By: Keith Donaldson Intercept Technology Group

Transcription

1 By: Keith Donaldson Intercept Technology Group Red Bickerstaff FPM Inc

2 The goal of this paper is to review advances in anti-corrosion packaging in order to achieve enhanced operational readiness Changes in technology can be slow in the packaging world but the demands on packaging and what we need it to do are increasing. We need to start demanding more from our packaging, because the requirements are increasing, so what is needed is Complete Corrosion Protection, plus

3 Need Anti-Corrosion Protection that is effective not just at protecting against rust but also providing: - Protection Against the elements (indoor and outdoor storage) - Protection Against corrosive gases - Protection Against mold and mildew - Protection Against insects - Protection for items containing rubber and/or gaskets - Compliance with European environmental requiring oil free solutions - Ease of use including ease of opening and closing in the field - Shelf life of 10+ years and long useful life - Temperature independent: Effective -42oF to 160oF

4 Improving Operational Readiness: - Reduce service and maintenance intervals - Eliminate the need for volatile packaging and oils - Extend the lifetime of military assets Advantages over use of Aluminum Foil: - Unlike Al foil, RP works without hermetic seals/ vacuum and will continue to protect if folded / creased - Faster loading / closing time - Can be opened and closed easily in depot and/or the field - Without needing oil can be operationally ready faster RFID Transparent - You can read RFID Tags through the material - Can tag and find your assets

5 Pollution The Global Silent Killer A World Health Organization (WHO) report estimates that diseases triggered by indoor and outdoor air pollution kill 656,000 Chinese citizens each year... " [March 8, 2007]. Air pollution is estimated to cause approximately two million premature deaths worldwide per year" said Michal Krzyzanowski, an air quality adviser at the WHO Regional Office for Europe. (In 2012 this number increased to 7 million deaths) In neighboring India, air pollution is believed to cause 527,700 fatalities a year. In the United States, premature deaths from toxic air pollutants are estimated at 41,200 annually. Kevin Holden Platt in Beijing, for National Geographic News, July 9, 2007

6 It s an increasingly polluted world out there - 27% of all deaths in China are now lung related - If it is impacting tissue, what is it doing to metal objects, electronics, military equipment?

7 Earlier this year, an unusually large dust cloud that originated in northwest China drifted across the continental United States and lingered over Denver and other areas, at times obscuring views of the Rocky Mountains by Reggie Royston - June 1, 2001 for National Geographic News "Over the last few years, there has been a growing awareness that air pollution from China is affecting us," said Russ Schnell, an official at the U.S. National Oceanic and Atmospheric Administration, which tracked the recent dust clouds. National Geographic News Oct. 28, 2010

8 Air Quality Images from May 2013 from Shanghai, before and after a heavy rain Last measurement of H 2 S in the general area: 1,500 ppb Jointly with increased Cl levels on shore in Asia there are increased defects visible

9 Air Quality The Air Quality in Asia is getting worse and unfortunately it is impacting areas far from the shores of where the pollution originates. Studies at the Waseda University in Tokyo show that humidity is not necessarily the prime culprit in non-ferrous (non-iron) based corrosion, but it s the pollution levels. In the case of electronics and the silver used in electronics, it s the level of Sulfur gases in the air that drive the corrosion rate. H2S Levels Worldwide (Test data obtained by Bell Labs 2003) Average Level USA Average Level Europe Brazil (Rio de Janeiro) Shanghai, China (outdoors) Suzhou, China (inside cleanroom) 7 ppb 15 ppb 650 ppb 800 ppb 1500 ppb

10 Air Quality When looking at materials and what damages them, the same gases keep coming up. Controlling these gases you can positively impact assets. Metals Plastics Rubber Paint Fabric Paper Leather Ceramic Digital/Magnetic Rust/Corrosion, discoloration, staining & weakening from all corrosive gases. Strength loss & discoloration due to Ozone, UV Rays, & Nitrogen Oxides. Flexibility & strength loss due to Ozone, UV Rays, & Nitrogen Oxides. Surface erosion by Sulfur Oxides, Hydrogen Sulfides & Nitrogen Oxides. Reduced strength & degradation by Sulfur Oxides & Nitrogen Oxides. Embrittlement, degradation & discoloration by Sulfur Oxides. Weakening & powdery surface by Sulfur Oxides. Changing surface appearance by acid gases. Changing surface topography by acid gases or erasure of data from electric fields.

