Adhesives & Sealants Industry July 2011

July 2011 • Volume 18, Issue 7 • www.adhesivesmag.com ❯ Dispensing Advances ❯ Composite Applications 18 below in C...

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July 2011

• Volume 18, Issue 7

•

www.adhesivesmag.com

❯ Dispensing Advances ❯ Composite Applications

18 below in Chicago. Super De-icer. Dreams take flight. NuSil Technology.

New ways to get from here to there. Silicone-coated aircraft wings that, one day, will enable planes to take off in extreme, icy conditions. Ultra-low-outgassing products that decrease volatility and increase longevity in outer space. Whatever your needs, the scientists at NuSil are dedicated to helping innovators innovate. As the leader in silicone solutions with nearly 30 years of aerospace experience, we can provide you with precise, custom formulations that make your ideas take off. What? When? Where? If it’s NuSil, it’s no problem.

©2010 NuSil Technology LLC. All rights reserved. ASI0410-A

What’s your challenge? www.nusil.com/asi USA +1-805-684-8780 Europe +33 (0) 4 92 96 93 31

“Now we can mix high viscosity emulsions 600% faster.” The Ross PreMax is the first batch rotor/stator mixer that delivers both ultra-high shear mixing quality and high-speed production. In side by side tests, the PreMax produces viscous emulsions and dispersions much faster than a traditional high shear mixer.

John Paterson PreMax Inventor Employee Owner

With a patented, high-flow rotor/stator design, the PreMax also handles viscosities far beyond the capacity of ordinary batch high shear mixers. In many applications, this can eliminate the need for supplemental agitation.

Contact Ross today to arrange a no-charge test in our laboratory. Call 1-800-243-ROSS Or visit mixers.com

The PreMax with a Delta generator operates with a tip speed of 5,000 fpm and handles viscosity up to 50,000 cP.

*Patent No. 6,000,840

INNOVATION = VALUE COATINGS: Go ‘green’ with innovative binder and additive technologies.

ADHESIVES & SEALANTS:

Conserve energy in production and product use.

ELASTOMERS:

Formulate with alternative raw materials, and do it competitively.

YOUR CUSTOMERS DEMAND ENVIRONMENTALLY-FRIENDLY PRODUCTS. LET UNIVAR SHOW YOU HOW YOU CAN GO GREEN. Univar supplies the CASE industry with much more than a comprehensive line of sustainable ingredients — we can provide you with an innovative approach to your green formulation challenges, offering you technical expertise from concept to production. Consider Univar your partner in sustainable product development. We connect you to the latest materials and technologies, and help you bring environmentally-friendly products to market. Innovation, sustainability, expertise — it all adds up to value.

INNOVATION > TECHNICAL EXPERTISE > MARKETING > SALES > LOGISTICS > DISTRIBUTION

1.877.203.0045 | [email protected] www.univarcorp.com

IN THIS ISSUE ADHESIVES & SEALANTS INDUSTRY, VOLUME 18, NUMBER 7

13 19 21 23 25 28

DEPARTMENTS

Q&A ABOUT POLYURETHANE Scientists from the Business Development Group of Bayer MaterialScience LLC answer readers’ questions.

6

Editor’s Memo

8

Company News

SHHHH…IT’S A SECRET

11

People

Manufacturers should know the limitations of trade secret law when protecting adhesive and sealant formulae.

12

Calendar

14

Strategic Solutions

16

Focus On: Chemsultants

17

Advancing Adhesives: Oregon State

THE NEXT STAGE OF COMPLIANCE Compliance with REACH regulation requires companies to have up-to-date information on chemical substances.

BENEFITS OF RECIRCULATION

21

18

Focus On: Wacker

Recirculating valves reduce maintenance and downtime for applications using filled two-component materials.

39

Advancing Adhesives: BASF

DRIVING DISPENSING SYSTEMS

40

Corporate Spotlights

Servo motors improve adhesive and sealant application quality and product assembly flexibility.

41

What’s New

41

Product and Literature Showcase

43

Services Marketplace

44

Classifieds

46

Ask Dr. Dave

46

Ad Index

PUSHING THE BOUNDARIES OF INDUSTRIAL PRODUCTION Booming demand calls for advanced automation in the manufacturing industry.

30

DISPENSING FOR LARGE-SCALE COMPOSITES Advancements in novel pumping technology for paste adhesives are successfully addressing the challenges of large-scale composite industrialization.

34 36

25

GETTING STRONGER

July 2011

• Volume 18, Issue 7

•


A Rice University lab has created a self-strengthening nanocomposite material.

BONDING COMPOSITES AND OTHER STRUCTURES

❯ Dispensing Advances ❯ Composite Applications

Structural adhesive technology comes in many forms and can be used in a variety of applications. Cover.indd 1

6/9/11 11:48 AM

ON THE COVER:

34

Cover design by Lindsay Leusby.

FOR SUBSCRIPTION INFORMATION OR QUESTIONS, CONTACT: Customer Service: (847) 763-9534 ADHESIVES & SEALANTS INDUSTRY (ISSN 1070-9592) is published 12 times annually, monthly, by BNP Media, 2401 W. Big Beaver Rd., Suite 700, Troy, MI 48084-3333. Telephone: (248) 362-3700, Fax: (248) 362-0317. No charge for subscriptions to qualified individuals. Annual rate for subscriptions to nonqualified individuals in the U.S.A.: $178.00 USD. Annual rate for subscriptions to nonqualified individuals in Canada: $216.00 USD (includes GST & postage); all other countries: $228.00 (Int’l mail) payable in U.S. funds. Printed in the U.S.A. Copyright 2011, by BNP Media. All rights reserved. The contents of this publication may not be reproduced in whole or in part without the consent of the publisher. The publisher is not responsible for product claims and representations. Periodicals Postage Paid at Troy, MI and at additional mailing offices. POSTMASTER: Send address changes to: ADHESIVES & SEALANTS INDUSTRY, P.O. Box 2148, Skokie, IL 60076. Canada Post: Publications Mail Agreement #40612608. GST account: 131263923. Send returns (Canada) to Pitney Bowes, P.O. Box 25542, London, ON, N6C 6B2. Change of address: Send old address label along with new address to ADHESIVES & SEALANTS INDUSTRY, P.O. Box 2148, Skokie, IL 60076. For single copies or back issues: contact Ann Kalb at (248) 244-6499 or [email protected].

July 2011

Adhesives & Sealants Industry

Audited by BPA Worldwide.

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EDITOR'S MEMO

TAG, YOU’RE IT! I’ll begin with a confession: I’m not the most technologically savvy person in the world. OK, let’s face it—I’m not even the most technologically savvy person in the household. My 15-year-old daughter is my go-to person for all things gadget related. I maintain that this is not an indictment of my intelligence level, but merely an illustration of the differences in the way our minds work. (She never buys that, but I never believed my mother when she said the same thing to me, either.) When I first saw a mobile tag in a magazine, I thought that the publication had experienced some kind of technical problem. After all, at first glance, mobile tags are just bizarre-looking little squares with strange patterns in them. Imagine my surprise when I discovered that these little enigmas are actually pathways to a world of information. All the reader needs to do is download a free app on their mobile phone and scan the tag to be whisked away to a website, video, article—you name it; if it’s got a URL, a mobile tag can link to it. They’re quite amazing, and simple as can be. Take a look at the tag on the cover of this issue for an example, and be on the lookout for additional mobile tags in future issues of ASI. It’s appropriate that mobile tags are debuting in this issue, since we’re focusing on high-tech aspects of the industry. For example, millions of dollars are spent each year in developing high-tech formulations, but what should companies do to ensure that their formulae are protected? Learn about the limitations of trade secret law in “Shhhh… It’s a Secret” on pp. 19-20. We also detail high-tech applications in this issue, including an article on “Dispensing for Large-Scale Composites” (pp. 30-33). Be sure to take a look at the full Table of Contents on p. 5, or just scan the mobile tag on the cover to access all of the July issue content online.

Susan Sutton is Editor-in-Chief, Integrated Media for Adhesives & Sealants Industry and Ceramic Industry magazines. If you wish to send a letter to the editor, please email [email protected]. Letters must include the sender’s address, phone number and email address, when possible. Letters may be edited for space and clarity.

THIS MONTH ON www.adhesivesmag.com... Green Opportunities Our new green-focused e-newsletter provides a roundup of adhesives and sealants news and issues related to renewable energy, sustainability, and all things green. Subscribe today! Online Exclusive: SEMICON® West Preview We take an inside look at the upcoming SEMICON West 2011 show, to be held July 12-14 in San Francisco. Digital Edition ASI’s digital editions are easy to read, search and download. Site visitors can also subscribe and access the archives to view past digital editions.

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PUBLISHING STAFF John Schrei, Publishing Director — 248-786-1637, [email protected] Tom Esposito, Senior Group Publisher — 610-436-4220, [email protected] Amy Vallance, Publisher — 281-550-5855, [email protected] Susan Sutton, Editor-in-Chief, Integrated Media — 330-336-4098, [email protected] Teresa McPherson, Managing Editor — 734-332-0541, [email protected] Kelsey Seidler, Associate Editor — 614-789-1881, [email protected] Lindsay Leusby, Art Director — 248-244-1735, [email protected] Karen Talan, Senior Production Manager — 248-244-6246, [email protected]

SALES STAFF Amy Vallance, Sales Representative Midwest, West and Southwest U.S., and Western Canada 281-550-5855, [email protected] Brandon Miller, East Coast Sales Manager Eastern U.S. and Canada, Latin America 610-436-4220 x8513, [email protected] Patrick Connolly, Sales Representative, Europe Patco Media-London, 99 Kings Road, Westcliff on Sea, Essex SSO 8PH, England 44-1702-477341, FAX 44-1702-477559, [email protected] Peg Van Winkle, Inside Sales 614-760-4222, [email protected] Christopher Wilson, BNP Custom Media Group 248-244-8264, [email protected] Kevin Collopy, Postal List Rental Manager 800-223-2194 x684, [email protected] Michael Costantino, E-mail List Rental Account Manager 800-223-2194 x748, [email protected]

CONTRIBUTING EDITORS Dave Dunn, bms North America Dan Murad, The ChemQuest Group Inc. David P. Nick, DPNA International Inc.

EDITORIAL ADVISORY BOARD Steven Gailbreath, Arizona Chemical Richard P. Muny, Chemsultants International Network Larry Owen, Franklin International Lex Reynolds, Reynolds Glue Deborah Chrzanowski, Intertape Polymer Group and PSTC Technical Steering Committee Chair

AUDIENCE DEVELOPMENT Terry Owens, Corporate Audience Development Manager Kelly Carlson, Multimedia Specialist Carolyn M. Alexander, Audience Audit Coordinator For subscription information or service, please contact Customer Service at: Tel. (847) 763-9534 or Fax (847) 763-9538 or email [email protected]

CORPORATE DIRECTORS Publishing: Timothy A. Fausch Publishing: John R. Schrei Corporate Strategy: Rita M. Foumia Marketing: Ariane Claire Production: Vincent M. Miconi Finance: Lisa L. Paulus

Creative: Michael T. Powell Directories: Nikki Smith Human Resources: Marlene J. Witthoft Conferences & Events: Emily Patten Clear Seas Research: Beth A. Surowiec

BNP Media Helps People Succeed in Business with Superior Information

July 2011

Flying the flag for customized solutions Designed Polymers for Adhesives & Sealants

Discover our designed polymers for the industrial adhesive and sealant market! By focussing on customer orientation, reliability, know-how and future orientation Evonik´s Adhesive Resins Product Line is the right partner for your individual solutions in adhesive and sealant applications. We fly the flag for your success!

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COMPANY NEWS ACQUISITIONS EDGE ADHESIVES, a Fort Worth, Texasbased manufacturer of specialty materials, recently announced its acquisition of RUBEX INC. The transaction was completed with Edge Adhesives’ capital partner Superior Capital Partners LLC, a Detroitbased private equity firm. Edge Adhesives acquired Rubex from Chemence Inc., a diversified chemicals company with operations in the U.S. and UK. Based in Columbus, Ohio, Rubex manufactures engineered butyl mastics, converted tapes, and sealants that are used in electrical, automotive, construction, and industrial applications. The Rubex acquisition expands Edge’s end markets, manufacturing capacity, and portfolio of high-performance adhesives and sealants. Edge Adhesives also recently appointed Dave Burger its president and CEO. Burger is a 25-year veteran of the adhesives and sealants industry and former board chair of the Adhesive and Sealant Council Inc. For additional information, visit www.edgeadhesives.com or www.rubex-us.com. PPG INDUSTRIES has signed a share purchase agreement to acquire DYRUP A/S, a European coatings company based in Copenhagen, Denmark, from its owner, Monberg & Thorsen, a public holding company. The total transaction value, including assumed debt, is around @135 million (~ $200 million). The transaction is expected to close in the third quarter of this year, subject to regulatory approvals, customary closing conditions and consultation with appropriate employee representative bodies. Dyrup is a European producer of architectural coatings (particularly wood stains) and specialty products, with 2010 sales of approximately @ 190 million (~ $270 million). It employs about 950 people and operates six manufacturing facilities in Europe. Visit www.ppg.com or www.dyrup.com for additional details. RPM INTERNATIONAL INC. recently announced it has agreed to increase its minority ownership interest in KEMROCK INDUSTRIES AND EXPORTS LTD., a fiberglass-reinforced plastic composites manufacturer located in Vadodara, Gujarat State, India, with more than $200 million in annual sales. 8

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APPLAUSE TESA TAPE CELEBRATES 75 YEARS Company officials of tesa tape inc., an affiliate of tesa SE, recently announced that 2011 marks the 75th anniversary of the first tesa-branded product being produced and made available by parent company Beiersdorf. The roots of the first tesa product date back well beyond 75 years, with an initial adhesive medical bandage developed by Paul Beiersdorf in 1882 in Germany. Beiersdorf patented his adhesive technology, and the Beiersdorf Co. and the foundation of the tesa brand were formed. In 1906, the Beiersdorf Co., located in Hamburg, Germany, held a contest among its employees to suggest brand names for the adhesive tape line. Elsa Tesmer, a secretary at the company, submitted the word “tesa,” which represented a combination of letters within her name. The brand name became legalized, and the first tesa-branded product, tesa®-Klebefilm, a transparent filmbacked tape designed for general-purpose holding applications, hit the market in 1936. Today, tesa is one of the world’s largest manufacturers of pressure-sensitive adhesive tapes and accessories. The company employs more than 3,700 people based in over 51 affiliate offices worldwide, and produces more than 7,000 products for industries such as electronics, healthcare, renewable energy, automotive/transportation, printing, and consumer. For more information, visit www.tesatape.com.

