MATERIALS.

Pigment dispersions

Geometric pigment dispersions have been developed to impart a new dimension to silicone compounds. These specially developed pigments are said to offer a prismatic and even holigraphic dimension to silicone compounds. They can be used to provide unique optical effects such as providing multi-dimensional effects across the full color spectrum. They will also provide a chameleon effect to a compound when exposed to restricted spectral wave lengths (colors) in taking on the color of the ambient light. These pigment dispersions are said to be especially effective in transparent and translucent silicone compounds. The geometric properties of the compounds will not break down with compounding as would be the case with other pigments, according to the manufacturer. These materials are said to be very resistant to UV degradation, solvents and most adverse environmental conditions. The dispersions are available in dimethyl and vinyl terminated silicone fluid or silicone gum (VMQ) as the binders of choice. (Disco, 1010 Greenwood Lk. Tpk., Ringwood, NJ 07458)

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Mold release line

A water-based version of RR-5 Hot is available. RR5 Hot WB is a completely water-based, general-purpose semi-permanent release. It is said to be finding acceptance throughout the rubber molding industry for use in releasing a broad spectrum of polymers. It can be used as received or diluted to suit the molder's individual requirements. Also available is RC-7 Hot Aerosol. This fluorocarbon release is designed for application to hot mold surfaces. It is said to easily release silicone rubber, as well as other polymers and thermosetting plastics. RC-7 Hot contains no ODCs and has a reduced VOC content. (Releasomers, PO. Box 82, Bradfordwoods, PA 15015)

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Thermoplastic rubber

Porsche AG has chosen Santoprene thermoplastic rubber for components making up the highly engineered gear and select shift cable system in the Porsche Boxster. The system provides precision push and pull movements from the driver's gear lever to the five-speed manual gearbox. Various thermoset rubber parts were replaced with a 55 Shore A grade of Santoprene rubber. Santoprene is said to offer excellent elastic properties over a broad temperature range due to its fully cross-linked rubber phase, according to the company. Santoprene is also said to provide low scrap rates and full recyclability. (Advanced Elastomer Systems, L.P., 388 S. Main St., Akron, OH 44311-1059)

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Low density foamed TPR 

Sarlink TPR technology produces foamed thermoplastic rubber profiles on standard extrusion equipment with standard screws. Because the chemical foaming technology does not require specialized equipment, it is said to save customers capital investment costs. The same Sarlink grade can be used to make low, medium and high density foams. The proprietary Sarlink TPR technology incorporates the blowing agent in the product, eliminating the need for premixing or costly water-injection. Resulting profiles are said to have a fine closed cell structure with a smooth surface and are expected to compete effectively with thermoset EPDM sponge used extensively in the automotive industry for window, door and hood seals. (DSM Thermoplastic Elastomers, 29 Fuller St., Leominster, MA 01453)

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Water-based releases

Water-based, semi-permanent release coatings have been developed for the release of silicone and fluorosilicone rubber. These environmentally-friendly formulas contain no VOCs, ODCs, CFCs or hazardous solvents, and are intended for use on compression, transfer and injection presses. Production trials are said to show that the coatings improve productivity by reducing scrap rates, according to the company. Other reported benefits are no transfer to the molded part, improved part appearance, ease of application and multiple release cycles per single application, according to the manufacturer. The coatings are also said to reduce mold build-up, allowing for less down time for cleaning. The company also reports that knit and flow lines are eliminated. These products are available in aerosol, ready to use bulk and concentrated formulas. (McGee Industries, McLube Division, 9 Crozerville Rd., Aston, PA 19014)

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Liquid silicone rubber

A manufacturer of diving masks and snorkel tubes has specified the company's liquid silicone rubber (LSR) that is said to deliver shorter cycle times and easier processing than previous formulations. Advantages are said to be so significant that operators are able to run an additional 80 mold cycles per shift, an increase of about 15%. Silastic 9682-50 is a high-clarity, high-strength material specifically designed for liquid injection molding. Even with no post cure, the 50 durometer elastomer is said to deliver a typical tear strength of 275 ppi and tensile strength of 1,380 psi. The product also offers elongation of 620%, combining the strength and flexibility the application requires, according to the company. The LSR is a two-component product with a 1:1 mix ratio. The soft, grease-like consistency of Silastic 9682-50 allows the use of low-cost pumping equipment to automatically mix and deliver the material to the mold. (Dow Corning, Midland, MI 48686-0994)

