Extrusion

Guide

Lubrizol LifeScience Polymers

Links Science to Life™
 Extrusion Guide
(PE). Some of the harder TPU grades (~> 90 Shore A) could
Contents:
be considered semicrystalline. Softer grades (~62A–85A) can
Introduction 1
be nearly amorphous — they have no definite melting point but
Materials 1
soften gradually on heating. Upon heating and shear mixing within
TPU Crystallinity 1
an extruder, they achieve a viscous fluid state characteristic of
Maximum Processing Temperature 1
a polymer much like low-density polyethylene. Melt viscosities
Melt Viscosity 1
suitable for extrusion will be achieved at temperatures well below
Basic Guidelines/Equipment 2
the point of degradation. Initial softening points range from
Common Extrusion Issues 4
250°F–340°F (121°C–171°C) while melt temperatures suitable
Polyurethane Films 4
for processing will be generally about 20°C higher.
Cast Film and Sheet Extrusion 4
Equipment 5 Harder grades will require higher temperatures to achieve a
Extrusion Coating/Equipment 5 homogenous melt. They will also have a narrower processing
Blown Film 6 temperature range in which the melt viscosity is suitable for
Wire & Cable Coating, Hose Jacketing/Equipment 7 forming extrudate profiles. This behavior is a consequence of the
Tubing and Profile Extrusion/Equipment 8 degree of crystallinity of the TPU; in general, harder TPUs have
Troubleshooting Guide 10 higher crystallinity and require more heat/shear to melt.

Introduction Grades identified as injection molding grades generally are harder

LifeScience Polymers (LSP) is a business within The Lubrizol (~> 50D) and have this narrow processing range. Molding grades
Corporation that provides innovative polymer solutions for are usually not suitable for extrusion.
healthcare products. Among the chemical technologies employed
There are some hard (~> 50D) TPU extrusion grades. Greater
by LSP are thermoplastic polyurethane elastomers (TPUs). The
diligence in the processing operation is required. For example,
LSP TPUs are grouped into several families of products with
slow-moving materials can solidify within the extruder by an
varying chemical and physical characteristics. They can be readily
annealing process. Cloudy particles in the extrudate can indicate
converted to flexible, elastic forms such as tubing and film on
sloughing of annealed TPU.
conventional thermoplastic extrusion equipment.
Extrusion conditions specific to individual grades can be found in
This brochure is intended to provide general guidelines for
the product Technical Data Sheets.
equipment, procedures and extrusion conditions that will help the
customer obtain the best possible performance from the LSP line
Maximum Processing Temperature
of TPU extrusion grades. Additional information can be obtained
Temperatures in excess of 450°F (232°C) may result in polymer
by consulting individual product Technical Data Sheets or by
degradation as evidenced by bubble formation within the TPU
contacting your Lubrizol LSP technical service or
melt. If this occurs, a reduction in zone temperatures will restore
sales representative.
bubble-free extrudate and stabilize extrusion conditions. Generally,
temperatures near this maximum result in melt viscosities that are
Materials too fluid to maintain a viable form (tube, film, etc.) when exiting
The LSP TPUs are available in both aromatic and aliphatic types.
the die.
The choice of polyol raw material during manufacture leads to
the families of polyester, polyether and polycarbonate grades.
Melt Viscosity
Separate LSP literature is available describing detailed properties
A key TPU variable critical to extrusion processing is the molecular
of the various classes and grades. All of these TPU types have
weight. This is directly related to the length of the polymer chain.
common characteristics as far as extrusion processing behavior
This variable governs the melt viscosity achieved by the material
and practices. This guide covers those general characteristics.
in an extrusion process; higher molecular weights create higher
melt viscosities, which in turn have higher melt strengths when
TPU Crystallinity measured at the same temperature. Of course, melt strength
TPUs are generally not considered to be crystalline polymers that
determines how easily a melt can be handled to form
would be represented by a product like low-density polyethylene
a rod, a tube, a film, etc.

