www.borea|isgroup.com I www.borouge.com
`
`Dap|oyT"" HMS Polypropylene
`
`for Foam Extrusion
`
`PAGE 1 OF 20
`
`PAGE 1 OF 20
`
`9
`Borouge
`E BOREALIS
`SHAPING the FUTURE with PLASTICS
`BERRY 2001
`BERRY 2001
`BOREALIS v. BERRY
`BOREALIS v. BERRY
`IPR2016-00235
`IPR2016-00235
`
`

`
`www.borea|isgroup.com www.borouge.com
`
`About Borealis and Borouge
`
`Borealis and Borouge is a leading provider of chemical and innovative plastics solutions that create
`
`value for society. With sales of EUR 4.7 billion in 2009, customers in over 120 countries, and
`
`5,200 employees worldwide, Borealis is owned 64 % by the International Petroleum Investment
`
`Company (IPIC) of Abu Dhabi and 36 % by OMV, the leading energy group in the European growth
`
`belt. Borealis is headquartered in Vienna, Austria, and has production locations,innovation centers
`
`and customer service centers across Europe and the Americas. Through Borouge, a joint venture
`
`between Borealis and the Abu Dhabi National Oil Company (ADNOC), one of the world's major oil
`
`companies, the company's footprint reaches out to the Middle East, Asia Pacific, the Indian sub-
`continent and Africa.
`
`Established in 1998, Borouge employs approximately 1,400 people, has customers in more than
`
`50 countries and its headquarters are in Abu Dhabi in the UAE and Singapore.Building on the
`
`unique Borstar® technology and their experience in polyolefins for more than 50 years, Borealis and
`
`Borouge provide innovative, value creating plastics solutions for the infrastructure (pipe systems
`
`and power and communication cables), automotive and advanced packaging markets. In addition,
`
`Borealis offers a wide range of base chemicals from melamine and plant nutrients to phenol and
`acetone.
`
`Today Borealis and Borouge manufacture over 4 million tonnes of polyolefins (polyethylene and
`
`polypropylene) per year. Borouge is currently tripling its polyolefins manufacturing capacity to 2
`
`million tonnes per year (t/y) by mid—201 O and an additional 2.5 million t/y is scheduled for 2013. The
`
`companies continue to invest to ensure that their customers throughout the value chain, across the
`
`globe, can always rely on product quality, consistency and security of supply. Borouge and Borealis
`
`are committed to the principles of Responsible Care® and proactively contribute to addressing the
`
`world's water and sanitation challenges through their Water for the WorldT"" initiative.
`
`For more information:
`
`www.borea|isgroup.com
`
`www.borouge.com
`
`PAGE 2 OF 20
`
`PAGE 2 OF 20
`
`

`
`
`
`Contents
`
`02
`
`04
`
`O5
`
`08
`
`09
`
`12
`
`13
`
`15
`
`Polypropylene foam
`
`Daploym HMS—PP
`
`Foam extrusion process
`
`Daploy HMS—PP blends and foamability
`
`Providing PP foam solutions
`
`Basic material data for
`
`the homopolypropylene HMS - grades
`
`Basic material data for
`
`the random copolymer HMS - grades
`
`Processing guidelines for PP homopolymer
`
`and random copolymer HMS - grades
`
`
`
`PAGE 3 OF 20
`
`PAGE 3 OF 20
`
`

`
`
`
`02 Daploy HMS Polypropylene for Foam Extrusion
`
`Polypropylene foam
`
`Polymeric foams consume around 3.5 million tonnes of plastics materials
`
`annually and account for about 10 % of all polymer usage in Europe. Foamed
`
`polymers are used in a wide number of application areas, which range from
`
`construction, automotive and household products to food and protective
`
`packaging. Among the many benefits of foamed materials are their good
`
`mechanical rigidity at low specific gravity, thermal and acoustic insulation,
`
`cushioning against mechanical shock and a significant contribution to source
`
`reduction in raw material usage.
`
`The foam market is dominated by the amorphous polymers (such as PS, PU
`
`and PVC) which have been industrially foamed for more than 50 years.
`
`Polypropylene (PP) foams are a relative late comer to this market. The reasons
`
`for this lie in the molecular structure — standard PP’s are semi—crysta|line
`
`materials with a linear molecular structure. They lack the required extensional
`
`rheological properties in the melt phase which are required for the production
`
`of extruded low density foams with a fine and controlled cell structure. This
`
`limitation is resolved by the Borealis Daploy range of High Melt Strength (HMS)
`
`PP products. These are long chain branched materials, which combine both
`
`high melt strength and extensibility in the melt phase. They open up the
`
`possibility of bringing the numerous wel|—known property benefits of PP
`
`into the world of low density polymeric foams. These benefits include a wide
`
`mechanical property range, high heat stability, good chemical resistance.
`
`PP foams offer significant benefits versus other polymeric foam solutions in
`
`terms and sustainability:
`
`I
`
`0
`
`-
`
`0
`
`leight weight
`
`easy recycling
`
`no "monomer issues"
`
`single material solutions based on PP possibile
`
`From a fairly recent and small beginning, the global PP foam market is still
`
`growing.
`
`PAGE 4 OF 20
`
`PAGE 4 OF 20
`
`