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Peroxide curing coagents

Adding a Saret coagent to peroxide-cured elastomer systems is said to provide compounders with an alternative to traditional sulfur-curing systems. The addition of Saret coagents enhances such performance properties as strong rubber-to-metal bonds, high tensile and tear strengths, good resilience, high hardness and good heat aging, according to the company. Saret coagents can be used for such elastomers as HNBR, EPDM, NBR and silicone rubber. (Sartomer, 502 Thomas Jones Way, Exton, PA 19341)

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Non-silicone release

INT-52EPR is a proprietary robber additive and lubricating agent that is said to generally improve flow characteristics, yet eliminates the need for external release agents, as well as machine or mold cleaning, according to the manufacturer. The company reports that the INT-52EPR does not affect or alter the required mechanical properties of natural or synthetic rubbers, PR/EPDM copolymers, EVASBR and natural polyacrylate butyl EPDM. Secondary operations with the cured product such as gluing, bonding, coating, etc., are said to be easily completed. Users are said to have reported that often an increased elongation percentage in addition to greater tensile strength were the results when INT-52EPR was used in various robber formulations. By eliminating the need for any additional release agent, customers are said to minimize the potential for downtime because of mold and machine cleaning, according to the company. All of the company's products are formulated from raw materials which comply with the chemical substance inventory lists of TOSCA, DSL, MITI, EINECS, Australia and Korea. (Axel Laboratories, 5820 Broadway, Woodside, NY 11377)

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One-part fluoroelastomer

A one-part sealant/caulk, formulated from DuPont Dow Elastomers' Viton fluoroelastomer, is available. Unlike two-part sealants and caulks, which require a separate curative agent for activation, Pelseal 2077 is supplied in resealable 11- and 20-ounce caulking cartridges and is ready for immediate application, according to the manufacturer. Like other Pelseal fluoroelastomers, Pelseal 2077 is said to exhibit exceptional performance characteristics in those industrial applications where resistance to a harsh environment is crucial. Independent test results are said to show that Pelseal 2077 withstands temperature extremes of -40 [degrees] F to +400 [degrees] F and resists attack by over 300 corrosives and liquids, including gasoline, oil, hydraulic fluids, hydrocarbon solvents, etc. (Pelseal Technologies, LLC, 401 Lafayette St., Newtown, PA 18940-0309)

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Release/anti-stick coatings

Dry film anti-blocking and anti-stick coatings are available for use by gasket manufacturers. The water-based formulations are said to provide a dry, non-oily, colorless coating that has exceptional anti-stick characteristics and possesses a low coefficient of friction, according to the manufacturer. The elimination of sticking, no residual build-up accumulation on surfaces, no interference with post-decorating operations and lower scrap rates are said to be among the reported benefits of these anti-blocking and anti-stick coatings. Dry film anti-stick coatings are also said to be cost effective. They can by applied by spraying, wiping or brushing. (McLube Division, McGee Industries, 9 Crozerville Rd., Aston, PA 19014)

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Anti-blocking agents

The company's silicone-free, water-based anti-blocking agents, marketed under the tradename Aqualift, are said to have proven very valuable to molders for the transportation industries, predominantly with SBRs. These water-based Aqualift anti-blocking agents can be purchased as ready-to-use or in concentrate form, which is said to make them very cost effective compared to the stearate baths commonly used today, according to the manufacturer. (Franklynn Industries, 143 Commerce Blvd., Cincinnati, OH 45140)

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Polyurethane RIM system

Charter House uses the Baydur 730 IBS polyurethane structural foam reaction injection molding (RIM) system to make the seat portion of chairs and stools for restaurants. The seats have to be extremely durable, and have to be molded with different thicknesses at various points, according to the company. Using the Baydur polyurethane RIM system was also said to result in a significant reduction in the weight of the seats. (Bayer, Polymers Division, 100 Bayer Rd., Pittsburgh, PA 15205-9741)

