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Kaneka North America LLC High Performance Polymer Div.

High Performance Processing Aid Designed for PVC Foam

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Profile of Kaneka and KaneAce products

Application and process of PVC foam

Suitable processing aid for PVC foam

Formulation know how for better foam product

Kaneka lab capability

Content

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Kane Ace Products Line Up Description Application

Kane Ace® PA Acrylic processing aid

Rheology modifier for thermoplastics, PVC foam

Kane Ace® B

Kane Ace® FM

Kane Ace® M

Kane Ace® MR

Core/Shell rubber type impact modifier B : MBS type FM : Acrylic type M : BD / Acrylic MR : Silicone type

Impact modifier for thermoplastics

Impact modifier for window profile and siding

Impact modifier for engineering plastics

Flame retardant impact modifier

Kane Ace® A-15X SAN copolymer Heat distortion modifier for thermoplastics

Kane Ace® MP-90 Cross-linked acrylic core/shell type

De-glossing/light diffusing agent for plastics

Good balance with impact

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Types of PVC foam products

⇒ Profile

⇒ Board

⇒ Pipe

- Interior decoration - Siding

- Trim board - Decking

-Drain pipe -Exhaust pipe

PVC Foam Application

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Profile, pipe and board

Trim board

Three layer foam-core pipe

Decking board

PVC Foam Application

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Free foam process - Expand freely on exiting the die - Low set up cost - Mainly for board Celuka foam process - Die with an internal mandrel - Harder and smoother skin - Excellent product outlook - Mainly for profile and board

Inward Foaming

Outward Foaming

PVC Foam Process

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Processing Aid (KaneAce® PA) and Typical Application

Molecular weight (specific viscosity) of processing aid

0.1 1 2 3 4 5 6

Calendering

Low MW type

Foam Extrusion

High MW type

Extrusion

Standard MW type

Blow Molding

Calendering

Injection Molding

Plasticized PVC Compounding Calendering etc.

Ultra-high MW

Foam Extrusion

Calendering

Lubricant type

Extrusion

Extrusion

PA40 PA70, PA-75, PA-90

PA20

PA20

PA121

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Suitable Processing Aid for PVC Foam

Study to reduce density of PVC foam maintaining good foam cell morphology

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What does happen during PVC foam extrusion?

Zone 1 (Barrel)

Zone 2 (Die)

Zone 3 (Die exit)

PVC resin and additives Chemical blowing agent

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What does happen during PVC Foam Extrusion?

Zone 1 (Barrel)

PVC fusion ⇒ Homogenization

PVC powder

Gas generation ⇒ Holding the gas in PVC melt

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What does happen during PVC foam extrusion?

Zone 2 (Die)

Pressure release

Zone 3 (Die exit)

Cell growth Cell maintenance

Cell nucleation

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Minimum Density as Index of Foam-ability

0.3

0.5

0.7

0.9

1.1

1.3

0.0 0.5 1.0 1.5 2.0 2.5

Blowing Agent / phr

De

nsi

ty /

g/c

m3

d Min

Foam-ability

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0.20.30.40.50.60.70.80.9

1.0E+04 1.0E+05 1.0E+06

Viscosity (poise)

0.20.30.40.50.60.70.80.9

1.1 1.3 1.5 1.7

Die Swell (D/D0)

Min

.De

nsi

ty/

g/c

m3

0.20.30.40.50.60.70.80.9

6 8 10 12

Melt Tension (g)

Min

.De

nsi

ty/

g/c

m3

0.20.30.40.50.60.70.80.9

5 10 15 20 25

Elongation (m/min)

There is strong correlation between Die Swell and foam-ability

Correlation of Melt Properties on Foam-ability

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Molecular Weight Contribution on Foam-ability

0

0.2

0.4

0.6

0.8

1

1.2

0 1 2 3 4

De

nsi

ty [

g/c

m3]

Blowing Agent [phr]

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

1.1 1.2 1.3 1.4 1.5 1.6

Die Swell (D/D0)

1 x 106

2 x 106

4 x 106

5 x 106

Mw PA dosage: 8phr

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Improvement of Foam-ability by High Mw Processing Aid

Growth Rupture

Low Die Swell

High Die Swell

Shrink

Retain

Lower MW

Higher MW

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PA’s Effect on Foam-ability Improvement Foam-ability

(Density)

Cell stability (especially after cell collapse)

Die Swell (Melt elasticity)

Molecular chain entanglement between PVC and PA

Molecular weight of PA

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Kane Ace® PA Grades for PVC Foam

- PVC foam extrusion - Better foam ability

4.0 PA70 Ultra high MW type

- PVC foam extrusion - Rigid PVC extrusion - Plasticized PVC

3.6 PA40 High MW type

- PVC foam extrusion

- Better foam ability 5.1

PA-75

PA-90 Ultra high MW type

Application and Feature Specific

Viscosity PA Grades

*)Specific viscosity is measured by in 0.4% toluene solution at 30oC (ASTM D1646)

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Effect of Molecular Weight on Foam-ability

KaneAce PA PA40 PA70 PA-75

Specific viscosity* 3.6 4.0 5.1

Die swell [-] 1.58 1.72 1.86

Density [g/cm3] 0.57 0.54 0.51

Cell structure

*)Specific viscosity is measured by in 0.4% toluene solution at 30oC (ASTM D1646)

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Improvement of Physical Property of PVC Foam

< <

CaCO3

granular Talc Mica

Controlling the modulus of PVC

-Cell size : Combination use of blowing agents (ADCA and SBC)

-Kind of Fillers -Dosage of Fillers

Cell size

Mo

du

lus

Aspect ratio, dosage

Mo

du

lus

higher aspect ratio

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Effect of Blowing Agents on Cell Structure Blowing agent ADCA* SBC**

Generated gas (major) N2 CO2

Solubility constant

[cm3(gas)/cm3(PVC).Pa] 0.23 x 10-6 4.7 x 10-6

Swelling behavior

at die exit

Foamed cell structure at

same density (0.3g/cm3)

Minimum density [g/cm3] 0.3 0.18

*)ADCA stands for azodicarbonamide, **)SBC stands for sodium bicarbonate

0

0.2

0.4

0.6

0.8

0 1 2 3 4 5 6

ADCA

SBC

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Effect of Blend Ratio of Blowing Agents on Foam-ability and Cell Structure

SBC* [phr] 0.6 0.5 0.4 0.3

ADCA** [phr] 0 0.1 0.2 0.3

Density [g/cm3] 0.54 0.54 0.55 0.56

Foamed cell structure

*)SBC stands for sodium bicarbonate, **)ADCA stands for azodicarbonamide

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Effect of Blowing Agent and Inorganic on Mechanical Properties and Heat Resistance

Blowing agent

(dosage [phr])

SBC

(1.0)

SBC

(1.0)

SBC

(1.0)

SBC

(1.0)

SBC/ADCA

(0.9/0.1)

SBC

(0.6)

Inorganic

(dosage [phr])

CaCO3

(10)

Talc

(10)

Talc

(15)

Mica

(10)

CaCO3

(10)

CaCO3

(10)

Density [g/cm3] 0.4 0.4 0.40 0.41 0.41 0.56

Compression

strength [Pa] 2.6 2.9 3.3 3.4 3.6 4.2

Heat distortion

temperature [oC] 50 53 54 58 59 64

Combination use with KaneAce® FM should improve the impact strength of the PVC foam Combination use with KaneAce® A15X should improve the HDT of PVC foam

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High Mw processing aid and formulation know-how

realize very unique materials

Low weight

Low volume cost

Excellent surface finish

Good mechanical and thermal properties

“Wood-like” characteristics (milling, drilling, nailing,...)

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Foam Sheet Extrusion Line

Twin screw extruder Krauss-Maffei KMD 2-50 K (output: 50-100 kg/hr)

Sheet die: 325 mm Finished sheet : 350 mm x 7-13 mm

(Kaneka Belgium NV)

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Foam Profile Extrusion Line

Calibrator Die Cooling

Calibrator Die

Application

Foam sheets

Foam profiles

Process

Free foaming

Celuka

Lab equipment

Foam sheet line

Foam profile line

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Lab Scale Extruders

Single screw extruder (Brabender) Diameter=0.75”, L/D=20/1, C/R=2.5, Output: 3-5 kg/hr

Parallel twin screw extruder (Leistritz) Diameter=18mm, Output: 3-5 kg/hr

(Kaneka North America LLC)

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Physical and Analytical Lab Capability

Viscometer

Mechanical properties

Densimeter Microscopy (cell structure)

Capillary rheometer

Heat distortion temperature Impact tester

(Kaneka North America LLC)

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Thank You!