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Lubrizol TPU business has determined that the TPU molecular drying. Although LSP TPUs have low moisture content when
weight, melt viscosity, etc., can be correlated to the melt index manufactured, TPUs are hygroscopic (absorb and retain water
(MI) of the material. The relationship of melt viscosity to melt from the air). Subsequent handling, transportation and storage
index is inverse: higher molecular weight, higher viscosity TPUs conditions can increase the moisture content. Inadequate
have lower MIs. Conversely, lower molecular weight, lower melt drying can result in a loss of properties of the extruded product
viscosity TPUs have higher MIs. With years of experience and and may give a poor appearance. Extruder barrel and die
hundreds of customer experiences, Lubrizol has determined the temperatures must be set properly for each product. Deviation
optimal melt index range that is suitable for each product and from the recommendations may result in poor extrusion quality.
the extrusion process that would be used. For example, TPUs These recommendations can be found on the Technical Data
designed for fabric coating generally require lower melt viscosity Sheet. The rate of extrusion has a large impact on the
(higher MI); the lower viscosity provides a fluid melt to level out. quality of the product and should be adjusted accordingly.
The fabric provides support for the lower viscosity. Conversely,
TPUs in general can be tacky during processing, so rollers
TPUs intended for tubing may have higher melt viscosities
should be coated with suitable nonstick materials. Many LSP
(lower MI) to better maintain the unsupported shape.
TPU compounds are already formulated to reduce blocking and
Melt index is routinely determined for nearly all LSP TPU grades. tackiness. However, the addition of a lubricant masterbatch may
In comparing the MI of one TPU grade to another, it is critical be necessary to assure good processing. If a masterbatch or
that the MIs of both materials be carried out under the same regrind/recycle is added to virgin TPU, then these materials must
conditions of temperature and load. Although 190°C/8700 also be properly dried and may have a significant impact on the
grams is a common TPU MI condition, there are many other quality of the product. TPUs do not draw down well compared
combinations of temperature/load. to other thermoplastics like polyethylene; therefore, drawdown
should be minimized in the process. It is not recommended to
The individual MI value on a single box, bag or lot of TPU is
shut a line down on TPUs. Even during short breaks, material
generally of importance as it relates to prior experience with the
should be kept moving at slow rates through the system. This
product. Small changes to the extrusion process may be required
is particularly critical for the hard grades, which may undergo
if the MI is different. Customers extruding large quantities of TPU
an annealing process within the extruder and become more
continuously may stage their pallets of material by MI. Generally,
crystalline, and in excessively long stagnant downtimes,
it is better to run high MIs (lower viscosity) followed by low MIs
can solidify.
(higher viscosity).

Blending of TPU pellets to achieve a different set of properties Equipment

is generally not recommended. Mixing an 80A TPU with an Dehumidifying Hopper Dryer
85A TPU will achieve an intermediate hardness TPU extrudate, It is imperative to dry the material immediately prior to extrusion.
provided that the materials successfully melt blend in the extruder. This includes all raw materials containing TPU. Best results are
Achieving a uniform melt in a single-screw extruder can be difficult obtained with 0.02% or less moisture content.
with a mixture of soft and hard TPU pellets. In addition to the
Because of the relatively high consumption rate of an extruder, a
difference in hardness, the TPUs may also vary in melt viscosity
good desiccant hopper drier is a preferred method for delivering
(MI), as well.
consistently predried and preheated material to the feed screw.
A similar melt uniformity concern occurs when regrind is used. The inlet air to the hopper should be checked at intervals for both
Depending on the extrusion conditions at the time the “regrind dryness and temperature. For most extrusion-grade aromatic LSP
product” was created, the MI may be very different than virgin TPU products, the hopper should be sized so that all of the feed
resin. The shearing process can break polymer chains, resulting has been subjected to a minimum of two hours of dehumidified,
in a lower-viscosity (higher-MI) material. When this is mixed dried air at 220°F (105°C). A dewpoint of -40°C should be
with lower-MI virgin resin, achieving a uniform melt may require targeted. Review the product's Technical Data Sheet for
significant adjustments to the process. The worst combinations specific drying instructions.
to process are low percentages of low MI mixed with high
A device to measure actual moisture content of the resin may also
percentages of high MI. Knowing the MI of regrind may
be used, since dryer malfunctions can occur. Instruments that
be important.
measure weight loss are suitable, as water is the only significant
substance that contributes to weight loss. Refer to individual
Basic Guidelines Technical Data Sheets for drying recommendations that may be
LSP TPUs must be properly dried before processing.
specific to a grade.
There are no grades which can be reliably extruded without

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 Extruder
Most extruders are electrically heated with either band-lye resistance heaters, cast-in block heaters or tubular resistance heaters wrapped
around the barrel as seen in Figure 1. An efficient barrel cooling system is important to control the tendency for mechanical shear heat
developed in the melt to override the electrical heater controls.

