Dielux PTFE Filled Copolymer Delrin Sheet Rods

Delrin sheet and rods come in many forms, filled and unfilled. Dielux is a PTFE acetal (filled copolymer) known for the outstanding durability and wear features. Often this material is used in the place of machined metal and plastics when good dimensional stability, minimal friction and excellent resistance to wear are required. The filled PTFE allows this material to be utilized without any form of grease or lubricant. This particular feature is essential for specific industries that do not desire to have added chemical lubricants, such as the food industry. The white Dielux is completely compliant with the FDA and often found in machines used for food processing.

PROPERTIES

 


APPLICATIONS:Gears;Bearings;Bushings;Pads;Gaskets;Seals.

ADVANTAGES:Excellent performance in wet and dry environments;Low aborption to moisture;Minimal friction;Resistant to chemicals;Dimensionally stable;Ease in machining;FDA compliant (white sheet and rod only);Durable and stiff.

What is injection moulding and how does injection moulding work?

Injection moulding along with extrusion ranks as one of the prime processes for producing plastic articles. It is a fast process and is used to produce large numbers of identical items from high precision engineering components to disposable consumer goods.

Most thermoplastics can be processed by injection moulding; the most common materials used include:

  • Acrylonitrile-Butadiene-Styrene ABS
  • Nylon PA
  • Polycarbonate PC
  • Polypropylene PP
Injection mouldings count for a significant proportion of all plastics products from micro parts to large components such as car bumpers and wheelie bins. Virtually all sectors of manufacturing use injection moulded parts. The flexibility in size and shape possible through use of this process has consistently extended the boundaries of design in plastics and enabled significant replacement of traditional materials thanks to light weight and design freedom.
How Does Injection Moulding Work?
Material granules for the part is fed via a hopper into a heated barrel, melted using heater bands and the frictional action of a reciprocating screw barrel. The plastic is then injection through a nozzle into a mould cavity where it cools and hardens to the configuration of the cavity. The mould tool is mounted on a moveable platen – when the part has solidified, the platen opens and the part is ejected out using ejector pins.
After a product is designed, usually by an industrial designer or an engineer, moulds are made by a mouldmaker (or toolmaker) from metal, usually either steel or aluminum, and precision-machined to form the features of the desired part..
injection moulding machine process
An illustration of an injection moulding machine.
Parts to be injection moulded must be very carefully designed to facilitate the moulding process; the material used for the part, the desired shape and features of the part, the material of the mould, and the properties of the moulding machine must all be taken into account. The versatility of injection moulding is facilitated by this breadth of design considerations and possibilities.

Plastic Extruded Profiles Available in UHMW and MD-Nylon Materials

Slideways is the expert at providing extruded profiles. Profiles are available in UHMW, High temp UHMW, Oil filled UHMW MD-Nylon and PTFE (Teflon®). Rail covers and snap-ons are stocked in 10 and 20 foot lengths. Some are also stocked in 100 and 500 foot coils.
The extruded profile is also available in MD-Nylon J-Leg, UHMW J-Leg, UHMW Full Round, or UHMW Half-Round.
Extruded profiles can be used as belt guides, guide rails and protective edging.  They are high impact resistant and will not mar most cans or bottles.
 
Custom Angles and Channels
 
Slideways can machine custom angles and channels from any material for special applications.  Custom angles and channels are used for guiding plastic modular belts or chains. Slideways can add mounting holes or apply pressure-sensitive adhesive for easy installation.
UHMW guide angles and channels can be used to line the bottoms of steel channel to prevent metal-to-metal contact in wear strip applications.
Slideways machines custom sized angles and channels for specific applications.
 
Cut Plastic Wear Strip and Cut-To-Size Plastic
 
Slideways keeps an extensive inventory of plastic materials. The thickness can be planed to a plus or minus .01 inches; saw-cut widths to a plus or minus .03 inches; machined to a plus or minus .01 inches.
 
High Temperature Applications
 
Profiles are available in HT-UHMW for applications up to 275°F and PTFE (Teflon®) for applications up to 500°F. Glass Manufacturing, Food Processing, Chemical Processing and Bakeries are typical industries that require higher temperature profiles.
 
Advantages of PTFE Profiles:
  • Operating temperature – 350°F to + 500°F
  • Higher resistance to chemicals, allows operation in harsh environments
  • Very low coefficient of friction
  • Excellent insulating properties for electrical applications
  • Approved for direct food contact

UHMW-PE Oil Filled

UHMW-PE (ultra high molecular weight polyethylene) is an extremely tough and abrasion resistant thermoplastic that is used for applications that require durability and/or abrasive wear resistance.

