| HS Code | 783791 |
| Vinyl Acetate Content | 18 wt% |
| Melt Flow Rate | 2.5 g/10 min (190°C, 2.16 kg) |
| Density | 0.941 g/cm³ |
| Melting Point | 88°C |
| Vicat Softening Point | 61°C |
| Tensile Strength At Break | 14 MPa |
| Elongation At Break | 750% |
| Hardness Shore D | 40 |
| Flexural Modulus | 34 MPa |
| Brittleness Temperature | -100°C |
As an accredited Elvax 460 EVA Copolymer Resin,Foam & Footwear Grade factory, we enforce strict quality protocols—every batch undergoes rigorous testing to ensure consistent efficacy and safety standards.
| Packing | Elvax 460 EVA resin, foam/footwear grade, supplied as pellets in 25 kg paper bags on shrink-wrapped pallets. |
| Container Loading (20′ FCL) | 20' FCL: Elvax 460 EVA copolymer resin, foam & footwear grade, packed in 25kg bags on pallets, laden and secured. |
| Shipping | Elvax 460 EVA Copolymer Resin ships as a non-hazardous solid in sealed bags or drums, palletized for safe handling. Keep dry and away from excessive heat. Standard ground or freight carriers are suitable; no special hazmat endorsement required. Ensure proper labeling for foam and footwear manufacturing use. |
| Storage | Store Elvax® 460 EVA copolymer resin in a cool, dry, well-ventilated area away from direct sunlight, heat sources, and strong oxidizers. Keep original containers tightly sealed to prevent moisture absorption and contamination. Avoid dust accumulation; protect from mechanical damage. Store at ambient temperatures below 30°C with adequate ventilation. Properly stored, the material remains stable and suitable for foam and footwear processing. |
| Shelf Life | Store in a cool, dry place away from sunlight. Shelf life is typically two years from date of manufacture. |
Compression-moulded EVA midsole stock based on Elvax 460 is typically formulated with 100 phr resin, 2.2–3.5 phr azodicarbonamide, 0.7–1.1 phr dicumyl peroxide (40% active), 1.8–2.5 phr zinc oxide, 0.8–1.2 phr zinc stearate and 5–15 phr calcium carbonate. Elvax 460 contains 18% vinyl acetate and has a melt mass-flow rate of 2.5 g/10 min at 190°C/2.16 kg when tested to ISO 1133-1:2022; this reduces crystallinity and lowers viscous heating in the internal mixer while retaining sufficient green strength for two-roll mill sheeting. The compound is mixed in an internal mixer with a dump temperature of 105–115°C, homogenized on a two-roll mill at 95–105°C, and then cut into pre-weighed blanks. Expansion is carried out in a hydraulic compression press at 165–175°C under 120–160 kgf/cm² platen pressure for 6–8 min. The main process variable is the balance between dicumyl peroxide decomposition and azodicarbonamide gas evolution; premature press opening collapses cell walls, while excessive cure time drives compression set upward in the finished midsole and reduces the closed-cell recovery needed for repeated impact. Compliance of the finished foam is verified against ASTM D3575-20 for closed-cell foam physical properties and ASTM D395-18 compression set at 50% deflection. REACH Regulation (EC) No 1907/2006 Annex XVII screening applies to polycyclic aromatic hydrocarbon and heavy-metal content in finished consumer goods. Terminal articles include die-cut midsoles, platform wedge components, and footwear lift inserts. Amine-based antioxidants should be avoided because they interfere with peroxide cure kinetics.
