Applications of LyondellBasell Ultrathene UE635000 EVA in Industrial Manufacturing

LyondellBasell Ultrathene UE635000 EVA is a specialty ethylene-vinyl acetate copolymer formulated for consistent quality, offering downstream manufacturers precise control in demanding applications. Our material supports process stability and product performance in a range of industrial segments where compliance, formulation exactitude, and proven processing behavior are mission-critical.

1. Photovoltaic Encapsulant Sheet Manufacturing

Solar module manufacturers rely on high-melt index EVA grades for encapsulant films to deliver optical clarity, UV resistance, and reliable lamination. This EVA supports lamination at moderate temperatures and maintains material flexibility and adhesion needed to withstand thermal cycling and environmental stress over decades of module service life. Downstream users select specific process windows and formulation ratios based on thickness, cure speed, and performance targets required by photovoltaic standards.

Industry compliance standards

• IEC 61215: Crystalline silicon terrestrial PV modules – Design qualification and type approval
• UL 1703: Safety standard for flat-plate photovoltaic modules and panels
• TÜV Rheinland PV testing protocols
• RoHS/REACH compliance for materials in contact with electrical equipment

Typical usage ratio

• Formulators use 100% EVA for encapsulant sheet extrusion, sometimes blending with less than 5% crosslinking agents and stabilizer packages to achieve optimal curing and anti-aging properties, with exact proportions adjusted according to film thickness, cure speed, and E-modulus requirements.

Downstream process integration

• Granules are compounded with crosslinking agents and antioxidants, extruded into film, and laminated around PV cells between glass and backsheet under vacuum and heat (typically 140–155°C for 10–18 minutes) to yield encapsulated modules.

Final product types

• PVC-free photovoltaic encapsulant sheets
• Mono- and polycrystalline silicon PV modules
• Thin-film solar panels
• Building-integrated photovoltaic (BIPV) laminates

2. Wire and Cable Insulation & Sheathing

Producers of industrial and power cables use EVA-based compounds to achieve dependable electrical insulation, toughness, and low-temperature flexibility. EVA supports flame retardant property enhancements and boosts resistance to pressure-induced deformation, key for automotive, appliance, and power transmission cables. Strict adherence to electrical, fire safety, and processing regulations guide exact mixture design and extrusion conditions.

Industry compliance standards

• UL 1581: Reference standard for electrical wires, cables, and flexible cords
• IEC 60502-1: Power cables with extruded insulation and their accessories for rated voltages
• EN 50267 & EN 60332 (fire/non-halogen testing protocols)
• REACH/ROHS for hazardous substances

Typical usage ratio

• EVA typically comprises 15–35% of insulation and sheathing compounds, balanced with fillers (such as ATH for flame retardancy), plasticizers, and stabilizers. The specific percentage is determined by the voltage rating, abrasion demands, and targeted flexibility of the finished cable.

Downstream process integration

• The material is introduced at the compounding phase, mixed with additives via twin-screw extrusion, then directly extruded over copper or aluminum conductors, followed by continuous vulcanization or irradiation for crosslinking (when required).

Final product types

• Flexible power cords and appliance wires
• Automotive low-voltage cable sheaths
• Instrumentation and communication cable insulation
• Halogen-free flame-retardant (HFFR) wire sheathing compounds

3. Hot Melt Adhesive Formulation

Industrial adhesive formulators employ high-quality EVA to optimize hot melt adhesive strength, set time, and processability for packaging, woodworking, hygiene, and laminating lines. Key performance factors—such as open time, viscosity, and flexibility—are managed by the vinyl acetate content and molecular weight profile. Strict safety and performance requirements govern both raw material selection and finished adhesive properties.

Industry compliance standards

• FDA 21 CFR 175.105: Adhesives for food packaging applications
• ISO 9001:2015 certified quality management systems
• EN 923: Adhesives – terminology and definitions
• ASTM D1876: Peel resistance of adhesives

Typical usage ratio

• EVA-based adhesives usually contain 25–55% EVA by formula weight, adjusted for block stability, substrate type, and target set speed, together with tackifiers, plasticizers, waxes, and functional additives. Lower EVA ratios favor temporary bonds, while higher ratios increase elasticity and toughness.

Downstream process integration

• The material is batch-melted with tackifiers and plasticizers in a heated mixer or extruder; hot melt granules or blocks are fed to in-line applicators or extruders at 140–180°C and applied by spray, roll, or slot-die for immediate substrate bonding.

Final product types

• Case and carton sealing adhesives for food and beverage packaging
• Bookbinding glues
• Furniture and woodworking assembly adhesives
• Disposable hygiene product lamination and construction glues

4. Flexible Film and Packaging Production

Film converters integrate this EVA grade to stabilize mechanical strength, impact resistance, and sealing behavior in multilayer packaging. Its use is predominant in food-contact packaging, shrink film, and freezer wrap, where it provides low-temperature performance and transparency. Producers adjust formulations to fulfill local regulatory food contact approvals, barrier targets, and processing throughput.

Industry compliance standards

• EU 10/2011: Plastics in contact with food
• FDA 21 CFR 177.1350: EVA copolymers for food contact
• ISO 22000: Food safety management for packaging materials
• China GB 9685: Standard for additive use in food-contact plastic materials

Typical usage ratio

• EVA content typically ranges from 8–20% in multilayer food packaging to balance seal strength, flexibility, and optical clarity, with the exact level based on target thickness, line speed, and customer specified barrier properties.

Downstream process integration

• The granulate is dry-blended with LDPE, LLDPE, or mLLDPE and processed by blown or cast film extrusion. EVA-rich layers are often co-extruded for enhanced sealability and cold resistance, or used as sealant or shrink layers in multilayer structures.

Final product types

• Frozen food and fresh produce packaging films
• Shrink wrap film for palletizing and retail display
• Flexible pouch laminates
• Vacuum bag and lid sealing films

5. Foam Sheet and Gasket Production

Foam producers incorporate EVA for shock absorption, cushioning, and chemical resistance in automotive, electronics, and sporting goods. The copolymer supports consistent cell structure in physically and chemically blown foams, ensuring stable density and resilience. Processing conditions and blending ratios comply with sector-specific durability, emissions, and fire resistance guidelines.

Industry compliance standards

• FMVSS 302: Flammability of automotive interior materials
• RoHS/REACH (restricted substances for automotive and electronics)
• EN 71-3: Safety of toys—migration of certain elements (for sporting goods)
• ASTM D3575: Flexible cellular materials – EVA foam physical property testing

Typical usage ratio

• Foam formulations typically contain 65–98% EVA, with content reductions only when blending with PE or fillers. The precise level is set to adjust density, hardness, and compression set for the targeted foam type and thickness.

Downstream process integration

• Material is mixed with chemical blowing agents, crosslinkers, and pigments; foamed via extrusion or compression molding; and, for some types, crosslinked via irradiation or steam autoclave. Sheet rolls or blocks are then die-cut or laminated to size.

Final product types

• Automotive vibration dampening gaskets
• Consumer and industrial shock absorption mats
• Protective packaging inserts
• Sports and yoga mats