As a result of this agreement to increase its ownership interest above 15%, RPM is required under Indian law to commence a public offer for up to an additional 20% of the outstanding shares of Kemrock. RPM’s increased ownership of Kemrock signals its continued support and confidence in the company and its management, led by Kemrock’s founder and managing director, Kalpesh Patel, and further solidifies RPM’s position as a long-term investor in Kemrock. Additional information is available at www.kemrock.com or www.rpminc.com.

COMPANY NEWS BROOKFIELD recently announced it offers two hands-on courses to help users of its instruments get the most out of their viscosity test methods. The one-day training sessions help give attendees the working know-how to verify and improve upon the data required for meaningful R&D and successful QC testing. Courses can be scheduled to take place at Brookfield’s headquarters in Middleboro, MA, as well as metropolitan areas across the U.S. The “Practical Course on Viscosity Measurements” provides attendees with the tools and concepts they need to make precise viscosity measurements. The course is designed to benefit all operators, from beginner to advanced. “Applied Course on Viscosity Test Methods” is designed for the intermediate to advanced instrument user in R&D, analytical, and process engineer-

ing functions. For further information, phone (800) 628-8139 or visit www. brookfieldengineering.com/services/educational-programs. DOW CORNING CORP. has announced its first quarter 2011 financial performance. Sales grew 17% to $1.58 billion in the first quarter, while net income was $179 million, a decrease when compared with the first quarter of 2010. However, 2010 net income included U.S. Advanced Energy Manufacturing Tax Credits received by Dow Corning and its joint ventures. Dow Corning’s adjusted net income, which excludes these tax benefits, rose 2% in the quarter. Additional details are available at www.dowcorning.com. ELLSWORTH ADHESIVES announced it has added Sauereisen as a key new supplier. Sauereisen is a leading manufacturer of specialty adhesive and sealant cements. Ellsworth has also announced it is an authorized distributor of Dow Corning Solar Solutions in Mexico, Canada and Australia. The distribution agreement allows Ellsworth Adhesives to better serve the growing needs of the solar industry by providing technologically advanced products. For more information, visit www.sauereisen.com, www. dowcorning.com or www.ellsworth.com. H.B. FULLER CO. has announced the opening of its manufacturing facility in July 2011

APPLAUSE INTERTAPE POLYMER RECOGNIZED BY U.S. EPA FOR ENERGY STAR EFFORTS Intertape Polymer Group (IPG) has been recognized for meeting the U.S. Environmental Protection Agency (EPA) Energy Star Challenge, a national initiative for Energy Star partners to improve energy efficiency at commercial and industrial facilities by 10% or more within five years. Approximately 240 companies enlisted in the EPA’s call-to-action. However, only 34 facilities operated by 14 companies were publicly acknowledged for successfully reducing emissions at their manufacturing sites. IPG was cited for energy efficiency improvements of 29.1% in Carbondale, IL; 23.4% in Richmond, KY; and 18.3% in Menasha, WI. “IPG was able to achieve the Energy Star Challenge at its plants through the commitment and capability of our employees,” said Mike Jones, team leader of Corporate Energy for IPG. “We’re making energy efficiency part of our DNA. More specifically, various IPG plants implemented energy reduction initiatives by installing new insulation, variable frequency drives, energy-efficient lighting, improved compressed air systems, and economizers on boilers. They also reinforced shut off/turn down procedures, reduced the cycling frequency of boilers, and implemented dryer improvements.” Additional details are available at www.intertapepolymer.com.

Nanjing, China. The new plant, part of the company’s strategic growth plan, is reportedly the company’s first multinational reactive adhesives plant in China and is located in the Nanjing Chemical Industrial Park. The new facility and the company’s regional technical center in Shanghai will collaborate to serve the Asia-Pacific region. The Nanjing facility will produce urethanes and other reactive chemistries for customers in the construction, filter, flexible packaging, solar, textile, window, and woodworking markets. Visit www. hbfuller.com for details. HENKEL has announced that its first quarter 2011 sales were @3,823 million (~ $5,492 million), an increase of 8.9% compared to the prior-year’s first quarter. After adjusting for foreign exchange, sales improved by 6.8%. The Adhesive Technologies business sector continued to drive dynamic growth through the 2011 first quarter, posting a 14.1% increase in sales to a total of @1,884 million (~ $2,706 million). Organic growth, achieved through appreciable volume increases accompanied by a rise in selling prices, reached 11.5%, significantly exceeding market development. For more information, visit www.henkelna.com. H U N T S M A N C O R P. a n d W I L M A R INTERNATIONAL LTD. have announced a memorandum of understanding between their respective subsidiaries for Wilmar to build a state-of-the-art natural alcohol plant at Huntsman’s chemical site in Rozenburg (Rotterdam, the July 2011

Netherlands), and to supply natural alcohols to Huntsman. The facility is scheduled to come on stream by 2013. The plant will be owned and operated by Wilmar, which is reportedly one of Asia’s leading agricommodities companies and one of the world’s largest oleochemicals businesses. The project is subject to receipt of the relevant permits and regulatory approvals. For more information, visit www.huntsman.com or www.wilmarinternational.com. I N T E R TA P E P O LY M E R G R O U P I N C . recently released results for the first quarter ended March 31, 2011. First quarter revenue increased 11.3% to $192.6 million, compared to $173.1 million for the first quarter of 2010, and was up 7% sequentially from $180.1 million for the fourth quarter of 2010. Gross profit for the first quarter totaled $23.8 million, compared to $20.6 million a year ago and $21.2 million for the 2010 fourth quarter. First quarter gross margin was 12.4%, compared to 11.9% for the prior year and 11.8% for the fourth quarter of 2010. When compared to the first quarter of 2010, gross profit was higher due to an increase in sales volume, partially offset by rising raw material costs. Gross profit was also higher compared to the fourth quarter of 2010 due to an increase in sales volume and the non-recurrence of an impairment charge related to the write-off of lumber film automatic wrapping machines and related assets. Visit www.intertapepolymer.com for additional details.

COMPANY NEWS 3M has reported record first quarter sales of $7.3 billion, up 15.2% yearon-year, including an 8.9% increase in organic sales volumes. Sales increased at a double-digit rate in all geographic regions, with Asia-Pacific up 21%, Latin America/Canada up 19.5%, Europe up 13.1% and the U.S. up 10.2%. All six of 3M’s business segments expanded sales in the quarter, with particular strength in Electro and Communications at 20.5%; Industrial and Transportation at 20.3%;

and Safety, Security and Protection Services at 14.4%. Sales in emerging markets grew by 24% in the first quarter and now comprise 34% of 3M’s worldwide sales. Sales grew by 30% in India, 27% in China/Hong Kong and 25% in Brazil. For more information, visit www.3M.com. MCCOY SILICONES LTD. ( a M c C o y Group Company) recently announced that it has entered into 50:50 joint

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venture agreement with Soudal NV Belgium, a leader in sealants, foams, adhesives, and other related building materials. The new venture, McCoy Soudal Sealants Adhesive & Foams Pvt. Ltd., will manufacture, service, and supply sealants, adhesives, and foams in the Indian market under the co-brand McCoy Soudal. For additional details, v i s i t w w w. m c c o y g r o u p . i n o r w w w. soudal.com. MOMENTIVE PERFORMANCE MATERIALS INC. has reported its consolidated results for the first quarter ended April 3, 2011. Net sales were $660 million, compared to $605 million in the fiscal three-month period ended March 28, 2010, a 9% increase. The increase was primarily attributed to higher sales of specialty products improving the company’s overall product mix and ongoing pricing actions. In addition, the earthquake and tsunami in Japan in March and related events negatively impacted operations at the company’s Ohta site, primarily as a result of rolling power blackouts and transportation and supply-related issues, and reduced sales in the quarter by approximately $20 million. The company reported operating income of $73 million, vs. $63 million in the fiscal three-month period ended March 28, 2010. This improvement was primarily due to improved mix, ongoing pricing actions and savings from the shared services agreement with Momentive Specialty Chemicals Inc., partially offset by higher raw material costs. Visit www.momentive.com for more information.

John Paterson, vice president of ROSS MIXING INC. , recently announced the completion of a 12,000-sq-ft plant expansion, the facility’s fifth and largest renovation since opening in 1988. The 45,000-sq-ft plant is one of five U.S. manufacturing locations of Charles Ross & Son Co. In addition to the plant expansion, Ross Mixing has increased its workforce by 25%. The company’s Trial/Rental Program uses the Port St. Lucie plant to service and stock its inventory of new and reconditioned mixing equipment. A range of laboratory and productionscale models are also built in the facility. For additional details, phone (800) 243-ROSS or visit www.mixers.com. July 2011

PEOPLE JEROEN BLOEMHARD has been appointed business vice president and global executive director for Dow Corning’s XIAMETER® brand. Based in Midland, MI, he will oversee the operations and expansion of the XIAMETER brand globally. Bloemhard began his career at Dow Corning in 1991 and has since held a variety of worldwide marketing and commercial leadership positions. He most recently served as director in the company’s procurement organization. ROBERT CARROLL III , p r e s i d e n t o f R.E. Carroll Inc., has been honored as Executive of the Year by Biltmore’s Who’s Who for 2011-2012. According to Biltmore, recipients are individuals who have demonstrated leadership and achievement in their occupation, industry or profession. Carroll has been president of R.E. Carroll Inc. since 2009. He has been with the company in varying capacities for over 25 years.

Sea-Land Chemical Co. has announced several organizational changes. MARK CHRISTEON will be responsible for leading the sales organization for the company. He will manage the sales team leaders and focus on improving sales efforts. CRAIG LUNDELL has taken on the new position of team leader, Supplier Relations, managing his time between his sales territory and building relationships with business partners. KELLY KUHAR has been hired as administrative assistant II to provide additional support to the Procurement department. ROBERT J. KUMPF, Ph.D., chief administrative officer of Bayer MaterialScience LLC, was recently named chairman of the Industrial Research Institute (IRI) board of directors. Kumpf is also a member of Bayer MaterialScience’s North America Leadership Team with responsibility for Regional Business Support and Administration, as well as the Health, Safety, Environment organization; New Business; and Materials Characterization.

territory sales manager in the Field Sales department. Poinsot will provide a key service in helping manufacturers in the southwestern U.S. reduce manufacturing costs. The company also named BRIAN SCULLY inside sales manager in the Customer Support department. In his new position, Scully will perform the key role of managing and growing the company’s global customer service and inside sales team.

3M recently announced that INGE G. THULIN has been appointed executive vice president and chief operating officer (COO). Thulin has served as executive vice president of International Operations since 2003. He will have day-to-day responsibility for 3M’s six business segments and international operations, with the executive vice presidents of those businesses reporting to him.

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COMPANY NEWS CALENDAR JULY 15-1? COMPOSITES CHINA; Shanghai, China; chris. [email protected]

SEPTEMBER 13-14 Nanopolymers 2011; Dusseldorf, Germany; http:// ismithers.net/venue-details/XNAN11

20-22 Green Manufacturing Expo; Rosemont (Chicago), IL; www.canontradeshows.com/expo/gmx11/ ana_event.html 20-22 Assembly and Automation Technology Expo; Rosemont (Chicago), IL; www.aatexpo.com 26-28 CPP Expo; Las Vegas Convention Center: Las Vegas; www.cppexpo.com/

OCTOBER 6-8

16-18 ASC Fall Convention; Indianapolis, IN; www. ascouncil.org

NOVEMBER 1-3

15-16 FEICA Conference; Valencia, Spain; www.feica.eu

TURKCOAT COATINGS SHOW; Istanbul Expo Center; Istanbul, Turkey; www.turkcoat.com

2011 CHEM SHOW; Jacob K. Javits Convention Center; www.chemshow.com

9-10 The Composites Engineering Show; Birmingham, UK; www.compositesexhibition.com

A word from our customers: "Merlin's flexibility is remarkable. They stock our material and can turn on a dime when our requirements change. They always ship quickly, and more than once have responded to emergencies with next-day delivery. Nice people that are easy to work with. Overall, Merlin is an excellent supplier." B. S. Specialty polymer supplier Merlin customer for 9 years

21-23 Abrafati 2011; Sao Paolo, Brazil; www.abrafati2011.com.br/index_engl.html

"Merlin is extremely qualityconscious, with fast delivery and excellent attention to detail. They've given us the opportunity to be competitive on smaller orders by downpacking drums into custom cartridges. Our sales have grown steadily, thanks in no small part to Merlin Packaging."

FEBRUARY 2012

Eric Watson Purchasing Supervisor Rudolph Brothers & Co. Merlin customer for 10 years

APRIL

Merlin provides accurate filling of dual cartridges, syringes, pouches, mixed frozen, and many other packaging options. For fast delivery of big or small orders of quality custom packaging, call Merlin Packaging Technologies today.

14-16 Green Manufacturing Expo West; Anaheim, CA; www.canontradeshows.com/expo/gmx11/ ana_event.html 21-23 Composites 2012; Las Vegas, NV; www. acmashow.org 26-19 Adhesion Society Annual Meeting and Expo; New Orleans, LA; www.adhesionsociety.org

MARCH 11-16 Pittcon 2012; Orlando, FL; (800) 825-3221, ext. 203; www.pittcon.org

15-17 ASC Spring Convention; Denver, CO; www. ascouncil.org 30-5/4 PSTC Week of Learning; Boston, MA; www.pstc.org

MAY 2-3

Green Manufacturing Expo; Charlotte, NC; www. canontradeshows.com/expo/gmx11/tx_event.html

7-9

TAPPI European PLACE Conference; Seattle, WA; www.tappi.org

7-10 American Coatings Show 2012; Indianapolis, IN; www.american-coatings-show.com

JULY 10-12 SEMICON® West; San Francisco, CA; www.semiconwest.org

SEPTEMBER 18-21 8th World Adhesives & Sealants Conference (WAC2012); Paris; www.feica.eu.

861 Taylor Road, Suite E

Gahanna, OH 43230 Toll-free: 888-648-7878 [email protected] www.merlinpackaging.com

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OCTOBER 7-9

ASC Fall Convention; Louisville, KY; www.ascouncil.org

For a more detailed listing, visit www.adhesivesmag.com.

