DYNAFOAM® - Saint-Gobain Performance Plastics Foams

DYNAFOAM® - Saint-Gobain Performance Plastics Foams
DYNAFOAM®
T e c h n i ca l G u i d e
DYNAFOAM® is a proud member of the NORSEAL® family.
2
®
Dynafoam
Technical Guide
CONTENT
Content ................................................................................................................................................................... 3
List of illustrations ................................................................................................................................................... 5
Introduction ............................................................................................................................................................ 6
1.
2.
3.
What is DYNAFOAM® ...................................................................................................................................... 7
1.1
Definition ............................................................................................................................................... 7
1.2
Packaging, storage, shelf life ................................................................................................................. 7
Principal implementation properties .............................................................................................................. 8
2.1
Sensitivity to heat .................................................................................................................................. 8
2.2
Mono-component and thermoplastic ................................................................................................... 9
2.3
Curing in response to temperature and relative humidity .................................................................. 10
2.4
Density determines some of the gasket properties ............................................................................ 10
2.5
Post foaming ........................................................................................................................................ 11
2.6
Viscosity according to temperature .................................................................................................... 12
Implementation ............................................................................................................................................ 12
3.1
Nordson machine – general information ............................................................................................ 12
3.2
Changing dynafoam® drums ................................................................................................................ 13
3.3
Foaming instruction ............................................................................................................................. 15
3.3.1
Nordson machine ............................................................................................................................ 15
3.3.2
General information ........................................................................................................................ 16
3.4
Application ........................................................................................................................................... 16
3.4.1
Dispensing head .............................................................................................................................. 16
3.4.2
Application methods ....................................................................................................................... 17
3.5
Curing................................................................................................................................................... 18
3.5.1
Humidity/moisture (between 45% & 85%) ..................................................................................... 18
3.5.2
Temperature (between 40°C & 55°C) ............................................................................................. 18
3.5.3
Ambient temperature (room temperature) .................................................................................... 19
DYNAFOAM® is a proud member of the NORSEAL® family.
3
®
Dynafoam
Technical Guide
3.5.4
Curing time ...................................................................................................................................... 19
3.6
4.
Recommendations ............................................................................................................................... 20
Parameters affecting the appearance & quality of the gasket ..................................................................... 20
4.1
Temperature: ....................................................................................................................................... 20
4.2
The percentage of gas: ........................................................................................................................ 20
4.3
Pressure: .............................................................................................................................................. 20
4.4
The mixer: ............................................................................................................................................ 21
4.5
Inadequate purging: ............................................................................................................................ 22
4.6
The nozzle: ........................................................................................................................................... 22
5.
Maintenance ................................................................................................................................................. 23
6.
Repairs/troublshooting and faq .................................................................................................................... 24
6.1
Product repairs/troubleshooting ......................................................................................................... 24
6.1.1
Particles ........................................................................................................................................... 24
6.1.2
Damaged skin .................................................................................................................................. 24
6.1.3
Bubble or large cells ........................................................................................................................ 25
6.1.4
Poor/incorrect transfer moulding ................................................................................................... 25
6.1.5
Poor appearance of the gasket ....................................................................................................... 26
6.1.6
Waves in the skin ............................................................................................................................ 26
6.1.7
Stretch marks on the skin ................................................................................................................ 26
6.1.8
Uneven gasket height ...................................................................................................................... 26
6.1.9
Other repairs/troubleshooting ........................................................................................................ 27
6.2
Faq’s..................................................................................................................................................... 28
DYNAFOAM® is a proud member of the NORSEAL® family.
4
®
Dynafoam
Technical Guide
LIST OF ILLUSTRATIONS
Figure 1 : Density measurment test method ........................................................................................................ 11
Figure 2 : Nordson Machine .................................................................................................................................. 12
Figure 3 : Instruction label for changing a drum ................................................................................................... 14
Figure 4 : Nordson Machine .................................................................................................................................. 15
Figure 5 : Direct extrusion ..................................................................................................................................... 17
Figure 6 : Transfer Moulding ................................................................................................................................. 17
Figure 7 : Example of a high humidity drying oven ............................................................................................... 18
Figure 8 : Excess foaming ...................................................................................................................................... 21
Figure 9 : Density that is too high ......................................................................................................................... 21
Figure 10 : nozzle too far from the substrate ....................................................................................................... 22
Figure 11 : Gas injection valve .............................................................................................................................. 23
Figure 12 : Assembly prior to complete curing ..................................................................................................... 24
Figure 13 : Humidity damaging the skin ................................................................................................................ 26
Table 1 : General aspects of these thermoplastic products .................................................................................... 9
Table 2 : Principal foaming parameters ................................................................................................................ 15
Table 3 : Viscosity and nozzle diameter ................................................................................................................ 16
Table 4 : Summary for all products ....................................................................................................................... 19
Table 5 : Application temperatures....................................................................................................................... 24
DYNAFOAM® is a proud member of the NORSEAL® family.
