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.

IAL Consultants, May 2001

(Tonnes)

Polyurethane Elastomer Market

14%

19%

29%

38%Elastomers

RIM

Spandex

TPU

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

1,050 parts

122 parts

244 parts

0 parts

Time (hr)

Spray & Roll Covering One-shot systems MDI quasi prepolymers Polyurethane & Polyurea hybrids Fast setting & curing Excellent physical properties

RIM Elastomers

RIM Elastomers

Mail Chute

Truck Box

Snow Shoe

New Raw Materials

•  Liquid 4,4’-MDI1

•  Liquid MDI Prepolymers for hot-cast and one-shot processing

•  Freeze-stable MDI quasi-prepolymers2

•  TDI prepolymers with low monomer contents3

•  Low monol containing, high MW polypropylene glycols

1US Patent 6, 120, 699; 2US Patent 6, 482, 913; 2US Patent 6, 242, 556 3US Patent 5, 925, 781; 3US 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

•  Superior Properties Tensile ≈ 7000 psi Elong ≈ 550 % Split Tear ≈ 120 pli Hardness ≈ 70A - 70D Resilience ≈ 60% Softening Pt. ≈ 200°C Tg ≈ -60°C

Amine cured

Polyol/Amine blend

Optically Clear Elastomers - Applications

•  Security Glazing - building - vehicles

•  Transparent Armor

•  Eye & Face Protection

•  Aircraft Transparencies - canopies - windows

•  Sports Equipment

Energy-Absorbing Elastomers

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

Di-functional Prepolymer Tri-functional Polyol ± Di-functional Polyol

2.2-2.8 Functional Isocyanate Tri-functional Polyol ± Di-functional Polyol

Tri-functional Isocyanate Di-functional Polyol

Di-functional Isocyanate Di-functional Polyol

Component A Component B

o

o

o

o Tri-functional Polyol

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

Original condition of farm canal in Twin Falls, Idaho

Day 2, after cleaning

Canal Lining Systems

Day 3, Lining Installed

Day 4, Water flows in canal

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

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

Acknowledgements

Thank You for Your Attention