`
`
`
`03
`
`In the case of food packaging, PP foam offers a lightweight packaging
`
`solution with excellent grease/fat resistance (no stress cracking) and with
`
`no issues related to its monomer. Its high heat stability means products
`
`are microwaveable, with good thermal insulation giving them a ‘cool touch’
`
`during use.
`
`Automotive
`
`40-150 kg/m3
`Door liners
`Engine shields
`Roof/trunk liners
`Impact protection
`
`Insulation
`
`60-200 kg/m3
`
`70-200 kg/m3
`
`Food / Consumer packaging
`
`200-600 kg/m1
`Food trays
`Fruit trays
`Tableware
`Cap liners
`
`PP foam
`applications
`
`Protective packaging
`
`Figure 1: Some current applications
`for extruded PP foams
`
`In automotive applications, lightweight foam solutions are helping to improve
`
`vehicle performance and fuel efficiency. With increasing pressure for
`
`end—of-life vehicle recycling, mono—materia| solutions are being sought and,
`
`with PP becoming a preferred polymer, recyclable foamed PP solutions are a
`
`logical next step. PP foams have an excellent moisture barrier and chemical
`
`resistance which are important for durability and functionality in the presence
`
`of hot oil, grease or fuel. Its high heat stability also opens the possibility for
`
`under the bonnet applications. PP foams also have very good cushioning
`
`properties, thereby contributing to improved driver and passenger safety.
`
`As a leading PP supplier, Borealis is committed to support the further
`
`development of the extruded PP foam market through its Daploy HMS PP
`
`products and by offering PP foam solutions.
`
`PAGE 5 OF 20
`
`PAGE 5 OF 20
`
`

`
`
`
`04 Daploy HMS Polypropylene for Foam Extrusion
`
`Daploy HMS-PP
`
`
`
`The basic extensional rheological properties of the long branched Daploy
`
`HMS-PP products are shown in figure 2, in comparison to those of standard
`
`linear PP's. The window in the high melt strength and extensibility area of this
`
`graph defines the requirements for a high performance foaming grade. With
`
`such long chain branched polymers, it is possible to produce very low density
`
`(20 — 50 kg/m3) extruded PP foams which possess a fine and controlled closed
`
`cell structure. This is not possible with standard linear PP's or modified
`
`materials which fall outside the critical high performance foaming window.
`
`Melt strengfh
`
`
`
`Force(cN)
`
`Draw—down velocity (mm/s)
`
`High performance
`foaming window
`
`_ _ _ Daploy} ______ _ _
`WB140HMSI
`I
`Extensibility
`
`150
`
`Daploy HMS-PP products can be blended with the full range of standard PP
`
`extrusion grades and other polyolefinic products. This offers the opportunity
`
`to widely tailor the foam properties to meet the particular demands of the
`
`end—use application. Furthermore, Daploy HMS-PP products are specifically
`
`designed to be suitable for processing on most types of existing industrial
`
`foaming equipment.
`
`Daploy HMS-PP products and their blends are not crosslinked. This means
`
`that extruded PP foams produced from them are fully recyclable, an
`
`increasingly important environmental demand within the polymer industry.
`
`Figure 2: Extensional rheology curves
`for linear PP's and Daploy HMS
`
`PAGE 6 OF 20
`
`PAGE6OF20
`
`