5
®
Dynafoam
Technical Guide
INTRODUCTION
The aim of this application manual is to guide partners and customers through the use of SaintGobain’s Dynafoam® solution.
It is designed to provide general as well as precise information on phenomena and technical data,
along with advice and recommendations.
Initially, you will learn about Dynafoam® and the resulting foam-in-place gasketing solution.
We will then turn to the key properties of the product for its implementation.
In a more technical section, we will then deal with the implementation process and the different
pieces of equipment required.
The quality of the foamed gasket will subsequently become the focus of our attention, with examples
and influential factors.
A fifth section, on maintenance, will include recommendations and advice that are independent of
the manufacturer’s recommendations.
And, to conclude, an FAQ section will be provided to help you use this solution.
NB.: This manual is not a replacement for the technical specifications, the DYNAFOAM®
documentation or the documentation for the foaming machine.
DYNAFOAM® is a proud member of the NORSEAL® family.
6
®
Dynafoam
Technical Guide
1.
WHAT IS DYNAFOAM®
1.1
DEFINITION
DYNAFOAM® is the name of a flexible watertight foam-in-place gasket developed by Saint-Gobain. Its
main characteristics in an unfoamed state (as received by the customer) are as follows:
•
A mono-component product (PUR 1K)
•
Thermoplastic
•
Physically foamed with nitrogen (humidity/moisture must be below 5 ppm)
•
Applied in-place
•
Cured by its reaction with the humidity/moisture in ambient air
•
Vacuum packed in a contamination-free multilayer bag
•
Supplied in 20 or 200 litre metal drums (or in reusable plastic containers for 20 litre
deliveries)
This technology from Saint-Gobain has been helping industrial operators for almost 30 years. As it is
constantly evolving, one development follows another, enabling you to monitor and anticipate your
customers’ needs.
1.2
PACKAGING, STORAGE, SHELF LIFE
DYNAFOAM® is packaged in drums, containing a vacuum packed moisture-sealed bag.
Each drum bears a label containing the following information:
a.
The type of DYNAFOAM®
b.
The quantity of material in kg
c.
The batch number
d.
The expiration date
e.
The maximum application temperature (which must never be exceeded!)
DYNAFOAM® is a proud member of the NORSEAL® family.
7
®
Dynafoam
Technical Guide
Material stocks must be managed by applying the FIFO principle (First In First Out).
The temperature in the Dynafoam® storage area must not exceed 30°C and drums must be kept out
of direct sunlight.
DYNAFOAM® has a shelf life of 6 months from its date of manufacture in normal storage conditions
(ambient temperature and under cover).
It should be noted that the product’s viscosity increases during storage, but this phenomenon does
not radically alter its properties, even after a period of 6 months. 6 months is given as a reasonable
limit for using the product without any quality issues and offering optimum processability.
Nevertheless, we strongly recommend using the product within this period. Any claims/complaints
relating to a product that has exceeded its expiration date will be rejected by Saint-Gobain.
2. PRINCIPAL IMPLEMENTATION PROPERTIES
2.1
SENSITIVITY TO HEAT
DYNAFOAM® is sensitive to heat.
We recommend shutting off the system’s heating in the event of a stoppage lasting for more than
30 minutes. This will prevent accelerated ageing of the product, which could cause problems with
pumping or particles.
For each stoppage lasting for more than 1 hour, it is necessary to purge the system (the quantity of
®
product present in the mixer and in the hose between the mixer and the head) as the Dynafoam and
nitrogen mixture will no longer be uniform.
In the event of a stoppage lasting between 15 and 30 minutes, discharge a quantity equivalent to one
part, in order to prevent excess pressure building up at the nozzle, thereby impairing the quality of
foaming and/or damaging the nozzle needle.
Clean the heating platen every time the drum is changed. This cleaning helps prevent cured product
being transferred from the versa drum to the nozzle.
Do not exceed the mixer’s recommended speed. This could result in an increase in dynamic shear
and, because of this, in excess foaming as well as a rise in temperature.
Temperature changes the viscosity, which, itself, has an effect on the quality of the foam and smooth
operation of the system.
DYNAFOAM® is a proud member of the NORSEAL® family.
8
®
Dynafoam
2.2
Technical Guide
MONO-COMPONENT AND THERMOPLASTIC
DYNAFOAM® is designed to be automatically applied in-place to create foamed gaskets.