UHMW-PE Oil Filled


A subset of the thermoplastic polyethylene, UHMW (aka UHMWPE) is characterized as one of the miracle polymers of the 20th century. UHMW’s host of exceptional attributes such as high abrasion resistance, low coefficient of friction and unparalleled impact resistance, even in cryogenic environments, make it a favorite among engineers and designers in nearly every industry worldwide. UHMW modified to meet particular application requirements through formulations with additives and fillers create special and premium grades with the enhanced desired property.

Oiled filled UHMW is the material of choice for packaging, bottling, and food processing and handling applications requiring FDA and USDA compliance. This advanced product enhances the dynamic coefficient of friction by adding oil filled polymers which helps to lubricate mating surfaces.

APPLICATIONS:Conveying components: bearings, belt guides;Bushings, rollers, gears;Sprockets;Wear strips;Chutes, hoppers;Chain guides.

ADVANTAGES:Corrosion and wear resistant;Vibration resistant;Easily machinable;High chemical resistance;low coefficient of friction;Light weight;Generally FDA and USDA compliant;Good abrasion resistance;Moisture resistant;Good electrical resistance;Self lubricating.

PC(Polycarbonate) Machine Grade

The characteristics of polycarbonate are quite like those of polymethyl methacrylate (PMMA; acrylic), but transparency, excellent toughness, thermal stability and a very good dimensional stability make polycarbonate one of the most widely used engineering thermoplastics in applications demanding high performance properties. This amorphous thermoplastic is highly transparent to visible light – it rates highest among transparent, rigid thermoplastics – and has better light transmission characteristics than many kinds of glass.

Polycarbonate



Machine grade polycarbonate exhibits superior impact strength and rigidity over a wide range of service temperatures and is often used for structural applications where transparency and impact strength are essential. Machine grade polycarbonate is stress relieved, making it ideal for close tolerance machined parts.

Clear, standard, and custom colors are available in coated, laminated, twin walled, patterned, or mirrored stock.

A large number of end use applications, i.e.,special grades that provide specific properties or processing characteristics (weatherability, abrasion/ scratch resistance, heat/flame retardance, UV stability, and static dissipation) for polycarbonate are possible by tailoring grades with specific molecular properties and additives during its manufacture. Contact an Emco Industrial Plastics representative who can help you choose the correct material to meet the needs of your applications.

APPLICATIONS:Manifolds;Glazing;Optical components;Industrial equipment and housing components;Electrical insulators and connectors;Medical equipment components;Machine guards, equipment covers;Non-automotive vehicle windows.

ADVANTAGES:High impact strength;Low moisture absorption;Resists acids;Transparent;FDA compliant;Good dielectric properties;Good mechanical and electrical properties;Transparent up to 2″ in special grades.

PTFE Sleeves/Tubing

PTFE (Polytetrafluoroethylene)   The combination of chemical and physical properties of PTFE is a consequence of its true fluorocarbon structure.  This unusual structure leads to a material which has an almost universal chemical inertness; complete insolubility in all known solvents below 300°C; excellent thermal stability; and unsurpassed electrical properties, including low dielectric loss, low dielectric constant and high dielectric strength.  Furthermore, PTFE does not embrittle at very high or at very low temperatures.
PTFE Sleeves
ADVANTAGES
  • High Performance from -200°C to 260°C (Peak 300°C)
  • Unaffected at soldering temperatures; Autoclavable
  • Suitable for High-Density wiring
  • Smooth Internals allow closer fit
  • Superior Tape-Wrapping-Sintering (TWS) Method provides good mechanical stability, high burst pressure and long flex-life 
  • High Dielectric Strength
  • Resistant to UV Radiation
  • Fire non-propagating
  • Inert to almost all chemicals (few exceptions), solvents, fluxes, oils; Zero extractables
  • Freedom from Ageing, Fungus and Water Absorption
  • Biocompatible
APPLICATIONS
     Our PTFE Sleeves/Tubings find uses in the following application areas
  • Defence andMilitaryElectronics, RadarsAircraft and Satellites
  • Communcations/Electronics
    • Control Systems
    • Computers and Professional Electronics
    • RF Signal transmission, antennas
  • Electrical
    • Insulating cover for Transformer winding leads and other electrical joints, including heater interconnections
    • Insulating cover over immersion heaters for aggressive chemicals or corrosive liquids
    • As stress relief boots at connector ends for harnesses/cable assemblies
    • Protective cover over electrical leads in Air-conditioning/Refrigeration sealed units
  • Medical
    • Highly Flexible PTFE/PFA Dual-wall tubings for semi-medical (low-pressure, low-diffusion, gas flow devices) applications
    • For manufacturing Resection Loops for Prostate surgery
    • Endoscopic, Eurodormia applications
    • Cover for Sclerotherapy needles
    • In catheters and canulas
  • Chemical/Petroleum
    • As carriers for corrosive, high viscosity chemicals or fluids, also under high pressure and temperature
    • As flexible Carriers for steam
    • As Ink capillaries for pen recorders
    • Gas Discharge tubes
    • Bushes cut to size, distillation column packing
    • Insulating cover over stirrers for acids and corrosive liquies
  • Hydraylic/Pneumatic
    • As protective cover over hoses for injection moulding machines
    • Hoses (with or without stainless steel wire braid) for hydraulic/pneumatic applications
  • Automotive

Plastic Extrusion Screw Design and Types of Extrusion Process

Plastics extrusion is a high-volume manufacturing process in which raw plastic is melted and formed into a continuous profile. Extrusion produces items such as pipe/tubing, weatherstripping, fencing, deck railings, window frames, plastic films and sheeting, thermoplastic coatings, and wire insulation.

