Lotte Chemical ABS TE-1020 is an acrylonitrile-butadiene-styrene copolymer positioned within the extrusion segment of the manufacturer’s Starex ABS portfolio. The material consists of a continuous styrene-acrylonitrile matrix and a dispersed polybutadiene rubber phase; the rubber phase contributes low-temperature impact resistance, while the matrix governs stiffness, surface hardness, and chemical resistance. The designation TE-1020 distinguishes the grade from high-flow injection molding ABS by a lower melt flow rate and higher melt strength, both of which are required for heavy-gauge sheet, profile extrusion, and thermoforming. The resin is supplied as cylindrical pellets and is processed after desiccant drying. Typical physical properties include a density of 1.04 g/cm³ when measured by ISO 1183-1:2019 and a melt flow rate of 3 g/10 min at 220°C/10 kg when measured by ISO 1133-1:2022. These values are representative published values; they are not specification limits and must be confirmed against the certificate of analysis for the production lot.

The two-phase morphology is stabilized by graft copolymer formed during polymerization. The polybutadiene domains absorb impact energy through cavitation and shear yielding of the SAN matrix. In extrusion grades such as TE-1020, the rubber particle size distribution is controlled to retain impact strength in heavy-gauge sheet and to resist edge-tear propagation during trimming. The SAN molecular weight distribution is broad enough to provide melt elasticity at low shear rates, but the grade is not designed for thin-wall injection molding; the high-shear viscosity is higher than that of high-flow ABS, which reduces flow length in thin sections below 1.5 mm.

Thermal and Mechanical Property Envelope

Table 1 reports representative values collected from publicly available trade literature for TE-1020. Batch-to-batch variation in melt flow rate and impact strength is normal for ABS polymerization and compounding. Tensile values measured according to ASTM D638-14 using Type I specimens are not directly interchangeable with ISO 527-2:2012 values because gauge length and strain rate differ. For qualification, one test-method set shall be selected and applied consistently.

Flexural modulus is used as a comparative stiffness indicator for extruded sheet. The notched Izod value at 23°C is not sufficient to characterize low-temperature behavior; a separate measurement at -30°C should be requested when the formed part is used in cold environments. The heat deflection temperature under load is measured at 1.82 MPa; the Vicat softening temperature is a separate thermal resistance indicator and cannot be used as a substitute for the HDT under structural load.

Before melt processing, the pellets shall be dried to a moisture content below 0.05 wt%. A desiccant dryer with a dew point of -40°C or lower is specified because ABS moisture regain is rapid above 60% RH. Drying at 80°C for 3–4 hours is typical for hopper residence times. If the material has been stored at higher humidity or the dryer dew point is above -40°C, drying time should be extended to 4–6 hours. Moisture content is verified by halogen moisture analyzer or Karl Fischer titration; the latter is preferred for quantitative lot acceptance. Inadequate drying produces splay and silver streaks on extruded sheet and reduces notched Izod impact strength through hydrolytic degradation of the polybutadiene phase. Dried pellets shall be conveyed with dry air and not left uncovered in humid plant environments.

The melt is non-Newtonian; a single MFR value does not define the viscosity curve. Capillary rheometry data, when available from the manufacturer, show shear-thinning behavior typical of ABS. The low shear melt viscosity controls sheet sag and thermoforming, while the high shear viscosity controls die pressure drop and motor load. Processors should request the full viscosity curve when designing a coat-hanger die or specifying an extruder drive. Published data for the exact power-law index of TE-1020 is limited in public literature; die design calculations should use capillary rheometry data generated on the actual lot.

Does TE-1020 Operate Within a Narrow Melt Temperature Window?

The recommended melt temperature range for extrusion of TE-1020 is 210°C to 240°C. The upper limit is 260°C for short residence times. Above 250°C, the polybutadiene phase undergoes thermal crosslinking, and the SAN matrix can release styrene and acrylonitrile volatiles. The residence time at melt temperature should therefore be kept below 5 minutes. For sheet extrusion, barrel zones are typically set from 180°C in the feed throat to 220–230°C at the die adapter. The melt temperature is measured by an immersion thermocouple inserted into the extrudate; barrel set points alone are not reliable because shear heating can raise the melt temperature by 5–15°C depending on screw speed and back pressure.

For injection molding of thick-wall fittings, barrel temperatures are set from 180°C in the rear zone to 230°C in the nozzle. Injection pressures between 70 MPa and 100 MPa, hold pressures between 50 MPa and 70 MPa, and back pressure up to 1.0 MPa are used. Mold temperatures are maintained at 40–70°C. Screw speed is kept at 30–60 rpm to avoid excessive shear heating. Clamp force requirements are calculated from the maximum cavity pressure and projected area; for thick-wall parts, cavity pressures may be lower than those of thin-wall injection grades because the melt fills more slowly.