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Polybutene chemistry

Polybutenes are synthetic hydrocarbon polymers manufactured by the polymerization of a C4 olefins stream consisting principally of isobutene, according to the company. A unique combination of properties is said to mean that polybutenes are ideally suited for applications such as lubricating oil and fuel additives, lubricants, adhesives, sealants, putties, cable, plastics, robber, agriculture, inks, bitumen, thermoplastic road markings and masonry paints. The polymers are viscous liquids at normal temperatures but do possess rubber-like characteristics and high degrees of tackiness. They can provide significant cost savings either by reducing the amount of adhesive required or substituting expensive rubbers with the polybutenes, according to the company. No other manufacturer is said to have a polybutene such as Hyvis 2000, with a molecular weight of 5,900, according to the manufacturer. (Loos & Dilworth, 61 E. Green Lane, P O. Box 25, Bristol, PA 19007)

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Laser marking system colors

This global supplier of color and additive concentrates and performance solutions offers enhanced color laser marking packages. The color laser marking systems are formulated to improve color marking of PET, PBT, PC, PX, PE, POM, TPU, nylon, acetal, polyolefins, (HDPE, LDPE, LLDPE,PP) and ABS resins. Available in a wide range of tailor-made colors, the color laser marking systems are said to be compatible with medical, pharmaceutical, automotive, electronics, business machine, cosmetic and food industries where products require expiration dates, lot identification or serial numbers. The company's system approach to color laser marking is said to incorporate base resin and specific concentrate carrier, and pigments for coloring. This combination of select color concentrates and specialty additives is said to provide optimal integration with a wider range of aromatic and aliphatic polymers for laser marking. (Clariant Masterbatches Division, 111 N. West St., P.O. Box 1563, Easton, MD 21601)

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Maximum release formula

Frekote's Aqualine R-150 is said to give molders of most rubber goods an exceptionally high number of releases between release agent applications. Aqualine R-150 is a water-based microemulsion. When spray applied to a heated metal surface, the reactive resin crosslinks and physically bonds to the metal surface. Superior multiple release performance results from a high crosslink density and strong affinity for mold surfaces, according to the manufacturer. Aqualine R-150 is said to provide a durable release surface which does not transfer to released parts. Aqualine R-150 is recommended for applications where maximum multiple release performance is paramount, according to the company. (Dexter, Polymer Systems, One Dexter Dr., Seabrook, NH 03874-4018)

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Purging compounds

A fresh scent has been added to the company's line of high-performance Dyna-Purge purging compounds. Dyna-Purge is designed for use with extrusion machines processing all thermoplastic resins. The company states that the scented Dyna-Purge neutralizes odors that can be associated with the purging process. The scent is designed to work in concert with existing Dyna-Purge formulations to clean processing equipment safely and efficiently in one pass, according to the company. Cleaning action is described as different from that of other purging products. The compound does not melt completely. Instead, it scrubs and pushes its way through the injection cylinder, screw and runner system, purging thoroughly on the first run, according to the manufacturer. (Shuman Plastics, 35 Neoga St., Depew, NY 14043)

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Thermoplastic rubber

To enhance part performance while reducing both cost and weight, Daimler-Benz has specified Santoprene thermoplastic robber to encapsulate the quarter-light windows of the A-Class series, according to e material s manufacturer. Santoprene rubber is said to eliminate multiple parts that would have been required with traditional EPDM rubber seals, and is also said to provide excellent sealing performance, as well as ozone and UV resistance. Santoprene robber is offered in high-flow grades for glass encapsulation in 50, 62 and 75 Shore A hardnesses that are fully cured alloys of EPDM and polypropylene. The elastic performance of these grades, identified with an M 100 suffix, is said to be comparable with EPDM formulations, but the grades process with the ease and efficiency of thermoplastics, according to the company. (Advanced Elastomer Systems, L.P, 388 S. Main St., Akron, OH 44311-1059)

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Silicone lubricant

The company's #111 silicone lubricant is said to be resistant to oxidation, thermal degradation and a broad range of chemicals. Because #111 silicone lubricant is inert to rubber and other elastomers, it is said to be particularly useful for lubricating o-rings, gaskets and seals in pumps, mixers and valves, electrical connectors, splices, terminations, switch gears, battery terminals, auto ignition components, as well as a myriad of other electrical devices and moisture seals, according to the company. In ovens, fan bearings and other high temperature applications, the #111 silicone lubricant is said to exhibit superior stability and durability. (Frank Hillson, P. O. Box 2231, Cupertino, CA 95015-2231)

