Choosing the Best Polyurethane Cast Elastomer for Demanding Applica:ons. Sco< Archibald 10 May 2014

Transcription

1 Choosing the Best Polyurethane Cast Elastomer for Demanding Applica:ons Sco< Archibald 10 May 2014

2 Polyurethane Industry The 2016 market for polyurethanes is es:mated to be over $55 Billion. The 2016 diisocyanate (limited to MDI and TDI) market is es:mated at $22 Billion. The 2016 US polyurethane market is expected to reach over $19 Billion and employ over 200,000 jobs. *2014 UTECH Conference Website

3 Overview Markets Applica:ons Urethane Chemistry Reasons to use urethane elastomers Applica:on types Urethane elastomer comparisons to metal, rubber, and plas:c Urethane limita:ons Control of Urethane Proper:es Urethane general selec:on Selec:ng the best urethane for a new applica:on Field Tes:ng

4 Major Polyurethane Markets Construc:on rigid foam insula:on Automo:ve sea:ng, vehicular interiors, facia Bedding and Furniture Footwear shoe soles Tex:les Spandex, Adhesives and Sealants - flooring Electronics Machinery & Foundry Thermoplas:c Urethanes (TPU) Coa:ngs CAST ELASTOMERS 2-3%

5 Major Cast Elastomer Polyurethane Applica:ons Agriculture and Food Processing Office Machinery Oil and Gas Pipeline Parts Tire and Wheels Papermaking and Printer rolls Mining Parts Recrea:onal Golf Balls, Inline Skate wheels, Skateboard wheels, bowling balls

6 Urethane Prepolymer Synthesis

7 Cast Elastomer Produc:on

8 Produc:on Supply Arrival Prepolymer Cura:ve / Chain Extender

9 Prepolymer Prepara:on Prepolymer Mel:ng in Oven Transfer to Machine Tank or Dispense to Pail Degassing Maintain Produc:on Temperature

10 Cura:ve/Chain Extender Prepara:on Transfer to Machine Tank for Mel:ng or Melt enough for single pour Maintain Liquid State Degassing Maintain Produc:on Temperature

11 Polyurethane Processing Meter Streams Mixing (Mel:ng), Warming & Degassing Molding Dispensing Curing (Mel:ng), Warming & Degassing Demold Post- Curing Finishing

12 Polyurethane Processing Meter Streams Machine Mixing Mixing Dispensing Dispensing Molding Hand Batching

13 Polyurethane Processing Molding Curing Oven Curing Demold Demolding

14 Polyurethane Processing Demold Post- Curing Oven Post- Curing Finishing Tradename Prin:ng Finishing

15 Polyurethane Elastomer Think Elas:c

16 Urethane Elastomer Performance Advantages Tear Resistance Abrasion Resistance Toughness Load- bearing Ability

17 Urethane Elastomer Cost Advantages Reduced Down:me in Manufacturing Processes Ø Mining Ø Paper Mills Ø Pipelines Ø Machine Parts Lower Tooling and Equipment Costs for Small Produc:on Runs

18 Mining - Hydrocyclones

19 Mining - Hydrocyclones

20 Urethane Lined Hydrocyclone Distributor

21 Paper Mill Rolls

22 Pipeline Pigs/Spheres

23 Pipeline Cleaning Pigs

24 Crossover Pads

25 Wheels for Forklids and Lid Trucks

26 Molding Urethane Prepolymers Open Cas)ng (Most Common, low cost) Compression Molding (for Precision Parts) Centrifugal Molding (Pipelining, mul:- cavity, circular molds) Liquid Injec)on Molding (low pressure bo<om fill) Most Common Ribbon Molding (Rolls, to big to open cast) Spraying (High/Low pressure; No Solvent/Solvent) Rota)onal Molding (Hollow Items) Vacuum Cas)ng (Wire or Fiber Inserts) Transfer Molding (Mul:ple Precison Parts) RIM Reac)on Injec)on Molding (High Pressure Impingement Mixing) B Staging (When molds can t hold liquid) Pressure Cas)ng (Pressure Chamber) Solvent Cas)ng (Low Viscosity for Fabric Penetra:on) Trowelling (Repairs and Special Apps) Dipping (Long Pot life, Heat Ac:vated) Least Common