`
`
`
`05
`
`Foam extrusion process
`
`The first steps in the foaming process (polymer feeding and melting) are
`
`common to all extrusion processes. However, three later stages are specific
`
`and critical to the process, as illustrated in figure 3.
`
`These three specific steps in the foam extrusion process comprise of
`
`(a) dissolving of a blowing agent gas in the polymer melt
`(b) cell nucleation
`
`(0) cell growth and stabilisation
`
`In order to perform these additional steps, foaming extruders are longer
`
`than standard types, typically with an overall L/D ratio>40, in either a single
`
`or tandem extruder configuration.
`
`High pressure gas
`
`Extruder
`
`Mixing
`
`Po|ymer—gas
`solution
`
`Feeding
`
`and stabilisation
`
`nucleation
`
`Cell growth
`
`Figure 3: Schematic illustration of processing
`steps in foam extrusion —
`direct gas injection/annular die
`
`Polymer-gas solution
`
`A blowing agent is introduced into the polymer melt either by direct gas
`
`injection (physical foaming) or by decomposition of an added chemical
`
`blowing agent (chemical foaming). In both cases, a key requirement for a
`
`uniform and controlled cell structure is a homogenous polymer-gas solution.
`
`This is controlled by two factors: the solubility of the blowing agent gas in the
`
`polymer and the sorption kinetics. The solubility itself is not the limiting factor
`
`Figure 4: Solubility of commonly
`used blowing agents in PP
`
`for foaming when using the more common industrial
`
`foaming agents: butane and carbon dioxide. With the gas
`
`concentrations typically used in foam extrusion, these
`
`can be quantitatively dissolved with standard extrusion
`
`pressures up to 10 MPa (100 bar). Figure 4 shows the
`
`equilibrium solubility curves for the commonly used
`
`blowing agent gases in PP.
`
`The achievement of equilibrium solubility is determined by
`
`the sorption kinetics and this is therefore a time dependent
`
`process. This process can be accelerated by raising the
`
`melt temperature and using screw designs which promote
`
`good mixing of the polymer melt and injected gas.
`
`PAGE 7 OF 20
`
`PAGE 7 OF 20
`
`
`
`
`
`Gassolubility(wt%)
`
`Pressure (MPa)
`
`

`
`
`
`06 Daploy HMS Polypropylene for Foam Extrusion
`
`
`
`Cell nucleation
`
`Control of cell nucleation is crucial to obtaining the desired fine and uniform
`
`cell structure of the final foam. It is a complex area with several, often
`
`interrelated, factors playing a role. The three main factors which influence
`
`the cell nucleation are the pressure drop in the die, the concentration of the
`
`blowing agent and the concentration of the external cell nucleating agent.
`
`The rate of pressure drop at the die is determined by the die geometry.
`
`Higher rates of pressure drop at the die significantly increase the cell density,
`
`irrespective of the concentration of blowing agent gas or external nucleator.
`
`High shear rates are also believed to play a role in promoting cell nucleation.
`
`The content of the blowing agent, as well as the one of the nucleating agent,
`
`has a direct impact on the cell density. Figure 5 shows an example of the
`
`influence of these two factors on cell density in the case of PP foamed with
`butane and talc as the nucleator.
`
`I
`I
`Source: Univ.Toronto — Prof. Park
`Die geometry: I = 0.3',' d = 0.018"
`Die temperature = 140°C
`
`'77
`
`
`
`E3>
`
`-3:V)::1:‘D
`7)Q._
`no.4:
`EZ
`Z
`
`Figure 5: The effects on cell density of blowing
`agent and nucleating agent concentrations
`
`PAGE 8 OF 20
`
`PAGE 8 OF 20
`
`