11 Air Quality NOx Gas (Nitrous Oxide) O3 (Ozone) HCl (Hydrogen Chloride) H2S (Hydrogen Sulfide) COS (Carbonyl Sulifide) SO2 (Sulfur Dioxide) Explanation / Source Effluent from gas powered vehicles is an accelerant to corrosion Ground level smog is an accelerant to corrosion Typically, high concentrations near ocean surfaces can travel in high concentrations 50 miles or more from ocean One of the most reactive forms of Sulfur gases Prevalent near or on ocean surfaces very reactive Requires particles in the air to be reactive more of an issue in Asia, South America

12 Air Quality Part of looking at air quality is considering the impact of the air on and near an ocean surface. The three main impacts of salt air are high levels of Chlorides, Carbonyl Sulfide and Hydrogen Sulfide. Chlorine Permeation through 2 mil PE Film Film Actual Time to Simulated Time to Simulated Time to Description Chlorine Break-through ppm PE Film 16.6 min yrs 7.4 days Reactive Polymer (RP) 473 hrs 3455 yrs yrs

13 S/Cu Ratio Air Quality Sulfur Penetration into 3 mil RP Film Test Using SEM-EDX (Scanning Electro-Microscope) H2S 10 Equiv. Years Exposure to 7ppb H2S 58 um Penetration Depth (um) 12 um Since the material is typically w ound onto itself, looking at th e Sulfur and Chlorine impact on the film it becomes obvious that basically there are no real shelf life concerns and that there is a very long useful life for RP Products, since the primary functionality is acting as a reactive barrier

14 Unique Points with Reactive Polymer (RP) (1) Volatile free corrosion protection, does not outgas and deposit any coating or contamination on the part(s). (2) Permanently anti-static, which is key for protecting electronics and for protecting Aluminum based materials. RP is also safe for polycarbonate materials. (3) Long, stable shelf life (in excess of 15 years) and long stable useful life (4) Prevents mold and mildew no other material does this. (5) Covers and RP Shrink Film are designed for up to 5 years outside in harsh desert environments (6) Covers and RP shrink film are RFID Transparent (7) RP has a color change indicator it starts out dark brown on the inside which changes colors to jet black as it is used up. (8) RP by blocking ozone, UV and mold can help protect gaskets, tires and rubber based materials Intercept will not adversely impact rubber or gaskets, will not cause swelling. (9) RP has been shown to be effective at blocking Termites. (10) Developed by Bell Labs

15 It comes down to Great Chemistry Only Intercept utilizes high-surface area Copper particles (CU) that are bound firmly into the polymer-matrix. Their unique ability to quickly and efficiently neutralize corrosive gases provides protection against corrosion like no other material available for industry. RP creates a reactive barrier keeping the gases that cause corrosion out, and provides cleansing of the trapped air inside the package, creating a clean micro-environment. This allows for re-use and opening in the field.

16 Temperature Range Deployment and operational temperatures need to be in synch with the effective range of your packaging materials Because the RP material is Copper based, it has no volatiles or oils it provides: Indoor Storage - tooling - Preferential Corrosion site - Reactive Barrier - Reactivity of Copper is a function of temper ature, but it still works within the temperat ure range of the polymer (-42 o F to 160 o F) Gazprom (Eastern Europe) down to -40oF Storage outdoors

17 Cleanliness Considerations Ionic contamination often comes from additives and other substances added to polymers either for functional or processing reasons Cat-Ions-Measurement (Tested by Balazs Labs, USA) Cat-Ions Limits RP Lithium 0.1 ng/cm2 Not detectable Sodium 0.1 ng/cm2 Not detectable Ammonium 0.2 ng/cm2 Not detectable Potassium 0.2 ng/cm2 Not detectable Magnesium 0.2 ng/cm2 Not detectable Calcium 0.2 ng/cm2 Not detectable