It reacts with the humidity/moisture in ambient air to acquire elastomeric properties, as well as
those required for smooth application.
These products need to be heated in order to be pumped because of their viscosity.
In addition, cooling them creates the cohesion needed for them to retain the desired shape.
Finally, curing them gives them the required elasticity, chemical resistance and thermal resistance.
Product
512
7440 Series
Base
Polyester base
Polyether base
With a high humidity
drying oven
Between 350 & 400
Between 220 & 280
Thixotropy
Very high
High
Height/width ratio
0.9
0.65
Application Temperature
Between 70° & 80°
Between 30° & 40°
3D application
yes
yes
Density (kg/m³)
Table 1 : General aspects of these thermoplastic products
DYNAFOAM® is a proud member of the NORSEAL® family.
9
®
Dynafoam
2.3
Technical Guide
CURING IN RESPONSE TO TEMPERATURE AND RELATIVE HUMIDITY
DYNAFOAM® reacts to temperature and relative humidity, forming a three-dimensional structure.
The curing time for this product depends on various parameters, including:
•
initial density (close to 1,100 kg/m³),
•
the diameter and shape of the gasket,
•
physical configuration (presence of a groove or not),
•
curing conditions (temperature and relative humidity).
Curing will be quicker if the gasket’s diameter is smaller at a high temperature and, above all, with
high humidity.
2.4
DENSITY DETERMINES SOME OF THE GASKET PROPERTIES
The properties that are determined (wholly or in part) by density are:
•
Hardness and compression force,
•
Curing speed, which is inversely proportional to density,
•
The size of the gasket
•
Compression set
Density and hardness are not systematically related when comparing two chemically
different products. One product may have a compression force (and/or hardness) that is lower than
another, which has stronger chemical bonds.
In this respect, it is important to check the density following complete curing of the DYNAFOAM®
gasket, in order to verify the latter’s properties. In addition, this check enables you to see whether
the density of the gasket is stable throughout production (i.e. the machine is operating normally).
To do this, Saint-Gobain proposes using the following verification method:
1. Cut off a ± 3 cm long strand. Do not squeeze it.
2. Calibrate the scales and weigh the sample to the nearest 1/100 g. Note the weight (A = in
grams).
3. Hang a plumb line with a needle from the bottom of the scales.
4. Place a beaker filled with water on the scales’ lower plate.
DYNAFOAM® is a proud member of the NORSEAL® family.
10
®
Dynafoam
Technical Guide
5. Dip the lead weight and the needle into the water, without touching the walls of the beaker.
6. Calibrate the scales.
7. Lift up the lead weight and the needle and hang the previously weighed sample piece on it.
8. Dip all of this into the water, without touching the walls. Note the weight of the sample in
the water (B = grams).
Density (kg/lit) =
A (= gram)
A (= gram) – B (= gram)
Figure 1 : Density measurment test method
2.5
POST FOAMING
The gasket leaving the nozzle is subject to a pressure drop, which makes it foam as a result of the
expansion of the nitrogen trapped within it. In addition, once the gasket is extruded, it reacts
chemically with the humidity/moisture in the air; this is known as “post foaming”. This chemical
reaction generates CO2, which makes the gasket swell to its final size.
The extent of post foaming also depends on various parameters:
•
The diameter of the initial gasket,
•
Curing speed,
•
Relative humidity,
•
Temperature.
Therefore, it is important to take post foaming into account, in order to obtain the desired
dimensions and shapes.
DYNAFOAM® is a proud member of the NORSEAL® family.
11
®
Dynafoam
2.6
Technical Guide
VISCOSITY ACCORDING TO TEMPERATURE
DYNAFOAM® is a thermoplastic material and its viscosity changes in a manner that is inversely
proportional to temperature.
This means that viscosity decreases as the temperature rises and vice versa.
In the event of too much shear (specifically in terms of the mixer), the temperature will rise
but the shear stresses will increase the product’s viscosity.
3. IMPLEMENTATION
3.1
NORDSON MACHINE – GENERAL INFORMATION
Figure 2 : Nordson Machine
The Nordson machine is made up of four units:
-
The drum unloader
The drum unloader enables the product’s viscosity to be reduced in order to pump it. It loads
the equipment with material, by pumping it from the metal drum to the foaming machine.
-
The foaming machine
Comprising two pumps with their speeds adjusted to the foaming ratio, it enables nitrogen to be
incorporated into the Dynafoam® product using the dynamic mixer.
DYNAFOAM® is a proud member of the NORSEAL® family.
12
®
Dynafoam
-
Technical Guide
The extrusion head
This allows the quantity of product to be deposited to be measured.
