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

0.0000

0.0200

0.0400

0.0600

0.0800

0.1000

0.1200

30 50 70 90 110

130

150

170

190

210

230

Temperature, C

Tan

Del

ta

Tan(d) - RFB1090

Tan(d) - New RF ether

Tan(d) L100/E300

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 single-pass Ribbon Flow.

RF One-Pass Video Clip

Special Thanks to the Following For Their Contributions:

Charles Mallon Tom Peter

Vince Gajewski Donna Day