July 2011

QA &

About Polyurethane

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YOU’VE PREVIOUSLY DISCUSSED POLYOL RECOMMENDATIONS FOR FORMULATING A TWO& COMPONENT POLYURETHANE ADHESIVE. DO YOU HAVE SIMILAR RECOMMENDATIONS FOR THE ISOCYANATE COMPONENT? In many ways, the recommendations for choosing the proper isocyanate parallel those used in choosing the polyol formulating components. The isocyanate content, functionality and viscosity are all important variables that influence performance. In this discussion, the assumption is made that the isocyanates will all be reacted with the same polyol blend to allow valid performance comparisons to be made. The percent isocyanate content is a measure of equivalent weight and thereby the molecular weight of the isocyanate. In general, using an unmodified polyisocyanate with high isocyanate content (e.g., ~ 30% for MDI-based products) will produce a higher modulus polymer compared to using a modified polyisocyanate with lower isocyanate content (e.g., ~15%) and higher molecular weight. The higher molecular weight prepolymer will produce a softer polymer since the base isocyanate has often been modified with a flexible polyether polyol. Modified isocyanate prepolymers also have the advantage of being more compatible with the polyol component, which leads to more efficient mixing. As mentioned in a previous column (May 2011, p. 15), the average functionality of the polyol blend and the isocyanate determine the crosslink density of the adhesive. Typical functionalities of isocyanate prepolymers can range from 2-3. A formulation that uses an isocyanate with a high functionality often produces an amorphous polymer that is highly crosslinked and may be hard and brittle. An adhesive of this type would not be able to absorb stresses put on the bond line during use. The isocyanate content is also important for the practical reason of determining the mix ratio of the adhesive’s isocyanate and polyol components. Various types of mixing equipment are available, but many have a fixed volume/ volume mix ratio (typically 1:1 or 2:1). Disposable fixedratio mixing systems are available for commercial and DIY applications. Fixed-ratio mixing equipment often forces the adhesive formulator to modify the isocyanate content of the two-component mixture to more closely match the polyol component’s molecular weight. This can be accomplished by blending available polyisocyanates or by manufacturing a unique isocyanate prepolymer. The most flexibility in processing is possible through the use of plural component

July 2011

meter/mix dispensing equipment, which can deliver a range of volume/volume mix ratios. With this equipment, there is no need to artificially restrict formulating options. Adhesive performance can be negatively impacted by foaming in the bond line as the curing reaction takes place. Formulations using an isocyanate with a low molecular weight and high isocyanate content have a tendency to foam due to the large number of isocyanate groups needed to cure with the polyol before a side reaction with water takes place. The water reaction generates carbon dioxide. Foaming is also influenced by the chemical ratio of isocyanate to polyol groups. Over-indexing with an excess of isocyanate groups does improve the adhesive performance, but foaming can occur in the bond line if over-indexing is excessive. The viscosity of the isocyanate prepolymer is linked to the isocyanate content. If the adhesive formulation is designed to use an inorganic filler, such as talc, a lower viscosity isocyanate prepolymer has an advantage. The amount of filler used directly impacts the viscosity of the polyisocyanate reactant. Once again, a balance must be achieved between the percent polyisocyanate, the filler level and the viscosity. If the viscosity of the filled prepolymer is too high, the efficiency of the mixing process with the polyol component can be negatively impacted. In previous columns, it was noted that prepolymers containing the 2,4’-isomer of diphenylmethane diisocyanate have a reduced viscosity, but the reactivity of the system is reduced. Multiple factors relating to the isocyanate component can impact the performance of a structural adhesive. Extensive formulating studies are needed to produce an adhesive with the desired performance.

ABOUT THE AUTHOR Dr. Jeffrey F. Dormish is Senior Principal Scientist, Business Development Group, Bayer MaterialScience LLC. He is responsible for the development of new polyurethane adhesive applications, with a focus on waterborne raw materials. Dr. Dormish joined Bayer in 1980. Since that time, he has held various research and application development positions of increasing responsibility, and worked in polyurethane research at Bayer AG in Germany for two years. He has a B. S. in chemistry from the University of Dayton and a Ph.D. in chemistry from the Pennsylvania State University. For additional information on the topics addressed or to ask another question, e-mail [email protected] with the subject line “Polyurethane Q&A.” Any views or opinions expressed in this column are those of the author and do not represent those of Adhesives & Sealants Industry, its staff, Editorial Advisory Board or BNP Media.


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STRATEGIC SOLUTIONS

THE NORTH AMERICAN POLYMERIC CONCRETE REPAIR MARKET By Richard B. Jones, Vice President, The ChemQuest Group, Inc.

uch has been written and published about the U.S. construction chemicals market, which is estimated to be valued at close to $8 billion and growing at a rate of over 3% per year. The market encompasses a number of different products made with myriad materials. One of the fastest growing sub-segments within the construction chemicals industry is polymeric systems for concrete repair. While concrete admixtures, cementitious grouts and onecomponent sealants make up the bulk of the products used, polymeric reactive systems are estimated to be $1.1 billion of the overall construction chemicals market. These systems are growing twice as fast as GDP because the construction industry is continually finding greater use for them (see Figure 1). Rather than demolishing and rebuilding commercial, industrial, and civil infrastructure, construction companies are repairing, rehabilitating, and restoring increasing numbers of concrete facilities with polymeric reactive systems.

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Figure 1. Market Segmentation for Polymeric Concrete Repair Systems

Figure 2. Functional End Uses for Polymeric Concrete Repair Systems

INFRASTRUCTURE ISSUES While the use of polymeric materials to repair or restore concrete is gaining wider acceptance and thus growing in volume, the fact still remains that overall construction spending in the U.S. is still very depressed as a result of the protracted economic recovery. An even bigger issue is the overall lack of available state and local funding to perform the requisite maintenance, repair, and/ or replacement. According to the U.S. Treasury Department, infrastructure spending in the U.S. now stands at just 2% of GDP, which is half of what it was in 1960. By comparison, this spending amount is substantially below regions 14

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like China (9%) and Europe (5%). The critical problem, unfortunately, is that the bulk of the current U.S. infrastructure was originally built for a 50-year lifecycle—in some cases, it is now approaching 60 years old. In its latest report card, the American Society of Civil Engineers gave U.S. public works a “D” grade for their current state. It calculated that the U.S. would need to spend upwards of $1.1 trillion over the next five years to restore roads, bridges, dams, levees and other infrastructure to good condition. At the same time, however,

maintenance costs have increased far faster than state and local tax revenues. The situation is further exacerbated by an inability to borrow money due to existing high debt obligations and/ or very high borrowing costs as a result of low bond ratings. Last year, the U.S. government proposed a $50 billion infrastructure “bank” (in addition to money already allocated to infrastructure in the earlier stimulus packages) to support the revitalization of 150,000 miles of roads, 4,000 miles of rail and 150 miles of runways. The problem is that these funds are targeted at the state July 2011

and local levels, where the financial strain to balance budgets is most acute and where borrowing more money is not always feasible. The end result has been delays or project cancellations.

A POTENTIAL SOLUTION Given all the current economic forecasts, the near future looks cloudy for new commercial and civil construction in the U.S. The one thing that remains favorable, though, is the fact that using polymeric systems has been proven to be a very cost-effective method to repair, restore and rehabilitate concrete structures (vs. more traditional practices that use mechanical and/or cementious materials). Europe has seen a much broader acceptance of these polymeric materials due to a longer history of successful usage in the repair and restoration of concrete. In the U.S., acceptance levels have generally been lower, but they are significantly increasing. The costeffectiveness and financial pragmatism behind repairing vs. rebuilding is the underlying reason why the use of these types of repair systems is forecasted to grow at 64% annually in the coming years, despite the projected softness in new construction activity.

• Stabilization: Involves providing structural stabilization to soil as well as precision alignment of equipment under severe torque and vibration; typical pro ducts here would be hydrophilic or hydrophobic polyurethanes to stabilize walls, as well as epoxies to stabilize chock under heavy equipment. Aside from purely economic considerations, polymeric concrete repair systems also make notable c o n t r i b u t i o n s t o a b u i l d i n g ’s sustainability rating. Because these systems facilitate repair and restoration vs. rebuild, they significantly reduce the amount of building debris that is taken to landfills following demolition. In addition, by allowing for more repairs in existing structures, the amount of required new concrete is reduced. Since a tremendous amount of CO 2 is generated during the production of cement (i.e., 1.4 tons of CO2 for each ton produced), there is a growing focus on reducing the overall need for new concrete by repairing what is already in place. Other positive implications

stem from the fact that polymeric repair systems do not use water, unlike many typical cementitious systems.

SUSTAINED GROWTH While smaller in volume and revenue compared to more traditional cementitious repair materials, polymeric systems are gaining increasing recognition for their inherent performance characteristics and the value they bring to repairing, restoring, and rehabilitating the concrete found in any of a long list of civil or commercial structures. This wider acceptance, coupled with costeffectiveness, is spurring engineers and architects to specify these types of polymeric systems more frequently, which will lead to strong, sustained growth in the foreseeable future. Richard B. Jones is vice president of The ChemQuest Group Inc., an international strategic management consulting firm specializing in the adhesives, sealants, and coatings industries, headquartered in Cincinnati. For more information, phone (513) 469-7555 or visit www.chemquest.com.

POLYMERIC PERFORMANCE This construction market, while somewhat finite in scope, is diverse in the products used and involves such formulative chemistries as two-component acrylics, epoxies, and urethanes (and various hybrids thereof). These products are typically used in any of three functional end-applications (see Figure 2): • Strengthening: Involves restoring structural strength and integrity to concrete beams, slats, walls, columns, piers, etc. Strengthening enhances l o n g - t e r m p e r f o r m a n c e ; f i b e rreinforced polymer (FRP) systems are one of the more noteworthy products used here. • Structural Repair and Bonding: Involves the bonding of concrete slabs, the repair of concrete cracks, and the overall restoration of concrete that has deteriorated (or spalled) and been compromised due to environmental conditions; typical end-use products include epoxy- or acrylic-based chemical anchoring systems or epoxy-based systems to repair cracks or bond adjacent concrete slabs. July 2011


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FOCUS ON

CHEMSULTANTS INTERNATIONAL CELEBRATES 25 YEARS What began in a 550-sq-ft office space is now housed in a 10-acre corporate headquarters.

hemsultants International announced that July 15 will mark the 25th anniversary of the company’s founding. Richard P. Muny started the company in 1986 as a one-man pressure-sensitive adhesive (PSA) consultancy; Chemsultants has since become a premier product and service provider to industries worldwide. The company began in a 550-sq-foot rented office space in Painesville, Ohio; it now includes two companies and employs 33 people. Chemsultants International Inc. and ChemInstruments Inc. both focus on the areas of adhesives, specialty coatings, polymers, and materials. Chemsultants International provides a variety of services, including physical and analytical testing, product development, contract research, consulting, education and training, process development and optimization, specialty pilot coating, and small-scale manufacturing of web-coated materials. A 10-acre technology campus in Mentor, Ohio, serves as the corporate headquarters for Chemsultants International, and includes the research facility and coating production operations. ChemInstruments is located in Fairfield, Ohio, and manufactures an extensive line of pressure-sensitive adhesive test equipment, materials characterization equipment and lab

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sample preparation equipment for product development in the PSA industry. Chemsultants International is a family-owned and operated business. It has realized double-digit sales growth each year for 25 years through the expansion of core company product lines and services, penetration of new markets (e.g., energy, electronics and medical devices), and strategic acquisitions. Chemsultants International acquired and absorbed Adhesive Consultants Inc. in 2003, and ChemInstruments acquired the Tantec® line of contact angle meters in 2004. Chemsultants International has been recognized for its business growth and success four separate times in the past eight years by the Case Western Reserve University Weatherhead School of Business. “We are proud to have reached this milestone in our company history,” said Gary Avalon, COO. “While Dick Muny has retired from day-to-day activity in the business, all of us who are part of Chemsultants and ChemInstruments are carrying on the entrepreneurial spirit that was the basis for the founding of the company and is the basis for our continuing success.” For more information, visit www.chemsultants.com.

July 2011

ADVANCING ADHESIVES

Microchannel array.

SURFACE-MOUNT ADHESIVES COULD LEAD TO MICROCHANNEL REVOLUTION By David Stauth, Oregon State University

ngineers at Oregon State University (OSU) have invented a new way to use surface-mount adhesives in the production of low-temperature, microchannel heat exchangers—an advance that will make this promising technology less expensive for many commercial applications. According to researchers, this type of technology will be needed in next-generation computers, lasers, consumer electronics, automobile cooling systems, fuel processors, miniature heat pumps and more. In addition, new industries and jobs are possible thanks to this technology. A patent has been applied for and the findings were reported in the Journal of Manufacturing Processes. In addition, the university is seeking a partner for further commercial development.

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July 2011

“Even though microchannel arrays have enormous potential for more efficient heat transfer and chemical reactions, high production costs have so far held back the broad, mainstream use of the technology,” said Brian Paul, a professor in the OSU School of Mechanical, Industrial and Manufacturing Engineering. “In certain applications, this new approach has reduced material costs by 50%,” he said. “It could cut production bonding costs by more than 90%, compared to existing approaches to microchannel lamination. And the use of surface-mount adhesives is directly translatable to the electronics assembly industry, so there is less risk going to market. “This type of manufacturing research could enable a microchannel revolution,” Paul said.

Microchannels, which are the diameter of a human hair, can be patterned into the surface of a metal or plastic, and can be designed to speed up the heat exchange between fluids, or the mixing and separation of fluids during chemical reactions. The accelerated heat and mass transfer leads to smaller heat exchangers and chemical reactors and separators, such as a portable “home dialysis” system that evolved out of previous OSU research. Cost and production issues, however, have until now constrained the wider industrial use of this technology. The new manufacturing technique developed at OSU should help change that. “We have demonstrated the use of surface-mount adhesives to create microchannels on a wide variety of metals, including aluminum, which is very cheap,” said Prawin Paulraj, an OSU doctoral candidate and lead author on the recent study. “Bonding aluminum is difficult with conventional techniques.” These very thin pieces of patterned metal—akin to aluminum foil—can be bonded one on top of another to increase the number of microchannels in a heat exchanger, as well as the amount of fluid that can be processed. The creation of laminated microchannel arrays in a variety of materials is possible, including aluminum, copper, titanium, stainless steel and other metals. “In computers and electronics, the heat generated by the electrical circuit is a limiting factor in how small you can make it,” Paulraj said. “Microchannel process technology provides an efficient way to cool computers and consumer electronics, and make them even smaller.” The adhesives are limited in temperature to about that of boiling water. The researchers say that possible uses might include radiators to cool an automobile engine or small, very efficient heat pumps for efficient air conditioning within buildings. This research was conducted at the Microproducts Breakthrough Institute, a user facility of the Oregon Nanoscience and Microtechnologies Institute. University officials are now seeking a commercial partner in private industry to continue the development and marketing of the technology, according to Denis Sather, a licensing associate in the OSU Office for Commercialization and Corporate Development. For more information, visit http://oregonstate.edu.