Figure 1
Extruder.
A - Drive
B - Feed
C - Screw
D - Barrel (heater bands) B C D E H I
E - Barrel Liner
F - Screen Pack
G - Breaker Plate
H - Die Body
I - Die Head
A FG
The optimal extruder barrel length for LSP TPUs is 30–32 times its internal diameter (30:1 L/D, 32:1 L/D). Although shorter barrels such
as 24:1 can be used, mixing efficiency and melt uniformity may be less than optimal. Cooling the extruder feed throat is critical to prevent
surging or bridging. Internal cooling to the screw is not needed.

Screw Design
Excellent-quality product has been obtained consistently with screws having the following characteristics:

• Barrier screw construction • Long metering section (30%–45% of screw length)

• Compression ratio of 3:1 • Hard-chrome, pinhole-free, highly polished surface
• Long transition section (30%–45% of screw length) • Clearance between screw and barrel liner

A properly designed screw should melt the pellets and subsequently homogenize the TPU melt completely, and develop a melt
temperature about 10°F below the recommended melt temperature. Barrier-type screws will give the best-quality output, and several
designs have been used successfully. A mixing section is suggested at the end of the screw, particularly if color concentrates are added.
The best performance has been with the Saxton and pineapple-type mixers.

The design recommendations for a series of 30:1 and 24:1 screws are listed in Table 1. Proper maintenance of the screw will pay off in
higher-quality output, quicker startups, better output rates and more reliable run-to-run performance consistency.

Table 1
Suggested Screw Design for Extrusion of LifeScience Polymers Thermoplastic Polyurethanes
Extruder Size 1½" 2½" 3½" 4½"
Recommended Horsepower 25 50 100 200
L/D Ratio 30/1 30/1 30/1 30/1
Feed Section - number of flights 8 8 8 8
Feed Section - number of flights 0.270" 0.360" 0.450" 0.525"
Transition Section - number of flights 10 10 10 10
Metering Section - number of flights 9 9 9 9
Metering Section - flight depth 0.090" 0.120" 0.150" 0.175"
Mixer - number of flights 3 3 3 3
Compression Ratio 3.0:1 3.0:1 3.0:1 3.0:1
Cored for Temperature Control No No No No
Hard Chrome; Pinhole-Free; Polished Yes Yes Yes Yes
LID Ratio 24/1 24/1 24/1 24/1
Feed Section – number of flights 6 6 6 6
Feed Section – flight depth 0.285" 0.375" 0.45" 0.525"
Transition Section – number of flights 9 9 9 9
Metering Section – number of flights 9 9 9 9
Metering Section – flight depth 0.095" 0.125" 0.150" 0.175"

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Feed Throat (less than 0.02%), then the melt may be too hot; lower
Feed throat cooling with water is frequently recommended to the temperatures.
provide protection for the drive bearings and to prevent bridging
Surging (pressure and power widely fluctuating)
and agglomeration of the pellets entering the screw. Ambient tap
Surging is rarely caused by the resin. Check the feed throat
water is adequate; the flow rate should be slight to moderate.
cooling and focus on extruder zone 1 for resolution. Slowing the
rate down may help. The screw design may need to be modified
Pressure Gauges
to insure continuous feed.
Changes in melt viscosity and output should be monitored by
a melt pressure gauge. Monitoring melt pressure provides an Gels or Contaminants
indication of extrudate quality and/or uniformity. It is also helpful at Make sure you are at the proper process conditions. Run hotter
startup to determine whether there is proper flow, if the material is and slower if you can. Remove any additional components you
bridging in the feed throat or freezing off in the die. If it is freezing may be adding (regrind, masterbatch, etc.). If possible, try a
off in the die, head pressure beyond the extruder’s operating limits different lot of resin; if the problem is solved, contact your Lubrizol
may occur. Diaphragm-type transducers are preferred because representative. Saving a sample of the problem lot and a lot that
they are responsive and very accurate. Bourdon gauges that use worked on your process can be helpful in avoiding the problem in
silicone grease to transmit melt pressure are also satisfactory in the future. What appears to be cloudy contaminants is a separate
many instances. issue that should be reviewed with a Lubrizol representative.

