Dial-a-Durometer (DAD): A Versatile Approach for Polyurethane Elastomer Production

Transcription

1 Dial-a-Durometer (DAD): A Versatile Approach for Polyurethane Elastomer Production Steve Seneker Jordan Duckett Robert Czeiszperger Jessica Lampkowski Timothy O Brien Anderson Development Company

2 Cast Elastomer Introduction Polyurethane Elastomer Composition Diisocyanate (TDI or MDI) Polyol (Polyester, Polyether PTMEG, PPG) Curative (Aromatic Diamine MBOCA or Short Chain Diol 1,4-BDO) Processing Approaches Prepolymer Quasi-Prepolymer One-Shot MDI versus TDI

3 Dial-a-Durometer Approach TDI/Ester Prepolymers: 70A, 80A, 83A, 90A, 93A, 95A, 60D, 70D TDI/PTMEG Prepolymers: 83A, 90A, 92A, 95A, 60D, 70D, 75D Dial-a-Durometer Approach: Low-Hardness TDI Prepolymer High-Hardness TDI Prepolymer Blend the two prepolymers to achieve any hardness in between

4 DAD Advantages/Disadvantages Advantages: Achieve any hardness Reduce prepolymer inventory Eliminate out-of-date prepolymers Reduce exposure to humidity and excessive heat history Cost savings purchasing fewer products at higher volume Disadvantages: Hand Casting: weigh out two prepolymers instead of one Dynamic Applications (high-load wheels ) High Hardness TDI prepolymers: short-chain diols (DEG, DPG, 1,4-BDO) Hard segment with lower melting or softening temperature

5 Experimental Low-Hardness/High-Hardness TDI Prepolymer Blended at 10 wt% increments Prepolymer temperature: 150 to 212 F MBOCA temperature: 230 to 250 F Curene 107 temperature: Ambient Stoichiometry: 0.95 Mold temperature: 212 F Post-cure conditions: 212 F Ambient conditioning: One month prior to testing

6 Physical/Mechanical Properties Hardness, Shore D2240 Elongation, % D412 Tensile Strength, psi D % Modulus, psi D % Modulus, psi D412 Die C Tear, pli D624 Split Tear, pli D1938 Compression Set, % D395, Method B (22 70 C) Compression Deflection, psi 5, 10, 15, 20 and 25% Bashore Rebound D2632

7 DAD Systems Evaluated TDI/Ester Prepolymers Andur 7 APLM/7 DPLM 70A and 70D Conventional Andur 7-3 APLF/7 DPLM 73A Low-Free and 70D Conventional Andur 7 APLF/6 DPLF 70A and 60D Low-Free TDI/PTMEG Prepolymers Andur 80-5 AP/1-75 DP 83A and 75D Conventional Andur 85 APLF/75 DPLF 85A and 75D Low-Free TDI/PPG Prepolymers Andur 8000 AP/7500 DP 80A and 75D Conventional Andur 8000 APLF/6500 DPLF 80A and 65D Low-Free

8 TDI/Ester DAD Systems Andur 7 APLM 70 Shore A Conventional TDI/ester prepolymer Liquid at ambient temperature Viscosity: F (100 C) Andur 7 DPLM 70 Shore D Conventional TDI/ester prepolymer Liquid at ambient temperature Viscosity: F (100 C)

9 Andur 7 APLM/7 DPLM (MBOCA) Andur 7 APLM(wt%) Andur 7 DPLM (wt%) % NCO (calc.) Stoichiometry (actual) Hardness, Shore 70A (20D) 79A (26D) 88A (32D) 92A (37D) 94A (42D) 96A (47D) 52D 56D 60D 64D 70D ElongaMon, % Tensile Strength, psi % Modulus, psi % Modulus, psi Die C Tear, pli Split Tear, pli Compression Set C *** Compress Bashore Rebound, %