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WACKER ACADEMY OPENS IN MICHIGAN The academy seeks to actively engage in networking with North America-based customers, distributor partners and Wacker experts in market/industry-specific seminar-style training and expertise transfer. acker Chemical Corp. recently announced the opening of its Adrian-based Wacker Academy. It joins with the Allentown, PA, Wacker Academy to engage in networking with North America-based customers, distributor partners and Wacker experts in market/industry-specific seminarstyle training and expertise transfer. The Adrian Academy is the ninth Wacker Academy serving customers located in regions around the globe, and the third located in North and South America. The Adrian-based academy will focus on silicone chemistry solutions and, like its counterparts, will include technical and commercial small group classroom training and hands-on laboratory learning experience. According to Laurent Morineaux, project leader for the Adrian, MI, Wacker Academy, the keywords “Learn. Discuss. Connect. Meet” describe how the Wacker Academy concept invests in its customers and distributor partners. “Wacker has long recognized the value created through close customer collaboration in building long-term successful business relationships,“ he said. “The Wacker Academy is a natural

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extension of this philosophy. By learning and doing, we are all able to improve our skills and discover how we can lead to creating competitive advantages in the marketplace.” The Wacker Academy is an added-value service enabling Wacker customers and distributor partners to tap into the Wacker knowledge pool, and thereby help them enhance their own business success. “Through training courses and seminars that are hosted by our technical experts who are actually specialists in specific market categories, we provide our customers essential information, ranging from basic silicone chemistry to hands-on lab application experience,” Morineaux said. According to Kristen Ross, Wacker Academy program coordinator, chemists, formulators, and design and application engineers could benefit from attending the academy, as well as sales and marketing people who desire greater technical knowledge. “Our initial course offerings include HDK® Pyrogenic Silica for Rheology Control and Silicones for Masonry Protection,” she said. For more information, email [email protected] or visit www.wacker.com/ wacker-academy.

July 2011

Shhhh…

IT’S A SECRET Manufacturers should know the limitations of trade secret law when protecting adhesive and sealant formulae. By Paul Dalley, J.D., President, Dalley Law Office, S.C., Elkhorn, WI

magine this scenario: The lead chemist of Sealco, a manufacturer of compounded adhesives and sealants, quits. The chemist then joins another adhesive and sealant manufacturer, Tackco. Shortly thereafter, Tackco begins producing a line of adhesives and sealants that are the equivalent to a product line made by Sealco. Moreover, the new product line is very similar to products that were developed by the former employee during his tenure at Sealco. However, Tackco is not selling its new product line into the same applications or to the same customers as Sealco’s. Sealco lawfully obtains and de-formulates Tacko’s new line and determines that the new products are chemical equivalents to their products. The question is: Under the law of trade secrets, can Sealco prevent Tackco from manufacturing its new product line?

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July 2011

Probably not. Even a signed non-compete agreement will be of little help. It is useful to examine the limitations of the law of trade secrets in protecting formulated pro ducts from unfair competition. A large portion of the business of the adhesives and sealants industry is the development, manufacture and sale of formulated products. Unlike the pharmaceutical industry, which extensively uses patent law to protect its products, most adhesive and sealant manufacturers use the law of trade secret to protect their products. Contracts not to compete are also commonly used. It is important for adhesive and sealant manufacturers to understand the limitations of these laws.

ENFORCING THE LAW In general, U.S. law disfavors restraints on trade. A contract not to compete is a restraint of trade and therefore disfa-

vored at law. This disfavor makes the contract difficult to enforce. In the previously mentioned case, Sealco will have to prove that it had a protectable interest in the formulae that made up the product line and that the provisions of the contract were reasonable in protecting that interest. Formulae are a protectable interest. An employee’s knowledge to create those formulae, however, is not. Sealco would have to prove that there was no way that its former employee could have developed the new line of products without using its protectable interest. This would be a very difficult task in an industry rife with competitive raw materials that skilled employees can easily use to create an offset. Absent misappropriation, in this case, the law of trade secret does not provide much relief. A company’s formulae are its property. Under the Adhesives & Sealants Industry

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SHHHH... IT'S A SECRET legal doctrine of Hired to Invent, any formula created by an employee whose job is to invent new formulae is the property of the company. An equivalent formula that is made up of raw materials that are mere competitive offsets to the original formula is not. The law of trade secret does not provide any relief for two reasons. First, the doctrines inherent in the law limit its ability to provide relief. Second, the legal doctrine of preemption prevents trade secret law from providing relief for equivalent formulae.

PRODUCT PROTECTION It is not misappropriation under the law of trade secrets to reverse-engineer a product. Any competitor who lawfully obtains, de-formulates and reproduces the exact formula has not misappropriated its competitor’s product. Thus, Sealco will not be afforded any relief if the product line is reverse-engineered. What if reverse engineering did not occur with these formulae? Rather, the formulae are derived from the past knowledge and experience of Sealco’s former employee, and the products are made of equivalent raw materials provided by competitors to their current raw material suppliers. Does the law of trade secret provide any protection in this case? Again, no. The law of trade secrets cannot provide protection against equivalent or knock-off formulae. Only a valid patent would provide relief against equivalent formulae. A patent prevents the use, manufacture, sale or importation of the patented invention. It also provides protection against an equivalent product under the Doctrine of Equivalents. Trade secret law cannot be expanded to include equivalent formulae because it is preempted by patent law.

More importantly, the U.S. Supreme Court has further defined Congress’ intent. That is, the Court has explained that Congress’ intent is: (1) to provide an incentive to invent and (2) to ensure that information already in the public domain remains there. If trade secret law provided protection for equivalents, it would be an additional restraint of trade beyond patent law and would create a disincentive to invent. In addition, equivalent formulae would be removed from public domain. Thus, any attempt to provide relief under the law of trade secret would be preempted by the Doctrine of Equivalents under patent law.

invention. The U.S. Court has reasoned that Congress’ intent is to promote the disclosure of inventions to the public. Keeping an invention secret goes against public policy, so the court allows the second inventor a patent. In doing so, the court is encouraging other inventors to obtain a patent as well—but the trade secret owner will still lose their trade secret. Once the patent is granted, the invention, by definition, is in the public domain—the trade secret is lost. Once an invention is in the public domain, it is no longer a protectable interest. In this case, even if a formula was sufficiently unique to be a protectable interest, a contract not to compete would no longer have an effect on that particular formula.

SUPPRESSION AND CONCEALMENT THE DOCTRINE OF PREEMPTION Preemption flows from the Supremacy Clause of the Constitution, which states that “This Constitution and the Laws of the United States…shall be the supreme Law of the Land.” Preemption prevents the several states from enacting and enforcing laws in areas where Congress clearly intended to regulate. In the case of patents, Congresses’ intent is clear. First, the U.S. Constitution requires Congress to provide rights for inventors to their inventions. Second, Congress has enacted a detailed patent statute. 20

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There is another limitation of trade secret law that adhesive manufactures should be aware of: the loss of their trade secret through the patenting of their secret by another. Patent law allows the patent applicant to obtain his patent over another inventor who suppressed or concealed the same invention. The other inventor will be granted the patent, even if the trade secret holder invented first and has been continuously using the trade secret for years. Maintaining a trade secret is considered suppression and concealment of an

TRADE SECRET STRENGTH A trade secret does have one great strength—it can last forever. Patents expire, copyrights expire, but trade secrets do not. Rather, they are lost. In effect, formulae are only weakly protected by trade secret law, particularly formulae that can be reproduced from equivalent raw materials. Therefore, the best protection is secrecy. Keep your formulae secret, and keep them safe: that is a manufacturer’s best protection. For additional information, contact the author at paul@ dalleylaw.com.

July 2011

Compliance with REACH regulation requires companies to have up-to-date information on chemical substances.

By Malcolm Carroll, Managing Director, REACH Delivery

EACH (Registration, Evaluation, Authorization and restriction of Chemicals) is the European Union (EU) regulation that focuses on the safe use of chemicals. The regulation came into force in June 2007 and is arguably one of the most complex and far-reaching pieces of legislation to impact chemical manufacturers, importers, distributors, and downstream users of chemicals worldwide.

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The regulations affect companies of all sizes—regardless of where they are based in the world—as REACH applies to any company that imports to or manufactures in the EU. To comply with REACH, organizations are now responsible for registering chemicals and ensuring the delivery of material safety data sheets (MSDS, now known simply as safety data sheets, or SDS) and associated documentation to their customers. Companies are also responsible for keeping these documents up to date in the event of any changes or clarifications.

RECENT DEVELOPMENTS According to Geert Dancet, executive director of the European Chemicals Agency (ECHA), the first phase of REACH compliance was completed successfully on November 30, 2010. This phase involved the registration of widely used chemicals, particularly those that are hazardous, with the ECHA. Beginning December 1, 2010, all unregistered manufacturers and importers of over 1,000 tons/year were considered to be operating illegally. With registration complete, it is time for organizations to consider some of the additional requirements of REACH, including the regulations surrounding the delivery of SDSs to customers in Europe. Organizations must also remain aware of the proposed new U.S. legislation, similar to REACH, that is under consideration for shipments into the U.S. market. The goal of REACH is to improve the available information about chemical substances, including details regarding how they should be used and what risks they pose. REACH focuses on ways to improve the safety of workers and the public, protect the environment, reduce the risk of chemical contamination, July 2011


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THE NEXT STAGE OF COMPLIANCE and ensure a competitive and innovative chemical industry. Greater responsibility now lies with chemical manufacturers, importers, distributors, and downstream users who will need to carefully manage the chemical risks and provide detailed safety information. For many companies, this is a big challenge.

SDS DELIVERY The next phase of compliance concerns the production and delivery of the new SDSs, which are needed at every stage of the supply chain. REACH requires big changes for EU chemical importers in the way they are required to deliver, receive and manage SDSs. In a high-volume industry that has constant pressure on margins (like adhesives and sealants), the new regulations present manufacturers, importers, aggregators and even retailers with a tough administrative challenge that could prove to be incredibly costly. What is already clear is that traditional methods of delivering documents are not accurate, cost-effective or robust enough to meet the REACH compliance standards. Each traditional method of delivering documents has shortcomings; for example: • Email does not guarantee or record proof of delivery without significant time, effort and cost; this type of delivery obviously does not physically replace old, out-of date-versions of an SDS. • Regular mail has the same problems as emails, adding the additional costs and time associated with stationery, postage, and administration. • Placing documents onto a website will not suffice, as this provides no proactive delivery and is already rejected by REACH. In addition, these methods will not help with the intent of REACH. Customers will not be alerted to any changes in the SDSs, multiple recipients cannot be easily managed, and there are no standards in terms of the media on which the SDS is held—making easy and consistent access difficult. All of this could result in either significant additional costs for suppliers or the possibility of errors, leading to noncompliance with the regulations.

POSSIBLE SOLUTIONS As this next stage of REACH begins, the issues companies in the industry face are significant. How should companies fully comply with the legislation in respect of 22

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delivery and receipt of SDSs? How do they maintain their operations and ensure consistent use of current information across all operational areas? How do they effectively audit internal and external delivery, receipt and access of critical information by customers? Most importantly, how do they address possible legal action should the need arise? REACH Delivery is a new industry-wide SDS delivery service aimed at alleviating the compliance headaches concerning SDSs and other documents. This secure online service enables the electronic delivery, receipt, control, update, audit and tracking of SDSs in line with REACH regulations. It is free to use for anyone who receives an SDS, with an optional “pay as you send” area for users who need to send SDSs or other documents externally. After a simple registration process, users can immediately and securely send the latest SDSs to their customers’ desktops and receive proof of delivery. The service automates the entire sending process, including monitoring, tracking and reporting on all documents sent to customers. It also retains a delivery status for documents sent and alerts users only when they need to follow up, which enables them to get on with their business. Any document updates are automatically identified by REACH Delivery, and the new SDSs replace the previously sent versions. Customers and staff will receive alerts about the new SDS to ensure they are always up to date.

Documents from all suppliers are all stored in a single electronic database, thereby allowing users to maintain a single consistent point of access for the latest version of a SDS. Documents can also be stored locally (on your own PC) and are automatically kept up to date so you can work on- or offline. The flexibility and global nature of REACH Delivery is intended to meet the requirements of proposed new U.S. legislation, when required. In the meantime, in addition to being able to distribute the SDSs to EU customers, U.S. REACH Delivery users benefit by being able to distribute the sheets throughout their own company free of charge, which ensures that the latest SDSs are being used across their organization. The system is designed to make SDS compliance simple and cost effective for every organization in the supply chain. REACH legislation aims to improve health and safety surrounding the use of chemicals—certainly a shared goal for everyone in the industry. REACH Delivery eradicates the headaches caused by the need to securely send and receive SDSs; the system provides a simple and effective method for chemical manufacturers, importers, distributors and downstream users in the U.S. and elsewhere to meet the challenges of REACH compliance. For more information, visit www.reachdelivery.com.

July 2011

Recirculating meter/mix valve with inlet and output ports on both A and B sides.

Recirculating valves reduce maintenance and downtime for applications using filled two-component materials. By Tom Muccino, Product Sales Manager, Nordson EFD wo-component epoxies and polyurethanes are used in a variety of industries and applications. In the construction industry, for example, epoxies are used to anchor rebar and threaded rod, as well as for structural concrete repair and crack injection, while polyurethane foams are frequently used for insulation and soundproofing. In the automotive industry, polyurethanes are used to assemble filters, exterior lighting, motor covers, tail lamp lenses and other components. Regardless of the application, a proper mix of materials is critical to the success of any two-component dispensing process. In most instances, as long as the pumping system is capable of delivering both components to the valve in the correct ratio at the desired flow rate, and an appropriate static mixing nozzle is used, the materials will be thoroughly mixed. A common system configuration for large-scale, twocomponent dispensing applications consists of separate reservoirs for the base and catalyst, a pump, a meter/mix valve, and a mixing nozzle. Gear pumps or piston pumps are typically used to transport the two components from the base and catalyst reservoirs to the corresponding inlets on the meter/ mix valve. When the valve is actuated, the base material and catalyst are pushed through the manifold of the valve, out to the static mixing nozzle and onto the substrate.

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INCORPORATING FILLERS While this type of setup is satisfactory for most two-component processes, additional considerations are involved in situations July 2011

where fillers are added to one of the components, either to improve adhesion or to achieve a particular texture. Common filler materials include ground stone, metal alloy, fibrous materials or colored pigments. The challenge when applying components that contain fillers is to keep the filler in suspension so that a proper mix can be achieved. With the type of system described previously, fillers can separate inside the tank containing the filled component, the feed line running from that tank to the valve, or the meter/mix valve. Separation can create a couple of major issues. First, it can result in poor mix quality that compromises the performance of the material. Second, separation may produce sediment that creates the need to disassemble and clean the valve components and flush the fluid lines. Depending on the application, downtime for unscheduled maintenance can lead to thousands of dollars in lost productivity.