Breaker Plate and Screen Nonuniform Thickness in the Machine Direction

The primary function of the screen pack is to filter contaminants Check the extruder output for surging. If the output is stable, you
out of the plastic melt (e.g., paper, wood, metal, undispersed may be experiencing draw resonance. Reduce the drawdown. If
fillers, etc.). Screens should be constructed from stainless this is not possible, attempt to heat up the melt and die. It may be
steel wire for strength and corrosion resistance. Normally, a necessary to switch to a lower molecular weight lot.
screen pack makeup of 20-40-80-20 mesh screens is optimal.
Nonuniform Thickness in the Transverse Direction
However, some processes have used up to 200 mesh with good
This is seldom a resin issue. Insure that the adjusting bolts
results. Review the specific product's Technical Data Sheet for
are properly set. Check your system for buildup. Check for
recommended processing information. The breaker plate not only
nonuniformity in cooling. There is a detailed Troubleshooting
supports the screen pack, but also serves as a mechanical seal
Guide at the end of this Processing Guide.
between the barrel and the adapter to the die. The holes in the
breaker plate are normally 1/8" to 1/4" with a chamfer designed
Polyurethane Films
to give minimal obstruction to material flow. Screens and breaker
As a film, TPU is soft but very tough. It can be made by film-
plates increase the back pressure. Provided that this is not
blowing, extrusion-casting, solution-casting or by calendering.
excessive, this pressure can facilitate the homogenization
TPU film has a very high tear strength and high abrasion
of the TPU melt.
resistance, and is extremely resistant to oils and greases. This
combination of properties has led to its use for specialized
Dies and Takeup Equipment
packaging, sheaths for films for wound care, medical instruments,
Die and takeup considerations are so specific to the type of
garments, bags and other medical supplies.
processing that they will be discussed separately within the
respective process sections of this bulletin. A few general
Cast Film and Sheet Extrusion
guidelines are provided to minimize the drawdown and keep all
Procedure
flow channels streamlined with no dead spots.
The process for extruding film and sheeting is illustrated in
Figure 2. TPU pellets are compacted and melted in the extruder
Common Extrusion Issues barrel. The high-viscosity melted material is forced through a
Streaks or Die Lines
properly designed horizontal coat hanger die, cooled as the web
These are generally caused by buildup in the die or damage
is wrapped around the temperature-controlled polishing rolls
to the die. You will likely need to clean your die. Best results are
and then rolled up as needed on storage reels.
obtained by shutting down after purging with a non-TPU resin
like PE. By convention, gauges of thermoplastic webs under 0.010"
are called “film," whereas gauges in excess of this thickness
Sticking or Blocking
are usually called “sheet.” Some soft grades of LSP TPU will
TPUs are generally tacky. Insure that the proper formulation is
require the use of a release liner or the addition of lubricants to
being fed to the extruder. Check the coating on your rollers. A
the formulation to insure blocking does not occur. Most extrusion
nonstick coating is required and can be damaged over time.
grades of TPU can be converted into cast film or sheet. Rarely
Bubbles or Off-Gassing are TPUs extruded into sheet > about 0.250" thick. Refer to the
Check the moisture level of the resin. If moisture is acceptable Technical Data Sheet for information on specific materials.
4
 Figure 2
Film and Sheet Extrusion Line.
Die
Ç
Ç Ç
Ç
To Winder
Ç
Fabric
Unwind
Ç
Cooling Air Cooling Rubber Drawn
Extruder Rolls & Inspection Rolls
The dotted line indicates a fabric lamination possibility.
Equipment
Dies
Generally, successful extrusion of film of polyurethane is accomplished with a flexible lip film die as in Figure 3, whereas heavier gauges
up to 0.25" are extruded through a flexible lip sheet die with an adjustable restrictor bar as shown in Figure 4.

Figure 3 Figure 4
Flexible Lip Flat Film or Sheet Die. Flexible Lip Flat Sheet Die with Adjustable Restrictor Bar.

Lip Adjustment Screw Restrictor Bar Adjustment

Lip Adjustment Screw

Flexible Upper Lip

Secondary Manifold
Restrictor Bar
Manifold

Flat sheet dies are heated with electrical resistance cartridge heaters placed in holes drilled in areas carefully selected to avoid localized hot
spots that would affect melt flow uniformity. It is important to keep the drawdown to a minimum. This should be 20:1 or less. If deckles are
used, the internal flow channels should be streamlined so there is no stagnant TPU that would result in degradation.

Extrusion Coating
Procedure
The extrusion-coating process is illustrated in Figure 5. LSP TPU pellets are compacted and fluxed in the extruder barrel (not shown, but
perpendicular to the place of the paper). The molten material is forced through a slit due downward between two rolls. The substrate is fed
into the system between the molten plastic and the rubber pressure roll where the two materials are joined by controlled pressure between
the rolls. The product is cooled by passing around the temperature-controlled metal rolls and then trimmed and wound on film
windup equipment.