Comparative formulation addition ratios for selected downstream foam processes are summarised in Table 1.
| Additive | Compression-moulded midsole | Injection-moulded footbed | EB-crosslinked padding | EVA/EPDM dual-density sole | Cork-filled footbed | Laminated insock | High-filler matting |
|---|---|---|---|---|---|---|---|
| Elvax 460 | 100 phr | 100 phr | 100 phr | 40–70 phr | 55–70 phr | 100 phr | 100 phr |
| Azodicarbonamide active | 2.2–3.5 phr | 0.6–1.2 phr | 7.0–10.0 phr | 1.8–3.0 phr | 1.8–2.4 phr | 3.2–4.6 phr | 4.0–6.0 phr |
| Dicumyl peroxide (40%) | 0.7–1.1 phr | 0.4–0.8 phr | — | 1.4–2.2 phr | 0.5–0.8 phr | 0.8–1.0 phr | 0.9–1.3 phr |
| Zinc oxide | 1.8–2.5 phr | 1.0–1.8 phr | 1.0–2.0 phr | 3.0–5.0 phr | 1.2–2.0 phr | 1.6–2.2 phr | 2.0–3.0 phr |
| Calcium carbonate | 5–15 phr | 0–5 phr | 0–10 phr | 0–10 phr | — | 10–20 phr | 30–60 phr |
| TAIC/TAC co-agent | — | — | 0.8–1.5 phr | 0.5–1.0 phr | — | — | — |
When Elvax 460 is processed by injection moulding for closed-cell footbed components, the resin is pre-dried at 65°C for 4 h when storage relative humidity exceeds 60%, because absorbed water above 0.1 wt% creates surface pinholing and non-uniform cell nucleation. The compound is dosed with 0.6–1.2 phr active azodicarbonamide and 0.4–0.8 phr dicumyl peroxide, with barrel temperatures held between 180°C and 195°C. The injection screw is selected with 20:1 to 24:1 L/D and a shut-off nozzle to limit premature foaming in the barrel; check-ring non-return valves with restricted flow paths are avoided because shear heating can trigger gas separation before the cavity. Cavities are filled to 55–70% of volume, followed by decompression or precision mold opening. Shot weight is controlled to within ±0.4% to keep part density stable across a multi-impression tool, and clamp force is set between 250 t and 400 t depending on projected area and target expansion ratio. Compliance for finished footbeds is commonly governed by ZDHC MRSL v3.7 chemical screening and REACH Regulation (EC) No 1907/2006; mechanical properties are measured with ASTM D3575-20 for closed-cell foam tensile and ASTM D395-18 compression set at 50% deflection. Terminal finished types include foam footbeds, heel seats, rocker sole cores, and clog midsole blanks. The main processing boundary is the moderate melt index of Elvax 460: barrel temperatures above 200°C or residence time above 5 min can initiate pre-foaming, cause deposit build-up on the nozzle seat, and increase rejection rates from surface voids.
Electron-beam crosslinked foam sheet for protective sports padding and recreational matting is produced by feeding Elvax 460 with 7.0–10.0 phr azodicarbonamide, 0.8–1.5 phr triallyl isocyanurate co-agent, 1.0–2.0 phr zinc oxide, and 0.1–0.3 phr hindered phenolic antioxidant into a corotating twin-screw extruder with 40:1 L/D and barrel set points from 95°C to 135°C. The extruded sheet is calender-finished to uniform thickness, then passed through an electron-beam accelerator at a total dose of 40–80 kGy to partially crosslink the EVA matrix before entering a hot-air expansion tunnel at 200–220°C for 2–4 min. The radiation step replaces dicumyl peroxide and avoids residual peroxide decomposition products in the finished sheet, while also permitting continuous web processing. Gel content is generally bracketed between 35% and 65% because lower values permit cell coalescence in the expansion tunnel, whereas higher values reduce elongation below the level required for flexible protective padding. Compliance is screened against RoHS Directive 2011/65/EU and REACH Regulation (EC) No 1907/2006; protective sports padding may require impact attenuation testing under EN 1621-1:2012, while general closed-cell sheet is characterised to ASTM D3575-20. Terminal products are die-cut or thermoformed knee/elbow pads, helmet comfort liners, yoga mats, and gym mat top layers. Published plant-scale data for the exact electron-beam dose response of this specific grade is limited; the dose window should be bracketed during line qualification because under-dosing leaves partially coalesced cells and over-dosing raises gel content and reduces surface conformability.