Thermal degradation is accelerated by hold-up zones, dead spots, and frequent purging with low-viscosity resins that leave carbonized residue. Production-scale experience with ABS extrusion grades shows that melt temperature excursions above 245°C increase die drool and can cause black specks and edge tear in sheet. Vented single-screw extruders with vacuum capability of approximately -0.08 MPa gauge are used to extract residual moisture and monomer. A purge compound based on high-viscosity polyethylene or acrylic is used for shutdown. Purging with PVC or polycarbonate is not recommended because differences in thermal stability and melt viscosity can generate further residue and phase-separated domains.

On sheet extrusion lines, a single-screw extruder with an L/D ratio of 24:1 to 30:1 and a barrier-flight screw is preferred for TE-1020. The die body is a coat-hanger manifold with a flexible lip; die temperatures are maintained at 210–225°C. The extrudate is polished in a three-roll stack with roll temperatures between 70°C and 90°C. The roll nip gap is adjusted to the sheet gauge plus 5–10% to control surface finish and residual stress. A small rolling melt bank at the nip is maintained; an oversized bank causes shear heating and can introduce orientation. For profiles, calibration die temperatures of 60–80°C and uniform haul-off speed are used to control dimensional stability. The die lip opening is often set 10–15% below final sheet thickness to compensate for die swell; this compensation is verified by thickness mapping across the sheet width.

When TE-1020 Replaces General-Purpose ABS in Thermoforming

Substitution of TE-1020 for a general-purpose ABS with higher melt flow rate changes the thermoforming window. The lower MFR and higher melt strength reduce sheet sag during heating and allow deeper draw ratios in vacuum forming. Sheet surface temperature at forming is typically 140–180°C. At surface temperatures below 130°C, the sheet exhibits high elastic recovery and difficult corner definition; above 190°C, local thinning and sheet sag increase. The heating time depends on sheet thickness, heater bank density, and distance from the heating elements; for 3 mm sheet, total oven residence times in the range of 60–120 s are common. Mold temperature is held at 60–80°C to allow vacuum draw without premature solidification. Because TE-1020 retains heat longer than thin-wall injection grades, cycle times may be extended by 5–15% unless forced cooling is applied.

The primary difference between TE-1020 and a high-flow injection molding ABS is not solely MFR. The extrusion grade has a broader molecular weight distribution and higher melt elasticity, which increases die swell and melt strength. These characteristics improve sheet uniformity but reduce injection mold filling in thin sections below 1.5 mm. Compared with general-purpose ABS, TE-1020 typically retains higher notched Izod impact at low temperatures and is therefore specified for impact-critical extruded parts. The exact ranking depends on the test condition; notched Izod at -30°C should be obtained from the manufacturer because low-temperature data is not always included on the published datasheet.

At the compounding stage, color masterbatch addition is performed with a co-rotating twin-screw extruder at an L/D of 40:1 and screw speeds of 250–400 rpm. The carrier resin must be SAN-compatible; incompatible masterbatch carriers create laminar discoloration and delamination in deep-draw areas of formed parts. In production sheet lines, die drool accumulation is observed when melt temperature exceeds 245°C or when screw speed on a 90 mm extruder exceeds 100 rpm. Periodic die lip cleaning and ceramic die lip coatings reduce the frequency of surface defects. Published data for the precise correlation between die drool mass and melt temperature for TE-1020 is limited; the behavior is consistent with general ABS extrusion grade experience.

Typical extruded applications include refrigerator inner door liners, luggage shells, edge-banding strips, and automotive interior trim panels. In refrigerator liner production, the sheet is co-extruded with a cap layer; the TE-1020 substrate provides impact resistance, while the cap layer controls gloss and chemical resistance to blowing-agent oils. Edge-banding applications require uniform thickness and controlled orientation because the profiled strip is flexed repeatedly during application.

Regulatory Status Is Grade-Specific, Not Resin-Class Generic

Compliance statements for RoHS 2011/65/EU and REACH 1907/2006 are issued only for the specific grade and production lot. Unfilled ABS is not intrinsically flame retardant; TE-1020 is typically rated UL 94 HB at nominal thickness. A V-0 classification requires a flame-retardant ABS grade and must not be inferred from the TE-1020 designation. Food-contact suitability is not granted by the acrylonitrile-butadiene-styrene chemistry alone. Some ABS grades may meet FDA 21 CFR 180.22 for food-contact articles, but TE-1020-specific certification must be requested from Lotte Chemical. The end user is responsible for migration testing under actual use conditions.

Immersion in ketones, esters, chlorinated solvents, or aromatic hydrocarbons is not recommended. These solvents plasticize or stress-crack the SAN matrix, particularly in formed parts with residual orientation. Tensile strength retention after chemical exposure shall be validated by ASTM D543-21. The use of regrind above 30 wt% is not recommended without impact testing per ISO 180:2023 and melt flow verification per ISO 1133-1:2022. When regrind is used, it must be dried and blended with virgin pellets; direct feeding of undried regrind introduces moisture variability and reduces notched Izod impact strength.