Melting processible fluoropolymer

Extrusion guide
 Comparison of melting processible fluoropolymer

Fluoropolymer FEP PFA ETFE

F4603 A 06 F4002G
Grade Name F4604 A15 F4003G
F4605 A22 F4004G
A30
S.S.G 2.12～2.17 2.12～2.17 1.70～1.76
Melting point（℃） 255～270 302～310 260～270

MFR(g/10min) 3～27 1.5～30 4～24

Continuous working temp.(℃） 200 260 150
Tensile Strength (Mpa) 19 ～22 27 ～31 40 ～46

Elongation at break（%） 250 ～330 280 ～300 420 ～440

Bending resilience (Mpa) 539 ～637 647 ～686 882 ～1372
Dielectric constant (103HZ) 2.1 2.1 2.6
Dielectric losses (103HZ) 6× 10-5 1× 10-5 8× 10-4
Insulation failure strength (V/mil) 500 ～600 500 400
Flame retardant (limiting oxygen >95 >95 31
index%)
FEP Grade

Grade F4604,F4605 F4603 F4602 F4601

Bulk density About 1.2 About 1.2 About 1.2 About 1.0

Viscosity*(pa.s)
(380℃) (1.6~2.0)×104 (5.0~10.0 )×104 (12~22) )×104 (25~50) )×104

MFR
(g/10 min ) 15~32 6.0~14.0 2.1~5.9 0.8~2.0
(372℃,5kg)
Processing method Extrusion Extrusion Extrusion, Extrusion,
Injection molding Blow molding, Transfer molding,
Blow molding Compression Compression
molding molding
Application Best for high Suitable for Suitable for wire and Most suitable as
speed thin tube and jacket with soft and lining material
insulated wire wire thick insulation
Extruder structure

Feeder
Vent

Screw Barrel

Heater Zone Flange Cross die

Screw configuration

2 2 2 2
Reduction Ratio＝（Ｄ1 －ｄ1 ）/（Ｄ1 －ｄ2 ）＝３
Ｄ1：OD of screw、ｄ1：Diameter of feeding、ｄ2：Diemeter of metering

Size of screw parts （Unit：ｍｍ）

Dia of screw Feeding（H1） Metering（H２） Width（W） Range
３ ０ ５ ． ３ １ ． ８ ３ ． ０ ３ ０
４ ０ ６ ． ０ ２ ． ０ ４ ． ０ ４ ０
５ ０ ８ ． ４ ２ ． ８ ５ ． ０ ５ ０
６ ５ １ ０ ． ７ ３ ． ６ ６ ． ４ ６ ５
 Cross die structure

Cross die mold

Filter net, cut- structure
out board Control
Mold and
bolt
core

Wire
★ The surface of
wire should be
smooth and clean
without oil and
dust.

Vacuum
pump Melt
Heater cone
Thermel couple
Cut-out board
• Back pressure is applied to mix the raw materials in the
extruder and remove air and volatiles.

• The hole opening rate is 60% - 65% and the dia of hole is
about 2 mm.
Filter Net
• The purpose of use is to remove impurities and homogenize the mixing. Especially when
using color masterbatch to produce colored wire, filter screen must be used to achieve
good mixing state.
• Using corrosion-resistant nickel mesh, the mesh size is about 100 mesh.
• Generally, 40 mesh metal mesh is used on both sides, and 100 mesh metal mesh is used
in the middle for reinforcement.
 Temperature profile

Rear of ＃１： Material feeding, pre-heat the material and melt.

extruder （３２０～３６０℃）

Middle of ＃２： Set the shearing of the compression part to make it melt completely.
extruder （３６０～３８０℃）
Front of ＃３： Set the temperature to make the mixing full, stable extrusion and full
extruder stretching. When the temperature of this part is too high, it will lead to resin
deterioration and foaming
（３８０～４００℃）

Connector, neck, head： This molten state must be maintained until it flows to the mold.
The general set temperature is the same as the front of the extruder.

Mold： Set the temperature so that the inner and outer parts of the coated
wire do not melt and break. It is usually the same as the temperature
setting at the front of the extruder. A higher temperature should be
set at a high speed. （３９０～４１０℃）
Mold·core Structure

DD：Inner dia of mold

DT：outer dia of core
ｄb：outer dia of insulated wire
ｄc：outer dia of wire core
ｄｃ ｄｂ

ＤＤ ＤＴ

Draw deduction ratio （ＤＤＲ）＝（ＤD 2－D T 2）/（ｄb2－ｄc2）

Draw reduction balance （ＤＲＢ）＝（ＤＤ/ｄb）/（ＤＴ/ｄc）

Mold·Core
It is an important factor to determine the formability and physical properties of wire cladding.
• In order to increase the forming speed, the extrusion die which is different from PVC and
PE can be used to stretch forming

Suitable mold·Core design

• The higher the drawing ratio (DDR), the faster the forming speed, but various problems will
occur.
• The most suitable drawing ratio (DDR) and drawing balance (DRB) are different according to
the characteristics of forming resin (resin viscosity, easy to melt fracture, easy to stretch).

ＦＥＰ ＰＦＡ ＥＴＦＥ

ＤＤＲ 100（90～110） 100（90～110） 60（30～70）
ＤＲＢ 1.05（0.9～1.1） 1.05(0.9～1.1) 1.05(1.04～1.06)
（ ）inside means allowed range
• The values in the above table are the basic values, which will change according to the wire size.
• In order to avoid the eccentricity caused by cracking and resin sagging, DDR is smaller. (refer to
the forming example later)
Draw deduction ratio (ＤＤＲ)
Normally FEP、PFA selection range is 80～120，and ETFE
selection range is 30～50. When the melting viscosity is high, the
coating fracture is easy to occur, so DDR should be reduced.

