Current Advances in Technology Dr. Ashok M. Sarpeshkar PMA - 2003 Spring Meeting
Global Polyurethane CASE Market The image cannot be displayed. Your computer may not have enough memory to open the image, or the image may have been corrupted. Restart your computer, and then open the file again. If the red x still appears, you may have to delete the image and then insert it again. (Tonnes) IAL Consultants, May 2001
Polyurethane Elastomer Market Elastomers 38% Spandex 14% 19% TPU 29% RIM 2000 API End-Use USA Market Study
Objectives Elastomer Types Hot-Cast vs. One-Shot Elastomers New Raw Materials New Technologies, Applications Safety Conclusions
The World of Elastomers
Elastomer Types Hot Cast One-Shot Optically Clear Ultra Low Hardness Spray & Roll Covering Thermoplastic RIM
Hot-Cast Elastomers MDI or TDI prepolymer NCO content <10.0% Processed @ 80 C Extended with 1,4-BD or MOCA Postcured @ 110 C/16hr. Superior mechanical properties
Hot Cast vs. One-Shot Systems Hot Cast One-Shot Prepolymer, %NCO Low High Viscosity High Low Processing Temperatures High Low Mix Ratio 10: 1 1:1-1:2 Degassing Required Yes Not Usually Postcure Yes Yes & No Component Functionality 2 2 & higher Elastomer Performance High Low to medium
One-Shot Elastomers Electrical Encapsulation Furniture Edging Cable Splicing
Spray & Roll Covering One-shot systems MDI quasi prepolymers Polyurethane & Polyurea hybrids Fast setting & curing 1,050 parts 122 parts Excellent physical properties 244 parts 0 parts Time (hr)
RIM Elastomers
RIM Elastomers Mail Chute Truck Box Snow Shoe
New Raw Materials Liquid 4,4 -MDI 1 Liquid MDI Prepolymers for hot-cast and one-shot processing Freeze-stable MDI quasi-prepolymers 2 TDI prepolymers with low monomer contents 3 Low monol containing, high MW polypropylene glycols 1 US Patent 6, 120, 699; 2 US Patent 6, 482, 913; 2 US Patent 6, 242, 556 3 US Patent 5, 925, 781; 3 US Patent 5, 817, 734
New Technologies Optically Clear Elastomers Energy-Absorbing Elastomers earthquake control devices energy-absorbing cervical discs Ultra-soft elastomers use of high MW, low monol polyols wrist and mouse pads bicycle seats, medical prosthesis Elastomers with low compression sets seals, gaskets Elastomeric canal lining systems
Optically Clear Elastomers Impact resistant elastomer with embedded bullet
Optically Clear Elastomers Aliphatic Isocyanate Prepolymers Low & High NCO Hot-Cast & One-shot Systems Amine cured Polyol/Amine blend Superior Properties Tensile 7000 psi Elong 550 % Split Tear 120 pli Hardness 70A - 70D Resilience 60% Softening Pt. 200 C Tg -60 C
Optically Clear Elastomers - Applications Security Glazing - building - vehicles Transparent Armor Eye & Face Protection Aircraft Transparencies - canopies - windows Sports Equipment
Energy-Absorbing Elastomers o o o o Component A Di-functional Prepolymer 2.2-2.8 Functional Isocyanate Tri-functional Isocyanate Di-functional Isocyanate Component B Tri-functional Polyol ± Di-functional Polyol Tri-functional Polyol ± Di-functional Polyol Di-functional Polyol Di-functional Polyol Tri-functional Polyol U.S. Patent 5,013,810; U.S. Patent 5,081,210; U.S. Patent 5,079,328; U.S. Patent 5,081,204; U.S. Patent 5,079,327
Energy-Absorbing Elastomers
Energy-Absorbing Elastomers
Energy-Absorbing Elastomers 30-40 Shore A Elastomer
Ultra-Soft Elastomers Elastomers with hardness in the O, OO & OOO range One-shot systems processed at ambient temperature Prepolymers with low NCO content Polyethers with high MW Under-indexed or plasticized to achieve properties
Elastomers with Low Compression Sets User-friendly one-shot systems, prepolymers, PMDI Varying avg. functionality of iso or polyol component Presence of 2,4-MDI critical for low comp. Set Patented technologies for MDI systems US Patent 6, 248, 856; US Patent 6, 277, 943
Canal Lining Systems One-Shot Elastomeric System Applied to geotextile on site Good adhesion to geotextile Hydrophobic, durable & leakproof Excellent physical properties
Canal Lining Systems Day 2, after cleaning Original condition of farm canal in Twin Falls, Idaho
Canal Lining Systems Day 4, Water flows in canal Day 3, Lining Installed
Elastomer Applications boat fenders helicopter blade sleeves brake diaphrams hydraulic seals bumper pads rollers for steel & paper mills conveyor belts oil and mud hydrocyclones copier rolls O-rings crane-shock absorbers pipeline pigs dead blow hammers potting compounds die-cut pads (paper box industry) pump liners drilling-pipe thread protectors rod stock drive belts roller skate wheels elevator wheels shaft couplers encapsulated concrete-mixer blades sheet goods encapsulated gate valves skate board wheels encapsulated transponders (cattle tags) snowplow blades forklift tires and wheels sound-damping pads gears special running shoes grain and coal chutes sprockets grain buckets wheel chocks
Safety Safe handling of hot prepolymers Use of exhausts to vent isocyanate vapors, esp. TDI Temp. resistant gloves for handling molds, etc. Proper PPE needed for handling aliphatic isocyanates that are skin sensitizers
Conclusions User-friendly raw materials & systems New raw materials New technologies Applications limited only by formulator s imagination
Acknowledgements Forcefin forcefin.com Innovative Technologies Inc. innovativetechnologies.biz Urethane Services urethaneservices.com Algood Casters Ltd. algood-casters.com Sunray-Inc. Sunray-inc.com Cisco-Eagle cisco-eagle.com Seismic Shock Control Systems Inc. seismicshock.com Advanced Urethane Solutions, Inc. urethane.net Langeman Mfg. Ltd. reflextruckliners.com
Thank You for Your Attention