Elvax 460 is blended with EPDM for two-hardness sole units at 40–70 phr EVA and 30–60 phr EPDM to create a low-density foam layer co-vulcanized with a solid rubber outsole or midsole base. The compound contains 1.4–2.2 phr dicumyl peroxide, 0.5–1.0 phr triallyl cyanurate co-agent, 3.0–5.0 phr zinc oxide, 0.8–1.2 phr stearic acid, 10–30 phr N550 carbon black in the rubber-rich layer, and 1.8–3.0 phr azodicarbonamide in the foam-rich layer. Mixing is performed in an internal mixer; EPDM is first masticated at 60–70°C before addition of EVA to limit phase inversion and uncontrolled viscosity rise, then the batch is dropped at 115–125°C. The two layers are assembled as uncured sheets and press-cured at 160–170°C under 10–15 MPa for 7–10 min. The main process conflict arises from peroxide partitioning: dicumyl peroxide migrates preferentially into the amorphous EPDM phase, reducing crosslink density in the EVA foam phase and increasing compression set if co-agent addition is omitted. The triallyl cyanurate co-agent partially compensates by facilitating co-crosslinking at the EVA/EPDM interface, but exceeding 1.0 phr can produce a brittle foam layer. Compliance for the soling compound is anchored to ISO 4649:2017 abrasion, ISO 34-1:2015 tear strength, and ASTM D395-18 compression set. Terminal product types include dual-density sandal soles, outdoor shoe sole units, and foam-to-rubber transition strips. This configuration is unsuitable for amine-cured rubber additives, and mineral oil loading above 10 phr should be avoided because phase separation and surface bloom reduce interlayer adhesion.
Cork-filled EVA footbed shells are produced by mixing 55–70 phr Elvax 460 with 30–45 phr cork powder, 1.8–2.4 phr azodicarbonamide, 0.5–0.8 phr dicumyl peroxide, 1.2–2.0 phr zinc oxide, and 0.5–0.8 phr stearic acid. The mixer is run to a dump temperature of 105–115°C, then the stock is sheeted at 95–105°C and preheated in a compression press at 160–170°C for 6–8 min. Cork moisture content above 8% creates steam voids and splits at the foam core, so pre-drying of cork at 70–80°C to 2–4% moisture is mandatory in humid production sites. The cork particles act as nucleating agents and modify the recovery behavior of the EVA foam; below 30 phr the visual and mechanical effect is insufficient, while above 45 phr the sheet becomes brittle and die-cut edges chip. Compliance is screened under REACH Regulation (EC) No 1907/2006 and OEKO-TEX Standard 100 for footbed covers; mechanical properties follow ASTM D3575-20. Terminal products are contoured footbeds, sandal beds, and molded arch-support shells. This configuration is limited to compression moulding because cork-filled EVA cannot be safely processed through narrow-gap injection nozzles without hard particle bridging.
Textile-laminated EVA insock production begins with split crosslinked block foam produced from 100 phr Elvax 460, 3.2–4.6 phr azodicarbonamide, 0.8–1.0 phr dicumyl peroxide, 1.6–2.2 phr zinc oxide, 10–20 phr talc, and 0.5–1.0 phr polyethylene wax. The block is skived to 1.5–4.0 mm sheet, conditioned at 40–60°C, and corona-treated where adhesion must exceed 2.0 N/mm in subsequent peel. A solvent-free two-component polyurethane adhesive is applied by kiss-roll coating at 25–35 g/m², followed by nip lamination with polyester or cotton textile and 48 h aging before die cutting. The adhesive selection is critical because solvent-borne systems distort low-density EVA foam unless flash-off time and nip pressure are tightly controlled. Compliance for laminated insock articles is assessed using ISO 11339:2010 for T-peel adhesion, OEKO-TEX Standard 100 for textile components, and REACH Regulation (EC) No 1907/2006 for restricted substances in finished articles. Terminal products are die-cut padded insocks, footbed covers, heel grips, and tongue padding used in sport and casual footwear. Because the foam is skived from a block, local density variation is lower than in direct sheet foam, but thickness tolerance should be maintained within ±0.15 mm to avoid lamination voids.
