A scientific approach to rigid poly(vinyl chloride) extrusion

The control of flow balance at the die exit is the key for successful extrusion of polymers. The complex crosssectional variation in real-world hollow extrusion profiles intrinsically promotes flow imbalance in the die cavity. Special considerations are required for designing extrusion dies for such profiles. The die design for a complex door frame profile was computationally optimized in this study with the aid of a commercially available software package. The velocity distribution at the die exit, post-die extrudate deformation, temperature distribution, and pressure distribution of a traditional die was investigated in detail and found to be inadequate. A modified die incorporated three distinct features, flow restrictors, flow separators and approach angle of the torpedoes, to achieve a balanced and uniform velocity at the die exit. The flow restrictors and flow separators were added in the preparallel zone. Flow restrictors were added on top and bottom of the torpedoes to increase the restriction on polymer flow. A unique inclined flow restrictor was introduced to achieve uniform internal melt flow. Flow separators were added at junctions of outer wall and inner vertical walls to separate the polymer flow into different sections and minimize cross flow between these sections. The addition of these features proved to be highly effective for balancing the velocity distribution at the die exit. The combination of 3-D modeling and simulation is an effective cost and time efficient approach for optimizing complex die designs before manufacturing.

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“…In the simulations, a no-slip condition was assumed at the die wall. The polymer melt was considered to be an incompressible fluid [14].…”

Section: Simulation Conditionsmentioning

confidence: 99%

Internal flow optimization in a complex profile extrusion die using flow restrictors and flow separators

Xing

Alsarheed

Kundu

et al. 2022

Int J Adv Manuf Technol

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Vinyl Chloride Polymers

Summers¹

2000

Kirk-Othmer Encyclopedia of Chemical Technology

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PVC has a large sales volume, second only to polyethylene. Its high chlorine content provides it with a high level of combustion resistance for building products, electrical enclosures, and wire and cable insulation. PVC has a unique ability to be compounded with a wide variety of additives, making it possible to produce materials in a range from flexible elastomers (the first thermoplastic elastomers) to rigid compounds, materials that are weatherable such as for siding and windows, compounds that have stiff melts and little elastic recovery for outstanding dimensional control useful in profile extrusion, or low viscosity melts which compete effectively with ABS and PC/ABS in thin‐walled injection molding parts such as computer monitor housings. Some PVC properties are attributed to unique morphology. The polymer precipitates from its monomer and grows into primary particles, which are later the melt flow units. Fusion into larger structures and product strength are controlled by breakdown of the grains into primary particles, by choice of additives, by amount of melting (temperature), and by number of tie molecules (molecular weight). The main type of polymerization is the suspension process, with significant polymerization made by the mass, solution, microsuspension, and emulsion processes. In the suspension process, the polymerization takes place in droplets of monomer suspended in water. From an environmental viewpoint, PVC is over 50% chlorine and as a result, is one of the most energy‐efficient polymers. PVC is an inherent flame retardant, and acts as a marker, enabling automated equipment to sort PVC containers from other plastics in the waste stream. Vinyl is recycled by at least 170 recyclers in the United States and Canada and more than 3,500 communities accept vinyl products in their recycling programs. The analysis from 155 large‐scale, commercial incinerator facilities found no relationship between the chlorine content of waste nor the addition of PVC, and dioxin emissions from combustion processes. New requirements from the U.S. EPA make scrubbers mandatory on all incinerators and are necessary whether or not PVC is present in the waste feed.

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Vinyl Chloride Polymers

Summers¹

2006

Kirk-Othmer Encyclopedia of Chemical Technology

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PVC has a large sales volume, second only to polyethylene. Its high chlorine content provides it with a high level of combustion resistance for building products, electrical enclosures, and wire and cable insulation. PVC has a unique ability to be compounded with a wide variety of additives, making it possible to produce materials in a range from flexible elastomers (the first thermoplastic elastomers) to rigid compounds, materials that are weatherable such as for siding and windows, compounds that have stiff melts and little elastic recovery for outstanding dimensional control useful in profile extrusion, or low viscosity melts which compete effectively with ABS and PC/ABS in thin‐walled injection molding parts such as computer monitor housings. Some PVC properties are attributed to unique morphology. The polymer precipitates from its monomer and grows into primary particles, which are later the melt flow units. Fusion into larger structures and product strength are controlled by breakdown of the grains into primary particles, by choice of additives, by amount of melting (temperature), and by number of tie molecules (molecular weight). The main type of polymerization is the suspension process, with significant polymerization made by the mass, solution, microsuspension, and emulsion processes. In the suspension process, the polymerization takes place in droplets of monomer suspended in water. From an environmental viewpoint, PVC is over 50% chlorine and as a result, is one of the most energy‐efficient polymers. PVC is an inherent flame retardant, and acts as a marker, enabling automated equipment to sort PVC containers from other plastics in the waste stream. All types of vinyl products can be recycled and processed into second generation products. The analysis from 155 large‐scale, commercial incinerator facilities found no relationship between the chlorine content of waste nor the addition of PVC, and dioxin emissions from combustion processes. New requirements from the U.S. EPA make scrubbers mandatory on all incinerators and are necessary whether or not PVC is present in the waste feed.

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A scientific approach to rigid poly(vinyl chloride) extrusion

Cited by 9 publications

References 15 publications

Internal flow optimization in a complex profile extrusion die using flow restrictors and flow separators

Internal flow optimization in a complex profile extrusion die using flow restrictors and flow separators

Vinyl Chloride Polymers

Vinyl Chloride Polymers

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