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Water-based hose products

Water-based products for hose manufacturers have been developed by the company, including mandrel lubricants, pan cure anti-stick coatings and cure tape release coatings. These products are said to be user- and environmentally-friendly, and contain no VOCs, CFCs, ODCs or other hazardous ingredients. Mandrel lubricants for nylon and EPDM flexible mandrels, aluminum and steel mandrels are available, as well as products for formed hose. Anti-stick coatings for pan cured hose, tube i.d.s, tube covers and other anti-stick applications that will not discolor or stain the compound have been developed. These products are said to have no effect on the properties of the compound or contaminate the hose. Also available are coatings for cure tape that will allow for longer tape life, ease of release and reduced color transfer, according to the company. (McLube Division, McGee Industries, 9 Crozerville Rd., Aston, PA 19014)

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Thermoplastic elastomers

Warner Tools uses the company's overmolded thermoplastic elastomers in its ProGrip Series of paint scrapers and putty knives featuring soft-touch handles. The soft handle component was molded from Sarlink 3460, a high-flow TPE product, because of its processing abilities, strong chemical resistance and cosmetic appeal, according to the manufacturer. Considerations involved in the selection criteria of Sarlink, according to the company, included: aesthetics, whereby the grip needed to be recognized for its soft-touch and feel, overall comfort, safety and value; abrasive drywall compounds required a low-wear factor; the rigid handle base needed to be chemically compatible with the plastic substrate in order to create a strong bond formation (Sarlink is highly compatible with polypropylene); excellent chemical resistance from harsh cleaning solvents, water, mud and high temperatures; and Sarlink helps reduce costs when compared to thermoset rubbers because of its ability to be injection molded. (DSM Thermoplastic Elastomers, 31 Fuller St., Leominster, MA 01453)

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Fast-setting polyurethane

To quickly produce 1,500 high-quality, UL 94 V-Orated covers for automated teller machines (ATMs), Urgent Plastics Services generated a stereolithography model, built a complex tool from silicone and polyurethane, and formed multiple parts using a fast-setting Parts-In-Minutes polyurethane from the company. For prototype molds, toolmakers started with a stereolithography model and then poured platinum-based silicone rubber over the pattern to form the ribs. After the silicone rubber cured, the remainder of the tool was cast from Pro-Cast 20 fast-setting polyurethane filled with Cabosil and chopped fiberglass. The mold was completed in five days. The fast-setting RP 6453 R/H Parts-In-Minutes polyurethane was selected for the ATM covers. The material can be demolded in less than 30 minutes. Once cured, it is said to exhibit performance characteristics including a UL 94 V-O rating of 0.125 inches, heat deflection temperature of 208 [degrees] F, flexural modulus of 194,000 psi and impact strength of 0.70 ft. lb./in. Technicians prepared to inject parts by releasing all mold surfaces using Ren RP 805 paste wax and Ren RP 78-2 silicone release agent. The RP 6453 R/H Parts-In-Minutes polyurethane was then dispensed into the mold using automated meter/mix equipment. Facilitating complete mold filling on the complex part were the gate and vent designs. (Ciba Specialty Chemicals, 4917 Dawn Ave., East Lansing, MI 48823-5691)

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Elastomer emulsions

To meet a growing demand for water-based emulsions, the company has introduced Aqualast elastomer emulsions for adhesives and coatings manufacturers. These products are said to be a unique offering of high-molecular-weight elastomers in emulsion form. Aqualast emulsions are free of VOCs and HAPs, and they offer the formulator new tools to design environmentally friendly adhesives and coatings systems with exceptional performance properties, according to the company. These products are said to be so versatile and compatible with a variety of other water-based resins systems materials that Aqualast emulsions can improve the performance of almost any adhesive or coating, according to the manufacturer. For adhesives, Aqualast emulsions are said to be a key ingredient to customize tack and adhesion. Coatings made with these emulsions are said to exhibit excellent flexibility and resistance to aggressive environments. These emulsions are said to be easy to work with, since they contain no VOCs and clean up well with water. (Lord, 2000 W. Grandview Blvd., PO. Box 10038, Erie, PA 16514-0038)