RECIRCULATING VALVES An effective method of preventing filled two-component materials from separating is to keep them recirculating between dispensing cycles. Recirculation usually takes place at either the pump or the meter/mix valve (see Figure 1, p. 24). In systems where recirculation occurs at the pump, the primary feed lines are bypassed while the components are recirculated through secondary lines, either back to their original tanks or into separate holding tanks. The result is Adhesives & Sealants Industry

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BENEFITS OF RECIRCULATION

Figure 1. Two Options for Recirculating Filled Two-Component Materials

that the fluid left in the main feed line and valve remains stagnant whenever the system is not in operation. In processes that involve long periods of inactivity, this stagnant material can separate within the

main feed line and/or inside the meter/mix valve, leading to the maintenance and downtime issues mentioned earlier. Systems that recirculate the fluids at the meter/mix valve offer a more efficient

CONSULTING BY “DR. DAVE” Adhesives and Sealants-Technology, Applications and Markets

alternative. A conventional meter/mix valve has just two ports: one inlet port for the epoxy resin or polyurethane polyol, and another inlet port for the epoxy hardener or polyurethane isocyanate. In contrast, a recirculating meter/ mix valve has a total of four ports: one inlet port and one return port for the A component on one side of the valve, and separate inlet and return ports for the B component on the other side. With recirculating meter/mix valve systems, the material feed lines run from the pump to the A and B inlet ports on the valve. The material return lines run from the valve’s A and B return ports back to the original tanks or to separate holding tanks. While the system is dispensing, the meter/mix valve is open to allow the materials to flow through the static mixing nozzle. When the valve closes, the materials are continuously recirculated through the valve and back to their respective tanks, with no dead volume to become stagnant. In addition to preventing sediment from collecting inside the valve, having recirculation take place at the valve instead of at the pump eliminates pressure buildup in the supply lines that could produce a surge as the valve opens, resulting in an off-ratio mix. Some recirculating meter/mix valve designs also incorporate a snuff-back feature to keep material from dripping or oozing when the valve closes.

ADDITIONAL CONSIDERATIONS Dr. Dave Dunn writes the monthly “Questions and Answers” column in Adhesives & Sealants Industry magazine, and is a unique source of both technical and management consulting for the adhesives and sealants industry. Technical Consulting • Formulation advice • Sourcing information • New developments • Application development • Application troubleshooting • Problem solving Market Research • Opportunity analysis • Customer surveys • Mergers and acquisitions • New developments • Market analysis • Industry structure • Competitive intelligence • Key trends

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Technology Focus • Anaerobics • Cyanoacrylates • Reactive acrylics • Epoxies • Hot melts • Gasketing Market Focus • Industrial • Automotive OEM • Automotive aftermarket • Medical • Construction Management Consulting Innovation can be planned and managed to meet the strategic goals of a company. We have concentrated on integrating the R&D functions of companies into their strategic plans and putting systems in place to continuously measure the effectiveness of investments in R&D.


About the principal… Dr. Dave Dunn is President of F.L.D. Enterprises, which is located near Akron, Ohio, USA. He is a former Vice President and Director of Loctite Corporation and has consulted for many adhesives and sealants manufacturers and users in both North America and Europe. He is the author of several books and many articles, including the recent book Adhesives and Sealants-Technology, Applications and Markets, published by Rapra Technology Ltd. (www.polymer-books.com). F.L.D. Enterprises Inc. 242 Trails End Aurora OH 44202 Tel. 330-562-2930 FAX 330-247-1690 e-mail [email protected] web site www.fldenterprises.com

As with any two-component application, choosing the appropriate mixing nozzle is a critical consideration. Calculating the pressure drop across the nozzle is usually the first step in selecting an appropriate mixer. A pressure drop of between 30-80 psi is considered ideal and results in a good mixing environment. For most two-component materials, a range of nozzle configurations will be capable of producing a satisfactory mix. Mixing nozzle suppliers can help choose the right nozzle for the specific material and application. By eliminating the risk of filled materials separating in feed lines and valves, recirculating meter/mix valve systems ensure a proper mix and minimize maintenance and downtime, resulting in lower costs and higher productivity. For additional information, contact the author at (401) 431-7072 or [email protected], or visit www.nordsonefd.com.

July 2011

Servo motors improve adhesive and sealant application quality and product assembly flexibility.

By David Mandeville, Director of Marketing, and Dan Hutchens, Controls Engineering Manager, Sealant Equipment & Engineering, Inc.

dhesive dispensing systems can be difficult to specify when buying new machines and hard to understand when trying to improve existing performance. Two items critical to dispensing performance and resulting product quality are the metering principle and motor drive selection. The metering principle defines the adhesive delivery process, while the motor drive determines the fluid control method for adhesive delivery. This article explains the purpose of servo motor drives used in dispensing adhesives and sealants.

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HOW DOES IT WORK? In an adhesive dispensing system, the servo motor is controlled by a servo drive control. A programmable logic controller (PLC) communicates with the servo drive control via DeviceNet or equivalent network. At the human-machine interface (HMI) July 2011

panel, the operator first enters values to create a volume and flow rate for each of the dispense profiles stored in the PLC. The desired profile can be selected remotely by the user’s automation control for the defined part or manually by the operator on the HMI. The shot size and flow rate for this profile is then downloaded by the PLC into the servo drive control. When a dispense cycle is started—whether manually or through automation—the PLC commands the servo drive control to start the dispense cycle profile. The servo drive control then independently controls the closed loop motion of the servo motor, which provides the tightest loop with the best velocity control and the finest position resolution. Position and velocity feedback from the servo motor are monitored by the PLC over the DeviceNet connection and typically displayed on the HMI. Adhesives & Sealants Industry

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DRIVING DISPENSING SYSTEMS COMPARING MOTOR DRIVE TECHNOLOGY The technology for motor drives used in adhesive dispensing systems has evolved from the early pneumatic cylinder drives. A pneumatic drive is still a good choice for shot volume dispensing that has little need for repeatable flow control. When the air pressure varies, the flow rate varies. The need for improvement is the same today as when the air cylinder was upgraded to an air-over-oil drive or hydraulic cylinder. Air-over-oil drive motors are two cylinders where the air cylinder is attached to an oil cylinder with an oil flow control valve to provide smoother and consistent adhesive flow. A single hydraulic cylinder provides the same reliable adhesive flow, but requires a hydraulic power pack that can offer higher pressure and variable flow rates. Electric drive motors in adhesive dispensing systems provide a higher level of system capability and degree of performance, and may use gear reducers or ball-screws to control the flow rate. AC drive motors are low in cost and use variable-frequency drives to vary the flow. DC stepper motors are usually open-loop and do not know their position, which requires homing upon startup or after emergency stop. AC or DC servo motors are used with a closed-loop encoder, have higher resolution for better position control, and are normally smoother in motion.

When the dispense cycle profile is completed, the servo drive control signals the PLC and passes this indication to the user’s automation. The PLC then commands the servo drive control to start its “dispense cycle complete” profile to prepare for the next dispense cycle. The PLC coordinates the opening and closing of the material valves with the motion of the metering device that is controlled by the servo motor, monitors the system sensors, and delivers any necessary data and a “dispense ready” signal for the next part.

in process setup and programming time, material waste, product repair, scrap, returns, downtime, spare parts, and maintenance. Servo motors with related controls provide precise and repeatable control of both position and velocity, and their various feedback parameters allow users to closely monitor the dispensing process and detect any abnormalities before they can become major problems. Servo drive technology provides three main advantages in adhesive and sealant dispensing equipment: • Servo drive motors allow users to have preset, multi-segment shot profiles, with

each segment having its own material volume and flow rate, as well as the ability to smoothly blend the motion of each segment into the next one in the profile. The user can then select from among their preset profiles before initiating the dispense cycle. • Servo technology allows the user to continuously vary the material flow rate during the dispense cycle based on a command reference from the process control. This allows the user to either apply a continuous bead of material with varying bead widths, or, conversely, to maintain the same bead width despite changes in the applicator’s linear speed (e.g., when a robot slows down to negotiate a complex curve). • Servo control has the ability to reliably maintain the commanded volumetric flow rate of material despite changes in the physical conditions of the dispensing system or its environment. Examples of these types of changes are variations in material viscosity—and the related backpressure generated during the dispense cycle—due to such factors as variations in ambient temperature or differences in batches of material; variations in the plant utilities supplied to the dispensing equipment, such as air pressure or electrical voltage; and load changes due to physical wear on the dispensing equipment as it ages. The

SERVO MOTOR ADVANTAGES “Does the adhesive dispensing system have a servo drive motor?” That’s the question being asked today by many manufacturers that require quality parts and reliable production when dispensing adhesives and sealants. Servo drive technology continues to grow in product assembly but is sometimes overlooked by manufacturers due to its initial capital cost compared to non-servo drive equipment. While it is important to realize capital cost expenditures when buying motorcontrolled dispensing equipment, it is equally important to account for the full life cycle financial gains provided by servo drive technology. When dispensing adhesives and sealants onto products, bead placement and size are important factors to consider. Servo motor-driven dispensing equipment usually provides a better return on investment (ROI) than other lower cost drive devices, such as stepper motors, VFD motors, hydraulic drives and pneumatic drives. ROI considers the full life cycle of the production equipment and includes the initial capital cost, less the costs that arise from the increase in production rate and reductions 26

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Servo motor drive technology is recommended when there is a current or future need for dual independent drive meters.

Servo drive technology continues to grow in product assembly.

July 2011

servo drive simply increases or decreases the amount of current it supplies to the motor as required to maintain the commanded material flow rate, up to the current limits of the drive. If those limits are ever exceeded, the drive generates a fault and stops the cycle, which prevents the user from unknowingly producing out-of-spec parts.

APPLICATIONS Servo-driven adhesive dispensing systems should be considered when adhesive applications require higher production rates, multiple parts with different beads or volumes, correct bead size and placement, exact amounts of adhesives, fewer product and equipment repairs, and less product scrap for improved quality and lower costs. Many robotic systems already use high-end servo drive technology, but the adhesive dispensing system may use out-of-date pneumatic, hydraulic or electric drive systems that can cause monitoring, communication, and downtime issues. Servo drive innovations continue to develop in all industries and provide users with high-quality and easy-to-use dispensing equipment that cannot be made available without servo control devices. For example, a traditional mechanically linked drive and metering cylinders on twocomponent dispensing machines can now be independently servo driven and controlled by innovative servo drive technology that uses easy-to-understand and highly accurate operator interface controls. Innovation will continue for servodriven adhesive dispensing systems due to the requirement for equipment to be integrated with high-end automation, longer maintenance cycles, more precision, higher torque in smaller packages, and lower costs. The benefit for the system supplier with servo-driven equipment is to offer their customers the ability to have fully integrated systems that can be continuously monitored for performance, quickly adjusted for changes in product assembly or new products, provide warnings and fault data to address repairs and prevent scrap, and actually lower total system operating cost. Servo motor drive technology is recommended when there is a current or future need for: • Complex bead paths, tight tolerance beads, precise adhesive volumes • Multiple parts with different dispensing requirements • Varying the volume or flow of material during a dispensing cycle July 2011

Servo drive innovations continue to develop and provide users with high-quality and easyto-use dispensing equipment.

• High-speed automated dispensing • Integrating a dispensing system with robot automation • Using the dispensing system meter unit as a seventh robot axis • Meter systems with dual independent drive meters • Eliminating a stepper motor’s requirement for “homing” at startup or re-start • Eliminating a stepper motor’s accumulative position variances

tion and process. It’s not necessary to settle for a low-technology drive or the only motor drive available for a dispensing system, as it may cost a lot more during production. Manufacturers should define the important product and production requirements for their adhesive and sealant dispensing application, and request that the dispensing equipment manufacturer meet those specifications. For more information, contact Sealant Equipment & Engineering, Inc. at 45677 Helm, Plymouth, MI 48170;

THE BEST MATCH

phone (734) 459-8600; fax (734) 459-8686; email sales@

Manufacturers should select the motor drive to match their dispensing applica-

sealantequipment.com; or visit www.sealantequipment.com/ servo-motor.htm.


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CASE STUDY

Scheugenpflug designed a fully automated production line to support the resin casting of electronic components in countless different configurations.

PUSHING THE BOUNDARIES OF INDUSTRIAL PRODUCTION Booming demand calls for advanced automation in the manufacturing industry. By Franziska Weichhaus, Head of Marketing, Scheugenpflug ith the economy on the uptick and demand for sophisticated technology on the rise, electronic part manufacturers are looking for ways to streamline production and boost performance while keeping costs at bay. PRÜFREX, an international supplier of advanced digital ignition systems for the automotive, marine, heating, and lawn and garden industries, is a case in point. When PRÜFREX received a major new contract to produce small engine ignition control systems for forestry and garden machines, the company decided it was time to replace its existing semi-automated production line with a faster, more powerful alternative—one that would be able to handle a volume of approximately three million units per year. One critical part of the application included resin-casting the ignition systems in a way that would ensure both their high-voltage

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insulation and their resistance to outside factors such as temperature, humidity, vibration, and demolition. To this end, PRÜFREX called on Scheugenpflug, a leading specialist for automated mixing, metering and dispensing systems.

THE SOLUTION After carefully evaluating the application requirements, Scheugenpflug designed a fully automated production line to support the resin casting of electronic components in countless different configurations. With a 45 x 20-ft footprint, the system includes a linear transfer mechanism and a variety of process and measurement units, as well as several preheating and curing ovens loaded by a four-axis linear motion system. The ignition controls are transferred in part bins via conveyor belt from preproduction to a test cell for camera inspection (and to record their model type and exact position). Then the system automatically selects and sets the precise resin dosage for each component before ferrying it on to preheating. From there, all parts make their way to a two-chamber vacuum dispensing station. In the first chamber, any remaining moisture and air bubbles are effectively eliminated. Next, the parts are transported under vacuum to the second main chamber where the actual casting and sealing takes place. With both chambers working in unison and in parallel, production can be significantly accelerated. From the vacuum dispensing station, the parts make their way to a sensor-controlled unit that measures the casting levels with an accuracy of up to 0.004 in. The parts are then custom post-processed via an individually controlled, two-nozzle piston metering system. “To streamline the process, we first dispense the exact same amount of resin onto all components,” explains Erich Scheugenpflug, CEO of Scheugenpflug Group. “Due to certain tolerances of the injection molding parts and a minimal reduction of resin levels as a result of the pressure difference after leaving the vacuum station, custom postprocessing sometimes becomes necessary. The parts are therefore July 2011

PRÜFREX supplies advanced digital ignition systems for the automotive, marine, heating, and lawn and garden industries.

