Advances in Ribbon Flow Technology Audrey R. Emanuel Crompton Corporation Adiprene /Vibrathane
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 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
Advantages of Ribbon Flow versus Hot Cast No molds required Reduced Waste Lower Energy and Labor Costs Shorter turnaround times
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)
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 100:57 20-35 second pot life at 35ºC
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 100:61 15-25 second pot life at 30ºC
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 23-35 seconds at 35ºC
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
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
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
One Pass Ether System Physical Properties RFA 1100 RFB 1160 1195 DUROMETER 60A 94A 100% MOD,psi 350 1350 300% MOD,psi 670 2520 TENSILE, psi 3060 4590 ELONGATION, % 670 500 Trouser Tear, pli 28 200 Die C Tear, pli 200 670
One Pass Ether System Dynamic Properties Tan Delta 0.1200 0.1000 0.0800 0.0600 0.0400 0.0200 Tan(d) - RFB1090 Tan(d) - New RF ether Tan(d) L100/E300 0.0000 30 50 70 90 110 130 150 170 190 210 230 Temperature, C
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
One Pass Ester Physical Properties RFA 1004 RFB 4155 4171 DUROMETER 55D 70A 100% MOD,psi 1900 325 300% MOD,psi 6600 550 TENSILE, psi 7300 5250 ELONGATION, % 305 640 Trouser Tear, pli 150 85
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 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
Ribbon Flow Stream Die
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.
Ribbon Flow Stream Die
100 mm Stream Die
Mixing Requirements Size of the mixing chamber (volume) Moderate to high shear (rotor/stator) Minimum of about 7500-8500 RPM for good mix
Mix Chamber for Ribbon Flow
Mix Chamber for Ribbon Flow
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
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
Single-Pass Ether and Ester Ribbon Flow
Single-Pass Ester RFA 1004 RFB 4155/RFB4171
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.
RF One-Pass Video Clip
Special Thanks to the Following For Their Contributions: Charles Mallon Tom Peter Vince Gajewski Donna Day