCO3 Properties in Profiles

0 0.5 1 1.5 2 2.5 3 3.5 4

Median Particle Size (microns)

0

2

4

6

8

10

12

14

16

18

20

22

f t -

l b s / i n

0

100

200

300

400

500

600

700

800

900

1000

1100

J / m

Notched Izod Impact Strength

20 phr calcium carbonate filled rigid PVC

Small Particle SizeSmall Particle Size

Minimize oversizeMinimize oversize

Completely CoatedCompletely Coated

100% active100% active

In N.A.In N.A.

Only use one micronOnly use one micron

and finerand finer

SMI recommendsSMI recommends

TuffgardTuffgard®® PCCPCC



TuffgardTuffgard®®

Precipitated Calcium CarbonatePrecipitated Calcium Carbonate

0.35 Microns0.35 Microns DiscreteDiscrete

100% Active100% Active

High ImpactHigh Impact

StrengthStrength

Reduce ImpactReduce ImpactModifierModifier UseageUseage

<ONE MICRON>

1 micron



Effect of Calcium Carbonate on ProfilesEffect of Calcium Carbonate on Profiles

More Impact ModifierMore Impact Modifier

Low GlossLow Gloss

Low Carbonate PriceLow Carbonate Price

Standard Compound CostStandard Compound Cost

Less Impact ModifierLess Impact Modifier

Higher GlossHigher Gloss

Higher Carbonate PriceHigher Carbonate Price

Lower Compound CostLower Compound Cost

Standard 1Standard 1--4 micron4 micron

(coarse, agglomerated)(coarse, agglomerated)

0.35 micron0.35 micron

Tuffgard PCCTuffgard PCC

(fine, discrete)(fine, discrete)

T ff d PCCT ff d PCC



Tuffgard PCCTuffgard PCC

Allows Impact Modifier Reduction Allows Impact Modifier Reduction

How Much ?How Much ?

Depends onDepends on Current calcium carbonate type and levelCurrent calcium carbonate type and level

Current impact modifier type and levelCurrent impact modifier type and level

Starting PointsStarting Points

If now using 2If now using 2--3 micron carbonate3 micron carbonate

Remove about 4phr of modifierRemove about 4phr of modifier

If now using 1 micron carbonateIf now using 1 micron carbonate

Remove about 2phr of modifierRemove about 2phr of modifier



Adjust CaCOAdjust CaCO33

LevelLevel

If Increasing TiOIf Increasing TiO22

If TiO2 Then CaCO3

8 phr 8 phr

9 phr 7 phr

10 phr 6 phr

11 phr 5 phr

12 phr 4 phr

Total of CaCO3 + TiO2 = 16 phr



Optimizing a PVC Profile FormulationOptimizing a PVC Profile Formulation

Formulation DevelopmentFormulation Development Ingredient choices and levelsIngredient choices and levels

ProcessabilityProcessability Production TrialProduction Trial

Product TestingProduct Testing



Hints for a SuccessfulHints for a Successful

Production TrialProduction Trial

Do Only When Production LineDo Only When Production LineOperation is StableOperation is Stable

Take Control Samples at Start and EndTake Control Samples at Start and End Make One Change at a TimeMake One Change at a Time

Allow the Time to Re Allow the Time to Re--Stabilize BeforeStabilize BeforeSamplingSampling

Record All Machine ConditionsRecord All Machine Conditions



Hits For Product TestingHits For Product Testing Test to a Number Test to a Number –– not just pass/failnot just pass/fail

Compare Production Line Conditions, NotCompare Production Line Conditions, Not

J ust Formulation Variables, With Properties J ust Formulation Variables, With Properties

Test Enough Samples for Good Accuracy Test Enough Samples for Good Accuracy

If Parts FailIf Parts Fail –– Adjust FormulationAdjust Formulation

If Parts PassIf Parts Pass –– Extended Production RunExtended Production Run

SummarSummary



SummarySummary

Some major adjustments are needed to develop aSome major adjustments are needed to develop a

PVC window profile formulation for the NorthPVC window profile formulation for the North

American market.American market.

Choice of Calcium Carbonate is KeyChoice of Calcium Carbonate is Key

Achieving needed impact strengthAchieving needed impact strength

Minimizing costs by reducing impact modifierMinimizing costs by reducing impact modifierusageusage

0.35 micron Tuffgard PCC is recommended0.35 micron Tuffgard PCC is recommended

Use torqueUse torque rheometerrheometer to ensure formula will run onto ensure formula will run on

processing equipment.processing equipment.

Control and record machine conditions for bestControl and record machine conditions for best

information and optimization.information and optimization.

Documents

PVC Window Profile