27 Lined Steel Pipe Centrifugal Cast

28 Gaskets/Seals Compression Molding

29 Ride Wheels Open Cast

30 Big Rolls - Ribbon Molding

31 Polyurethane Advantages over Metal Impact Resistance Lighter Weight Less Noise Be<er Wear Corrosion Resistance Low Cost Manufacturing Non- Sparking Non- Conduc:ve

32 Mining Screen Opera:on

33 Polyurethane Working Hardness Range

34 Polyurethane Advantages over Rubber Abrasion Resistance Cut and Tear Resistance Oil Resistance Higher Load Bearing Harder Durometer Range Clarity; Translucence Non- Marking, non- Staining Pourable; Castable Ozone Resistance Microorganism Resistance * High or Low Hysteresis Versa)lity * Polyether only

35 General Comparison of Polyurethane Elastomers with Various Rubbers General Comparison of Polyurethane Elastomers with Various Rubbers Property Polyurethane Nitrile Neoprene Natural SBR Butyl Tensile Strength (MPa) 20.7 to / / / / /- Durometer 5A to 85D 40 to 95A 40 to 95A 30 to 90A 40 to 90A 40 to 75A Specific Gravity 1.10 to Tear Resistance Outstanding Fair Good Good Fair Good Abrasion Resistance Outstanding Good Excellent Excellent Good-Excel. Good Compression Set Good Good Fair-Good Good Good Fair Rebound Very High to Very Low Medium High Very High Medium Very Low Gas Permeability Fair-Good Fair Low Fair Fair Very Low Acid Resistance Fair-Good Good Excellent Fair-Good Fair-Good Excellent Aliphatic Hydrocarbons Excellent Excellent Good Poor Poor Poor Aromatic Hydrocarbons Fair-Good Good Fair Poor Poor Poor Oil and Gas Excellent Excellent Good Poor Poor Poor Resistance Oxidation Outstanding Good Excellent Good Good Excellent Resistance Ozone Outstanding Fair Excellent Fair Fair Excellent Resistance Low Temperature Resistance Excellent Good Good Excellent Excellent Good

36 Polyurethane Advantages over Plas:c Non- Bri<le Flex Resistance Abrasion Resistance Elastomeric Memory

37 Limita:ons of Polyurethane High Temperature Service Moist, Hot Environments Certain Chemical Environments Higher Cost versus other Polymers

38 Prepolymer Chemistry Controls Polyurethane Proper:es Diisocyanate Type TDI MDI Specialty (PPDI, Alipha:c, LF, etc.) Polyol (Prepolymer Backbone) Type PTMG (Premium) Polyether PPG Polyether Polyesters (%Ethylene, %Butylene, Adipate, Succinate) Specialty (Polycaprolactones, Polycarbonates, etc.)

39 TDI Diisocyanates PPDI CH 3 N C O O C N N C O CH 3 N C O N C O C N C 8 H 4 N 2 O Paraphenylene Diisocyanate O C 9 H 6 N 2 O Toluene Diisocyanate MDI O C N HDI C 8 H 12 N 2 O Hexamethylene Diisocyanate N C O O C N CH 2 N C O C 15 H 10 N 2 O Methylenediphenyl Diisocyanate

40 Prepolymer Backbones Polyethers HO O PPG Polypropylene glycol n OH HO O H n PTMEG Polytetramethylene ether glycol Polyesters HO O O PEAG Polyester O O n OH Polycaprolactone HO O O n OH PCl Polycaprolactone

41 Physical Proper:es Rela:ve Performance for MDI Systems (Performance: 1 = Best, 10 = Worst) Material Abrasion Low Temp Hydrolysis Oxida)on Ester (standard) Ester (high abr) Polycaprolactone PTMG Ether PPG Ether

42 Hard Segment Chemistry Controls Polyurethane Proper:es Cura)ve / Chain Extender Type Diamine (fast reac:vity - used with slower TDI Prepolymers) Diol, Triol (slower reac:vity - used with faster MDI Prepolymers) Polyol (Prepolymer Backbone) Type Cura:ve Ra:o Temperatures (Prepolymer, Curing, Post- curing) Addi)ves Plas:cizers Fillers Stabilizers

43 Common Cura:ves Equivalent Weight is ½ Molecular Mass for Di- func:onal Cura:ves Equivalent Weight is 1/3 Molecular Mass for Tri- func:onal Cura:ves

44 Tear Strength Versus Stoichiometry 120 Tear Strength Versus % Theory 560 ASTM D- 470 Split Tear Strength (LbF/in) ASTM D- 470 Split Tear ASTM D- 624 Die C Tear ASTM D- 624 Die C Tear Strength (LbF/in) MOCA Concentra)on (% Theory)