18 Cleanliness Considerations Ionic contamination often comes from additives and other substances added to polymers either for functional or processing reasons Cat-Ions-Measurement (Tested by Balazs Labs, USA) Cat-Ions Limits RP Lithium 0.1 ng/cm2 Not detectable Sodium 0.1 ng/cm2 Not detectable Ammonium 0.2 ng/cm2 Not detectable Potassium 0.2 ng/cm2 Not detectable Magnesium 0.2 ng/cm2 Not detectable Calcium 0.2 ng/cm2 Not detectable

19 Cleanliness Considerations Outgassing also factors into cleanliness it can potentially impact such things as gaskets (swellables), polycarbonates, etc. Outgassing Testing (RP Film) Volatile Organics (Headspace) Volatile Organics Values Test Method Total Hydrocarbons < I μg ASTM F Total Outgassing < I0 μg method B

20 ESD Considerations ESD (Electro-Static Discharge) can impact Al corrosion as well as possibly damaging to electrical equipment, systems, components, boards, spares With new military systems ESD (protecting against electro-static discharge) is more and more critical, especially for spares. RP was designed to provide permanent ESD protection that is: - Permanently anti-static (typically 10e6 ohms/sq) - Humidity independent - Temperature independent - Able to be cleaned with no impact on properties

21 ESD Considerations Sometimes its not just the item that needs ESD protection, but also only ESD safe materials can be used in ESD safe areas The heat shield needed ESD protection Heat Shield Being Inspected Heat Shield Wrapped in RP Shrink Film An additional advantage of a shrink film in this type of a barrier application, versus a Mil 131-J foil is that shrink films (PE) are RFID compatible not blocking the signals

22 Oil Free Considerations In many applications oil is not practical or easily removed which would greatly increase time required to make operationally ready RP Aerospace / Aviation Applications Jet engine Spare shipped from South Africa

23 Oil Free Considerations Cost is also a factor, but so are political, regulatory (European in this case), and environmental considerations Oiling costs: 3 De-Oiling costs: 24,80 Savings per unit using RP: 27,80 Oiling and De-Oiling have immense costs and a highly negative impact on the environment. RP, by providing corrosion protection that does not require oils, can drastically reduce the preservation cost and helps to avoid bottle necks in both preserving and cleaning by avoiding unnessesary steps for conservation.

24 Oil Free Considerations It is possible to have Corrosion Protection without the Use of Oils and/or Volatiles and be in compliance with the various environmental regulations. Camp Pendleton (USA) New European regulations ban the recycling of plastics if more than 50 ml of oil per 1 m3 of plastic material is present Oil free is critical in overseas deployment Sea Sprites Australian Air Force

25 Direct Military Applications Operational readiness requires effective protection and preservation, but also quick response and the ability to monitor / rotate / etc. CH47 Wrapped in Reactive Polymer Shrink Film with Inspection Access Door By being oil free, corrosion protection the items are ready to go into service quickly. Quick access to military assets was a key driver for the Singapore Military in deciding how to stage and protect assets.

26 Direct Military Applications A lot was learned from working with various Military organizations around the world Bronco Storage Prior to wrapping the units went through standard mothballing procedures as directed by the military operations. Once the engines and drive train systems were protected, the you can begin protecting the inside of the vehicles, using a bladder bag concept, coupled with the Reactive Polymer (RP) Film as dunnage bags, filled up inside the dead air space to minimize the amounts of desiccants required.

27 Direct Military Applications A lot was learned from working with various Military organizations around the world Inserting the RP Film Bladder and inflating Inflation of the RP Bladder When the equipment is needed, the bladder can be cut and removed quickly with no need to search for countless desiccant bags. The condensation inside the dead air space is mainly controlled in the bladder, which is taking up the vast amount of dead air space.

28 Direct Military Applications Weapons and Munitions Preservation and storage of heavy artillery Solution: Oil free protection - designed for rapid deployment Reduction of service required and extended maintenance interval

29 Direct Military Applications The Final Overwrap Using RP Shrink Film The asset can be stored inside or outside, and is ready for when it is required to be put into action.

