Ultradur® for Extrusion and Thermoforming
Ultradur®, the polybutylene terephthalate (PBT) from BASF, has a specific combination of properties making it an ideal material for particular use in extrusion manufacturing.
Ultradur® shows its strengths wherever high-quality, high dimensional stability, high deflection temperature and good barrier properties are required. A feature that is particularly important is the low water absorption and thus the fact that the mechanical and dimensional properties are largely independent of the moisture content or the climatic surrounding conditions. Particularly for components that have to work reliably for the entire lifetime of a component, Ultradur® is indispensable. Though, up to now the melt strength of PBT was not sufficient to make it a preferred product for extrusion. Therefore an interdisciplinary team of chemists, physicists, and engineers developed the Ultradur product family suitable for the extrusion market.
BASF offers a range of Ultradur® grades optimized for extrusion. They combine all positive Ultradur properties with enhanced high melt strength. This will open up new market segments for the use of PBT.
Available grades:
- Ultradur® B6551 LNI
- Ultradur® B6560 M2 FC TF for thermoforming
- Ultradur® B4040G11 HMG HP for co-extrusion applications
Key advantages of Ultradur® for extrusion
- High rigidity and strength
- Impact resistance also at low temperature
- High melting point
- Very good dimensional stability under heat
- Low water absorption
- Good resistance to many chemicals
- Exceptional resistance to weathering
- Excellent heat aging behavior
- Excellent barrier properties
A broad range of possible extrusion applications
Ultradur® B6551 LNI for extrusion and the worldwide first thermoformable PBT Ultradur® B6560 M2 FC TF combine all the well-known characteristics of the Ultradur® family like high melting point, low water uptake, high dimensional stability and good barrier properties. Though, up to now the melt strength of PBT was not sufficient to make it a preferred product for extrusion. By connecting and branching the polymer chains via tailor-made additives the experts of BASF gained a very high melt strength. This makes the Ultradur® B6551 LNI the perfect material for pipes, profiles and mandrels – and the Ultradur® B6560 M2 FC TF the material of choice for extrusion of films and thermoforming of packaging or technical parts. Both grades now offer good mechanical properties, is easy to color, even foaming is possible
Typical applications for Ultradur® B6551 LNI are:
- Profiles
- Pipes
- Mandrels
For the thermoformable grade Ultradur® B6560 M2 FC TF suitable applications are:
- Films
- Packaging
- Technical parts
The innovative mono material product combines all the well-known characteristics of the Ultradur® family like the high melting point with excellent barrier properties against oxygen, water vapor and aroma. This makes Ultradur® B6560 M2 FC TF the perfect material for extrusion of films and thermoforming of packaging as well as high temperature applications. Even extrusion of coffee capsules is feasible.
The world’s first thermoformable Ultradur® grade for high barrier packaging
The monomaterial Ultradur® for thin wall food packaging enables a mechanical recycling concept. On top, the excellent barrier properties extend the shelf life which leads to reduced food waste and transport costs. The excellent mechanical properties allow very thin wall geometries. All this makes Ultradur® a sustainable alternative to PET/PO solutions and aluminum.
Properties of Ultradur®
The Ultradur® grades are polyalkylene terephthalate molding compounds based on polybutylene terephthalate. Ultradur® is produced by polycondensation of terephthalic acid or dimethyl terephthalate with 1,4-butanediol using special catalysts. Terephthalic acid, dimethyl terephthalate and 1,4-butanediol are obtained from petrochemical feedstocks, such as xylene and acetylene.
The processing of Ultradur® for extrusion
Ultradur® can be processed by all methods known for thermoplastics. The main methods, however, are injection molding and extrusion. The extrusion process is used to produce profiles, pipes, mandrels and semi-finished products. Semi-finished products are for the most part machined further by means of cutting tools to form finished moldings.
By connecting and branching of the polymer chains via tailor-made additives the experts of BASF gained a very high melt strength which makes the Ultradur® B6551 LNI for extrusion the perfect material for pipes, profiles and mandrels. Ultradur® B6560 M2 FC TF is the only PBT solution for extrusion of films and thermoforming for appliances in packaging or technical parts. The excellent processability was confirmed by our innovative partner ILLIG, one of the biggest producers of thermoforming machines.
Ultradur® for extrusion and thermoforming: technical details
Ultradur® shows a fast and very constant degree of crystallization - ideal conditions for stable and easy processing.
The new Ultradur product family shows high impact strength combined with good heat ageing properties at 150 °C.
Melting points and heat deflection temperatures of thermoplastics. PBT is a fast crystalizing polyester.
Low water uptake ensures excellent dimensional stability of the end product.
The quality of packaging is highly determinated by the properties of the material used. The new Ultradur® B6560 M2 FC TF offers a good balance between oxygen and water barrier. Therefore it can excellently protect the packed goods against the detrimental effects of environmental influences and increases their shelf life.
The recirculation of production waste into the process chain is possible without any negative effect on the mechanical properties.
Co-extrusion with Ultradur®
Ultradur® B4040G11 HMG HP is highly stiffened and has a lowered melting point, so it can be co-extruded with PVC, but also with ASA, ABS, PC or PMMA. In the case of PVC profiles, this is used to obtain a significant stiffening effect. Applications can be found in PVC windows but also in other technical profiles.
