Capstan drive units Mechanical handling rollers
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1 PRODUCT INFORMATION PROVISIONAL TECHNICAL DATASHEET 8/6/2013 Introduction MONOTHANE is a range of single component, ready formulated polyesterbased polyurethane elastomers, available in the hardness range of 20 to 90 Shore A. The advantages of MONOTHANE over all conventional polyurethane elastomers are: MONOTHANE THE SINGLE COMPONENT ELASTOMER Single Component Each hardness grade is supplied pre- formulated - no mixing is required. No Degassing As MONOTHANE is cured it goes through a water thin stage. It thus automatically degasses, and this means bubble free castings with uniform physical properties. Low Capital Costs No mixing or dispensing equipment is needed. No vacuum degassing equipment is needed. An efficient aircirculating oven is required for melt down at 70 C and curing at 135 C. A well sealed mould is also vital. There is no waste. After melt down the required amount is tapped off; the drum may then be resealed for use again, provided an accurate melt down temperature has been maintained. Although nitrogen flushing is recommended, it is not essential. Ease of Handling MONOTHANE may be melted down in the container at 70 C, poured into a well-sealed, pre-heated metal mould and then cured at 135 C. Simply HEAT POUR CURE. MONOTHANE is free from any volatile toxic materials such as isocyanates both as supplied and during the curing process. Applications MONOTHANE TM is used on a world-wide basis for the manufacture of: Printing rollers Capstan drive units Mechanical handling rollers Seals Steel mill rollers Gaskets Anti vibration mountings Rings Textile spinners Isostatic press bags MONOTHANE exhibits extreme durability and performance in these demanding applications when compared with rubbers and other urethane systems. MONOTHANE overcomes one of the major problems in manufacturing vertically cast rollers, i.e. air entrapment. MONOTHANE passes through a water-thin stage during the curing process allowing it to automatically degas, producing bubble-free mouldings. This is particularly important when making long rollers of small overall diameter. MONOTHANE can be used for horizontally and vertically cast rollers. In many applications MONOTHANE has a higher abrasion resistance than metals. Page 1 of 6
2 Processing Details The following information is given as a guide to processing this product. It is recommended that optimum conditions for a specific application are determined experimentally. Our Technical Service Department can offer more detailed advice about oven design. Processing Equipment Ovens Ideally two fan ovens should be employed, both capable of rapid air circulation from top to bottom of the oven, one as a melt-down oven set at 70 C, and the other as a curing oven set at 135 C. Alternatively a curing oven and a hotbox or heating mantle arrangement for melt out at 70 C should be used to hold the product at this temperature during the period of use. It is recommended that the oven temperature is controlled at 135 C ± 2 C. The oven type should be sufficient to ensure that the curing temperature is reached quickly. An even temperature distribution throughout the oven is extremely important to achieve product consistency. Mould Preparation Ensure the mould is cleaned thoroughly. Use a well sealed, metal mould. During the curing process as MONOTHANE TM goes through a water-thin stage and will leak if a sealed mould is not used a good quality silicone sealant can be used. Treat the mould with the recommended mould release agent. Pre-heat the mould up to 135 C before casting; this ensures a uniform melt down and cure cycle, giving the best operating procedure for producing uniform castings. Preparation of Bonded Components MONOTHANE can be bonded to metal or plastic components using a suitable bonding agent which has been fully evaluated first. Prior to bonding the metal or plastic should be fully degreased and grit blasted first. Your bonding agent supplier would be able to advise the best bonding agent. Melt Down MONOTHANE - as supplied is a high viscosity resinous material. Melt at 70 C to reduce to a pourable viscosity kg containers melt for typically 12 hours 200 kg drums melt for typically 24 hours Place in a dry oven for the periods indicated above. To reduce preparation times MONOTHANE can be held in the container at 60 C for up to 4 days, and dispensed as required. CAUTION: DO NOT EXPOSE TO TEMPERATURES ABOVE 75 C PREMATURE CURE WILL BE STARTED. Hot spots can cause localize polymerisation. Moisture Some of the curatives in MONOTHANE are hygroscopic. Care should be taken to avoid moisture contamination. If containers are vented during the warming period, a drying tube or dry nitrogen should be used. If the resin is to be heated then cooled and reheated, a blanket of dry nitrogen should always be used. For satisfactory results PROTECT FROM MOISTURE. Pouring MONOTHANE elastomers when heated to 70 C can be poured directly into moulds from containers as supplied. Care should be taken to eliminate contact with moisture and pouring should be slow to ensure the minimum of air entrapment. Page 2 of 6
3 Curing The material will start to cure above 75 C. This process is extremely slow at first and increases as the temperature is raised to the optimum level of 135 C. The higher the hardness of the system, the faster it will gel. Above 170 C gassing and degradation of the polymer backbone will take place. The minimum viscosity is obtained in the region of 110 C to 115 C and this low viscosity phase allows all entrapped air to escape with ease. The cure time will depend upon the mass of the mould, the type of metal, the curing temperature, the circulation of air in the oven, the size of the moulding and its cross sectional thickness. MONOTHANE TM resin has a very low co-efficient of heat transfer compared to metals and the inside portions of thick sections will take longer to heat up, hence will cure more slowly. As a general guide when curing at 135 C with a material poured at 70 C into a mould made of steel at a temperature of 70 C the following cure times are suggested: Up to 2 cm Cross Sectional Thickness - Cure time 6 hours Greater than 5 cm Cross Sectional Thickness - Cure time 8 hours In the case of large mouldings, it may be necessary to extend the cure time to hours. It is recommended that the optimum conditions for a particular application are determined experimentally by the user. The recommended curing temperature for all hardnesses is 135 C. Curing at other temperatures is possible, although the cure time should be adjusted accordingly. Again, it is recommended that the optimum conditions for a particular application are determined experimentally by the user. Typical cure times are: Temperature Typical cure time for cast sections up to 2.5mm thick below 125 C (257 F) Incomplete cure, hence should be avoided. 127 C (260 F) 8 14 hours 135 C (275 F) 6 8 hours 149 C (300 F) hours 166 C (330 F) 1 hour 170 C (338 F) Degrades In some cases it may be necessary to carry out a further degassing step. This can be done either by melting out the product overnight at 70 C or, after casting, hold the MONOTHANE for two hours at 90 C 110 C in the mould before increasing to the curing temperature of 135 C. Demoulding MONOTHANE elastomer can be demoulded hot. Removal from the mould should not be a problem, providing the correct release agent has been employed. Care should be taken when demoulding large or complicated mouldings to avoid causing damage or distortion whilst hot. INCREASING MOULD UTILISATION - Once the polymer has reached 135 C, the mouldings are structurally stable typically within 2 hours, although larger mouldings may take considerably longer. It is recommended that the optimum conditions for a particular application are determined experimentally by the user. They can be demoulded and immediately returned to the oven to complete the curing cycle. Excessive stress should be avoided during demould. DO NOT ALLOW THE MOULDINGS TO COOL DOWN SIGNIFICANTLY BEFORE RETURNING TO THE OVEN. COOLING FOLLOWED BY RE-HEATING CAN RESULT IN STRESS CRACKING AND AN UNEVEN STATE OF CURE. Page 3 of 6
4 Cured System Typical Properties Hardness of the finished part may vary from the exposed surface into the matrix. Surfaces exposed to air during cure will generally be 3-10 points harder than all other portions of the finished part. Products SA20 SA30 SA40 SA50 SA60 SA70 SA80 SA90A UNIT Hardness (Shore A) 20±3 30±3 40±3 50±3 60±3 70±3 80±3 90±3 Tensile Strength mpa Tensile Strength kg/cm² Tensile Strength psi Elongation % Modulus at 100% Extension mpa Modulus at 100% Extension kg/cm² Modulus at 100% Extension Psi Modulus at 300% Extension mpa Modulus at 300% Extension kg/cm² Modulus at 300% Extension psi Viscosity (Brookfield at 77 C) cp Specific Gravity at 70 C Cured Density g/ml Tear - die C N/mm Tear - die C kg/cm Tear - die C pli Resilience % Water Absorption 24 hours soak 22+/-1 C Water Absorption 24 hours soak 100 C Compression Set 22 hours at 70 C Compression Set 72 hours at 23 C % % % <1.0 < % Volume Resistivity 7.01x x10 11 ohm.cm Specific heat of uncured MONOTHANE elastomer is 0.45 cal/g/ C. MONOTHANE elastomer is suitable for continuous operation at temperatures up to 80 C but will withstand short periods (up to 24 hrs) where the operating temperatures rises up to 120 C. Test Methods Hardness ISO 868 Viscosity Brookfield LV4 6 rpm ASTM D4889 Tensile Strength ISO 527 Type 5 (2mm) Elongation at Break ISO 527 Type 5 (2mm) Tear Resistance ISO 34 - Pt B, Proc A (2mm) Page 4 of 6
5 Solvent Swell Properties Procedure Products SA20 SA50 SA80 SA90A Toluene 67.0% 70.0% 48.0% 30.3% Gasoline Petrol 18.2% 16.6% 12.8% 8.0% Methyl Ethyl Ketone 185.0% 129.0% 67.0% 46.5% Methylene Chloride 902.0% 647.0% 336.0% 210.0% 1. Rectangular samples (50mm x 25mm, uniform thickness of 2-4mm) were placed in solvent at 23 C for 48 hours. 2. The samples were removed and the mass measured. The swell is calculated as a percentage increase relative to the initial mass. The results were reported as the average of three measurements. Storage and Handling MONOTHANE Should preferably be stored in a dry cool environment free from direct sunlight. After use ensure container is will sealed and for best storage conditions flush with nitrogen. Shelf life is up to 1 year if unopened and not exposed to temperatures above 50 C. Shelf life 12 months More detailed information on the storage and handling of polyurethane components can be obtained by contacting our Technical Service Department. Packaging MONOTHANE TM Kgs, 200 Kgs Page 5 of 6
6 Product Stewardship Safety Considerations Customer Notice The Dow Chemical Company and its subsidiaries ( Dow ) has a fundamental concern for all who make, distribute, and use its products, and for the environment in which we live. This concern is the basis for our Product Stewardship philosophy by which we assess the safety, health, and environmental information on our products and then take appropriate steps to protect employee and public health and our environment. The success of our Product Stewardship program rests with each and every individual involved with Dow products from the initial concept and research, to manufacture, use, sale, disposal, and recycle of each product. Safety Data Sheets (SDS) are available from The Dow Chemical Company (Dow). SDS are provided to help customers satisfy their own handling, safety and disposal needs, and those that may be required by locally applicable health and safety regulations. SDS sheets are updated regularly. Therefore, please request and review the most current SDS before handling or using any product. Copies of the SDS are available on request through the nearest Dow Sales office. Dow strongly encourages its customers to review both their manufacturing processes and their applications of Dow products from the standpoint of human health and environmental quality to help ensure that Dow products are not used in ways for which they were not intended or tested. Dow personnel are available to answer your questions and to provide reasonable technical support. Dow product literature, including safety data sheets, should be consulted prior to use of Dow products. Contact information: For more information about this product please call The Dow Chemical Company. North America: Latin America: (+55) Europe: (+31) Asia/Pacific: (+60) NOTICE: No freedom from infringement of any patent owned by Dow or others is to be inferred. Because use conditions and applicable laws may differ from one location to another and may change with time, Customer is responsible for determining whether products and the information in this document are appropriate for Customer's use and for ensuring that Customer's workplace and disposal practices are in compliance with applicable laws and other government enactments. The product shown in this literature may not be available for sale and/or available in all geographies where Dow is represented. The claims made may not have been approved for use in all countries. Dow assumes no obligation or liability for the information in this document. References to Dow or the Company mean the Dow legal entity selling the products to Customer unless otherwise expressly noted. NO WARRANTIES ARE GIVEN; ALL IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ARE EXPRESSLY EXCLUDED. Page 6 of 6
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