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violin: EXTRUSION and MOLDING /\edm<k am/ TECHNICAL DATA MARCH 1953 BAKELITE COMPANY A DIVISION OF UNION CARBIDE AND CARBON CORPORATION CONTENTS PAGE NO. Foreword ... ............................................................................ 4 Introduction .... ....................................................... 5 Formulation of Vinylite Plastic Extrusion and Molding Compounds 5 Resins ........................................................................................ ,. 5 Plasticizers....................... 5 Stabilizers ..... 6 Colorants ........................... 6 Lubricants 6 Fillers .......................................................................................... 6 Development Requests ......................... 6 Applications of Vinylite Plastic Extrusion and Molding Compounds Elastomeric Extrusion Compounds............. 7 S Elastomeric Molding Compounds ... 10 Rigid Extrusion and Molding Compounds 12 Some Special Properties of Vinylite Plastics 14 Extrusion and Molding Materials of Vinylite Plastics 15 Suggestions for the Design Engineer 16 Average Properties of Extrusion and Molding Compounds . vp Other Plastics for Extrusion and Molding 17 22 Tlie terms Bakelitl, Vinm.ite, ll.isitLWv, ;iiicl Hawks Stei.i.ite are registered ti.ide-m.uks of Union Carbide and Carbon Corporation. Cop\n^ht UViO and UH.j hv Union Carbide and Carbon Corporation 34450; TftADC'MA*K EXTRUSION AND MOLDING TECHNICAL DATA MARCH 1953 bakelite company A DIVISION OF UNION CARBIDE AND CARBON CORPORATION ms 30 East 42nd Street, New York 17, N. Y. ucc 04450 FOREWORD Bakelite Company, a Division of Union Carbide and Carbon Cor poration, is a supplier of a number of synthetic resins and plastics. These are available in a variety of forms and are suitable for use in a number of compounding, processing and fabricating techniques. Included in this group of synthetic materials are a number of important members: Vinyute Plastic flexible film and sheeting, rigid sheets, electrical insulating materials, extrusion and molding materials, and resins for calendering and the formulation of surface coatings; Bakelite phenolic resins and plastics for use as molding materials and for the formulation of coating, adhesive, impreg nating and sealing compositions; Bakelite styrene ^plastics for extrusion, molding, and surface coatings; and Bakelite polvethylene resins and plastics for molding, extrusion and surface coatings. The extrusion and molding of these important plastic materials has resulted in useful products that have been valuable assets to a number of industries. The information contained in this booklet should suggest many new applications and inquiries from all those interested in these materials are invited. "VINYLITE" BRAND RESINS AND PLASTICS Extrusion and Molding Materials The superior properties imparted to products made from Vinylite resins and plastics have been evidenced time and again -- as film and sheeting, electrical in* sulating materials, and as surface coatings. These same superior properties can be imparted to a wide variety of applications by use of molding and extrusion tech niques. They are tough, strong, light-in-weight, dura ble, and chemically inert. They can be compounded so that they are either rigid or as flexible as desired. The color range of these materials is virtually un limited. Extrusion and molding of Vinylite plastic com pounds are economical mass production methods by which outstanding articles have been created. The scope of the designer has been substantially broad ened. Manufacturers have been benefitted by the avail ability of unique materials from which his products can be made. The consumer has found a host of qual ity products that serve his needs better. Bakelite Company is a supplier of both Vinylite plastic compounds for use in molding and extrusion techniques and Vinyltte resins from which these com pounds may be formulated. In addition to the infor mation contained in this booklet, more specific tech nical data inav be obtained from anv one of the sales offices listed on the back cover. Formulation of "Vinylite" Plastic Extrusion and Molding Compounds The compounds used for the extrusion and molding of Vinylite plastics are scientific mixtures of several in gredients, each of which contributes valuable proper ties to the final product. These ingredients include the basic vinyl resin, plasticizer (if a flexible product is desired), stabilizers, lubricants, colorants, and fillers. The choice of any materials to be used is dependent on an analysis of properties which the final plastic product must possess. Resins Vinylite resins for use in extrusion ami molding com pounds are high molecular weight oiganic substances synthesized In reacting vinvl chloride, a gas, with itself or with vinyl acetate, a liquid, mi that the mole cules add together and form long chain compounds, which can be compared in structure to a string of paper clips. In appearance, after manufacture, the resins are fine, white powders, but after the application of heat, the resin particles fuse together. When the mass is cooled, a hard, rigid plastic results. This plastic will soften when heated above a definite temperature and thus allows its use in extrusion, molding, and cal endering operations. The properties of these resins can be modified by varying molecular weight or the ratio of vinyl chloride to vinyl acetate, and thus provide the formulator with a wide range of base resins for use in compounding. These Vinylite resins first became commercially available in 1934. Since then an intensive development program, which has involved thousands of chemical and processing experiments has been prosecuted to determine the resins and ingredients which are best suited for the various type compounds. From these many years of development have evolved the generalpurpose and specialty compounds which are available today. Formulating and processing data is available for those companies that wish to manufacture their own compounds from Vinylite Resins. Plasticizers Plasticizers are high boiling organic liquids or low melting solids which are added to the resins to make the final plastic compound flexible. Plasticizers accom plish this by separating the resin chains and reducing intermolecular forces, hence allowing the resin chains to move over each other more freely. No one plasticizer has been found suitable for all types of vinyl plastic applications. A number are very useful as general-purpose plasticizers and others are available for use in specialty type compounds. For example, compounds for use in garden hoses must exhibit good resistance to water and sunlight, and must possess a high strength at elevated temperatures with out being so stiff on a cool evening that the hose can not be coiled. On the other hand, the, flexibility, and hence the plasticizer requirements, of a compound for a deep freezer lid gasket are quite different. Here, the compound must possess good low temperature flexibil ity, good color, and must not mar paints and other plastic components. The only high temperature re quirement is that the 'compound must not exude plasti cizer if the gasket is stored at room temperature or higher. Similarly, a compound for use as distributor cap nipples will require outstanding electrical proper ties as contrasted with the mechanical and color needs of a compound for vacuum cleaner bumpers. Stabilizers Stabilizers are added to vinyl resins for the purpose of stabilizing against the degrading action of heat and light. Compounds which are to be used in exclusively exterior applications are stabilized more strongly than compounds intended for interior use. This fact should be taken into consideration when specifying compounds. Colorants Vinylite resins are essentially colorless and hence per mit the use of a wide variety of coloring agents. The principal limitations to the use of any colorant involve possible undesirable chemical interaction with the other ingredients in the plastic, or a tendency of the colorant to bleed in the presence of oils or liquids. The light stability of any colorant must also be considered when formulating compounds, especially for exterior use. The end-use and the exact color of the final com pound dictate the colorants to be used in its formula tion. Lubricants Lubricants are oils or waxes or other chemicals which are incorporated into plastics to prevent sticking dur ing hot compounding, molding, and extrusion opera tions. A lubricant does this by forming a thin film on the hot metal surfaces of the equipment. Lubricants are selected according to the type of fabrication method to be used. Fillers Economical mineral fillers are sometimes used to ex tend the resin. This is done only when the properties of unfilled Vinylite plastic compounds are much su perior to those actually needed bv an application. An excess of filler, however, results in drastic reduction of the outstanding properties available with unfilled formulations. Development Requests Occasionally a new application will arise which cannot use any of the many general-purpose and specialty type compounds av ailable. If the use of a plastic com pound in such an application appears reasonable, the laboratories of Bakelite Company will assist in develop ing a compound to meet the requirements of this appli cation. When a new compound is requested for a special application, the problem is assigned to a group of engineers and chemists in the various development laboratories. These engineers and chemists are experi enced in plastics and plastics processing and have at their