Figure 5 Heaters Windup

Substrate
Extrusion Coating Line. Letoff Film Die Slitters

16" Chrome-Plated Rolls

Dia. (Chill) (100°F)
Aluminum Roll
(Water-Cooled)
Silicone Rubber Pressure Roll
Equipment
Dies
The die design that has been found to be most suitable for the flow characteristics of LSP TPU compounds has a coat hanger flow
pattern and teardrop cross-section as illustrated in Figure 3. A heated adapter tube carries the TPU melt from the extruded head to the
opening in the center-fed die. For best results, the adapter tube and die should be maintained carefully at the same temperature.

The die is heated with electrical resistance cartridge heaters placed in holes drilled in placement areas selected to avoid localized hot
spots, which would affect melt flow uniformity. The die lips are V-contoured to minimize the air gap between the die and the roll nip
whenever necessary.

5
Pressure Roll
The uncoated substrate is led over the pressure roll where it meets the hot melt cascade flowing downward from the die. The pressure
roll, activated by a pair of pneumatic or hydraulically loaded air cylinders, forces the substrate and the hot melt together in the roll nip
as in Figure 5.

Adhesion and appearance can be controlled to a degree by using rubber pressure rolls of varying hardness. The pressure roll is usually
cooled both by internal circulating high-velocity water and by placing a water-cooled aluminum roll against the trailing edge of the pressure
roll as a heat sink.

Chill Roll
The chill roll freezes the molten plastic to the substrate almost instantaneously; therefore, it must have an adequate water cooling system.
The controlled speed determines film thickness and overall coating efficiency, and its surface finish determines the texture of the coating.
Commercial controllable line speeds can range from 30 feet/minute to 120 feet/minute.

Unwind and Rewind

Sophisticated tensioning, positioning and aligning devices are normally installed between the unwind and windup stations to ensure flat,
smooth-edged rolls at high production speeds. Flying splice equipment makes it possible to have long, continuous runs at high speeds.

Preheat
Preheating of the substrate is one of the methods of controlling adhesion of the coating. The preheating can be done with open-flame, cal-
rod heating banks or preferably by passing the substrate over metal heating drums that can be controlled by internal electrical or pressure
steam systems to temperatures approaching 350°F (177°C).

Adhesive Bonding
Several types of specialty urethane adhesives may be considered for bonding the TPU compounds to various substrates.

Startup Conditions
With the extruder moved away from the threaded substrate coating line, the extrusion conditions are lined out and the die lip adjustments
made to give a uniform melt at the desired output rate, die-lip opening and melt temperature. With chill roll temperatures of 80°F–100°F
(27°C–38°C), preheating systems of 160°F–200°F (71°C–93°C) and the substrate moving at minimum speed, move the extrusion line into
place and bring the coating line up to the predetermined line speed to deposit the required coating weight.

Adjustments in preheated control, die-to-roll distance and roll pressure can be made to modify substrate adhesion. Coating weight is
usually controlled by adjusting line speed. Generally substrates are preheated to 160°F–200°F for improved bonding.

Blown Film
Procedure
The importance of drying has been covered in the preceding text on drying (see Equipment). Improper or insufficient drying can adversely
affect both material properties and the extrusion process.

Blown TPU film can be made using most standard side- and bottom-fed die types, Figures 6 and 7, both rotating and stationary.
Rotating dies are preferable because of their ability to minimize gauge bands. In addition, conventional bubble-cooling methods and
takeoff equipment used for other resins are suitable.

Figure 6 Driven Pinch Rolls Figure 7

Extrusion of Blown Film. Wind Up Blown Film Die.
Die Opening

Die Mandrel
Collapsing Plate
Adjustable Bushing

Guide Rollers Die Adjustment Bolt

Blown Tube
Bleed Plug
Mandrel
Heaters
Cooling Ring Bleed Outlet
Air Inlet Locking Nut
Extruder Adjustable Section of Die
Air Inlet
Die
Valve
Air Supply 6
 Polyurethane polymer containing no additives has a high coefficient of friction. Depending on the hardness, the film may be tacky and
sticky. To avoid problems stemming from tackiness, use compounds tailored to provide good release. Also, contact between the film and
processing equipment should be kept to a minimum. It may be necessary to devise a technique for maintaining the separation between
individual plies once the bubble is collapsed and the film trimmed. These might include the use of A-frames with TFE (tetrafluoroethylene)-
coated slots and rubber-coated rolls.