-
The control panel
The control panel contains all the modifiable parameters, as well as information on the process.
It allows the settings to be changed in order to influence the product/nitrogen mixture as well as
the quantities extruded.
3.2
CHANGING DYNAFOAM® DRUMS
For optimum use, care must be taken not to damage drums during storage and handling.
The condition of Dynafoam® drums is checked by Saint-Gobain and carriers leaving the factory, to
ensure that drums despatched by Saint-Gobain are clean and smooth, with no dents.
The carrier is liable for damage caused during transport.
We strongly recommend checking the condition of drums when the material is received and, should
any damaged be observed, do not hesitate to reject them or, failing this, to have the carrier sign a
document stating clearly the damaged condition of the drums (with a photograph, if possible). SaintGobain will not bear the costs of drums damaged by the carrier.
DYNAFOAM® is a proud member of the NORSEAL® family.
13
®
Dynafoam
Technical Guide
To change a DYNAFOAM® drum, simply follow the instructions appearing on the label affixed to the
lid of each drum.
Figure 3 : Instruction label for changing a drum
For your safety, follow the machine manufacturer’s instructions (see the user manual).
Every time a drum is changed, clean away product residue from beneath the platen as well as the
platen’s seals (“O-ring”) using a plastic spatula, in order to prevent cured material entering the
system and damaging the various coatings. It is also feasible to place a thin layer of grease on the
“O-ring” seals, in order to facilitate insertion of the platen.
DYNAFOAM® is a proud member of the NORSEAL® family.
14
®
Dynafoam
3.3
Technical Guide
FOAMING INSTRUCTION
3.3.1
NORDSON MACHINE
Our tests and prototyping phase were carried out using a Nordson “Ultra Foam Mix” laboratory
machine with a 20 lit vacuum “Versa Drum” drum.
Figure 4 : Nordson Machine
The following parameters are generic parameters observed during our various studies.
Product
512
7440 Series
Gas set point
Between 26% & 32%
Between 35 & 45%
Target density
Between ±350 kg/m³ &
±450 kg/m³
Between ±220 kg/m³ &
±240 kg/m³
Gas pressure
6 bar
6 bar
Product pressure
Between 60 & 80 bars
Between 60 & 80 bars
Mixer speed
Between 60 & 80 rpm
Between 60 & 80 rpm
Application T°
Between 70° & 80℃
Between 30° & 40℃
Table 2 : Principal foaming parameters
These figures are provided for information only. The parameters need to be adjusted for each
application, in order to obtain an optimal result. There will be vast differences between curing in
ambient conditions and curing in a high humidity drying oven.
DYNAFOAM® is a proud member of the NORSEAL® family.
15
®
Dynafoam
3.3.2
Technical Guide
GENERAL INFORMATION
For initial adjustment, you must always measure the density of the foam and adjust the settings
accordingly. We recommend using the parameters applied during the prototyping phases when
starting-up the system. This should normally allow you to create conditions that are as close as
possible to normal production conditions.
As a general rule, the temperature is set in the same way in all areas, but it is possible to create a
temperature gradient for certain applications, or even to reduce it in certain cases (including,
occasionally, for the mixer as the shear generated there raises the temperature).
3.4
APPLICATION
3.4.1
DISPENSING HEAD
The recommended nozzle diameter for DYNAFOAM® is between 1mm and 1.9mm, depending on the
product used, its viscosity, the intended gasket size or even the application method.
Product
512
Series 7440
Viscosity
Between 70 & 160
Pa.s (at 100°C)
Between 30 & 80
Pa.s (at 40℃)
Nozzle diameter
1.2 mm – 1.9 mm
1 mm – 1.6 mm
Table 3 : Viscosity and nozzle diameter
The nozzle diameter must also be tailored to the flow (the shear rate) and throughput (speed of the
applicator gun’s pump) needed for the project.
NB.:
These machine parameters (settings and nozzle) are provided for information only.
For each application, the parameters need to be tailored to the production site depending on the
cycle used.
DYNAFOAM® is a proud member of the NORSEAL® family.
16
®
Dynafoam
3.4.2
Technical Guide
APPLICATION METHODS
DYNAFOAM® can be applied in two ways:
•
By direct extrusion
Figure 5 : Direct extrusion
This method allows great freedom in terms of the shape of the part. It also permits vertical
application or even application from underneath, in order to reach relatively delicate areas.
•
By transfer moulding: the process should be defined on a case-by-case basis.
Figure 6 : Transfer Moulding
In the case of transfer moulding, it is important to treat the mould and to cool it to a temperature of
10°C. Commonly used treatments involve sandblasting or even plasma.
This method allows a gasket to be applied to the edge of a part or even to give the gasket a specific
shape (higher than it is wide, for example).
Pay attention to the condition of the mould’s surface. It can very quickly ruin the gasket if it is
damaged. Saint-Gobain is not responsible in any way for treating moulds and their impact.
DYNAFOAM® is a proud member of the NORSEAL® family.
17
®
Dynafoam
3.5
Technical Guide
CURING
As Dynafoam® is reactive to ambient humidity and heat, it is of paramount importance to monitor
these two parameters at all times, in order to guarantee the repeatability of the foamed gasket’s
properties. In this respect, it is possible to use different conditions and equipment to maintain the
chosen curing climate.
Figure 7 : Example of a high humidity drying oven
3.5.1
HUMIDITY/MOISTURE (BETWEEN 45% & 85%)
•
DYNAFOAM® is reactive to humidity,
•
Hygrometry and temperature are the main factors influencing curing speed.
•
The higher the humidity, the faster the curing process.
•
DYNAFOAM® will not cure without humidity/moisture.
3.5.2
TEMPERATURE (BETWEEN 40°C & 55°C)
•
The higher the temperature, the faster the curing process.
•
However, there are limits beyond which temperature has a negative effect on the quality
of the foam and its skin.
•
While reacting with humidity/moisture, Dynafoam® produces CO2 that is partially
trapped inside the product. This phenomenon tends to reduce the density of the
product, while encouraging it to cure.
•
Curing in a climatic chamber, with controlled relative humidity and temperature, results
in dimensional stability and density that meet expectations.
DYNAFOAM® is a proud member of the NORSEAL® family.
18
®
Dynafoam
3.5.4
o
A higher density
o
A harder foam
o
A longer curing time
o
Possibly exceeding the gasket’s dimensional tolerances
Any change in relative humidity and/or temperature (differences between summer and
winter, morning and evening, etc.) has the result of altering the curing time and, above
all, the gasket’s dimensions and density.
CURING TIME
Bead Height
3 mm 4 mm 5 mm 6 mm 8 mm
Product
512
•
Curing at an ambient temperature results in:
7440
•
AMBIENT TEMPERATURE (ROOM TEMPERATURE)
7440FC
3.5.3
Technical Guide
NA* =
NT** =
Curing Conditions
10 mm
Curing Time (min)
55°C / 85% RH
40°C / 60% RH
30°C / 50% RH
20°C / 40% RH
55°C / 85% RH
40°C / 60% RH
30°C / 50% RH
20°C / 40% RH
55°C / 85% RH
40°C / 60% RH
30°C / 50% RH
10
30
60
NA*
12
30
50
NA*
9
15
25
15
30
60
NA*
15
35
60
NA*
9
15
30
15
30
NA*
NA*
15
40
NA*
NA*
10
20
30
15
30
NA*
NA*
20
50
NA*
NA*
12
20
35
25
40
NA*
NA*
NT**
NT**
NT**
NT**
NT**
NT**
NT**
25
NA*
NA*
NA*
NT**
NT**
NT**
NT**
NT**
NT**
NT**
20°C / 40% RH
50
60
NA*
NA*
NT**
NT**
Above 1h, test stoped
Not tested, max height 7mm
Table 4 : Summary for all products
DYNAFOAM® is a proud member of the NORSEAL® family.
19
®
Dynafoam
3.6
Technical Guide
RECOMMENDATIONS
•
•
It is generally necessary to adjust the equipment’s parameters depending on the
customer’s production conditions:
o
Temperature parameters
o
Density parameters
o
Climate oven
o
…
It is also possible to provide training on the process, use of the equipment and the
procedures, on the customer’s premises:
o
Principles and use of the equipment (Nordson)
o
Basic principles of DYNAFOAM® (Saint-Gobain)
o
Changing drums (Nordson and Saint-Gobain)
o
System maintenance (Nordson and Saint-Gobain)
o
Basic guidelines for repairs/troubleshooting (Nordson and Saint-Gobain)
4. PARAMETERS AFFECTING THE APPEARANCE & QUALITY OF THE GASKET
4.1
4.2
4.3
TEMPERATURE:
•
Excessive temperatures harm the appearance of the skin.
•
Temperatures that are too low can affect the density.
THE PERCENTAGE OF GAS:
•
A gas ratio that is too low creates a higher density than required.
•
A gas ratio that is too high (exceeding the permissible level) creates a poor quality foam,
spitting, coarser cells and open cells.
PRESSURE:
•
Pressure that is too low within the system harms the quality of the foam: spitting, orange
peel skin, poor cellular structure and poor dispersal of gas.
•
Pressure that is too high in the nozzle risks damaging the needle or even having extrusion
that will not be controllable in terms of direction.
DYNAFOAM® is a proud member of the NORSEAL® family.
20
®
Dynafoam
4.4
Technical Guide
THE MIXER:
•
The mixer’s speed must relate to material throughput and the production cycle.
•
Material throughput must not exceed the machine’s capacity (+/- 6kg/h).
•
The mixer must not operate continuously in order to avoid over-foaming the
DYNAFOAM®.
•
Once the applicator gun has stopped, the mixer’s rotation falls sharply (to 5 rpm
approximately)
•
It is necessary to adjust the mixer’s rotation (optimum speed) in order to properly mix
the gas and the DYNAFOAM®.
o
There is no need to exceed the gas dispersal limit in DYNAFOAM®: overly
increasing this speed (the mixing effect) causes the material to shear, which
disrupts the machine’s operation and results in an increase in the product’s
viscosity.
o
Overly reducing the mixer’s speed causes weak dispersal of gas in the material,
meaning that the density is higher and the cellular structure is no longer uniform.
Figure 8 : Excess foaming
Figure 9 : Density that is too high
DYNAFOAM® is a proud member of the NORSEAL® family.
21
®
Dynafoam
4.5
Technical Guide
INADEQUATE PURGING:
•
•
Inadequate purging (continuously or intermittently)
o
affects the density, which is no longer controlled,
o
causes spitting and affects the quality of the foam.
Therefore, it is preferable to use a purge cycle, similar to the production cycle.
o
•
4.6
For example: 7 sec on, 5 sec off.
Material throughput must not exceed the machine’s capacity.
THE NOZZLE:
•
The shear rate is the key factor influencing formation of the foam and its skin.
•
The shear rate is directly related to dynamic pressure (in the applicator gun) and the
nozzle’s design:
•
•
o
The higher the pump speed, the higher the dynamic pressure,
o
The larger the nozzle diameter, the lower the dynamic pressure.
o
Low shear results in poor quality skin and poor cellular structure (open cells).
Nozzle position:
o
A nozzle that is too close to the substrate will result in a flat gasket.
o
A nozzle that is too far from the substrate will cause waves on the gasket’s
surface.
o
The nozzle’s normal distance from the substrate is 1 - 2mm.
A clogged nozzle may cause defects in the gasket produced (particles in the gasket, holes,
etc.).
Figure 10 : nozzle too far from the substrate
DYNAFOAM® is a proud member of the NORSEAL® family.
22
®
Dynafoam
Technical Guide
5. MAINTENANCE
For optimum use of the foaming system with Dynafoam®, we recommend cleaning the foaming
equipment at regular intervals. This is defined in the machine manual, in terms of Nordson
recommendations.
Additional recommendations from Saint-Gobain, which are specific to Dynafoam®:
The most sensitive points are:
The gas injection valve: should be checked every 3 months
The check valve for gas injection: should be checked every 3 months
Figure 11 : Gas injection valve
The applicator gun unit (opening/closing system): should be checked every 3 months
The mixer: should be checked once a year
For application by transfer moulding, a second set of moulds is recommended in order to avoid
interrupting production in the event of problems or cleaning.
NB.: For normal maintenance, follow the machine manufacturer’s instructions.
DYNAFOAM® is a reactive material, and as such, it is necessary to observe the following points, the
majority of which are covered in detail in other sections of this manual:
1. Avoid allowing the material to stand for too long when heated with no production (period
during which the machine is heated up without any material throughput)  if the stoppage
needs to exceed 1 hour, shut off the heating
2. Avoid prolonged contact (a few minutes) between the product and humidity/moisture, in
particular when changing a drum
3. Use nitrogen containing less than 5 ppm of water (dew point -70°C)
DYNAFOAM® is a proud member of the NORSEAL® family.
23
®
Dynafoam
Technical Guide
4. Do not exceed the recommended application temperature:
Product
512
7440 Series
Application T°
Between 70° & 80℃
Between 30° & 40℃
Table 5 : Application temperatures
6. REPAIRS/TROUBLSHOOTING AND FAQ
6.1
PRODUCT REPAIRS/TROUBLESHOOTING
6.1.1
PARTICLES
A particle may have various causes, depending on its nature, colour and shape:
6.1.2
o
From cured DYNAFOAM® within the system
o
A skin on the drum’s surface
o
The heating platen was not properly cleaned when the drum was changed
DAMAGED SKIN
Squeezing the gasket prior to complete curing results in the foam having a short life. The product’s
skin can also be damaged if an object comes into contact with it immediately after extrusion.
Figure 12 : Assembly prior to complete curing
DYNAFOAM® is a proud member of the NORSEAL® family.
24
®
Dynafoam
6.1.3
•
6.1.4
•
Technical Guide
BUBBLE OR LARGE CELLS
Bubbles may have different causes:
o
A drop in pressure
o
Cavitation of the vacuum barrel pump
o
The product is cured within the system
o
High viscosity
o
Inadequate purging (continuously at high speed)
o
Too much gas
o
The mixer’ speed is too low
o
Excess foaming
o
The mixer is in continuous operation
o
There is air in the product
o
The temperature is too high
POOR/INCORRECT TRANSFER MOULDING
Check:
o
The release from the mould
o
The water spray
o
The cleanliness of the mould
o
The quantity of DYNAFOAM® deposited
o
The density
o
The nozzle (position in the mould, opening and closing the needle)
o
Indexation of the part in the mould
o
The part (oily, misshapen)
o
Adhesion
DYNAFOAM® is a proud member of the NORSEAL® family.
25
®
Dynafoam
6.1.5
•
Technical Guide
POOR APPEARANCE OF THE GASKET
This could be caused by various factors:
o
High temperatures
o
Poor purging
o
The product’s viscosity is too high
o
A machine problem
o
An incorrect quantity of water
o
Incorrect oven settings (HHB)
Figure 13 : Humidity damaging the skin
6.1.6
•
6.1.7
•
6.1.8
•
WAVES IN THE SKIN
It is essential to check the nozzle's position in relation to the substrate (too high).
STRETCH MARKS ON THE SKIN
This could be caused by various factors:
o
Inadequate adhesion (too high in a deep groove, etc.)
o
Density that is too high
UNEVEN GASKET HEIGHT
This could be caused by various factors:
o
Trajectory
o
Density
o
Adhesion
o
Inappropriate groove design
DYNAFOAM® is a proud member of the NORSEAL® family.
26
®
Dynafoam
6.1.9
Technical Guide
OTHER REPAIRS/TROUBLESHOOTING
•
It is imperative to adhere to the specified range of temperatures for the product in
question
•
Excessive temperatures cause:
o
A poor surface appearance
o
A coarse cellular structure
o
An increase in the product’s viscosity
•
A change in the vacuum drum’s temperature has no effect on the foam’s
properties.
•
Certain applications may require a specific configuration of the machine’s temperatures
(settings).
DYNAFOAM® is a proud member of the NORSEAL® family.
27
®
Dynafoam
6.2
Technical Guide
FAQ’S
Symptoms
Potential causes
The material throughput is The pressure is too low
insufficient.
The density is too high
Remedy
Check the pressure regulator.
Check the vacuum drum level.
Check the gas level.
Check whether the bottle is open
and whether the air inlet is open.
Check whether the injector is
blocked.
Purge the system after a prolonged
stoppage.
Cured product: obstruction
The temperature is too high.
The extruded
“swirling”.
strand
Clean the machine.
The temperature is rising in Check the mixer’s speed.
the mixer.
Adjust the mixer’s rotation to suit
the throughput.
is The nozzle is too far from Correct the application gun’s
the substrate.
trajectory.
The quantity of DYNAFOAM® Increase the quantity.
is insufficient.
DYNAFOAM® is a proud member of the NORSEAL® family.
28
®
Dynafoam
The gasket
appearance.
Technical Guide
has
a
poor The nozzle needle is closed Check the air solenoid valve.
too far.
Increase the needle’s stroke.
The gas is dispersing poorly.
Adjust the mixer’s speed.
Do not exceed the machine’s
capacity.
The material pressure is too Check the pressure in the system.
low.
Adjust the pressure.
Purge the machine.
Check the density.
The temperatures are too Check the machine’s heating
high or too low.
Adjust the temperature.
The oven’s temperature Purge if necessary.
and/or relative humidity are
Check proper operation of the HHB
not correct.
Reduce the temperature and
relative humidity if necessary (only
to check proper operation of the
HHB).
Foaming is excessive.
DYNAFOAM® is a proud member of the NORSEAL® family.
Reduce the gas level.
29
®
Dynafoam
Technical Guide
The curing time is unusually Ambient temperature.
long.
The temperature and
relative humidity in the
premises are too low.
The HHB is not working
properly.
Increase the temperature in the
premises.
Use an air humidifier.
Check the HHB’s operating
parameters.
Check the temperature, water and
relative humidity.
The product’s density is too The gas injection valve is
high
blocked
The dynamic mixer is
damaged or clogged
Clean the valve (or change it)
Carry out a lengthy purge in order
to clean the mixer.