The Source For Customized Technology For 30 Years “CHEMICAL GRAFTING” APS’ chemical grafting process permanently attaches new properties to substrates to enhance their performance properties and make them more durable even under severe conditions. The result: high performance and longer life.

automatically transferred to a recasting station, and resin is cast under normal atmospheric pressure to reach the required level. The process is both very precise and extremely fast.” After recasting and final control, the parts are forwarded by a fouraxis linear transfer to one of three double-chamber curing ovens for custom curing. Since the delicate, fully filled components would be ruined by the slightest impact, the precision linear axis system must remain rigid in a completely horizontal position and guarantee smooth, vibration-free handling throughout the process. The oven doors even slide open through a precisely calibrated linear axis system.

HIGH-POWERED OUTPUT

APS’s proprietary process can be tailored to accommodate individual product requirements and production capabilities. Many materials can be improved through chemical grafting including metals, plastics, rubber, glass and cellulose. In addition to chemical adhesion via a covalent linkage resulting in superior bond, additional properties may also be imparted to your material. For more information, please contact us. ADVANCED POLYMER SOLUTIONS 99 Seaview Blvd. Port Washington NY 11050 TEL: 516-621-5800 FAX: 516-621-5850 Or Visit our website: www.advancedpolymersolutions.com

With a MobileTag Print to Web

ASI12094Advpoly.indd 1 With maximum quality, speed and precision, Scheugenpflug’s state-ofgo from the-art system is helping PRÜFREX meet the rapidly rising demand for its ignition systems. What’s more, the system is fully upgradable and well-suited to support the company’s future growth. “Instant access to the supplier was key for us, and the responsiveness of Scheugenpflug’s project team was nothing short of amazing,” says PRÜFREX’s Alfred Pretzl. “Whether we wanted to share an idea or voice a concern, we were always able to reach their engineers within the hour. For example, when we started operating the recasting cell, we realized that we needed dispensing needles to ensure the accurate positioning of the dosage. We called Scheugenpflug and they had their modular solution meet the new requirement in a snap, which is testament not only to their outstanding customer service, but also to their flexibility and openness to innovation.”

11/5/09 9:34:21 AM

ABOUT SCHEUGENPFLUG Scheugenpflug is a leading supplier of mixing, metering, and dispensing systems for resins, adhesives, and other industrial materials. For more than two decades, the company has been at the forefront of automating and streamlining the process of preparing and utilizing complex materials for a wide range of industrial manufacturing needs. Scheugenpflug products include everything from simple metering systems to fully automated production lines that span the entire process from pre-heating to testing and assembly. Scheugenpflug has dedicated offices in the U.S., Germany, and China, and maintains a worldwide distribution network. For more information, phone (770) 218-0835 or visit www.scheugenpflug-usa.com.

ABOUT PRÜFREX PRÜFREX develops ignition systems for the lawn and garden, heating, marine, and automotive industries. Headquartered in Germany, PRÜFREX supplies cutting-edge control system technology to

Simply snap a photo of the mobile tag with your Smartphone, and you can conveniently go from a page in our magazine to a webpage.

customers around the globe. For more information, visit www.pruefrex.com.

July 2011


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Advancements in novel pumping technology for paste adhesives are successfully addressing the challenges of large-scale composite industrialization. By Mac Larsen, Director, Application Development, Applied Fluid Technologies Division, Graco Inc.

he joining together of large structures such as wind turbine blades or ship hulls strictly with adhesives (vs. mechanical fastening techniques) has become a common practice. The current challenge is how to bring the adhesive bonding process into a mainstream operation that increases production throughput while maintaining control and minimizing manufacturing costs. Many factors need to be addressed when scaling up the bonding process, not the least of which is the question of how to reliably dispense thousands of pounds of adhesive each day, with minimal waste. Advancements in novel pumping technology for paste adhesives are successfully addressing the challenges of large-scale industrialization by quickly and reliably meter-mixing significant volumes of reactive twocomponent adhesives. The reactive mix is then directly dispensed to bond lines hundreds of meters long or manually pumped into buckets for manual application.

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PROPERTIES OF PASTE ADHESIVES Paste adhesives are usually non-slumping fluids (thixotropic pastes) that are supplied as separate A and B components in 200-liter drums. Mix ratios are anywhere between 1:1 and 3:1 by volume for epoxies or urethanes, and as wide as 100:2 for catalyzed polyesters. All types may include variable or selectable hardeners for faster or slower curing times to counteract ambient plant temperature changes. Care must be taken to prevent fluctuations in ambient plant temperatures that are lower than 20°C or over 35°C. If temperatures are too cold, the flow rates and cured properties are negatively affected; if too high, the adhesive mix might become runny and cure too fast to assemble the components. The rule of thumb is that work life is affected by a factor of two for every 10°C change in temperature. For example, an adhesive work life of two hours at 25°C will be cut down to only one hour at 35°C. July 2011

Direct dispensing along a bond line using a whip hose and forming applicator.

Figure 1. Homogeneous Mix Evaluation

Another rule of thumb involves material flow rates: Viscosity is inversely related to material temperature. The viscosity drops rapidly as the temperature increases. Depending on the materials, a 10°C increase can lower the viscosity by 50%. Many other issues come into play with these rules, so they should be used only as rough guidelines. Six important areas should be considered when qualifying a viable high-flow adhesive dispense process and machine for paste adhesives.

MIX RATIO Material suppliers report physical cured properties of their adhesives at their specified ratio of resin to hardener, such as 1:1 or 100:50 pbv (parts by volume). They may also specify a ratio tolerance of ± X%, within which suitable physical attributes of cured adhesive can be achieved. Most meter/mix machines specify the delivery of a mix ratio to within ± 1-2% of a set point, which is often well within the range of an adhesive supplier’s recommended ratio. When considering the application of a “wet” adhesive to large-scale composite parts, verification of ratio becomes an important aspect of the entire adhesive a p p l i c a t i o n p r o c e s s . To a i d r a t i o verification, many adhesives are supplied with part “A” being a different color than part “B,” so a correct blended color can be quickly observed when the parts are mixed at the proper ratio. Ratio variances large July 2011

Close up of platen during changing of a drum.

enough to result in a blended color change observable to the naked eye indicate an obvious “event” that can usually be diagnosed and corrected, such as an empty container, damaged delivery hose or partially cured mixing tube. Precision inline flow meters, one for Part A and one for Part B, are used if more precise verification is needed (e.g., 1-2% accuracy). The Graco VPM (Variable Paste Machine) employs inline flow meters for each component and a process of calibration using weight sampling. Electrical pulses from these two flow meters are processed in the

onboard computer and provide both real-time process information and data streams that can be saved as a historical record of the dispensing process. The end result is a robust adhesive delivery process that provides a high degree of certainty that the proper ratio is delivered to the substrate.

A/B MIX QUALITY Once proportioned, the individual components are delivered into a high-flow inline mixer. While dynamic mixers are used in some cases to blend difficultto-mix chemistries, the majority of disAdhesives & Sealants Industry

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DISPENSING FOR LARGE-SCALE COMPOSITES

Figure 2. Blue Stripes Indicate Adhesive Use in Blade Bonding (Image courtesy of Henkel Corp.)

The key design criteria for an inline mixer include a tube diameter that is sized to the flow rate and viscosity, and the number of dividing elements inside the mixing tube. The more dividing elements, the more mixing occurs. A good starting point is 24 elements that will divide the streams by 2 24 , or over 16,000,000 times.

FLOW RATE

Example of a 1,200-liter bulk supply container.

pense machines use static mixing to take advantage of their low maintenance. The Graco VPM uses a 1-1.5 in. diameter static mixing tube with 24 interior mixing elements that divide the material back and forth to accomplish blending. Since the individual A and B components are different colors, a good mix emerges as a homogeneous color with no striations or lead-lag concentrations. 32

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Figure 1 (p. 31) shows a test sample being evaluated by spreading a bead of dispensed material to check for color uniformity throughout. During the qualification testing of a new adhesive, the material supplier can perform more quantitative tests on a cured sample, such as glass transition, one-hour water boil test, thermo mechanical analysis (TMA), etc.

High flow rate is important in largescale bonding processes for two reasons. First, the work life of the mix is short (less than one hour, in many cases). Hundreds of pounds of adhesive need to be dispensed, and the faster the adhesive can be laid down, the more time is left for assembly. Second, production capacity and cost are critical. Molds are expensive, space is at a premium, and capacity is strained due to the market demand of wind energy turbines and other large composite structures. The faster a blade can be turned around, the more capacity a given plant can provide. A typical 2.5 MW wind blade is 50 m in length and can use up to 600 kg (1,300 lbs) of mixed adhesive for all its various bonded areas (see Figure 2). If the working life of a mixed adhesive is one hour and assembly time is 30 minutes, less than 30 minutes is left for the dispensing of what may be 1,000 pounds of adhesive. In one test, the Graco VPM dispensed a 3:1 ratio paste adhesive at 75°F and achieved a flow rate of 330 gms/s (43.5 lbs/m). At 85°F, the flow rate increased to 400 gms/s (52.8 lbs/m), which illustrates the importance of ambient temperatures on flow rate. (These rates are for illustration purposes and may vary depending on many factors.) July 2011

VPM metering system in a mobile configuration.

It is also important to factor in the effect of the A:B ratio. As the ratio increases (e.g., 2:1 vs. 3:1), more part A material is required to meet the flow rate. The part A (resin) material is typically the higher viscosity component. This results in greater flow rate of the higher viscosity material. Thus, the A material pump must work harder to obtain the flow rate and usually is the limiting factor to increasing the flow rate.

BULK SUPPLY Once the dispensing process starts, a 200-liter drum of resin can be emptied in as little as 15 minutes. The requirement for replacing an empty drum with a full one is a frequent occurrence during a large-scale bonding process. The Graco VPM features semi-automated controls to enable an operator to quickly change out a drum, minimizing the impact on the entire bonding process. Taking time out of the dispensing process to change out a drum is yet another reason to design high-flow-rate machines. To eliminate the change-out time, a tandem drum set can be used for each component. When one drum becomes empty, the new full drum automatically takes over. July 2011

Figure 3. Sample Production Display

A third alternative to bulk supply is the 1,200-liter drum. The unit shown on p. 32 is used for polyester adhesives that are mixed in a 100:2 ratio, thus putting virtually the entire flow rate demand on the base component. By using a 1,200-liter container, a large volume of adhesive can be supplied to the bonding process without interruption.

MOBILITY Designed for mobility, the Graco VPM allows better positioning along the blade structure as the bonding process continues. In a manual troweling process, as many as 20 people may be going to the dispenser to fill up a bucket of premixed adhesive. The ability to follow along the work area is an important criterion to speed production and reduce operator fatigue. In more automated processes, the VPM dispenser can be pulled along the work piece and, with the use of a whip hose and forming head, a formed bead can be directly applied to the bond line, thus eliminating buckets and reducing labor.

use and maintenance. Figure 3 is a sample of a graphic user interface that provides a production snapshot of all the relevant parameters during the bonding operation. Displays include intuitive procedures that assist in the startup, operation, shut-down and maintenance of the dispensing unit. Key to this technology is the ability to transfer historical data surrounding every bonding process so a record is available for every pound of material dispensed onto a structure.

INCREASING INDUSTRIALIZATION The manufacture of adhesive-bonded composite structures is rapidly evolving into an industrialization phase. Manufacturing speed and reliability are essential to the continued adoption of composites technology in large-scale markets. The Graco VPM adhesive machine is a cost-effective and reliable tool for processing considerable volumes of the paste adhesives required for bonding large-scale composite structures. For more information, contact Graco at 8400 Port

EASE OF USE AND MAINTENANCE

Jackson Ave. NW, North Canton, OH 44720; phone

The final consideration for an automated meter/mix machine is its ease of

(800) 746-1334; fax (330) 966-3006; email ohiocs@ graco.com; or visit www.graco.com/sae.


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Rice University graduate student Brent Carey positions a piece of nanocomposite material in the DMA device. (Credit: Jeff Fitlow/Rice University)

A Rice University lab has created a self-strengthening nanocomposite material. esearchers at Rice University have created a synthetic material that gets stronger from repeated stress, much like the body strengthens bones and muscles after repeated workouts. Work by the Rice lab of Pulickel Ajayan, professor in mechanical engineering and materials science and of chemistry, shows the potential of stiffening polymer-based nanocomposites with carbon nanotube fillers. The trick, it seems, lies in the complex, dynamic interface between nanostructures and polymers in carefully engineered nanocomposite materials. The team recently reported its discovery in the journal ACS Nano.

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TESTING MATERIAL PROPERTIES Brent Carey, a graduate student in Ajayan’s lab, found the interesting property while testing the high-cycle fatigue properties of a composite he made by infiltrating a forest of vertically aligned, multi-walled nanotubes with polydimethylsiloxane (PDMS), an inert, rubbery polymer. To his surprise, repeatedly loading the material didn’t seem to damage it at all. In fact, the stress made it stiffer. Carey, whose research is sponsored by a NASA fellowship, used dynamic mechanical analysis (DMA) to test this material. He found that after 3.5 million compressions (five per second) over about a week’s time, the stiffness of the composite had increased by 12% and showed the potential for even further improvement. 34

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“It took a bit of tweaking to get the instrument to do this,” this ” Carey said. “DMA generally assumes that your material isn’t changing in any permanent way. In the early tests, the software kept telling me, ‘I’ve damaged the sample!’ as the stiffness increased. I also had to trick it with an unsolvable program loop to achieve the high number of cycles.” Materials scientists know that metals can strain-harden during repeated deformation. Such strain-hardening is a result of the creation and jamming of defects—known as dislocations—in their crystalline lattice. Polymers, which are made of long, repeating chains of atoms, do not behave the same way. Thus, the team is not sure precisely why their synthetic material behaves as it does. “We were able to rule out further crosslinking in the polymer as an explanation,” Carey said. “The data shows that there’s very little chemical interaction, if any, between the polymer and the nanotubes, and it seems that this fluid interface is evolving during stressing.” “The use of nanomaterials as a filler increases this interfacial area tremendously for the same amount of filler material added,” Ajayan said. “Hence, the resulting interfacial effects are amplified as compared with conventional composites. For engineered materials, people would love to have a composite like this. This work shows how nanomaterials in composites can be creatively used.” July 2011

A small block of nanocomposite material proved its ability to stiffen under strain at a Rice University laboratory. (Credit: Ajayan Lab/Rice University)

BONE BEHAVIOR The researchers also found one other truth about this nanocomposite phenomenon: Simply compressing the material did not change its properties; only dynamic stress—deforming it again and again—made it stiffer. Carey drew an analogy between their material and bones. “As long as you’re regularly stressing a bone in the body, it will

remain strong,” he said. “For example, the bones in the racket arm of a tennis player are denser. Essentially, this is an adaptive effect our body uses to withstand the loads applied to it. Our material is similar in the sense that a static load on our composite doesn’t cause a change. You have to dynamically stress it in order to improve it.” Cartilage may be a better comparison—and possibly even a future candidate for nanocomposite replacement. “These properties may be attractive for the development of an artificial cartilage that can respond to the forces being applied to it while remaining pliable in areas that are not being stressed,” Carey said. Both researchers noted this is the kind of basic research that asks more questions than it answers. While they can easily measure the material’s bulk properties, it is an entirely different story to understand how the polymer and nanotubes interact at the nanoscale. “People have been trying to address the question of how the polymer layer around a nanoparticle behaves,” Ajayan said. “It’s a very complicated problem. But fundamentally, it’s important if you’re an engineer of nanocomposites. From that perspective, I think this is a beautiful result. It tells us that it’s feasible to engineer interfaces that make the material do unconventional things.” The co-authors of the paper are former Rice postdoctoral researcher Lijie Ci; assistant professor of mechanical engineering at the University of Bridgeport Prabir Patra; and associate professor at the Federal University of Minas Gerais, Brazil, Glaura Goulart Silva. Rice University and the NASA Graduate Student Researchers Program funded the research. For more information, visit www.rice.edu.