45 Selec:on of a Polyurethane Elastomer for a Specific Applica:on Proper:es Needed for the Job Most Probable Failure Mechanism Processing Characteris:cs Pot Life Ra:o Control Viscosity Demold Time Process Temperatures

46 Polyurethane Elastomer Selec:on Guidelines Property Greatest Least Hardness N/A N/A Tensile Strength Ester Ether Elonga)on N/A N/A Modulus N/A N/A Tear Strength Ester PPG Ether Compression Set TDI MDI Rebound MDI Ether PPG Ether/ Ester Low Temperature Usage MDI Ether TDI Ester High Temperature Usage TDI MDI Sliding Abrasion Resistance Ester PPG Ether Impingement Abrasion Resistance MDI Ether PPG Ether Heat Buildup Ether Ester Hydrolysis Resistance MDI Ether TDI Ester Oil Resistance Ester Ether Heat Aging Ester PPG Ether Low Cost PPG Ether Ether

47 Polyurethane Elastomer Other Selec:on Guidelines Property Greatest Least Low Durometer Formula:ons (<60A) TDI Ester Ether Formula:on Flexibility MDI TDI FDA Dry Food N/A N/A FDA Wet Food MDI Ester TDI Low Cost PPG Ether MDI Ether

48 FDA Food Contact Systems Wet Food regulated by 21CFR Dry Food regulated by 21CFR Your prepolymer supplier can determine if their resins meet chemical standards Wet food approval requires water extrac:on of final part Dry food approval requires abrasion test of final part surface that contacts food Wet food formula:ons chemically qualify for dry food approval with posi:ve abrasion test Some catalysts, plas:cizers are also allowed

49 Polyurethane Elastomer Applica:on Selec:on Applica)on Urethane Type Basis of Choice Squeegees MDI Ester Chemical Resistance Paper Mill Rolls TDI Ether Hydrolysis Resistance, Hardness Stability, Dynamics Laundry Equipment MDI Ether Hydrolysis Resistance Sandblast Curtains MDI Ether High Resilience, Impingement Abrasion Resistance Hammers TDI Ester Tear Resistance, Low Resilience, Fork Li^ Tires TDI Ether (TDI Ester) Low Heat Buildup Grain Handling Equipment MDI Ester Abrasion Resistance Oil Pipeline Pigs TDI/MDI Ester Oil and Abrasion Resistance Roller Skate Wheels MDI Ether High Resilience Prin)ng & Coa)ng Rolls TDI Ester Solvent Resistance, Good Physicals at Low Durometers

50 Low- Free Diisocyanate Prepolymers ( <0.1% Free Diisocyanate TDI, MDI, PPDI, HMDI, etc) Easier Processing Lower Viscosity Longer Pot Life Be<er Dynamics Less Heat Buildup Health & Safety Easier Plant Engineering Controls

51 Selec:ng a Polyurethane Elastomer for a New Applica:on Decide What Proper:es are of Key Importance Physical Requirements and Environmental Resistance Consider most likely Mechanism of Failure Select Prepolymer / Cura:ve Systems Which are Likely Candidates Consider the Engineering Design of the Part Consult Your Suppliers for Recommenda:ons and Further Informa:on Review Your Plant/ Processing Capabili:es

52 Selec:ng a Polyurethane Elastomer for a New Applica:on Next Steps Run Whatever Preliminary Tests are Available Make Prototype Units of One or More Candidate Systems Field Test in Actual Service, Make Comparisons to Exis:ng Materials Get Approval from Future Customers Gear up for Produc:on

53 Field Tes:ng Scrapper Blades Is the Scrapper Blade used outside or is in contact with water? Is Abrasion the most likely failure mechanism?

54 Field Tes:ng Track Pads Track Pad is used outside. Is Impingement Abrasion Resistance or Sliding Abrasion Resistance most important? Is Cut and Tear resistance important?

55 Field Tes:ng Chock Blocks What materials will bear the load required to keep cargo in place? Will the new material be tough enough to resist wear and tear?

56 Review Applica:ons Urethane Technology Overview Why use Urethane elastomers Types of Applica:ons Comparisons to metal, rubber, and plas:c Limita:ons of Urethane What Controls Urethane Proper:es Urethane Selec:on Selec:ng Urethane for a new applica:on Field Tes:ng

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