10 TDI/Ester DAD System (1) Andur 7 APLM/7 DPLM/MBOCA Hardness 70A to 70D Tensile Strength 5500 psi to 8100 psi (64D) to 7400 psi (70D) Die C Tear Split Tear 290 to 960 pli 120 to 400 pli Compression Set 22 to 40% (65D) Bashore Rebound 47% to 38% (88A) to 47% (70D) Andur 7 APLM/7 DPLM/Curene 107 Hardness 72A to 68D Split Tear 160 to 530 pli Compression Set 26 to 40% (93A)

11 TDI/Ester DAD System (2) Andur 7-3 APLF/7 DPLM/MBOCA 7-3APLF Viscosity: 1000 cps ( F (100 C) Hardness 73A (70A) to 70D Tensile Strength 7500 (5500 psi) to 8200 psi (58D) to 7400 psi (70D) Split Tear 200 (120) to 400 pli Compression Set 25 to 40% (53D) (65D) Andur 7-3 APLF/7 DPLM/Curene 107 Tensile Strength 6600 (5200 psi) to 7000 (92A) to 6700 psi (68D) Compression Set 26 to 40% (80A) (93A)

12 TDI/Ester DAD System (3) Andur 7 APLF/6 DPLF/MBOCA Hardness 70A to 60D (70D, 70D) Tensile Strength 6600 (5500, 7500) to 7800 psi (48D) to 7200 psi (60D) Split Tear 90 (120, 200) to 290 pli Compression Set 25 to 40% (60D) (65D, 53D) Andur 7 APLF/6 DPLF/Curene 107 Hardness 72A to 58D (68D, 68D) Tensile Strength 7200 (5200, 6600) to 7500 (94A) to 7300 psi (58D) Compression Set 26 to 40% (88A) (93A, 80A) Compression 53% (80%, 95%)

13 TDI/PTMEG DAD System (1) Andur 80-5 AP/1-75 DP/MBOCA Hardness 82A to 75D Tensile Strength 5300 psi to 8300 psi Die C Tear Split Tear 270 to 1100 pli 60 to 240 pli Compression Set 22 to 40% (65D) Bashore Rebound 64% to 48% (93A) to 58% (75D) Andur 80-5 AP/1-75 DP/Curene 107 Hardness 80A to 69D Tensile Strength 6100 psi to 8300 psi (65D) to 7700 psi (69D) Compression Set 30 to 40% (93A)

14 TDI/PTMEG DAD System (2) Andur 85 APLF/75 DPLF/MBOCA Hardness 85A (82A) to 75D Split 85A: 40 pli (70 95A: 80 pli (95 pli) Bashore Rebound 0 to 5 units higher

15 TDI/PPG DAD System (1) Andur 8000 AP/7500 DP/MBOCA Hardness Tensile Strength 80A to 75D 2100 psi to 6200 psi Die C Tear 220 to 1000 pli Split Tear 55 to 210 pli Compression Set 24 to 40% (57D) Bashore Rebound 20% to 52%

16 TDI/PPG DAD System (2) Andur 8000 APLF/6500 DPLF/Curene APLF Visc: C (77 F) 6500 DPLF Visc: 79, C (77 F) C (122 F) Hardness 80A to 65D Tensile Strength 2300 psi to 5100 psi Die C Tear 220 to 700 pli Split Tear 55 to 190 pli Compression Set 64 to 100% Bashore Rebound 58% to 46% (90A) to 57%

17 DAD Conclusions (1) Broad hardness range with only two prepolymers Physical/mechanical properties comparable to straight prepolymer/curative approach. Useful for both hand cast and meter, mix and dispense operations

18 DAD Conclusions (2) Limitless Formulation Possibilities: Ester, PTMEG, PPG MBOCA, Curene 107, Lonzacure MCDEA, Versalink 740 M Systematic qualification is recommended for dynamic applications where high load and heat build up is a concern

19 Questions? Acknowledgments Jordan Duckett Robert Czeiszperger Jessica Lampkowski Timothy O Brien