The ChemQuest Group, Inc. TM

8150 Corporate Park Drive ∞ Suit e 250 ∞ Cincinnati, OH 45242 PH. (513) 469-7555 ∞ FAX (513) 469-7779

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Global Strategic B usiness Management C onsulting to the Coatings, Adhesives and Sealants Industries Office Locations: OH – NC – MA – NJ – CA – MN – SC GERMANY – EGYPT – ARGENTINA – INDIA – CHINA

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July 2011

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Structural adhesive technology comes in many forms and can be used in a variety of applications. By John Dubber, Senior Technology Specialist, Henkel

tructural bonds are used to join critical load-bearing parts of an assembly. The adhesive technology for such bonding replaces (or in some cases, augments) methods such as riveting, welding or mechanical fastening with bolts and screws. It is worth noting that adhesive and other joining methods can work together. While adhesive bonding provides sufficient strength, the addition of a few appropriately placed rivets provides instant alignment, jigging and clamping advantages. To meet the requirements of structural applications, suitable adhesives must have a combination of high shear, tensile and peel strength, along with maximum stress, impact, and shock absorbent capabilities. Because this particular set of criteria is not always easy to combine, structural adhesives feature a range of differing product characteristics and chemistries. In addition, they are designed to bond a diverse selection of materials, including composites, wood, metal and glass. Structural adhesives also provide benefits over conventional methods of joining that include reduced weight, improved fatigue resistance, uniform stress distribution and the ability to join dissimilar materials. In many instances, less critical tolerances can be specified because of the gap-filling capability of many structural adhesives. Structural adhesives can fall into five technologies: epoxies, acrylics, polyurethanes, modified silanes and silicones. Why is such a variety needed, and where is each adhesive used?

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EXAMINING EPOXIES When it comes to high-strength structural bonding, epoxy resins are the acknowledged leader. They can be found in industries as varied as aerospace, automotive, marine, oil drilling, leisure goods, civil engineering, electronic assembly and medical device manufacturing. Epoxies are available in two-component, room-temperature-curing formulations or one-component, no-mix, heat-curing variations. Epoxy formulation comes with a huge degree of freedom, and virtually any characteristic can be formulated on demand. Structural epoxies are generally slower to cure than other technologies, but this makes them ideal for complex applications where a significant period of time is required for assembly purposes. Fast curing is not always an advantage. In one epoxy application example, a manufacturer uses a structural two-part epoxy for bonding magnesium, aluminium and composite components in the fabrication of its super-lightweight bicycle forks. Adhesives allow the seamless bonding of these structural substrates to provide an immensely strong and lightweight structure. According to the viscosity of the selected product and the joint geometry being bonded, different application techniques (e.g., injection or bead application) can be used. Another company uses an epoxy to secure the shaft of an ice axe to the head. This joint takes the full impact when the axe is dug into ice and snow. The substrates involved July 2011

are steel and aluminium, which have a tolerance of 0.15 mm. The epoxy provides a secure bond and hermetically seals the joint against water ingress. For even greater security, the joint is then riveted—a good example of two technologies complementing each other.

ACRYLIC ASSURANCE Unlike two-part epoxies, which require the resin and hardener to be mixed before application, some two-part acrylic adhesives provide the benefit of a “no mix” application process. In this process, the adhesive and initiator are applied to opposite faces of the joint. They are suitable for bonding a range of materials and are regularly used for sheet metal, especially on applications where the substrates might flex. Some grades of toughened acrylics can be used on “as received” steel and will withstand paint bake cycles. Toughened acrylics are often used in place of spot weld or blind rivets, especially where the appearance of the finished product is important, or where there is a requirement to spread any load over a wider area and reduce stress concentrations. A key characteristic of the acrylic family is their speed of set. Handling strength is generally achieved in less than 30 minutes at room temperature, thus allowing these adhesives to be used where speed of manufacture is an important requirement. Another major benefit of using toughened acrylics on sheet metal applications is their superior ability to deaden sound, compared to traditionally fastened metal sections. Applications that have embraced the use of toughened acrylics include the bonding of office partitions, air conditioning units and garage doors. One specific application involves the construction of a folding ramp that allows wheelchairs and prams to have easy access onto buses. The design calls for a cassette-type unit that is light, compact, flush-fitting and modular. This ramp also needs to be dropped straight into the vehicle chassis and connected to the operating mechanism during bus construction. Aluminium is used for lightness within the base and ramp floor, while the frame is formed using steel. To achieve the required strength, the floor is stiffened with an interfacing box section and wedge-shaped stringers (also manufactured from aluminium). Rivets were first considered for this assembly process. However, the number July 2011

Structural adhesives can provide benefits such as reduced weight, improved fatigue resistance, uniform stress distribution and the ability to join dissimilar materials.

that would have been required was prohibitive, and they would have spoiled the appearance of the ramp. More importantly, when the ramp is in service, it will often need to be able to twist and flex in order to unfold onto an uneven surface. As the ramp is retracted, it will also need to return to the original shape in order to fit into its housing. Adhesives provided the more acceptable answer. Simply applying a sheet steel bonder with an air-operated cartridge gun is enough to secure the stringers and the floor. The adhesive ensures a more flexible finished product and does not mark the surfaces. The lightweight ramp is extremely tough and withstood loads of 254 kg (560 lbs) during comprehensive testing.

POLYURETHANE POSSIBILITIES Polyurethane adhesives (PUs) have large gap-fill properties and are available as one- or two-part products. These structural versions should not be confused with the elastomeric lower modulus versions. Key advantages of highperformance polyurethanes include high strength, excellent gap fill capability, low temperature performance, and the ability to bond and seal a variety of substrates. Elastomeric versions are widely known for direct glazing applications, but the structural versions are typically used for large-panel bonding applications, such as those used in the construction of

refrigerated trucks. Polyurethanes are also used in building construction, machine assembly, boat building, ventilation systems and wind turbine blade construction. In this latter example, composite “stringers” are bonded inside the blade to provide stiffness and torsional rigidity. No mechanical fasteners are used in this process.

MULLING OVER MODIFIED SILANES Modified silanes cannot compete on a strength basis with any of the previously discussed adhesive groups. They can, however, bond to just about any substrate and are compatible with many paint systems. They also possess good UV resistance and can be used for interior and exterior applications. Modified silanes are primarily onecomponent products, although some twopart systems exist. They cure by reaction with moisture; no primer is required to achieve a good bond. However, the skin formation and curing times do depend on the ambient humidity, temperature and glue line geometry. Higher temperatures and relative humidity levels reduce cure times, while the reverse extends the cure process. Modified silanes are odorless and are free of solvents, isocyanates, silicones, and PVC. Typical uses for modified silanes include sealing the joints and seams on containers, railway carriages, shower screens, air conditioning, and ventilation equipment. Adhesives & Sealants Industry

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Fast-curing elastic adhesive products can bond and seal with a high level of adhesion to metal and glass.

A major benefit of using toughened acrylics is their superior ability to deaden sound.

SILICONE SUITABILITY Silicones, which are available in one- and two-part versions, also allow the bonding of a range of substrates. The key characteristics of this group of materials are low modulus, high elongation to failure (200600%) and the ability to withstand temperatures of up to 250°C. Some grades even offer performance up to 350°C. Silicones are known for their good durability; they have a high gap-filling and sealing capacity and are resistant to humidity, ozone and UV radiation. Standard, single-part silicones have traditionally been relatively slow to cure and have limited cure-through volume capabilities. In addition, their adhesion qualities depend to a great extent on the substrates being bonded. Although singlecomponent products have provided good service in diverse applications, adhesive manufacturers have invested resources in developing formulations that will overcome these “limitations” and enable silicone adhesives to be used more efficiently. 38

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In the case of Loctite products, these improvements have centered on the creation of two-part silicone adhesives and sealants. These materials are applied from a twin cartridge using standard static mixer technology. These fastcuring elastic adhesive products can bond and seal with a high level of adhesion to metal, glass, ceramics, and most plastics and elastomers (in most cases without the need for either a primer or surface preparation). In addition, these silicones work just as effectively on narrow or wide joint application areas and achieve handling strength within minutes. The two-part formulations are based on neutral cure technology that provides significant health and safety advantages. With low odor and no release of acetic acid, metal corrosion and plastic degradation are avoided. Typical uses for the new products include the bonding and sealing of glass and ceramic stove tops to appliance frames, securing brackets to the back of stove tops, bonding glass to microwave

oven doors, and the sealing of washing machine drums. Beyond the appliance market, they can be utilized for cabinet and panel bonding and sealing, replacing gaskets and mechanical fixing, bonding glass to reflectors or frames, the assembly of light bulbs, and joining integrated electrical ballast.

ACQUIRING ASSISTANCE Of course, numerous specific factors determine the choice of any adhesive technology for individual applications. Many adhesive manufacturers provide help desks where technology specialists are available to answer questions and provide advice. Through the provision of details about the application, substrates, glue line thickness, production process and other relevant factors, these specialists will likely be able to determine not only the most suitable adhesive technology, but a specific grade of adhesive within that technology as well. For more information, visit www.loctite.com.

July 2011

ADVANCING ADHESIVES

A new composite made up of natural fiber boards and polyurethane foam exceeds the performance requirements of Toyota’s Lexus RX 350. Photo courtesy of Toyota.

COMPOSITE CONCEPT Lightweight composite technology from BASF and Concept Industries receives Toyota Technology and Development Award. ASF recently announced that a new jointly produced lightweight load floor composite has been recognized by the Toyota Motor Corp. with the Technology and Development Award, one of the automaker’s highest supplier honors. The innovative design created by BASF and Concept Industries is a sandwich panel consisting of natural fiber skins bonded together with Elastopor, a lightweight, poured-inplace BASF rigid polyurethane (PU) foam core. The product reportedly delivers low-weight, high-strength performance with sustainable manufacturing and production efficiencies. In addition, the natural fiber boards from Concept Industries, together with the rigid polyurethane foam chemistry from BASF, form a composite that exceeds the performance requirements of Toyota’s Lexus RX 350 load floor, upon which the technology launched in late 2010. Concept Industries was recognized by Toyota Motor Corp. for the new deckboard material at Toyota’s 2011 Global Supplier Convention in Nagoya, Japan. The honor recognizes top performance innovation and development during the past year. “Concept Industries has always been about more than simple products,” said Shawn Eshragh, president and CEO of Concept Industries. “We believe we have a responsibility to work for the betterment of mankind. We are obligated to act in the best interest of our employees and the environment to ensure that our actions support a strong and sustainable future for ourselves and our children. Toyota’s recognition of this sustainable composite technology reinforces Toyota’s shared commitment to this vision.”

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“BASF is focused on the development of sustainable solutions,” said Joel Johnson, vice president of BASF Polyurethane Systems. “This collaboration with Concept Industries is an excellent example of market-driven innovation. The combination of lightweight materials, superior load strength, and renewable materials makes it a very compelling solution.”

ABOUT BASF POLYURETHANES BASF is a leading supplier of polyurethane solutions for systems, specialties and PU basic products. With its global network of 38 polyurethane system houses and its comprehensive product and ser vice portfolio, BASF is the preferred partner of its customers in many industries. The BASF brand “Polyurethane S o l u t i o n s ” r e p r e s e n t s o v e r 4 0 ye a r s o f e x p e r i e n c e o f t h e m a r k e t a n d technology leadership for polyurethane systems. For more information, visit www.polyurethanes.basf.com.

ABOUT BASF CORP. BASF Corp., headquartered in Florham Park, N.J., is the North American affiliate of BASF SE, Ludwigshafen, Germany. BASF has approximately 16,400 employees in North America, and had sales of $17.7 billion in 2010. For more information about BASF’s North American operations, visit www.basf.us.

ABOUT CONCEPT INDUSTRIES Since 1984, Concept Industries has been a full ser vice provider of unique innovative products that combine superior performance with cost effectiveness. For more information, visit www.conceptind.com.


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CORPORATE SPOTLIGHTS BAYER MATERIALSCIENCE B a y e r M a t e r i a l S c i e n c e ’s enhanced polyurethane dispersions for adhesives— Dispercoll ® U XP 2643 and Dispercoll ® U XP 2673/1— exhibit room temperature tack and bonding characteristics, making them appropriate for such automotive interior bonding applications as dashboards and door and instrument panels. They are suitable in lowtemperature bonding situations and successfully bond flexible plastic films for food and packaging applications. Dispercoll C XP 2694 and Dispercoll XP 2717 dispersions are ready to use for foambonding applications. They exhibit high wet tack, generate fast-crystallizing, highstrength bonds, are supplied at 30% solids with a pH of approximately 9, show excellent shear and storage stability (>10 d@ 70°C), and are fully compatible with existing Dispercoll C and S grades, allowing for customization of performance characteristics. Desmodur® XP 2763 aliphatic “engineered prepolymer” was designed for use in polyaspartic ester coatings and high-filmbuild, moisture-cure urethane topcoats. When used with polyaspartic ester Desmophen® NH resins, it can improve 2K coating performance.