Depending on the product and thickness, it may be necessary to add a lubricant masterbatch to prevent blocking. Commercially
available polyurethane masterbatches lend themselves well to blown TPU film. Polyurethane-based concentrates are preferable to vinyl-
or polyethylene-based products. Not all grades of TPU are suitable for blown-film processing. Some grades lack suitable melt strength,
and some crystallize too fast. Refer to the Technical Data Sheet or contact your Lubrizol representative to discuss the best process for
a given grade.

Wire & Cable Coating, Hose Jacketing

Procedure
The process of coating wire & cable by extrusion is diagrammed in Figure 8. LSP polyurethane pellets are compacted and fluxed in the
extruder barrel. The molten material is extruded in the crosshead, at which point the direction of flow is changed 90˚.

Figure 8
General Wire Coating Setup.
A - Extruder G - Spark Tester
B - Payoff H - Capstan
C - Preheater I - Diameter Control
D - Crosshead Die J -Linear Footage
E - Controls Counter
F - Cooling Trough K - Takeup

B C A D E F K J I G H

It is in the crosshead that the wire, coming from the unwind and preheater, comes in contact with the molten TPU. The crosshead also
holds the guide tip and the wire die. The guide tip keeps the wire centrally located in the molten insulation, and the properly selected die
controls the wall thickness of the final construction. The driven capstan pulls the hot-coated wire through the water-cooling trough and the
high-voltage spark tester. The choices of die opening, capstan speed and screw RPM are all variables that determine the dimensions of
the coated wire.

Equipment
Unwind
Very small single conductors running at high lineal velocities (4,000+ feet/minute) are paid off from stationary reels similar in action to that
of a spinning reel used for fishing. Larger wires and multistrand wires where even slight twisting during the unwind cannot be tolerated are
normally paid off from rotating reels. The payoff reels are usually installed in pairs so that as one reel is emptied the other can be hooked in
by splicing on the fly without the need for lengthy shutdowns.

Preheater
Preheating of the conductor prevents stresses that may occur in the jacket due to premature chilling of hot plastic from the relatively cold
conductor. In the case of small conductors, this can be accomplished by using a low-voltage resistance applied between two properly
insulated metallic rolls placed just before the bare wire goes into the crosshead. In larger-diameter conductors and for secondary jacketing
operations, the preheating can be done with either a gas flame or water-cooled quartz preheater tunnels.

Dies
The two basic types of dies are “pressure” dies and “tubing” dies. In both types, the wire is led into the die opening through a guide tip.
In order to maintain concentricity, the clearance between the wire and the tip is minimal. In order to minimize the abrasion that occurs
between the wire and the inside of the guide, the guide tip is made from a very hard metal such as Carboloy.

In the pressure die, Figure 9, the plastic is still under some pressure inside the die when it contacts the conductor. As the conductor
emerges from the die, it is coated. The tubing die, Figure 10, extrudes plastic tubing concentrically around the emerging conductor.
The tubing is collapsed onto the conductor just after the die face by controlled vacuum drawn from behind the crosshead and through
the same passage in which the conductor travels. For best results, dies should be hard-chrome-plated.

7
Figure 9 Figure 10
Tip and Die - Pressure Extrusion Over Water (Not to Scale). Tubing Die (Not to Scale).

a A
A C
C a c
c
A - Die B E
B B - Tip
C - Melt Flow D
D D
D-A  ir (or conductor F
passageway) B
B E
F E - Die Land = O.D. d
d of finished cable A
C b
C b A F - Outside Tip Land
a - b - Die Angle
c-d-T  ip Angle
A - Die
B-T  ip (O.D. inside tip approximately 1 mil over the O.D. Normal drawn-down for wire cable is between 10-15%. This may be aided
br the use of a vacuum of at least 20mm of mercury. The clearance between
conductor. A die O.D. of 5% larger than the O.D. of the Conductor and the Guider in the land area = 0.005".
insulation should be used as a starting point.)
C - Melt Flow A. There are two common ways of calculating drawdown ratio. The 10-15%
mentioned above is based on the linear ratio of D1 - T0 1.10 1.5
D - Conductor Land Length = to
O.D. - C. 1 1
E - Land = O.D. of extrusion (Land ratio = O.D. of insulation )
The second one described by the ratio pertains to the cross
A ratio of 1:1 meets most applications; 2:1 for thin walls. (D1) 2 - (T0) 2
sectional area of the die gap divided by the cross-sectional
F - Tip Spacing (Tip spacing must at least equal wall thickness.) area of insulation. The ratio calculated by the method should (O.D.) 2 . - (C) 2
be 1.50:1 to 1.75:1.
a - b - Die Angle
c - d - Tip Angle D1 - Die Hold Diameter O.D. - Finished Cable or Tube
(Tip angle should be slightly less than die angle.) T0 - Tip O.D. (diameter of F) C - Core Diameter