disposal the latest of modern laboratory and in dustrial plastics equipment. In addition to their own extensive personal experiences, these engineers are assisted by the many thousands of chemical, mechani cal, weathering, and processing experiments which have been conducted in the past. "VINYLITE" PLASTIC ELASTOMERIC EXTRUSION COMPOUNDS A Resist Sunlight and Oxidation Carden hose extruded from Vinylite plastics resists the ac tion of sunlight, oxygen, water, oils, greases and other agents which rot most hoses. These plastic hoses are lightweight and strong; and they possess high scuff resistance and excellent color stability. Vinylite plastics are used both as the sole ma terial in hoses or as a jacket over cotton-braided, rubber core hoses. Both types are products that sell -- because they utilize the colors and long life of prop erly formulated plastic com pounds. Outstanding Electrical Properties Vinylite plastics are outstanding for insulating and jacketing wires and cables. The electric plug and the wire are insulated with Vinylite plastics, each compound being formulated to fulfill its specific role. ucc 044508 8 Good gloss, smart colors Flexible costume belting and straps extruded from Vinylite plastics are glossy, smart appearing, and colorful. Such belting is often embossed or printed to produce a wide variety of styles and designs. Resist Abrasion and Scuffing Treads for ladders used in sleeping cars resist abrasion, scuffing, and exhibit excellent non-skid characteristics. Well designed, the tread is easily extruded and fits snugly to the steps to give a durable, low cost step-ensemble. Tough and durable gaskets, welting and other complex shapes also are produced easilv from Vinylite plastics. Chemically Inert Intravenous tubing for use in blood transfusions is ex truded from Vinylite plastics. The chemical inertness, the flexibility, and the ease of handling of this tubing demon strate the outstanding properties available in Vinylite plastics. . ' nxr- - ' j '' * !'**&***-] "VINYLITE" PLASTIC ELASTOMERIC MOLDING COMPOUNDS Pleasing Appearance and Smart Colon Vacuum cleaner bumper* molded from Vinylite plastics are tough, resilient, economical to mold, and have a smart, pleasing appearance. Stock, made-to-order, or special color matched compounds assure colors that match, complement, or contrast with the colors of the other parts of the cleaner. Low Temperature Flexibility This gasket for an ice cream freezer lid is manufactured from a compound formulated to be flexible at room tem peratures and at temperatures below freezing. In addition to life-long low temperature flexibility, the gasket has a clean, glossv color and resists the action of food fats and greases. Resist Ozone Electric spai ks such as are encountered in automobile igni tion distributors convert oxygen into highly destructive ozone. Tests which invohed exposure to concentrated ozone at room temperature tor over six hours have shown that distributor cap nipples molded from Vinylite plastics (at extreme left in photograph) are unaffected bv ozone. Natural and synthetic rubber nipples failed in the same test. Easv to mold, the plastic nipples stay soft and flcxil^k for the life of the automobile. ' Wide Range of Colors Handle bar grips cxemplifv some ol the smart colors which make a selling product. Because the colorants arc properly selected, the colors will not bleed out or rub off onto a person's hands as was the case with lormer materials. % Soft and Pliable--or Hard and Stiff A wide range of flexibility is available when Vinylite plastics are specified. The hair curlers shown exemplify a soft, pliable compound. These curlers, molded in one piece to save assembling costs, are so soft and flexible that they can be worn even while sleeping. They are permanently flexible and are unaffected bv hair dressings, soap, and water. Resist Scuffing and Abrasion Tough Vinyute plastics protect smart lug gage from scuffs and kicks. Such edging is not only attractive but can be wiped clean with a damp cloth. And despite the large mold draft of this item, fill-out problems were reduced to a minimum with the use of olite plastics. Low Cost Babies' shoe lifts injection molded in one piece from Vinylite plastics serve for either shoe and require no assembly operations. Faster cycles, fewer rejections, no assembly problems, and a durable plastic create an efficient, low cost article. 