| Application | Standard or regulation | Test condition or requirement |
|---|---|---|
| Finished EVA articles, EU | REACH Regulation (EC) No 1907/2006 | SVHC screening; Annex XVII PAH and heavy metal limits |
| Electrical and consumer mouldings | RoHS Directive 2011/65/EU | Pb 1000 ppm, Cd 100 ppm, Hg 1000 ppm, Cr6+ 1000 ppm, PBB/PBDE 1000 ppm per homogeneous material |
| Melt flow control | ISO 1133-1:2022 | 190°C/2.16 kg nominal MFR 2.5 g/10 min |
| Closed-cell foam | ASTM D3575-20 | Density, tensile, compression set, and cell structure classification |
| Compression set | ASTM D395-18 | 50% deflection, 24 h at 23°C or 70°C |
| Soling abrasion | ISO 4649:2017 | Rotative abrasion mass loss; brand-specific limit |
| Tear strength | ISO 34-1:2015 | Trouser or angle tear; brand-specific limit |
| Textile lamination | ISO 11339:2010 | T-peel adhesion after 48 h adhesive cure |
| Footwear chemical management | ZDHC MRSL v3.7 | Restricted substance limits in input chemicals and produced articles |
In anti-fatigue matting, Elvax 460 is formulated with 100 phr resin, 30–60 phr calcium carbonate, 4.0–6.0 phr azodicarbonamide, 0.9–1.3 phr dicumyl peroxide, 2.0–3.0 phr zinc oxide, and 0.6–1.0 phr stearic acid. The compound is mixed in an internal mixer, sheeted on a two-roll mill at 95–105°C, and compression-moulded at 165–175°C for 8–10 min. The high filler level increases melt viscosity and gas nucleation pressure, producing smaller cells, but compression set rises rapidly when calcium carbonate exceeds 60 phr, and filler content below 30 phr seldom achieves the flex fatigue required for industrial standing mats. The production press should use daylight evacuation to limit trapped air and edge checks, and the compound must be cooled below 40°C before stacking to avoid blocking. Compliance for industrial mats is typically evaluated under ASTM D3575-20 closed-cell foam tensile, ASTM D395-18 compression set, and RoHS Directive 2011/65/EU; flame-resistance claims require separate additive validation because unfilled EVA is not inherently self-extinguishing. Terminal products are anti-fatigue standing mats, workshop floor top layers, and fitness mat underlays. The substitution of vulcanized rubber with high-filler EVA reduces part weight, but the material retains the characteristic EVA compression set and should not be specified where exposure to swarf oil or hot metal shavings is expected.
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Elvax 460 EVA Copolymer Resin, Foam & Footwear Grade, is an ethylene-vinyl acetate random copolymer in which the nominal vinyl acetate comonomer content is 18 wt%. The resin is supplied as free-flowing pellets with a specific gravity of 0.941 when tested under ASTM D792, and the melt flow rate is 2.5 g/10 min at 190 °C under a 2.16 kg load according to ASTM D1238. These base-resin parameters position the grade for chemically blown, peroxide-cured closed-cell foam and for footwear components such as midsoles, unit soles, and expanded sheet. The 18 wt% vinyl acetate fraction lowers polyethylene crystallinity sufficiently to improve flexibility, filler wetting, and compatibility with polar additives, while the remaining ethylene segments maintain the melt strength required to resist cell-wall rupture during gas expansion. This balance is not universal across EVA copolymers; it produces a narrower processing window than high-vinyl acetate foam grades but yields higher hardness retention at equivalent foam density.
The CAS registry number for ethylene-vinyl acetate copolymers of this class is 24937-78-8. Elvax is a registered trademark of DuPont or its affiliates. The grade is not sold as a ready-to-use compound; typical foam formulations require addition of azodicarbonamide, dicumyl peroxide, zinc oxide, zinc stearate, and mineral fillers before expansion. Manufacturer documentation identifies the grade as suitable for crosslinked block foam, injection-molded footwear midsoles, compression-molded sheet, and expanded profiles. Because the product is an unmodified base resin, downstream melt blending and cure conditions control final density, cell size distribution, hardness, and compression set. Published data for the unfilled resin are limited to a nominal property set; compound-specific performance must be verified on production tooling.