NUSIL TECHNOLOGY New Thermally Conductive Silicone Adhesive for Electronics Industry from NuSil Technology EPM-2890 is a one-part, white silicone adhesive that will vulcanize at room temperature, with moisture, in 72 hours. It can be used as an adhesive, sealant, caulking or potting material in sensitive electronic applications that require a material of minimal volatility to provide protection from condensation. For applications in which adhesion is important (e.g., bonding for ruggedizing LCD displays), EPM-2890 offers 100 psi minimum primerless adhesion on aluminum. It provides enhanced thermal conductivity at 0.6 W/(mK) for applications in which stress relief during thermal cycling and heat management is desired.

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July 2011

WHAT’S NEW RAW MATERIALS SARTOMER USA OLIGOMER

CN9025 is a new aliphatic urethane acrylate for use in UV/EB-cured hard-coat applications in the automotive industry, including body panels, head lamps, plastic parts and accessories. The material is non-yellowing and fast curing. It is a PETA-free product, providing reduced irritation risk to formulators and production personnel. Coatings that use the material reportedly demonstrate outstanding abrasion resistance, chemical resistance and weatherability compared to products formulated with competitive hexafunctional urethane acrylate oligomers. Thus, CN9025 may increase the resilience and lifespan of coated automotive components Web: www.sartomer.com

FORMULATED ADHESIVES 3M AEROSPACE STRUCTURAL VOID FILLING COMPOUNDS

3M™ Scotch-Weld™ structural void filling compounds EC-3550 B/A FST and EC-3555 B/A FST are low-density void fillers. The compounds can reportedly help save time and costs in aircraft production by eliminating process steps, reducing worker time, and speeding throughput. With a combination of easy dispensability and non-sag performance, the compounds offer a number of productivity-enhancing advantages. The lightweight, extrudable, and pumpable compounds can offer superior handling attributes and dispensability. The compounds’ simplified preparation and cleanup eliminates weighing, mixing and potential re-packaging, thus saving production time. With fast, direct application, the products can reduce—and in some instances, eliminate—hand troweling and trapped air, helping to avoid pinholes, voids, and porosity. Web: www.3M.com/ldvf

OMNOVA SOLUTIONS ACRYLIC POLYMER ADHESIVE

NovaCryl™ PS-R 30 pressure-sensitive adhesive (PSA) is available for use in the vinyl film, tape and label markets. The water-based acrylic polymer adhesive is designed for ultra-removable label applications, including those used for storage identification, decals, and window cling graphics, as well as protective films for glass, automotive components, electronics, and displays. The July 2011

product reportedly features excellent cling and electro-wetting characteristics, and delivers clean removability with no “ghosting.” NovaCryl PS-R 30 is free of alkyl phenol ethoxylate (APE)-type surfactants, offering environmental benefits for certain end use applications. It is available as a base polymer or a coater-ready formulation, and is compatible with many wetting agents, defoamers, and rheology modifiers. Web: www.omnova.com

NORDSON ASYMTEK

EQUIPMENT DIGITAL LIGHT LABS UV LED SPOT-CURING SYSTEMS

A new, portable UV LED illumination system intended for the low-cost UV-curing market, as well as spectroscopy and general fiber illumination applications, is now available. The CompactCure offers an all-in-one design that contains a multi-watt, high-powered UV LED; internal optics; driver; dimming controller; and active cooling packaged in a compact enclosure. The systems offer several different UV wavelengths, including 365, 385, 400, and 420 nm. Different built-in optics are available for different UV patterns, as well as optional adaptors for fiber optics and liquid light guides. Other deep UV (254, 280, 320, and 350 nm), visible, and NIR wavelengths may be custom ordered for OEM applications. Web: www.digitallightlab.com/page.php?10

FILM COATER

A new film coater is offered for the automated, selective and precision application of conformal coating materials. The Nordson ASYMTEK Select Coat® SC-280 reportedly provides greater than 99% fluid transfer efficiency, improving material utilization by 30-50%. It selectively coats complex circuit boards in seconds. Because the coating material is not atomized and is applied to the selected areas, overspray, masking, and rework associated with conventional conformal coating processes are minimized or eliminated. “Nordson invented film coating over 20 years ago and is continuing to make evolutionary improvements to this process using our years of experience and customer feedback,” said Hector Pulido, conformal coating product specialist. “Nordson ASYMTEK’s SC-280 design is based on the popular Nordson SC-104/204 film coater, which has been an industry standard for many years. The new coater has an even faster response, is more repeatable, and the

DURALABEL LABEL PRINTING SYSTEM

Toro is a portable, fully integrated label printing system that combines a full-sized flip-down keyboard, tilting touch screen, OSHA-ANSI compliance software and a thermal transfer printer into one unit. “We engineered Toro to be network independent because many of our customers needed it,” said Steve Stephenson, chief marketing officer. “Many government agencies and industrial IT departments have strict security rules regarding the connection of peripheral equipment like label printers to their networks. Toro has its own customized software so it doesn’t need a network.” Network independence, along with a rugged, lightweight design and optional battery power, allows the unit to print labels and signs at several locations within the same facility or at remote sites. The battery reportedly provides the power to print continuous labels for three hours without a charge. Web: www.DuraLabelToro.com

P R O D U C T & L I T E R AT U R E

Showcase Leading the Way in 2K New catalog from Nordson EFD offers the complete line of TAH systems for meter mix and cartridge applications for two-component adhesives, including mixers, cartridges, dispensers, and valves. For a free copy, visit www.nordsonefd.com/ads/asi-1010.


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WHAT’S NEW solenoid has a longer life. It’s easy to clean and is environmentally friendly. The system improves material utilization, achieves less waste and reduces costs.” Web: www.nordsonasymtek.com

by preventing kinking, a common cause of downtime for such demanding applications. Web: www.plastics.saint-gobain.com

RESOURCES AMERICAN CHEMISTRY COUNCIL NEW WEBSITE

CHARLES ROSS & SON CO. TRIAL/RENTAL PROGRAM

Chris Ross, vice president of Sales, recently announced this company’s newly expanded Trial/Rental Program. Hundreds of pieces of mixing and blending equipment, from 1-quart to 400-gal capacities, are now available for short- and long-term rental. In addition, several laboratory models are available for free consignment. The Trial/Rental Program enables process managers to optimize efficiency on their process line. Whether increased mixing capacity is needed online no later than the end of next week, or mixer testing is intended for only a couple of months, the program allows the flexibility to match capacity to demand without purchase. Mix vessels and auxiliary equipment, including vacuum pumps and heating units, can also be rented as a package with any mixer or blender. This reduces extra steps in sourcing and installation, allowing users to start testing or production sooner. Once a mixing strategy is confirmed and a new mixer is selected for purchase, a significant portion of trial fees are credited against the purchase price. Phone: (800) 243-ROSS Web: www.mixers.com

SAINT-GOBAIN CHEMICAL TRANSFER HOSE

A superior flexible and kink-resistant hose, Chemfluro® Convoflex™ WCSR multipurpose chemical transfer hose is designed to solve issues in bulk chemical transfer processes where corrosive chemicals such as acids may damage the stainless steel braid commonly used as a cover on transfer hoses. From solvents to bulk chemical transfer, the hose can reportedly withstand aggressive chemicals during chemical processing. Its highly engineered low-profile helical convoluted inner core design can provide superior flexibility while maintaining the productivity of plant operations 42

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A new website and integrated messaging platform highlights the importance of chemistry in driving innovation, creating jobs and enhancing safety. “Ninety-six percent of all manufactured goods and five million U.S. jobs are touched by the business of chemistry, making it an essential part of our nation’s economy,” said Cal Dooley, president and CEO of the American Chemistry Council (ACC). “Now, more than ever, it is important that we elevate the conversation and remind policymakers in Washington and across the country of the importance of our industry and the consequences of bad policy.” ACC’s new platform was designed to amplify the new messaging among a more targeted audience. The launch of both represents a shift from ACC’s consumer-facing “essential2” campaign to one aimed at influencing decision makers at the local, state and federal levels. In addition, the website reflects the organization’s advocacy priorities and magnifies the role the chemistry industry plays in addressing today’s critical issues. The site reportedly features a more dynamic, engaging, and action-oriented design to enhance the users’ experience and take them from awareness to engagement and mobilization. Web: www.americanchemistry.com

BROOKFIELD TEXTURE ANALYZER SOFTWARE

TexturePro CT software can help users perform detailed texture analysis on test samples of various shapes and sizes. The software provides test procedure automation and removal of operator bias from the test. Real-time graphic plotting lets operators create custom reports and graphs directly from a menu screen during tests. The newly released version 1.3 is an optional item available for purchase and use with all CT3 texture analyzer orders. TexturePro CT software, which connects directly to a computer via USB, is designed specifically for use with Brookfield’s CT3 texture analyzer. Customers currently using v1.2 can upgrade to v1.3 free of charge on the company’s website. Major enhancements include the capacity to run on 32- or 64-bit operating systems; the addition of a new rupture test used to determine the break point of a sample; and a reorganized, expanded probe and fixture selection.

Phone: (800) 628-8139 or (508) 946-6200 Web: www.brookfieldengineering.com/products/software/ updates/TextureProCT/setup.htm

ELLSWORTH ADHESIVES FRENCH WEBSITE

This company recently announced that has launched a new website in France. The site provides a comprehensive source for adhesives, sealants, encapsulants, lubricants, conformal coatings, dispensing and UV-cure equipment. Visitors to the site can request a quote and search for products by name, vendor, type and physical attribute in any combination. “The site provides our customers with an easy, convenient and functional way to search for product and obtain competitive quotes,” said John Henderson, managing director of Ellsworth Adhesives, Europe. “The launch of this website supports our strategic objective to provide our customers with the resources they need to reach their business goals,” said Jeff Payne, Ph.D., chief marketing officer. “We plan on continually expanding the site by adding content and e-commerce functionality.” Web: www.ellsworth.fr

HENKEL ELECTRONICS REDESIGNED WEBSITE

This website has been redesigned to reportedly deliver a simple, yet comprehensive, resource for customers’ and partners’ daily use. “The new website was thoughtfully reworked, with input from customers regarding functionality and data requirements as key criteria for the project,” said Doug Dixon, director of Marketing Communications. “With our broad-based portfolio, it was essential to develop a tool where customers can easily search for products and obtain all reference materials for that specific product through a single access point. For any given material, website users will be able to view all available data—whether that’s technical data sheets, videos, press announcements, technical articles, images or tutorials.” The site offers improved search capabilities, access to Henkel communication resources such as the company’s catalogs and quarterly newsletters, and details regarding upcoming events that Henkel will attend. Web: www.henkel.com/electronics

Have Product News to Share with the Industry? E-mail news releases to Teresa McPherson at [email protected].

July 2011

M A N U FA C T U R I N G & P R O C E S S I N G S E R V I C E S

SERVICES MARKETPLACE D I S T R I B U T I O N S E RV I C E S Heigl Technologies ...................................................................................... 43

L A B O R AT O R Y & T E S T I N G S E R V I C E S Chemsultants International Network ............................................................ 43 Delsen Testing Laboratories .......................................................................... 44

M A N U FA C T U R I N G & P R O C E S S I N G S E R V I C E S Polymeric Systems, Inc. ............................................................................... 43 Resin Lab .................................................................................................... 43

P R I VAT E L A B E L I N G S E R V I C E S ChemLink.................................................................................................... 43 This index is a feature maintained for the convenience of the advertiser. It is not part of the advertiser’s contract, and ASI assumes no responsibility for its accuracy.

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DR.DAVE

QUESTION: We are using an ultraviolet (UV) adhesive to bond and seal a polycarbonate medical pump. We get a large reject rate when pressure testing the seal with air. Could you suggest some possible problem areas and improvements? ANSWER: Part design could be contributing to the complicaMany early UV tion. Make sure you have good molded flat parts with sufficient adhesives had bond area. I have seen some problem designs where sealing problems in bonding issues have been solved merely by increasing the seal area. plastics because In order to get a strong bond and seal, you need to ensure certain plastics that your adhesive is applied well and is cured completely. don't transmit UV It is also crucial to achieve light very well. good adhesion to the surface. Many early UV adhesives had problems in bonding plastics because certain plastics don’t transmit UV light very well (particularly those that contain UV absorbers to prevent UV degradation). Remember that if a plastic is transparent, it can transmit the visible part of the electromagnetic spectrum, but it will not necessarily transmit UV light. You can easily investigate this on your plastics by using a UV radiometer. Make sure you measure the intensity of the UV either in the bondline or underneath the plastic. Some modern adhesives cure using both UV and visible light. When you seal a component this way, you need good adhesion to the surface because—unlike a conventional pre-formed gasket— the seal will not be compressed. It is also important to ensure that there is no contamination of the plastic surface that might preclude good adhesion. Make sure that mold release agents, which are actually designed to prevent adhesion, are not causing surface contamination. Some plastics have internal release agents added to them. In particular, silicones can often cause adhesion problems. Silicones are extremely valuable materials in medical device manufacturing as sealants or lubricants. However, I have seen numerous instances where the use of silicones in a clean room has caused adhesion problems with other adhesives. Do not forget that silicones can “creep” over surfaces due to the handling of parts, and many silicones contain volatile cyclic siloxanes that can move through the air and condense on nearby parts.

Advanced Polymer Solutions

www.advancedpolymersolutions.com

29

Bayer MaterialScience Llc

www.bayermaterialscienceNAFTA.com 15

Chemquest Int’l Network

www.chemquest.com

35

Conn & Co.

www.connblade.com

11

Evonik Industries AG

www.evonik.com/adhesives-sealants

F.E.I.C.A.

www.feica-conferences.com

IBC

F.L.D. Enterprises

[email protected]

24

Green Manufacturing Expo

www.GreenMfgExpo.com

10

KCC Central Research Institute

[email protected]

45

Merlin Packaging Tech. Inc.

www.merlinpackaging.com

12

Nusil Technology

www.nusil.com/asi

Ross, Charles & Son Co.

www.mixers.com

3

Scheugenpflug USA

www.scheugenpflug-usa.com

9

Univar USA Inc.

[email protected]

4

Wacker Silicones

www.wacker.com/knows-solutions

7

IFC

Dr. Dave Dunn is a former vice president and director of Loctite Corp. and has spent many years troubleshooting adhesive and sealant problems in the adhesives, sealants, specialty rubbers, and plastics fields. Questions for publication

BC

should be directed to him at 242 Trails End, Aurora, OH 44202; (330) 562-2930; FAX (330) 247-1690; email [email protected]; or visit www.fldenterprises.com. Any views or opinions expressed in this column are those of the author and do not represent those of Adhesives & Sealants Industry, its staff, Editorial Advisory Board or BNP Media.

46

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This index is a feature maintained for the convenience of the advertiser. It is not part of the advertiser’s contract, and ASI assumes no responsibility for its accuracy.

July 2011

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