144511 Vixylite rigid plastics resist the action of most chemicals. They exhibit excellent resistance to mineral acids, dilute or concentrated, to sodium and potassium hydroxide, to Hydrogen peroxide, chlorine water, tincture of iodine, and other corrosive chemicals. They exhibit good resistance to alcohols, oils, fats, and waxes. The photograph shows a solvent resistant cologne flask cap molded from Vinylite rigid plastics. However Vinylite plastics are soluble in ketones, such as acetone, methyl ethyl ketone, and cyclohexanone: and they dissolve or swell in organic acids, esters,, or others, de pending upon the specific organic fluid. This highly selec tive resistance to solvents imparts good chemical resistance to articles made from these plastics, yet allows the use of solvents and solvent-base adhesives when joining and welding plastic items into complex shapes. Long Lasting Monofilaments extruded from Vinylite rigid plastics for brooms and brushes are tough, long-lasting, resilient and easy to clean. They weigh one-third less than older mate rials and make a light-weight, cuss-to-usc broom or brush. Attractive Colors Stripping for finishing linoleum edges makes a colorful and attractsc aiticle when extruded horn \ iwlite rigid plas tics. The stripping has to be tough and scuff and kick re sistant to perform well in such tut application. 12 Records molded from Vinylite plastics reproduce all the notes -- lugh or low -- with supreme clarity and absence of needle scratch noises. They are virtually non*breakable and non-warping. These records, molded from compounds specially designed for phonograph records, have been tested for hours and hours in the laboratory and after even hundreds of playings their surface noise is less than that of many unplaved records produced from older materials. Excellent Dimensional Stability and Low Mold Shrinkage For molding to close tolerances and for fabricating articles where an inch must remain an inch, Vinylite rigid mold ing compounds are outstanding. The linear coefficient of thermal expansion in inches per degree Centigrade is 0.000069 and the mold shrinkage is 0.1 per cent, the low est mold shrinkage of any commercial plastic. Vinylite rigid plastics were chosen for the dispenser unit shown in the photograph because of their excellent dimensional stability, their low mold shrinkage, their chem ical resistance, and their ability to mold to a beautiful finish. 13 SOME SPECIAL PROPERTIES OF "VINYLITE" PLASTICS : The general properties of Vinylite plastics which are available by means of correct and scientific formula tion have been described on previous pages, and spe cific values of the properties of many popular Vinylite plastic compounds are also reported on pages 17-20. A few special properties which require further discussion and the general limitations of Vinylite plastic com pounds are discussed on this page. Toxicity While unmodified Vinylite resins are of a very low order of toxicity, the toxicity of extrusion and molding compounds may be affected by the plasticizers, sta bilizers, and other materials used. Suitable compounds must be selected by the fabricator for his own applica tions, Inquiry should be made in doubtful cases. Water Absorption Articles fabricated from Vinylite rigid plastics have been immersed in warm water for a period of two years with water absorption in percent by weight being only 0.155. The absorption of water by plasti cized compounds is slightly higher, but in general the resistance to absorption is considered excellent. Aver age values of water absorbed bv standard elastomeric compounds range from 0.06 to 0.305. Values of soluble matter lost range from 0.05 to 0.305 (A.S.T.M. Test D 570-42). Flame Resistance Vinylite plastics are classified as slow-burning or selfextinguishing materials. They will burn when exposed to a direct open flame though they exhibit marked resistance to burning and upon removal from the flame the burning decreases to a very low rate or ceases entirely, depending upon the particular compound. Rigid compounds are self-extinguishing, while the flammabilitv for standard elastomeric compounds is only 0.25 -- 0.35 sq. in. per sec. for .020" samples (ASTM Test D-56S-43). Plasticized compounds can be formulated to be self-extinguishing. Weathering When desired, compounds with substantially increased resistance to sunlight can be formulated. High Temperatures^ Vinylite plastics are thermoplastic or heat softening by nature, and hence they are not recommended for applications where excessive or prolonged high tem peratures are encountered. In general, molding and extrusion compounds are suitable at temperatures up to 60 ck-g. C (140 deg. F), However, fur some special applications, compounds are available for use at tem peratures approaching 100 deg. C (212 deg. F). Plasticizer Migration Many plasticizers which possess most of the desired propel ties, exhibit migration, i.e., the plasticizer will migrate slowly into adjoining materials such as poly ethylene. polystyrene, and varnishes to their detriment. However, because some compounds possess consider ably lower plasticizer migration than others, careful selection of the compound for a given application will generally avoid difficulties with plasticizer migration effects. EXTRUSION AND MOLDING MATERIALS ws" OF "VINYLITE" PLASTICS .