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Mechanical Stabilization of
Rigid PVC Compositions
Mechanical Stabilization of Rigid PVC
Compositions
Thomas C. Pedersen & Robert R. Kwapisz, Jr.
Rheogistics LLC
Picayune, MS USA
PPI TR-2 PVC Pipe Formulation
Ingredient Usage Leve
PVC Resin 100.0 parts
Tin Stabilizer 0.30 – 1.00 phr
Paraffin Wax 0.60 – 1.50 phr
Polyethylene Wax 0.00 – 0.30 phr
Calcium Stearate 0.40 – 1.50 phr
Calcium Carbonate 0.00 – 5.00 phr
Titanium Dioxide 0.50 – 3.00 phr
Process Aid 0.00 – 2.00 phr
Rigid PVC Lubricants
• Define rheology and control fusion.
• Allow the compound to be adjusted to the process.
• The keys to better rigid PVC products and processing
• Prevent rigid PVC from degrading when heated and
sheared
Rigid PVC Lubricants
• Paraffin waxes have been used for more than 40
years to lubricate rigid PVC.
• Large volume rigid PVC applications using paraffin
waxes as the primary lubricant include:•
• PVC Pipe
• Vinyl Siding
• Vinyl Windows
• PVC Fencing
• PVC Boards
Typical Rigid PVC Lubricant System
• Paraffinic Hydrocarbon Wax
• Refined from crude or synthetic based on ethylene or methane
• Typical C32H66
• Calcium Stearate
• Calcium salt of acid from natural fats and oils
• Ca(C18H35O2)2
• Oxidized PE Wax
• Ethylene based
• C100+H200+O?
Paraffin Waxes
Paraffin waxes are mixtures of branched and straight chain molecules
Normal Straight Chain Content
CH3CH2CH2CH2CH2CH2CH2CH2CH2CH2CH2CH2CH2CH2CH2CH2CH2CH2CH2CH2CH2CH2CH2CH2CH2CH2CH2CH2CH2CH2CH2CH3
Branched or “Non-normal” Content
CH3
CH3CH2CH2CH2CH2CH2CH2CH1CH2CH2CH2CH2CH2CH2CH2CH2CH2CH2CH2CH1CH2CH2CH2CH2CH2CH2CH2CH3
CH2
CH2
CH3
Over 1,000,000 different C32+ H66+ molecular structures are possible.
Effect of Molecular Size on Rheology
Carbon Number Fusion Time Fusion Torque Equil. Temp
26 166 sec 31.2 Nm >195°C.
32 352 sec 15.2 Nm 188°C.
40 2,120 sec 10.2 Nm 188°C.
100+ 182 sec 18.9 Nm >195°C.
C26 more soluble in rigid PVC. C40+ less soluble in rigid PVC.
Rigid PVC Lubricants
• Lubricants prevent rigid PVC from degrading when
heated and sheared.
• Lubricants are often adjusted to eliminate shear
burning issues.
• In the USA, many rigid PVC formulations run very low
levels of tin stabilizer and rely on lubrication for
adequate stability.
Recent Rheogistics Study
• What happens when heat stabilizer is reduced
and eliminated?
• Could rigid PVC be processed without a
conventional heat stabilizer?
• Are lubricants mechanical stabilizers?
Mechanical Stabilization of Rigid PVC
Pipe Grade PVC Resin 100.0 parts
RX-165 Paraffin Lubricant 1.30 phr
RX-215 Oxidized Polyethylene 0.15 phr
Calcium Stearate 0.65 phr
Calcium Carbonate 5.00 phr
Titanium Dioxide 1.00 phr
19% Methyl Tin Stabilizer 0.50 phr, 0.25 phr, 0.125 phr,
0.0625 phr and zero
Processed on a Brabender Torque Rheometer for one hour (65 gram charge,
60 rpm, 175° set point, no cooling)
Rigid PVC – Higher Stabilizer
0.50 phr
0.25 phr
Rigid PVC – Lower Stabilizer
0.125 phr
0.0625 phr
Rigid PVC – Lubricants Only
Zero Tin
Reducing Tin Stabilizer
• Shifts rheology
• Fusion time and torques remain remarkably
similar
• Post fusion torque decrease occurs quicker
• Longer term melt torque and temperature
remain remarkably stable
• Melt exhibits more “chatter”
Mechanical Stabilization of Rigid PVC
Color Development
Mechanical Stabilization of Rigid PVC
Color Development
• As the level of tin stabilizer is reduced,
color develops more quickly.
• When tin stabilizer is not present, early
pinking becomes an issue.
Conclusions
• In addition to their role in managing rheology,
lubricants serve as mechanical stabilizers.
• Rigid PVC free of conventional heat stabilizers may be
processed under certain conditions.
• Simple alkanes (paraffin waxes) are very versatile and
effective primary lubricants for rigid PVC.
Conclusions
• The paraffin wax, calcium stearate, and
oxidized polyethylene wax long used in the
USA is an excellent starting point for
alternate stabilization systems.
Thank You!