`
`
`
`07
`
`
`
`Cell growth and stabilisation
`
`Melt temperature is one of the most important process parameters in foam
`
`extrusion. In the case of PP foam, depending on the type and concentration
`
`of the foaming agent used, the optimum in melt temperature may vary from
`
`approximately 130°C to 180°C.
`
`When the melt temperature is too low, foaming is limited because the
`
`material solidifies before the cells have the possibility to expand fully. When
`
`the temperature is too high, the foam first expands, then collapses again due
`
`to lack of stabilisation of the structure. There is an optimum melt temperature
`
`window for foaming in which lowest densities are achieved; this temperature
`
`is lower than the standard PP melt temperatures (21 0°C to 240°C) — See also
`
`picture 6. The latter part of the foam extruder is dedicated to the melt cooling
`
`and intimate mixing of the polymer—gas system.
`
`It is during this part of the process that the Daploy HMS—PP plays its crucial
`
`role. Its high melt strength and extensibility help to control cell growth. By
`
`a ‘strain hardening’ mechanism it prevents rupture of the cell walls and
`
`coalescence, which would otherwise lead to a polymer containing a few
`
`rather large holes in it — far from the desired fine and closed cell structure.
`
`The foam is finally stabilised by a cooling stage before winding. This is
`
`either by means of a calibrating mandrel in the case of an annular die or by
`a conventional roll stack when a flat die is used.
`
`MeltTemperature (°C)
`
`‘I40
`
`160
`
`Figure 6: Temperature balance between unsufficient cell growth and collapsing cells.
`
`PAGE 9 OF 20
`
`PAGE 9 OF 20
`
`I
`I
`I
`I Foam Collapse
`‘Cell coalescence:
`
`Crysta lisation 4- —>
`
`as Loss
`
`0'4:m
`.9Inx:mD.XLI.I
`
`I:
`
`

`
`
`
`08 Daploy HMS Polypropylene for Foam Extrusion
`
`
`
`Daploy HMS-PP blends and foamability
`
`In order to modify the final foam properties, Daploy HMS—PP's can be blended
`
`with standard extrusion grade PP’s, as will be described in more detail in the
`next section.
`
`However, an important consideration is the foamability of such blends. When
`
`a long chain branched PP is mixed with a standard PP, it is evident that this
`
`will have a ‘diluting’ effect on the melt strength and extensibility of the blend
`
`compared with that of the pure HMS-PP. This effect is shown in figure 7.
`
`It can be seen, however, that quite high levels (approx. 60 %) of blend partner
`
`can be added before the extensional rheological properties of the blend begin
`
`to fall outside the critical high performance foaming window.
`
`This is further verified in figure 8, where the minimum achievable foam
`
`density is shown as a function of the HMS-PP content in the blend. A wide
`
`range of blend compositions can be used in order to reach low density
`
`(<100 kg/m3) PP foams or in order to adjust the extruded foam properties for
`
`the end application
`
`r
`r
`Daploy WB140HMS +
`block copolymer
`
`High performance
`foaming window
`
`2303Cl)
`2OLl.
`
`
`
`Density(kg/m3) N(A)OOOO
`
`Dap|oyWB140HMS (wt %)
`
`150
`100
`200
`Draw down velocity (mm/s)
`
`250
`
`I
`-5 wt % butane
`-10 wt % butane II
`25
`
`50
`
`75
`
`Figure 7: Extensinnal rheology curves
`for HMS-PPlb|ock copolymer blends
`
`Figure 8: Minimum achievable foam density
`as a function of Daploy HMS-PP content of
`the blend
`
`PAGE 10 OF 20
`
`PAGE 10 OF 20
`
`

`
`
`
`09
`
`Providing PP foam solutions
`
`The modification of foam properties is a crucial requirement in order to be able
`
`to produce PP foams with properties that meet the technical performance
`
`demands of particular end—use applications.
`
`The homopolymer based HMS-PP's can be used pure or in blends with
`
`standard homopolymers, providing foams with high stiffness and heat
`
`stability. Enhancements in impact strength and toughness of the foam
`
`can be achieved by using random or heterophasic (block) copolymers as
`
`blend partners. In the case of random copolymers, impact performance
`
`is improved at temperatures above approximately 0°C. If good impact
`
`performance is required at low temperatures (< 0°C), heterophasic
`
`copolymers should be used.
`
`Further interesting property modifications can be made available by using
`
`Borealis BorsoftT"" random heterophasic copolymers as blend partners. These
`
`are soft PP's (tensile modulus ~4OO MPa). The blend with these products
`
`provides the opportunity to produce soft PP foams with good impact strength
`
`and toughness at low temperatures. Even softer foams can be obtained
`
`by blending Daploy HMS—PP's with various polymeric materials such as
`
`metallocene LLDPE’s, TPO’s or EVA's.
`
`Borealis has also developed a random copolymer based HMS—PP. Blends
`
`with this product will result in even softer foam and enable their use in a wide
`
`range of existing and newly developed applications.
`
`Blend partner
`
`modifications
`
`Foam property
`
`Table 1: Blend partner types and their
`influence on foam properties using a certain
`HMS PP product as base resin
`
`Homopolymers
`
`Block copolymers
`
`Random copolymers
`
`Borsoft PP's
`
`High stiffness
`Reduced impact
`
`Low temperature impact
`Reduced stiffness
`Improved toughness
`
`Softer foams
`Improved toughness
`
`Soft foams
`Low tem peratu re impact
`
`* For more information and technical data sheets please consult our webpage wwwborealisgroupcom
`
`PAGE 11 OF 20
`
`PAGE 11 OF 20
`
`