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Semi-permanent releases

XTEND semi-permanent mold releases have been released after comprehensive research and development, and field testing, according to the company. This advanced line of releases is said to be engineered to enhance release performance in the most demanding applications. The types of applications include fiberglass composites for recreational products, helmets, skis and boats, RTM for auto products, epoxy for aircraft components, rubber hoses and gaskets, as well as a multitude of other plastic and robber products. XTEND release's proprietary chemistry is available in water- and solvent-based formulations, offering processors options for all types of resins and rubber, and for all types of molding operations occurring at temperatures ranging from ambient to 1,000 [degrees] F (538 [degrees] C), according to the company. (Axel Laboratories, 5820 Broadway, Woodside, NY 11377)

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Polyurethane RIM system

Minrad used the company's Prism CM-200 solid polyurethane reaction injection molding (RIM) system to form the housing for its DRTS platform dual radiation targeting system and Tri-Knew battery charger. The Prism CM-200 solid polyurethane RIM system, with a UL 94 flammability rating of V-O and 5VA, is said to be well suited for applications in medical, electronic and other markets. The material is excellent for thin-wall molding and offers improved strength, surface finish and large-part capability, according to the company. These properties were said to be instrumental in the selection of the Prism CM-200 RIM system over injection molding. The use of family molds was said to be another processing advantage. By using family molds, the company can produce five different molded parts from two molds. This is said to enable the company to yield 250 parts per day on two presses. (Bayer, Polymers Division, 100 Bayer Rd., Pittsburgh, PA 15205-9741)

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Polyether urethane foams

Tufcote polyether urethane foams and composites are said to effectively address noise and vibration problems in a wide range of demanding OEM applications, including enclosed equipment and vehicles of all types, according to the company. The Tufcote line includes textured-surface foams, faced foams and multi-function composites. Tufcote faced foams are said to offer high acoustical performance while eliminating pickup of oil, dirt, grease and water. They are widely used in demanding applications involving gas- and diesel-powered engines, according to the company. With textured surface treatment, Tufcote foams are said to effectively resist dust and particulate pickup in mechanical and electromechanical equipment such as computers, printers and other office equipment. To form integrated, multi-function composites, Tufcote foams are chemically bonded to barrier and damping materials. These composites are said to provide noise control. (E-A-R Specialty Composites, 7911 Zionsville Rd., Indianapolis, IN 46268)

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Epoxy adhesive

A toughened epoxy adhesive, 10-3216, is said to have a convenient 1:1 by volume mix ratio and forms strong bonds at room temperature. The 10-3216 product was formulated to provide the best balance of peel and shear strengths, according to the company. This adhesive is said to be a great choice when high impact and shock resistance are needed. Available in the Triggerbond adhesive dispensing system, 10-3216 is said to be easy to use, has a variety of packaging options available, and has outstanding bond strength, according to the manufacturer. (Epoxies, Etc., P. O. Box 508, Greenville, RI 02828)

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Self-healing gel

This producer of high technology polyurethane and epoxy resin systems has announced a new application for its Conathane FG-41 self-healing gel. Conathane FG-41 is said to act as a gasketing material designed to form a tight seal around Hepa filters. The gel is typically 20% resin and 80% hardener with a work life of 30 to 40 minutes at 25 [degrees] C and a cured specific gravity of 0.936, according to the company. (Conap, 1405 Buffalo St., Olean, NY 14760-1139)

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Thermoplastic elastomer

Using a two-shot injection molding process (also referred to as multi-shot) and the company's thermoplastic elastomers, Eastman Kodak was said to create a unique extension and update its existing Fun Saver camera product line. The new product features an overmolded TPE cover which is designed to provide a protective covering onto the camera's polystyrene case. The TPE provided a good surface feel, showed no flow lines and molded without surface blemishes, according to the company. In addition, the material is said to offer good UV protection for fade resistance and passed a variety of tests, including drop, suntan oil resistance, temperature extremes and humidity tests. (GLS, 740 Industrial Dr., Cary, IL 60013)

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Mold release agents

The company has developed a product for customers who mold hoses out of fluoroelastomer rubber. Not only do product trials demonstrate excellent release ease, but the product did not affect the adhesion in the joining operations, according to the manufacturer. This development is water-based and is said to provide surprisingly clean mandrels requiring less cleaning time, according to the manufacturer. This company manufactures a variety of release agents for the rubber industry. (Franklynn Industries, 167 Commerce Blvd., Cincinnati, OH 45140)