30 Award Winning Military Application This won a NIPHLE (National Institute of Packaging, Handling, and Logistics Engineers) Design Award The RP Film was used in a very unique design to allow a re-usable, returnable crate design for moving assets from the US to SWA and back to the US. Stewart & Stevenson packaging engineers were tasked to design a container for the Low Signature Armored Cab (LSAC). There were two main objectives for the container. First, the container needed to adequately protect the LSAC during shipment to SWA (Iraq, Kuwait and Afghanistan). Second, the container needed to be reusable. After the LSAC was installed on a truck chassis in SWA, the standard Family of Medium Tactical Vehicle (FMTV) cab (removed from the chassis during the retro fit) was shipped to the U.S. for storage. The reusable container needed to adequately protect the standard FMTV cab during shipment and long term storage. Both objectives were met.

31 Award Winning Military Application The trip over was critical. The other wall panels were all outfitted with RP Film covering each of the insider surfaces. The panels were secured with gaskets and locked into place using nail free crating. Front View of LSAC, With RP Film Underneath

32 Award Winning Military Application The cab ready for its return trip to the US. Safe and secure in the crate, protected against corrosion using oil free, contamination free reactive polymer film. Since there are no volatiles the RP film is safe for use with Polycarbonate films, optics, electronics as well as for protecting and use with gaskets and other items that could pose swelling or other degradation issues. Standard HIMARS Cab on Container Base

33 Outside the Box - Military Applications A military organization was looking for a better way to do short to medium term preservation the solution a portable hangar (indoor / outdoor) The savings and the applications are immediately seen; from reducing the need for electricity to reducing the amount of time required to remove the asset from storage. RFID signals are possible through the material, so remote monitoring is possible. The dehumidifier runs for 2-4 hours then is turned off (after enclsure is closed)

34 Outside the Box - Military Applications Same Concept for storage containers into long term, moveable storage capable of keeping assets free from corrosion, degradation and contamination. Ready to go into the Container Lining 20 or 40 Foot ISO Containers

35 Outside the Box - Military Applications German Military Shipping Tanks from Germany to Australia The addition of desiccant (16 units per m3 of free air space) is strongly advised to avoid condensation and flash rust remove (and replace) when access panel is re-opened The use of zipper access panels, taped into place after heat shrinking is complete, allows for re-entry. No hermetic seals required.

36 RP Canvas - Reusable Military Applications High Speed Army Watercraft allowing 50 caliber guns (protecting them from corrosion) to be protected but ready in seconds The solution, Reactive Polymer Canvas covers that utilized Velcro seals. The learning curve was that a separate design was required for the Port and Starboard side otherwise the cover would blow off. Operationally ready. No oils, no contamination, no volatiles, no temperature constraints, no smells and a design that will protect for years.

37 RP Canvas - Reusable Military Applications Land and Vehicle The M60A1 AVLB (Armored Vehicle Launched Bridge)

38 Insect Considerations Sometimes operationally ready also means not having to use dangerous chemicals to avoid insects Day 64 Wet wood placed inside of an RP bag then inside of certified termite mound No chew marks on the plastic, no holes in the plastic and 100% of the wood inside was completely intact Additional long term testing has been conducted at several US universities

39 Mold, Mildew and Microbe Considerations - Mold and mildew will not grow in the presence of Copper - Testing done with Marines at base in GA showed that even damp uniforms placed inside RP bags did not mildew or have mold growing even after 6 months of storage - Testing at the University of Wisconsin and SGS in Singapore confirm the fact that RP kills all dangerous microbes in a hospital (with the exception of spores)

40 Conclusions Reactive Polymer Technology Developed by Bell Labs to Provide Superior Protection: Protects all parts, components, and equipment Easy and Effective, can be easily repaired, reclosed in the field Designed for any environment Many styles + products (shrink film / Bags / Re-usable covers) Green, Clean and RFID transparent Uses no oils, does not outgas and approved by automotive companies for proven long term corrosion protection and storage (up to 15 years) as well as militaries around the world No outgassing, no fumes, no worker safety or material compatibility issues Learn more at: