Advances in Ribbon Flow Technology. Audrey R. Emanuel Crompton Corporation Adiprene /Vibrathane

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1 Advances in Ribbon Flow Technology Audrey R. Emanuel Crompton Corporation Adiprene /Vibrathane

2 What Is Ribbon Flow? A Process and system for the application of polyurethane elastomers to rolls or other cylindrical objects without the need for a mold.

Outline Advantages of Ribbon Flow versus

3 Outline Advantages of Ribbon Flow versus Hot Cast Types of Standard Ribbon Flow Improved Ribbon Flow Systems Improved physical and dynamic properties Advances in application method (One-Pass) and machine requirements to process new systems properly

4 Advantages of Ribbon Flow versus Hot Cast No molds required Reduced Waste Lower Energy and Labor Costs Shorter turnaround times

5 Types of Ribbon Flow Available High Performance Polyethers High Durometer System (RFA 1000) High Durometer Systems with LONZACURE (improved dynamics) Low Durometer System (RFA 1001) Polyester One-Pass System (RFA 1004) Polyether One-Pass System (RFA 1100) (improved properties and dynamics)

6 Ribbon Flow Systems High Performance-High Durometer Ethers Multi-pass 95A-66D available durometers Excellent mechanical and dynamic properties Good hydrolytic stability Mix Ratio range 100:35 to 100: second pot life at 35ºC

and hydrolytic stability Reduced Thermoplasticity Mix

7 Ribbon Flow Systems Superior Dynamic Performance Ethers Multi-pass 90A-70D Available Durometers Improved dynamics and hydrolytic stability Reduced Thermoplasticity Mix Ratio range from 100:39 to 100: second pot life at 30ºC

8 Ribbon Flow Systems High Performance-Low Durometer Ethers Multi-pass or Single-pass (60A-95A) available durometer Catalyst needed for one-pass Excellent Mechanical and Dynamic Properties Good Hydrolytic stability Mix Ratio range from 100:18 to 100:44 Pot life seconds at 35ºC

9 Why Single-Pass over Multi- Pass? Improved properties One prepolymer, two curatives (hard and soft), and optionally a catalyst Turnaround times No worries about grinding between layers

10 Improved Ribbon Flow Systems and Application Overview Uses a stream die for thick layers in one pass 5-6 second gel times Uses a 3 to 4 component machine with special requirements for processing

11 New Ribbon Flow Systems Ether One-Pass 60 A to 95A available durometers Short pot life (5-6 seconds) at 35ºC Improved dynamic and physical properties One-pass application only Mix ratio range from 100:27 to 100:140

12 One Pass Ether System Physical Properties RFA 1100 RFB DUROMETER 60A 94A 100% MOD,psi % MOD,psi TENSILE, psi ELONGATION, % Trouser Tear, pli Die C Tear, pli

13 One Pass Ether System Dynamic Properties Tan Delta Tan(d) - RFB1090 Tan(d) - New RF ether Tan(d) L100/E Temperature, C

14 New Ribbon Flow Systems Ester One-Pass 70 A to 55D available durometers Short pot life (5-6 seconds) at 60ºC Improved cut/tear, abrasion resistance, and solvent resistance versus ether materials One-pass application only Mix ratio range from 100:46 to 100:135

15 One Pass Ester Physical Properties RFA 1004 RFB DUROMETER 55D 70A 100% MOD,psi % MOD,psi TENSILE, psi ELONGATION, % Trouser Tear, pli

in the mix chamber Higher viscosities, higher pressures

16 Ribbon Flow Single-Pass General Material Characteristics Very short pot life, short dwell times in the mix chamber Higher viscosities, higher pressures Higher flow-rates compared to multi-pass Applied through a stream die

New Stream Die for Ribbon Flow Ability to apply thick layers of urethane, up to one inch, in a single-pass Eliminates chances for interlayer delamination

17 New Stream Die for Ribbon Flow Ability to apply thick layers of urethane, up to one inch, in a single-pass Eliminates chances for interlayer delamination Requires a high quality mix machine with ability to handle very short pour lives and high mix head pressure Tested in 50, 75, and 100mm sizes Crompton patent applied for

18 Ribbon Flow Stream Die

19 Processing with the Stream Die Roll size and material output must be consistent with the machine capability Machine output and desired thickness determines the die size and traverse rate Adjusting RPM is necessary to avoid dripping (RPM too low) or roping (RPM too high) of the material.

20 Ribbon Flow Stream Die

21 100 mm Stream Die

22 Mixing Requirements Size of the mixing chamber (volume) Moderate to high shear (rotor/stator) Minimum of about RPM for good mix

23 Mix Chamber for Ribbon Flow

24 Mix Chamber for Ribbon Flow

lines Ability to handle 5,000-10,000 cps Automatic flush system

25 Further Machine Recommendations Recirculating Metered lines (mass flow) Stainless Steel Moderate heat on tanks and lines, 1000 psi lines Ability to handle 5,000-10,000 cps Automatic flush system with no delay Computer recipe memory Adjustable set points on the fly

26 Challenges of Single-Pass Ribbon Flow Processing can be an art Initially more time and effort required Best used for a significant volume of rolls Machine limitations No interlayer adhesion without a rough, ground surface first

27 Single-Pass Ether and Ester Ribbon Flow

28 Single-Pass Ester RFA 1004 RFB 4155/RFB4171

Summary There are many advantages to using Ribbon Flow over

exist. Various systems to choose from depending on need.

29 Summary There are many advantages to using Ribbon Flow over hot cast, especially single-pass, if the right circumstances exist. Various systems to choose from depending on need. Advances in application and processing offer advantages over conventional Ribbon Flow systems. Special consideration must be given when choosing a suitable machine to run singlepass Ribbon Flow.

30 RF One-Pass Video Clip

31 Special Thanks to the Following For Their Contributions: Charles Mallon Tom Peter Vince Gajewski Donna Day

General Processing Information

COMPOSITE DATA VIBRATHANE General Processing Information Urethane Prepolymers CROMPTON CORPORATION CHEMICAL offers the most versatile line of liquid urethane prepolymers and curatives in the market today.