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Coatings flatting agent

The company's commercially available flatting agent is said to offer a low gloss-to-sheen ratio and minimal viscosity build. Higher performing and competitively priced in comparison to similar grades, Acematt HK 450 flatting agent has a larger average particle size of 10 microns and a unique particle size distribution, assuring greater flatting efficiency and surface smoothness in coil coatings and other industrial coatings, according to the manufacturer. Acematt HK 450 was tested in a white polyester coil coating, as well as a water-based vinyl formulation. In the polyester coil coating, HK 450 was said to exhibit greater flatting efficiency and surface smoothness than grades produced by other manufacturers, while exhibiting comparable viscosity and gloss to sheen ratio, according to the company. Acematt HK 450 was also said to perform better than any competing silica-flatting agent added to water-based vinyl coatings. (Degussa, 65 Challenger Rd., Ridgefield Park, NJ 07660)

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Mold releases, lubricants

Canadian firms can now specify and use all of the company's mold releases, rust preventives, lubricants, cleaners, purging compounds, cutting oils and more, since they are now WHMIS (Workplace Hazardous Materials Information Systems) compliant. This is said to be an advantage for firms in the United States and elsewhere who use the company's wide variety of products and want to be able to use the same products at manufacturing facilities in Canada. The company offers Econo-Spray mold releases, Mold Cleaner Plus Degreaser III and the P.D.Q. liquid purging compound. The company's products are free of methylene chloride and its mold releases, lubricants, cleaners and rust preventives are CFC-free. (Slide Products, 430 S. Wheeling Rd., Wheeling, IL 60090)

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Urethane foam materials

A thin cast version of the company's high performance Poron urethane foam materials has been introduced for making soft gaskets used in electronics applications. The material is said to be the thinnest (21 mils) version of Poron 4701-30 material, the softest foam in the 4701 product line. The thin materials are supported on (2 mil) PET film for stability during the fabrication of close tolerance parts. The film will remain with the fabricated component for greater ease of assembly with the finished product. Poron urethane materials are said to offer good resistance to ozone, UV light and other environmental stressors and chemicals, and do not tend to corrode, plasticize or otherwise cause stress to nearby components, according to the manufacturer. Poron materials are available in a firmnesses and thicknesses for high performance applications. (Rogers, One Technology Dr., P.O. Box 188, Rogers, CT 06263-0188)

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Synthetic elastomers

Specifically aimed at uses in bitumen modification for roofing membranes, Europrene Sol T 6316 is said to make it possible to get, by using a single copolymer, significant improvements in processability, as well as in technological properties, a result so far achievable only by blending various SBS copolymers, according to the company. With this latest development, the company's Europrene Sol T (both SBS and SIS copolymers) portfolio now consists of 21 grades. Dutral TER 4047 is an EPDM terpolymer designed to fulfill the requirements of the building profiles industry. When properly compounded, Dutral TER 4047 is said to be advantageously utilized in white profiles manufacturing. In this very demanding application, premium properties of Dutral TER 4047 are also an excellent elasticity even at very low temperatures and an outstanding weathering (UV and ozone) resistance, according to the manufacturer. An NBR (butadiene-acrylonitrile copolymer) grade, Europrene N 33R50P, is a powder-form, low viscosity product specifically aimed at NBR/PVC blending. Due to its combination of rheological behavior and physical-mechanical features, Europrene N 33R50P is said to significantly improve the processability and feasibility of NBR/PVC blends. (EniChem, Piazza Boldrini, 1, 20097 San Donato, Milan, Italy)

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Processing insulation

Pyropel MD-60 is a rigid, polyimide fiberboard insulation developed specifically to meet the stringent demands of robber and plastics processing, according to the company. It is designed to withstand temperatures up to 600 [degrees] F (315 [degrees] C) and is said to be two to four times more effective than other commonly used thermal insulation materials. Reinforced through a patented manufacturing process, it is dimensionally stable and exceptionally tough and durable, according to the manufacturer. Unlike other organic insulation boards which are said to crack when subjected to compression forces, thermal expansion or thermal shock, Pyropel has high compressive strength, is non-brittle and will not crack under extreme conditions, according to the company. (Albany International, High Performance Materials, 777 West St., R O. Box 9114, Mansfield, MA 02048-9114)

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