SCREW DESIGN:

The design of screw is important for plastic processing. It has mainly three different functions:namely, feeding mechanism; uniform melting and mixing of plastic and finally it generates the pressure to push the molten material through die. A screw length (L) is referenced to its diameter (D) as L/D ratio. Generally, L/D ratio is used as 24:1, but for more mixing and output, it may increase up to 32:1. There are three possible zones in a screw length i.e. feed zone, melting zone,and metering zone.
(a) Feed zone: In this zone, the resin is inserted from hopper into the barrel, and the channel depth is constant.
(b) Melting zone: The plastic material is melted and the channel depth gets progressively smaller. It is also called the transition or compression zone.
(c) Metering zone: The molten plastic is mixed at uniform temperature and pressure and forwarded through the die. The channel depth is constant throughout this zone.

TYPES OF EXTRUSION PROCESS

The extrusion process is broadly classified into seven different types depending upon the specific applications.
(a) Sheet/Film Extrusion
In this extrusion process, the molten plastic material is extruded through a flat die. The cooling rolls are used to determine the thickness of sheet/film and its surface texture. The thickness of sheet can be obtained in the range of 0.2 to 15 mm. The thin flat sheet or film of plastic material can be made. Generally, polystyrene plastic is used as a raw material in the sheet extrusion process.
(b) Blown Film Extrusion
In the blown film process, the die is like a vertical cylinder with a circular profile. The molten plastic is pulled upwards from the die by a pair of nip rollers. The compressed air is used to inflating the tube. Around the die, an air-ring is fitted. The purpose of an air-ring is to cool the film as it travel upwards. In the center of the die, there is an air inlet from which compressed air can be forced into the centre of the circular profile, and creating a bubble. The extruded circular cross section may be increased 2-3 times of the die diameter. The bubbles are collapsed with the help of collapsing plate. The nip rolls flatten the bubble into double layer of film which is called layflat. The wall thickness of the film can be controlled by changing the speed of the nip rollers.
The layflat can be spooled in the form of roll or cut into desired shapes. Bottom side of the layflat is sealed with the application of heat, and cut across further up to form opening; hence it can be used to make a plastic bag. The die diameter may vary from 1 to 300 centimeters.Generally, polyurethane plastic is used in this process.
Blown Film Extrusion
(c) Over Jacketing Extrusion
This is also called wire coating process. In this process, a bare wire is pulled through the center of a die. There are two different types of extrusion tooling used for coating over a wire i.e.pressure or jacketing tooling. If intimate contact or adhesion is required between the wire and coating, pressure tooling is used. If adhesion is not desired, jacketing tooling is used. For pressure tooling, the wire is retracted inside the die, where it comes in contact with the molten plastic at a much higher pressure. For jacketing tooling, the wire will extend and molten plastic will make a cover on the wire after die. The bare wire is fed through the die and it does not come in direct contact with the molten plastic until it leaves the die. The main difference between the jacketing and pressure tooling is the position of the wire with respect to the die.
Over Jacketing Extrusion
(d) Tubing Extrusion
In this process, the molten plastic is extruded through a die and hollow cross sections are formed by placing a mandrel inside the die. Tube with multiple holes can also be made for specific applications, by placing a number of mandrels in the center of the die.
(e) Coextrusion
Coextrusion is the extrusion process of making multiple layers of material simultaneously. It is used to apply one or more layers on top of base material to obtain specific properties such as ultraviolet absorption, grip, matte surface, and energy reflection, while base material is more suitable for other applications, e.g. impact resistance and structural performance. It may be used on any of the processes such as blown film, overjacketing, tubing, sheet/film extrusion. In this process, two or more extruders are used to deliver materials which are combined into a single die that extrudes the materials in the desired shape. The layer thickness is controlled by the speed and size of the individual extruders delivering the materials.
(f) Extrusion Coating
Extrusion coating is used to make an additional layer onto an existing rollstock of paper, foil or film. For example, to improve the water resistant of paper polyethylene coating is used. The applications of extrusion coating are liquid packaging, photographic paper, envelopes, sacks lining for fertilizers packaging and medical packaging. Generally, polyethylene and polypropylene are used.