&*4. *- ' v ' 1 Stock and Made-to-Order Compounds Over two hundred stock and made*to-order Vinylite Plastic Compounds are avail able from Bakelite Company for extrusion and molding. These materials offer a wide range of physical properties and colors for vour selection. A Bakelite Tech nical Representative can furnish technical information pertinent to these com pounds and can help select the proper compound for any application. Resins For those companies that wish to formulate their own plastic compounds, four resins -- Vinylite Resins VYNW, VYNS, VYHH and QYNA -- which vary in molecular weight and chloride-acetate ratio -- are available. A Bakelite Tech nical Representative can recommend a resin or resin mixtures and formulas for evaluation in the equipment available and for the applications intended. Extruded items Bakelite Company does not offer items extruded from Vinylite Plastics. However, an up-to-date list of extruders of Vinylite Plastics and information concerning suppliers of certain size or shaped articles or type of custom work are available upon request. Molded Items Bakelite Company does not offer items molded from Vinylite Plastics. However, an up-to-date list of molders of Vinylite Plastics and information concerning suppliers of certain size or shaped articles or type of custom work are available upon request. Technical Assistance The Technical Representatives of Bakelite Companv are available to assist hi choosing the correct material, in eliminating molding and extrusion difficulties, or in obtaining technical information pertinent to plastic products. Application Pump Sprayer for Bottles Refrigerator Ports: door bumpers shelf support grommets container cover bumpers tank banger hole plugs evaporator compartment door bumper drip tray gaskets breaker strips Shoe Lifts Stair Treads Tires for Toys Typewriter type bar rests Vacuum Cleaner Parts: brush cups brush nozzles adapters handies bumpers foot pedals Upholstery Welting Flexible or Jtigad R R R F F F F F F R R R F F F F F F F F F F Extrusion or Molding M M X M M M M M M X M M X M X M M M M X M X Appooronco translucent translucent opaque opaque opaque opaque opaque opaque opaque opaque opaque opaque opaque opaque opaque opaque opaque opaque opaque opaque opaque opaque Compound Nvndm VG-3624 Colors VG-3623 Colors VG-5885 Colors VG-9960 Colors VG-9960 Colors VG-9960 Colors VG-9960 Colors VG-9960 Colors VG-9960 Colors VG-5385 Colors VG-9980 Brown 08 VG-9930 Colors VG-5980 Colors VG-7734 Colors VG-7770 Black 02 VG-9970 Colors VG-9160 Colors VG-9970 Colors VG-9970 Colors VG-5980 Colors VG-9160 Colors VG-9930 Colors TM*1TT > -. . __ iv 1si "VINYUTE" RESINS FOR EXTRUSION AND MOLDING COMPOUNDS AVERAGE PROPERTIES 1S5IN DESIGNATION VYHH VYNS VYNW Appearance Powdered White Solid Powdered White Solid Powdered White Solid Odor All resins are substantially odorless. Approximate Composition-- Vinyl Chloride--weight, % Vinyl Acetone --weight, % 85.0-88.0 12.0-15.0 88.5-91.5 8.5-11.5 96.0-97.0 3.0-4.0 Specific Gravity Specific Viscosity* 1.36 1.36 1.39 1 0.536-0.567 0.875-0.925 -- 2-- -- 0.21 min. Screen Analysis-- Minimum % through U.S.B.S. Screen No. 20 40 80 98 -- -- 98 99.5 ---. 99.0 -- 50.0 Heating Lacs, Maximum, % 2.0 1.0 1.0 Type of Use: Sole resin or in resin mixtures for rigid compounds. In resin mixtures for Sole resin or in rigid and elasto- resin mixtures for meric compounds. rigid and elasto- meric compounds. *1. 1.00 gm. resin per 100 cc. of solution in methyl isobutyl ketone ot 20 deg. C. 2. 0.2 gm. resin per 100 cc. of nitrobenzene at 20 deg. C, QYNA Powdered White Solid 100 -- 1.40 -- 0.190-0.210 -- -- -- -- Sole resin or in resin mixtures for elastomeric compounds. 17 9 ` 'Thi-r- i m- BAKELITE COMPANY A DIVISION OF UNION CARBIDE AND CARBON CORPORATION 203 SALES OFFICES Boston 16, Mass...................... 930 Statler Office Bldg. Chicago 1, III...................... 230 No. Michigan Avenue Cincinnati, Ohio............................ 2506 May Street Cleveland 15, Ohio...................... 1501 Euclid Avenue Clifton, N. J............................1051 Bloomfield Avenue Detroit 2, Mich................................. 6560 Cass Avenue Hartford 3, Conn............................410 Asylum Street Los Angeles 58, Calif...................... 2770 LeOnis Blvd. New York 17, N. Y...................... 30 East 42nd Street Philadelphia 3, Pa...................... 117 South 17th Street Pittsburgh 19, Pa................................. 311 Ross Street Rochester, N. Y................................. 82 St. Paul Street St. Louis 22, Mo...................... 122 No. Kirkwood Road San Francisco 6, Calif...................... 22 Battery Street -T Jit..., J-47S-9 M-2 044517 Printed irt U.5.A.