`
`
`
`10 Daploy HMS Polypropylene for Foam Extrusion
`
`The general description of HMS blends can be further refined to provide more
`
`quantitative predictions of PP foam properties. This makes use of various
`
`theoretical models for describing foam properties. One of the more important
`
`foam properties is the tensile modulus which is determined by three basic
`
`parameters:
`
`0 Tensile modulus of the compact material
`
`0
`
`0
`
`Foam density
`
`Foam structure
`
`The tensile modulus of the starting (Compact) material is determined by the
`
`chosen blend partner and the composition — typically this modulus will be in
`
`the range of 750 to 2,000 MPa. The tensile modulus of the foamed material
`
`will decrease as the density decreases. The third parameter is foam structure
`
`and this relates to factors such as the relative proportions of open and closed
`cells and cell size.
`
`Figure 9 shows experimental data for tensile modulus as a function of
`
`foam density for different Borealis blend partners. The agreement with the
`
`theoretical predictions is good and this provides confidence in the ability to
`
`use this as a quantitative tool.
`
`I 50wt% block copolymer
`§50wt% random copolymer
`0 50wt°/o heterophasic random copolymer
`
`For the selection of the right
`
`polymer structure — density profile
`
`for your specific applications we
`
`will be able to provide support
`
`with experience of many years
`in the area of PP foam and a tool
`
`developed by Borealis to predict
`
`the final properties of a foam.
`
`Tensilemodulus(MPa)
`
`
`
`
`
`
`
`Density (kg/m3)
`
`Figure 9: Experimental data for the tensile
`modulus of various Daploy HMS-PP blends
`and theoretical curves
`
`PAGE 12 OF 20
`
`PAGE 12 OF 20
`
`

`
`
`
`11
`
`Basic material data for
`
`the Daploy HMS - grades
`
`Daploy HMS grades are PP—based polymers where long chain branching was
`
`introduced using a post rector step.
`
`This treatment results in an enhanced melt strength, improved drawability
`
`and also high stiffness.
`
`Daploy WB135HMS and WBl 40HMS are PP—homo based materials whereas
`
`WB260HMS is random—copolymer based and allows therefore the production
`
`Unit
`
`WB135HMS
`
`WB140HMS
`
`WBZGOHMS
`
`Method
`
`2.4
`
`32
`163
`
`128
`
`1,900
`
`2,000
`
`10
`
`60
`
`110
`
`155
`
`4
`1
`
`2.1
`
`36
`163
`
`127
`
`1,900
`
`2000
`
`10
`
`60
`
`110
`
`155
`
`3
`1
`
`2.4
`
`27
`146
`
`113
`
`850
`
`900
`
`520
`
`50
`
`70
`
`130
`
`8
`1
`
`ISO 1133
`
`‘es’
`ISO 11357
`
`ISO 11357
`
`ISO 178
`
`ISO 527-2
`
`ISO 527-2
`
`ISO 75-2
`
`ISO 75-2
`
`ISO 306
`
`ISO 179/1eA
`ISO 179/1eA
`
`Table 2: Comparison of Daploy foam grades
`
`of very soft foams.
`
`Property
`
`MFR 230/2.16
`
`Melt Strength
`Melting Temperature
`
`crystallisation temperature
`
`Flexural modulus
`
`Tensile modulus
`
`Elongation at break
`
`Heat deflection temp. A
`
`Heat deflection temp. B
`
`Vicat A
`
`g/10 min
`
`cN
`°C
`
`°C
`
`MPa
`
`MPa
`
`%
`
`°C
`
`°C
`
`°C
`
`Et':_“;';‘;;:‘(’ja:;3,c
`Charpy impact str. notched -20°C
`
`kJ/m2
`kJ/m2
`
`PAGE 13 OF 20
`
`PAGE 13 OF 20
`
`