Draw reduction balance (ＤＲＢ)

Normally selec1.05,the allowed range is 0.9～1.1.
When the DRB is too large (more than 1.1), the strength and crazing resistance of
the coating will be insufficient; when the DRB is too low (less than 0.9), the circular
shape cannot be obtained, and the ellipse and coating fracture will occur.

ＤＲＢ＞１.０

ＤＲＢ＝１０

撕裂发生 定心不良
(DRB>1.1) (DRB<0.9)
ＤＲＢ＜１０
 Operation before extrusion
１）Material feeding
• In order not to let the surface of the raw material particles absorb moisture, it is
necessary to store it in a place with low humidity.
• If it is damp, it should be dried at 120-150 ℃ for more than two hours
• In order to avoid contamination from outside, the following steps should be took:
①Wipe the outer bag and to remove the attached foreign matters.
②When use the raw material, it shall be opened carefully. When there is material left,
it must be completely sealed to prevent the mixing of moisture and foreign matters
③Must ensure there is no materials left in the hopper after the previous use, and can
only be used again after cleaning.

２）Before extrusion
When changing different resins for extrusion, the hopper, screw, extrusion cylinder,
cut-off plate, cross head, mould and die core must be disassembled and cleaned
before extrusion
Various problems and causes
No Problem Possible reasons
1 Impurities in insulation １) Corrosion in equipment
２) Contamination in material
３) Dirty in feeding hopper
２ Color change in insulation １) Over temperature setting
２) Long residue time in extruder
３) Contamination inside
４) Barrel and screw is not clean
３ Rough surface on insulation １) Over extrusion speed
２) Lower material
temperature
３) scratches, corrosion or poor design
in the mold
４ Bubble in insulation １) Over material
temperature
２) Long residue time in extruder
３) too fast in cooling (vacuum
bubble)
４) Over pre-heat line temperature
5) Oil or grease in the line
No Problem Possible reasons
６ Not round １）Mold ·core off center
２）DRB too small（less than 0.9）
３）ＤＤＲ too big
４）too long corn
５）Low viscosity of material
７ Big change in OD 1) The discharge volume fluctuates
2) the core speed changes greatly
3) the vacuum degree changes greatly
4) the core diameter changes greatly
5) the cone is too long
８ Occurrence of pinhole 1) Mixed with foreign matters;
2) too short cone length;
3) too fast extrusion speed;
4) uneven dispersion of pigment
5) DRB too small (below 0.9)
6) Too large drawing
7) low resin temperature
8) low mold temperature
9) foaming

９ Melt fracture 1) Extrusion speed is too fast

2) set temperature is too low
3) die diameter is small
No Problem Possible reasons
１０ Cone rupture 1) Mixed with foreign matters, uneven dispersion of
pigment
2) too short cone length
3) Extrusion speed is too fast
4) DRB is small
5) Too large drawing
6) low resin temperature
7) low mold temperature

１１ Slow extrusion speed 1) DDR too small

2) Mold temperature is too low
3) Resin temperature is too low
4) Screw design is poor

1) Resin temperature is too high (resin degradation)

１２ Craze
2) resin retention time is too long
3) Weak welds (low resin temperature)

１３ Large shrinkage 1) Too short air cooling distance

2) Too long cone
Poor core tightness
3) DDR too large
4) Insufficient core preheating
5) low cooling water temperature

Weak mechanical strength 1) Resin temperature too high (resin degradation)

１５
2) impurities
（TS／ＥＬ） 3) Uneven coating thickness
4) bubble
FEP AWG and Mold·Core
Wire D Insulation Mold D Core D
Grade ＡＷＧ ＤＤＲ ＤＲＢ
(mm) (mm) (mm) (mm)

30 0.250 0.15 6.6 3.1 141 0.97

26 0.483 0.15 8.5 4.8 130 1.09
F4604
F4605 24 0.510 0.25 12.0 6.0 142 1.01
20 0.800 0.15 12.0 8.0 140 1.09
16 1.448 0.30 20.4 14.4 100 1.00
F4603 14 1.803 0.30 24.0 18.0 100 1.00
12 2.286 0.30 28.8 22.8 100 1.00
10 2.819 0.63 24.5 16.9 36 1.00
F4602 4 6.655 0.88 28.8 21.2 14 1.07
1/0 10.500 1.90 35.0 24.0 7 1.07
FEP suggested extrusion Temperature
Screw Temperature profile(℃)
Grade
(rpm) Real Middle front Mold
5-10 340 350 370 370
F4604
F4605 10-40 345 385 390 390
5-10 340 370 390 390
F4603
10-30 345 380 390 390
5-10 340 380 400 400
F4602
10-20 370 390 410 420
PFA suggested extrusion Temperature
Screw Temperature profile(℃)
Grade
(rpm) Real Middle front Mold
5-10 315 345 390 390
A30
A22 10-40 360 365 385 390
A15
5-10 350 360 390 395
A06
A03 10-20 360 380 400 400
ETFE suggested extrusion Temperature

Screw Temperature profile(℃)

Grade (rpm) Real Middle front Mold
F4001 5-20 290 320 330 340
F4002
20-40 290 320 335 345
F4003
F4004 5-20 310 335 345 345
F4005
20-30 315 335 345 345
 Forming process of melt resin pipe

Dia
setting
Vacuum
Vent valve water
Extruder Water
tank
removal
device

Extrusion
status Drawing Rolling
Water Sewage Pressure
device device
discharge tank reducing
pump
Thank you!