RF Works Extrusion Laboratory

Mission

The intended purpose of RF works Extrusion Laboratory is:

  • to provide a means of formulating thermoplastics into compounds suitable for extrusion or injection molding using small sample quantities of resins.
  • to extrude pilot scale film or sheet(1) suitable for physical testing and prototype samples
  • to test heat seal properties of experimental pilot film or sheet

Operations


Non-Disclosure Agreements (NDA)

If the customer requires an NDA, two signed originals should be forwarded to RF Works. The agreement must be approved and signed by the RF Works CEO. One of the signed original agreements is returned to the customer and one is placed in the customer's file. A generic NDA is available from RF Works.

Test Plan

The customer should submit a Test Plan with MSDS sheets to the RF Works Technical Director via email, FAX or post. The test plan should state the target specifications of the thermoplastic formulation to be developed, and the specifics resins that are to be used. Each test plan should be accompanied by the MSDS sheets for each resin or additive that will be used.

Quotes

A quote will be prepared by RF Works Technical Director estimating the cost of completing the test plan.

Data and Reports

RF Works will provide a report with plastograms and a physical sample of each formulation.

Basic Lab Concepts


Torque Rheology

Brabender DigiSystem Plasticorder with a Type Six oil-heated roller measuring head is used to quantigy the melt fusion behavior and heat shear stability of experimental thermoplastic extrusion formulations. The effect of polymers, ratios, lubricants, fillers, pigments, and other additives on the extrudivity of an experimental formulation is characterized with speed and accuracy in the lab before any pilot extrusion run is considered. An Absorbtometer can be mounted to study liquid absorption in powders and dry blend batching. A few kilograms of experimental raw materials are sufficient for a complete study. The latest Brabender Winmix software is used to produce and evaluate the Plastigrams and Absorptograms.

Extrusiometer

A Brabender Extrusiometer is driven by a high powered, dead weight Plasticorder to extrude experimental formulations through either a sheet die or a 0.25 inch diameter aluminum capilary die. Speed and temperature can be varied as the torque is recorded to quantify the extrudability and energy requirements for experimental formulations. Extruded rod or film is produced that can be used to determination the engineering properties of the experimental formulation. The rod samples can be used to produce Instron stress/strain curves. Modulus of elasticity, tensile strength, elongation, resilience and toughness of the experimental formulation can be determined. These samples can also be used for flammability comparison studies such as verticle burn length. These data allow formulations to be ranked by engineering properties as well as flamability to produce a comprehensive study. Other Capabilities include:

  • Color matching
  • Quality control of incoming raw materials
  • Diagnosis of production batch problems
  • Dry blend or pellet bulk densities and feed/flow properties

Pilot Extrusion Line


Extruder

The 60 mm 25:1 single screw pilot film and sheet extrusion line can convert as little as 25 pounds of experimental raw materials into 15 inch wide prototype extruded film or sheet that is representative of full scale production. The high flow hopper and slotted feed throat are large enough to accommodate dry blend powders, pellets or any combinations thereof.

If the need be, an extrusion screw can be designed specifically to produce an experimental formulation. RF Works can supply a prototype screw, cut to prove a design, that will fit the pilot extruder. Pilot extrusion runs, using the prototype screw with its experimental formulation, are the best means of evaluating a screw design. The adapter holds a breaker plate with a 40/60 mesh screen pack.

Pilot Die

The pilot film and sheed die is a high inventory 17 inch wide, flex lip design with a fully chromed interior. It has three temperature controlled heat zones.

Roll Stack

The roll stack consists of two (2) water-cooled chrome rolls, pull rolls and variable speed drive. Two verticle, twenty-seven (27) inch wide water cooled chrome rolls pull the melt from the sheet die to form a sheet, i.e., a web. The web tension in the stack is adjusted at the nip rolls. It can convey a web up to 24 inches wide at a maximum rate of thirty-five (35) feet per minute. All experimental film is cast, i.e., no top embossing roll is used. This allows the production of strain free prototype film.

Pilot Extrusion Cast Film Over Release

Pilot film extrusion over release paper is an option when lay flat is required, extremely light gage film is to be run or an adhesive film is being produced that may adhere to itself.

Release film can be driven through the stack under tension to support the cast film. This line has produced 3 mil heat activated adhesive film by extrusion casting over 1.5 mil polyester differential release film.

Experimental formulations, to be extrusion cast over release, can be evaluated in the lab using available release papers and films. Practical release film recommendation can be made.

Radio Frequency (RF) Heat Welding

Prototype film or sheet can be tested for heat sealability and joined on site using a full scale RF heat seal machine.

 

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