`
`
`
`12 Daploy HMS Polypropylene for Foam Extrusion
`
`: Daploy WB140HMS
`: Daploy WB26OHMS
`
`— Daploy WB135HMS
`— Daploy WB140HMS
`— Daploy WB260HMS
`
`
`
`Force(cN)
`
`150
`100
`Draw down velocity (mm/s)
`
`Figure 10: Shear rheology at 230°C (|SO67211)
`
`Figure 11: Rheotens curves at 200°C
`
`250
`(ISO 527-2)
`
`Tensile
`Mod.
`(ISO 527-2)
`
`Elong. at
`Break
`
`MFR 230/2.16
`(ISO 1133)
`
`NIS +23°C
`(ISO 179 1eA)
`
`Figure 12: Comparison Daploy
`WB140HMS vs. WBZGOHMS
`
`PAGE 14 OF 20
`
`PAGE 14 OF 20
`
`

`
`13
`
`Processing guidelines for PP homopolymer
`
`and random copolymer HMS grades
`
`Daploy HMS—PP’s and their blends with standard polypropylenes can be
`
`processed on all types of conventional foam extrusion equipment.
`
`The final foam density and quality will depend not only on the polymer,
`
`blowing agent, processing aids or masterbatches, but also on design
`
`and process settings of the machine.
`
`The following tables offer some general process setting guidelines for
`
`foaming with Daploy HMS—PP, in the cases of chemical foaming with CO2
`
`and physical foaming with CO2 or butane.
`
`WB140HMS/
`WBBSHMS
`15 - 25
`
`0.4 - 1.2
`0.15 - 0.30
`
`WB260HMS
`15 - 30
`
`0.4 -1.2
`0.15 - 0.30
`
`Unit
`kg/h
`
`%
`%
`
`°C
`°C
`
`°c
`
`°C
`°c
`
`‘C
`‘C
`
`°C
`‘C
`
`“C
`‘C
`
`°C
`
`bar
`bar
`bar
`
`rpm
`m/min
`
`kg/m=
`
`T“"'° 3’ '''‘‘'‘‘°‘‘' '°“''“"‘‘ °’
`Daploy WB140HMS and WB260HMS with co,
`
`150-160
`170-180
`
`210 - 220
`
`230 -240
`215 - 225
`
`165 - 175
`155-165
`
`145 - 155
`140 -145
`
`140 -145
`140-145
`
`140 - 150
`
`70 - 90
`50 - 70
`25 - 40
`
`15 - 25
`2.5 - 4
`
`1so - 4oo
`
`Parameter
`Mass flow
`
`CO:
`Nucleating agent*
`
`Extruder temperatures:
`- zone1
`- zone2
`
`- zone 3
`
`- zone 4
`- zone 5
`
`- zone 6
`- zone7
`
`- cooling extension
`- mixer
`
`- adapter
`- die
`
`Melt temperature
`
`Melt pressures:
`
`- extruder (injection)
`- mixer
`- die
`
`Screw speed
`Take off speed
`
`160-170
`180-190
`
`200 - 220
`
`220 - 240
`220 - 240
`
`220 - 240
`180
`
`175 - 180
`175
`
`175 - 180
`165-170
`
`165 -170
`
`50 - 80
`40 - 65
`30 - 50
`
`15 - 25
`2.5 - 4
`
`120 - 4oo
`Foam density
`Example for single screw 60 mm, annular die
`*Hydrocerol® CF20E
`
`PAGE 15 OF 20
`
`PAGE 15 OF 20
`
`