Cooling Trough
All thermoplastic covered wire is cooled by passing through a water trough. Sufficient immersion time is needed to allow cooling of the
coated product without distortion of the jacketing.

Takeup
The wire or small cable is pulled through the line by a capstan puller or, for large-diameter cables, caterpillar capstans that are basically the
same type of haul-off as rigid PVC pipe pullers. From the pulling capstan, the wire is then taken up on reels for storage.

Tubing and Profile Extrusion

Procedure
The process for extruding profiles is shown schematically in Figure 11. TPU grades with high melt strength are best-suited for tubing
and unsupported profile extrusions. TPU pellets are compacted and fluxed in the extruder barrel. The molten material is extruded in-line
under pressure through a die opening designed to yield the required profile. The hot extrudate is immediately passed through a cold-water
trough where it develops sufficient strength to be pulled away from the die by a suitable takeup. After the takeup, the dimensioned profile
is either cut to length or reeled as required.

Figure 11
Profile Extrusions Line (Plan View).

A B C C A - Extruder
B - Die Holder
C - Cooling Trough
D - Takeup
E - Cut-Off

8
 Equipment
Dies
For best results, dies should be highly streamlined and well-polished to prevent hangup. Narrow flow channels minimize residence time
and promote melt temperature homogeneity. Normally, a restrictor opening of 5/8" in the adapter will be satisfactory for 2½" through 4½"
extruders. Figure 12 represents a typical die for extruding tubing.

Figure 12
Tubing Die for Single-Screw Extruder.

Dies should be made from fine-grained tool steel, which will accept hardening without changing dimension. It is important to select a
steel that will take and hold a good polish and one which is free from gas pockets. The die should also be finished off with high-quality,
hard-chrome, pinhole-free plating. Dies should be heated by electrical band heaters specifically shaped to give complete and close
conformation to the outside die dimension. The die, adapter, breaker plate and front zone of the extruder should be maintained at the
same temperature, preferably 10°F lower than the melt temperature. Die lands should be 3–5 times the dimension of the die opening;
entrance angles to the land should be as small as practical for the special profile being considered; however, 30°–60° is common. The
die opening should be cut 20%–30% oversize to accommodate the drawdown caused by the constant tension necessary to draw the
molten material away from the hot die.

Cooling Trough and Takeup

Profiles of TPU are normally cooled by immersion in water, water-spray or a combination of the two. They are pulled through the cooling
zones by means of pull rolls or a caterpillar takeoff. Because of the soft nature of the polyurethane melt, mechanical sizing equipment such
as a vacuum sizer or internally cooled mandrel are not normally used. In several instances, modified vacuum sizing systems, together with
precooling of the melt prior to entering the vacuum tank, have been used successfully to size tubing.

9
Troubleshooting Guide
Here are some typical extrusion problems and several possible causes for each.

Common Problems Possible Causes

• High moisture content • Voltage fluctuation

• Die pressure too low • Temperature controller malfunction
• Rear barrel temperature • Metering depth too deep or too shallow
too high/too low • Warm/Hot feed throat
Surging • Screw speed too fast • Material bridging in feed throat
• Die land too short
• Die opening too large
• Extruder drive belt slipping
• Improper screw design

• Localized hot spot in die

Bubbles (localized in sections, • Material buildup in die

appearing sporadically) • Improper screw design
• Contamination in material

• High moisture content

• Melt temperature too high
Bubbles (uniformly distributed) • Improper screw design (excessive shear)
• Incompatible additive
• Die temperature too high

• Improper screw design • High moisture content

• Incompatible additive • Melt temperature too low
• Die temperature too low • Contamination
Rough Surface
• Die not streamlined • Excessive output
• Die land too long • Regrind is not melt-compatible
with virgin resin

• Incompletely melted pellets

Cloudy or Hazy Particles in • Annealed TPU “slough off” from stagnant TPU in extruder barrel, die,
Otherwise Clear Extrusion screw. Most commonly seen when extruding hard TPU grades or when
extruder is not purged at end of a TPU run