The compositional variable most often used to differentiate foam-grade EVA resins is vinyl acetate content. In lower vinyl acetate copolymers of 9–12 wt%, residual polyethylene crystallinity produces higher Shore hardness, higher flexural modulus, and a higher melting peak when evaluated by ASTM D3418, but the lower polar content limits filler acceptance and requires more intensive dispersion in highly filled foam compounds. In higher vinyl acetate copolymers of 25–28 wt%, crystallinity is suppressed, ductility and low-temperature flexibility increase, and melt temperature decreases; however, the same polar fraction reduces melt strength and can increase tack, causing roll-sticking on two-roll mills and die drool in extrusion if temperatures are not tightly controlled.
Elvax 460 occupies an intermediate position. The 18 wt% vinyl acetate comonomer content is high enough to provide useful adhesion to polar fillers and curatives, but low enough to preserve a crystalline network that contributes dimensional recovery in crosslinked foam. Compared with a higher-vinyl acetate grade of similar melt index, the 18 wt% copolymer typically produces higher hardness and lower compression set at equivalent foam density; compared with a lower-vinyl acetate grade, it reduces processing torque and improves low-temperature crack resistance. The property distinction is not governed solely by vinyl acetate content. Molecular weight distribution, long-chain branching, and residual catalyst residues also affect melt strength and cure response. A compounder seeking to substitute Elvax 460 with another 18 wt% vinyl acetate EVA should compare melt flow rate, density, and extrusion torque under identical screw configuration and temperature profile.
Standard mechanical characterization of base resin and foam uses ASTM D638 for tensile properties, ASTM D790 for flexural properties, ASTM D2240 for Shore hardness, and ASTM D3574 for flexible cellular materials. The exact values depend on foam density and cure state; no single Shore A or Asker C value can be assigned to the base resin alone.
In a typical crosslinked foam line, Elvax 460 is compounded on a co-rotating twin-screw extruder with an L/D ratio between 32:1 and 44:1, using distributive mixing elements rather than aggressive kneading blocks to limit shear heating. Barrel temperatures are maintained at 90–120 °C in the feed zone and 120–140 °C in the mixing zone; the die head is held below 130 °C because dicumyl peroxide decomposition becomes significant above 140 °C. Azodicarbonamide is typically added at 2.0–6.0 phr, dicumyl peroxide at 0.5–1.2 phr, zinc oxide at 1.0–3.0 phr, and zinc stearate at 0.5–2.0 phr. These loadings are adjusted to target foam densities from 0.08 g/cm³ to 0.30 g/cm³, with lower densities requiring higher gas generation and more precise control of melt strength.
On production-scale equipment, the main failure modes observed are premature blowing agent decomposition in the extruder head, peroxide scorch in stagnant zones, and cell coalescence after decompression. Screw elements with low free volume or worn barrel sections create local residence times long enough to initiate decomposition before the melt exits the die. Two-roll mill handling is also sensitive: roll temperatures above 120 °C can cause the compound to stick and wrap uncontrollably, while temperatures below 100 °C reduce dispersion of filler and curatives. Batch-to-batch variance in melt flow rate of the base resin is addressed by adjusting screw speed and back pressure; higher melt viscosity batches require lower screw speeds or increased barrel temperatures to prevent overtorque.
At relative humidity above 60%, hopper drying at 60–70 °C for 2–4 h is recommended to reduce surface moisture and prevent steam-induced surface defects. The resin should not be dried at temperatures that soften pellets or agglomerate in the hopper.
The relatively low melt flow rate of 2.5 g/10 min measured under ASTM D1238 indicates a high average molecular weight relative to injection-molding EVA grades that exhibit 10–30 g/10 min. In continuous foam extrusion, low melt flow index tends to correlate with high elongational viscosity and improved bubble stability. This is critical during pressure drop at the die, where dissolved gas separates from the polymer melt and forms cells. If the melt has low melt strength, cell walls drain and coalesce before cooling quenches the foam structure. Elvax 460 is therefore more suitable than high-melt-index EVA grades for thick crosslinked sheet and low-density foam where bubble stability is the controlling variable.