`
`
`
`14 Daploy HMS Polypropylene for Foam Extrusion
`
`Unit
`
`kglh
`
`% % °
`
`c
`
`°c
`°c
`
`°c
`
`°c
`
`°c
`°c
`°c
`
`°c
`
`bar
`
`rpm
`m/min
`
`kg/m3
`
`Unit
`
`kglh
`
`% % °
`
`c
`
`°c
`
`°c
`°c
`
`°c
`°c
`
`°c
`°c
`
`°c
`
`°c
`
`bar
`bar
`
`rpm
`m/min
`
`kg/m3
`
`Parameter
`Mass flow
`
`Foaming agent*
`
`Nucleating agent**
`Extruder temperatures:
`- zone 1
`
`- zone 2
`- zone 3
`
`- zone 4
`
`- zone 5
`
`- zone 6
`- zone 7
`- die
`
`Melt temperature
`Melt pressures:
`- die
`
`Screw speed
`
`Take off speed
`
`Foam density
`
`Range
`3 - 5
`
`0.5 - 2.5
`
`0 - 2
`
`240
`
`220
`180 - 200
`
`180 - 200
`
`180
`
`180
`180
`175 - 180
`
`180 - 190
`
`40 - 200
`
`30 - 60
`
`2.5 - 5
`
`250 - 600
`
`Example for single screw 30 mm, flat die
`*Hydrocero|® CF40E , **Hydrocero|® CT516
`
`Parameter
`Mass flow
`
`Butane
`
`Nucleating agent* 4 - 1.0
`Extruder temperatures:
`- zone 1
`
`- zone 2
`
`- zone 3
`- zone4
`
`- zone5
`- zone6
`
`- zone7
`
`- cooling extension
`- die
`
`Melt temperature
`
`Melt pressures:
`
`- extruder (gas injection)
`- die
`
`Screw speed
`
`Take off speed
`
`Foam density
`
`Range
`80 - 100
`
`4 - 8
`
`0.4 -1.0
`
`190 - 220
`
`220 - 240
`
`175 - 200
`175-180
`
`140-160
`140-150
`
`140-150
`
`140 - 150
`140 - 150
`
`140 - 150
`
`40 - 100
`40 - 100
`
`30 - 50
`
`3 - 5
`
`30 - 120
`
`Example for twin screw 60 mm, annular die
`* Hydrocero|® CT516
`
`Table 4: Chemical foaming
`of Daploy WB140HMS with 002
`
`Table 5: Physical foaming
`of Daploy WB140HMS with butane
`
`PAGE 16 OF 20
`
`PAGE 16 OF 20
`
`

`
`Borealis’ film and fibre business specialises in supplying advanced polyolefin plastics for
`
`the manufacture of film, fibre, coating and thermoforming products. Through foresight and
`
`focus on our customers’ needs, Borealis provides innovative solutions that add real value
`
`throughout the value chain. With over 50 years of experience and pioneering solutions for
`
`the film and fibre industry, Borealis has established a leading position on the film and fibre
`
`market across Europe, the Middle East and Asia.
`
`Disclaimer The information contained herein
`is to our knowledge accurate and reliable
`as of the date of publication. Borealis and
`Borouge extend no warranties and make
`no representations as to the accuracy or
`completeness of the information contained
`herein, and assume no responsibility regarding
`the consequences of its use or for any printing
`errors. It is the customer's responsibility
`to inspect and test our products in order
`to satisfy himself as to the suitability of
`the products for the customer's particular
`purpose. The customer is also responsible
`for the appropriate, safe and legal use,
`processing and handling of our products.
`Nothing herein shall constitute any warranty
`(express or implied, of merchantability,
`fitness for a particular purpose, compliance
`with performance indicators, conformity
`to samples or models, non—infringement or
`otherwise), nor is protection from any law
`or patent to be inferred. Insofar as products
`supplied by Borealis and Borouge are used in
`coniunction with third-party materials, it is
`the responsibility of the customer to obtain
`all necessary information relating to the
`third-party materials and ensure that Borealis
`and Borouge products, when used together
`with these materials, are suitable for the
`customer's particular purpose. No liability can
`be accepted in respect of the use of Borealis
`and Borouge products in conjunction with
`other materials. The information contained
`herein relates exclusively to our products
`when not used in conjunction with any
`third-party materials.
`
`Borstar is a registered trademark of
`Borealis A/S.
`Daploy, Borsoft, Borclear, Borflow, Borseal
`and Shaping the Future with Plastics are
`trademarks of Borealis A/S.
`
`
`
`PAGE 17 OF 20
`
`PAGE 17 OF 20
`
`

`
`16 Daploy HMS Polypropylene for Foam Extrusion
`
`PAGE 18 OF 20
`
`PAGE 18 OF 20
`
`

`
`PAGE 19 OF 20
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`PAGE 19 OF 20
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`

`
`PAGE 20 OF 20