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Mechanical Stabilization of Rigid PVC Compositions

  • 2. Mechanical Stabilization of Rigid PVC Compositions Thomas C. Pedersen & Robert R. Kwapisz, Jr. Rheogistics LLC Picayune, MS USA
  • 3. PPI TR-2 PVC Pipe Formulation Ingredient Usage Leve PVC Resin 100.0 parts Tin Stabilizer 0.30 – 1.00 phr Paraffin Wax 0.60 – 1.50 phr Polyethylene Wax 0.00 – 0.30 phr Calcium Stearate 0.40 – 1.50 phr Calcium Carbonate 0.00 – 5.00 phr Titanium Dioxide 0.50 – 3.00 phr Process Aid 0.00 – 2.00 phr
  • 4. Rigid PVC Lubricants • Define rheology and control fusion. • Allow the compound to be adjusted to the process. • The keys to better rigid PVC products and processing • Prevent rigid PVC from degrading when heated and sheared
  • 5. Rigid PVC Lubricants • Paraffin waxes have been used for more than 40 years to lubricate rigid PVC. • Large volume rigid PVC applications using paraffin waxes as the primary lubricant include:• • PVC Pipe • Vinyl Siding • Vinyl Windows • PVC Fencing • PVC Boards
  • 6. Typical Rigid PVC Lubricant System • Paraffinic Hydrocarbon Wax • Refined from crude or synthetic based on ethylene or methane • Typical C32H66 • Calcium Stearate • Calcium salt of acid from natural fats and oils • Ca(C18H35O2)2 • Oxidized PE Wax • Ethylene based • C100+H200+O?
  • 7. Paraffin Waxes Paraffin waxes are mixtures of branched and straight chain molecules Normal Straight Chain Content CH3CH2CH2CH2CH2CH2CH2CH2CH2CH2CH2CH2CH2CH2CH2CH2CH2CH2CH2CH2CH2CH2CH2CH2CH2CH2CH2CH2CH2CH2CH2CH3 Branched or “Non-normal” Content CH3 CH3CH2CH2CH2CH2CH2CH2CH1CH2CH2CH2CH2CH2CH2CH2CH2CH2CH2CH2CH1CH2CH2CH2CH2CH2CH2CH2CH3 CH2 CH2 CH3 Over 1,000,000 different C32+ H66+ molecular structures are possible.
  • 8. Effect of Molecular Size on Rheology Carbon Number Fusion Time Fusion Torque Equil. Temp 26 166 sec 31.2 Nm >195°C. 32 352 sec 15.2 Nm 188°C. 40 2,120 sec 10.2 Nm 188°C. 100+ 182 sec 18.9 Nm >195°C. C26 more soluble in rigid PVC. C40+ less soluble in rigid PVC.
  • 9. Rigid PVC Lubricants • Lubricants prevent rigid PVC from degrading when heated and sheared. • Lubricants are often adjusted to eliminate shear burning issues. • In the USA, many rigid PVC formulations run very low levels of tin stabilizer and rely on lubrication for adequate stability.
  • 10. Recent Rheogistics Study • What happens when heat stabilizer is reduced and eliminated? • Could rigid PVC be processed without a conventional heat stabilizer? • Are lubricants mechanical stabilizers?
  • 11. Mechanical Stabilization of Rigid PVC Pipe Grade PVC Resin 100.0 parts RX-165 Paraffin Lubricant 1.30 phr RX-215 Oxidized Polyethylene 0.15 phr Calcium Stearate 0.65 phr Calcium Carbonate 5.00 phr Titanium Dioxide 1.00 phr 19% Methyl Tin Stabilizer 0.50 phr, 0.25 phr, 0.125 phr, 0.0625 phr and zero Processed on a Brabender Torque Rheometer for one hour (65 gram charge, 60 rpm, 175° set point, no cooling)
  • 12. Rigid PVC – Higher Stabilizer 0.50 phr 0.25 phr
  • 13. Rigid PVC – Lower Stabilizer 0.125 phr 0.0625 phr
  • 14. Rigid PVC – Lubricants Only Zero Tin
  • 15. Reducing Tin Stabilizer • Shifts rheology • Fusion time and torques remain remarkably similar • Post fusion torque decrease occurs quicker • Longer term melt torque and temperature remain remarkably stable • Melt exhibits more “chatter”
  • 16. Mechanical Stabilization of Rigid PVC Color Development
  • 17. Mechanical Stabilization of Rigid PVC Color Development • As the level of tin stabilizer is reduced, color develops more quickly. • When tin stabilizer is not present, early pinking becomes an issue.
  • 18. Conclusions • In addition to their role in managing rheology, lubricants serve as mechanical stabilizers. • Rigid PVC free of conventional heat stabilizers may be processed under certain conditions. • Simple alkanes (paraffin waxes) are very versatile and effective primary lubricants for rigid PVC.
  • 19. Conclusions • The paraffin wax, calcium stearate, and oxidized polyethylene wax long used in the USA is an excellent starting point for alternate stabilization systems.