If this is insufficient, have the mixer
checked.
DYNAFOAM® is a proud member of the NORSEAL® family.
30
®
Dynafoam
Demoulding is difficult.
Technical Guide
The temperature in the Reduce the mould temperature.
mould, or of the material, is
Increase the cycle time.
too high.
The quantity of release
agent is not appropriate.
Adjust the quantity.
Adjust the spray trajectory; check
the distance from the substrate.
The transfer mould is dirty.
Clean the mould using a soft brush
and acetone.
The density is too high
Purge.
The quantity of DYNAFOAM® Adjust the quantity.
is insufficient.
Check the density.
DYNAFOAM® is a proud member of the NORSEAL® family.
31
Contact us for your
gasketing challenges :
Automotive HVAC filter
housing and air outlets
Automotive lightings
Automotive door cassette
modules
Home appliances
Electrical / Electronic
components
Audio speakers
Construction elements
And more ...
Saint-Gobain Performance Plastics
North & South America
One Sealants Park
Granville, New York 12832, USA
Tel. (800)724.0883
Fax (1)518.642.2793
R. Antonio Matheus Sobrino, 120
Vinhedo – SP Brazil
CEP: 13.280-000
Tel. (55)19.2127.8532/8530
Fax (55)19.2127.8540
Europe
Avenue du Parc 18
4650 Chaineux, Belgium
Tel. (32)87.32.20.11
Fax (32)87.32.20.51
13 Earlstrees Road
NN17 4NP Corby, Northants
Great Britain Tel. (44)1536.276.000
Fax (44)1536.203.427
My Office Gold
Altay Çeşme Mah. Öz Sok.
No:19; Kat 3
34843 Maltepe/Istanbul, Turkey
[email protected]
www.foams.saint-gobain.com
Asia
6th Fl, Fuchu South Building
1-40 Miyamachi, Fuchu-city,
Tokyo 183-0023
Japan
Tel: (81)42.352.2104
Fax:(81)42.358.2887
13th Fl Dongshin Bldg.
141-28 Samsung-Dong
Gangnam-Gu, Seoul 135-090, Korea
Tel. (82)2.508.8200
Fax (82)2.554.1550
3F-1, 147 Jianguo North Road, Section
2
Taipei 10477, Taiwan
Tel. (886)2.2503.4201
Fax (886)2.2503.4202
1468 Kun Yang Road
Minhang Economical & Technological
Development Zone
Shanghai, China 200245
Tel. (86)21.5472.1568
Fax (86)21.5472.2378
64/8 Moo 4 Eastern Seaboard
Ind. Estate T. Pluakdaeng, A.
Pluakdaeng, Rayong 21140
Thailand
Tel. (66) 3.866.7800
Fax (66) 3.866.7892
Devanahalli Road,
Via Old Madras Road
Bangalore 560 049
India
Tel. (91)80.2847.2900
Fax (91)80.2847.2616
Dynafoam is a proud member of the Norseal family
Dynafoam & Norseal are registered trademarks of Saint-Gobain Performance Plastics Corporation.
The data and details in this document were correct and up-to-date at the time of printing and are intended to provide information on our
products and their possible applications. It is the user’s responsibility to obtain the latest version of the product data sheet. This data sheet
is not a specification and does not assure specific product characteristics or make reference to the suitability of the product for a specific
application. Because Saint-Gobain cannot anticipate or control every application, we strongly recommend testing of this product under
individual application conditions. The application, use and conversion of this product are the user’s responsibility.
Limited Warranty: For a period of 6 months from the date of first sale, Saint-Gobain Performance Plastics warrants this product(s) to be
free from defects in manufacturing. Our only obligation will be to provide replacement product for any portion proving defective, or at
our option, to refund the purchase price thereof. User assumes all other risks, if any, including the risk of injury, loss or damage, whether
direct or consequential, arising out of the use, misuse, or inability to use this product(s).
SAINT-GOBAIN PERFORMANCE PLASTICS DISCLAIMS ANY AND ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING THE IMPLIED
WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE.
NOTE: Saint-Gobain Performance Plastics Corporation does not assume any responsibility or liability for any advice furnished by it, or for
the performance or results of any installation or use of the product(s) or of any final product into which the product(s) may be
incorporated by the purchaser and/or user. The purchaser and/or user should perform its own tests to determine the suitability and
fitness of the product(s) for the particular purpose desired in any given situation.
SPE5231E-pdf-March 2014
Was this manual useful for you? yes no
Thank you for your participation!

* Your assessment is very important for improving the work of artificial intelligence, which forms the content of this project

Download PDF

advertisement