Published capillary and elongational viscosity data for Elvax 460 are limited in commercial product literature. Processors commonly quantify lot-to-lot consistency via melt flow rate and use a Rheotens-type melt strength test at haul-off speeds matched to line speed. Because the resin is extruded at shear rates between 10 s⁻¹ and 1000 s⁻¹, single-point melt flow rate is insufficient for process transfer; a capillary rheometry sweep at 160 °C, 180 °C, and 200 °C is recommended when changing screw design or die geometry.
Thermal stability boundaries are more restrictive in the melt phase than in solid-state storage. Barrel residence above 220 °C accelerates acetic acid elimination from vinyl acetate sequences, causing gel formation, discoloration, and corrosion risk on downstream equipment. The resin should therefore be purged before extended shutdowns, and stagnant zones in screen changers and die lips should be minimized. Incompatibility with amine-based additives or amine-functional masterbatches is reported because amines can interfere with peroxide cure kinetics and stabilize free radicals, reducing final gel fraction.
The most demanding part of EVA foam processing is the simultaneous peroxide cure and blowing agent decomposition. Dicumyl peroxide decomposes at 150–170 °C through a free-radical mechanism that abstracts hydrogen from the polyethylene backbone and forms covalent crosslinks. Activated azodicarbonamide begins gas release in the same temperature region when zinc oxide and zinc stearate are present; without activators, neat azodicarbonamide decomposition occurs at 205–215 °C. In a compression-molded foam cycle, the compound is heated under hydraulic pressure of 5–15 MPa at 160–175 °C for 8–15 min. The external pressure keeps blowing gas dissolved or finely dispersed while the cure network develops. At the end of the cycle, depressurization triggers cell growth; the crosslink density at that instant determines whether cells remain closed and uniform or collapse.
Gel fraction is the critical quality parameter. A solvent extraction test based on ASTM D2765 using xylene is used to measure the insoluble fraction after reflux. Production experience for EVA foam midsoles indicates that gel fraction below 50% produces weak cell walls and high compression set, while gel fraction above 80% restricts expansion and increases boardiness. The optimal band is therefore compound-specific, but most footwear foam lines operate between 55% and 75%. When the ratio of dicumyl peroxide to azodicarbonamide is shifted too high, cure precedes gas evolution, producing dense skin layers and internal splits; when too low, gas evolution precedes cure, producing coarse cells and surface pinholes. These are not hypothetical edge cases; they are routinely observed on multi-daylight presses and continuous double-belt foaming lines.
The grade is evaluated in finished footwear components primarily through density, hardness, compression set, rebound, and peel adhesion. Density is measured according to ISO 845 for cellular plastics or ASTM D3574 Test A; compression set is measured at 50% deflection for 6 h at 50 °C according to ISO 1856; rebound is measured by DIN 53512; and hardness is reported as Shore A under ASTM D2240 or Asker C under JIS K 7312 for foam. A typical midsole compound based on Elvax 460 may show density 0.15–0.20 g/cm³, Asker C hardness 45–60, and compression set 25–40%, but these ranges are influenced by filler loading, blowing ratio, and cure state. Published data for this specific configuration are limited, so footwear producers generate their own specification limits on production molds.
Compared with a 25 wt% vinyl acetate foam grade of similar melt index, Elvax 460-based compounds generally deliver higher Asker C hardness and lower compression set at equivalent density, but sacrifice some low-temperature flexibility and may require slightly higher cure temperature or longer cure time. Compared with a 12 wt% vinyl acetate grade, Elvax 460 improves filler dispersion and reduces processing viscosity, which is advantageous in highly filled formulations containing 20–40 phr calcium carbonate or talc. The choice of grade therefore shifts the property envelope, not just the melt index.
Processors should not blend Elvax 460 with EVA grades containing high residual acidic comonomer or with maleic anhydride-grafted polyolefins without evaluating melt stability, because acid-catalyzed vinyl acetate cleavage may increase gel and cause plate-out. Long storage at ambient temperatures below 40 °C and dry conditions is recommended to preserve pellet flow and prevent agglomeration in silos.