• Metering depth too shallow

• Metering depth too deep
Melt Fracture • Feed insufficient
• Die land too short
• Rate too high

10
 Troubleshooting Guide (Continued)
Here are some typical extrusion problems and several possible causes for each.

Common Problems Possible Causes

• Melt temperature too high

• Cooling takeup too short
Blocking or Tacky Surface
• Output excessive
• Cooling water or air too cold (polyether type)

• Melt temperature too high

• Improper screw design
• Extruder output excessive

Flow Lines • Poor mixing

• Backpressure too low
• Dirty extruder or die
• Extruder surging

• High moisture content

• Die temperature too hot, too cold or not uniform
Die Lines
• Melt temperature too low
• Material buildup in die

• Screw overheated
• Rear zone temperature too high
Bridging in Feed Zone • Screw speed too low
• Poor shutdown procedure
• Hopper dryer temperature too high

• Dirty equipment
Carbon Specks • Improper resin handling
• Extruder run dry at shutdown and not cooled promptly

• Extruder surging
• Takeoff variable
Poor Gauge Control
• Temperature control inadequate
• High moisture content

11
Troubleshooting Specific Extrusion Operations
Here are some typical extrusion problems and several possible causes for each.

Common Problems Possible Causes

Tubing
• Do not use sizing rings to control O.D. of tubing on materials softer than
Tubing Dragging on Sizing Rings 50–55D; tubing should be via “free extrusion” with a vacuum chamber
Causing Erratic Size to maintain roundness (using low vacuum or internal low pressure)

• Mandrel and/or die temperature too high

Droplets or Lumps Appearing on I.D. of Tubing • Contamination

Tube Sagging Between Die and Cooling Trough • Melt temperature too high

• Melt temperature too high/internal air pressure may be

needed/vacuum trough with low vacuum can be used
Tubing Out-of-Round
• Cooling bath too short
• Use nonblocking rolls to keep extrudate submerged in cooling bath

Blown Film

• Melt temperature too high

• Line speed too fast
Poor Bubble Strength
• Inadequate cooling
• Moisture content too high

• Nip rolls too low (too close to die); nip roll pressure too high
• Melt temperature too high
• Line speed too fast
Blocking • Inadequate cooling
• Material requires additional slip agent
(different TPU grade or more masterbatch)
• Moisture content too high

Sheet Extrusion Cast Film

• Material sticking to roll – decrease melt temperature/decrease roll

Lines Perpendicular to Flow temperature/slow roller speed

• Poor or nonuniform contact on chill roll

Plate-Out on Roll • Insufficient roll pressure
• Nonuniform gauge

• Increase melt temperature

Poor Gloss or Transparency
• Increase cooling

• Line speed too high

• Melt temperature too high
Blocking • Material requires slip additive (or additional)
• Top roll temperature too high

12
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Global Locations
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13
LifeScience Polymers
Lubrizol Advanced Materials, Inc.
9911 Brecksville Road
Cleveland, OH 44141-3201
Telephone: 216.447.5000
[Link]/LifeSciencePolymers
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Lubrizol Advanced Materials, Inc.

Global Headquarters | 9911 Brecksville Road | Cleveland, OH 44141-3201 USA

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The information contained herein is believed to be reliable, but no representations, guarantees or warranties of any kind are made as to its accuracy, suitability for particular applications or the results to be obtained. The information often is based on laboratory work with small-scale equipment and does
not necessarily indicate end-product performance or reproducibility. Formulations presented may not have been tested for stability and should be used only as a suggested starting point. Because of the variations in methods, conditions and equipment used commercially in processing these materials,
no warranties or guarantees are made as to the suitability of the products for the applications disclosed. Full-scale testing and end-product performance are the responsibility of the user. Lubrizol Advanced Materials, Inc., shall not be liable for and the customer assumes all risk and liability for any use or
handling of any material beyond Lubrizol Advanced Materials, Inc.’s direct control. The SELLER MAKES NO WARRANTIES, EXPRESS OR IMPLIED, INCLUDING, BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. Nothing
contained herein is to be considered as permission, recommendation nor as an inducement to practice any patented invention without permission of the patent owner.

Lubrizol Advanced Materials, Inc., is a wholly owned subsidiary of The Lubrizol Corporation.
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The Lubrizol Corporation is a Berkshire Hathaway company. MAY 2014