DYNAFOAM® - Saint-Gobain Performance Plastics Foams
Contents
1. eseeseseseeeeeeneneren enne 20 4 1 Temperature secccacensstvesasecsaataivvsherescvasncohevaadeeseassds ohevsieeesavsnedehcesassesadsh iachevshevesdvsnsdofevsateenedsbaichevstecessvacs 20 4 2 Thepercentage OF gas oet ote deeds sendeadecdoetsehaveancadetoseeyianneseteaceetatbacteakadarsbeakisatsaedeuteetenteeses 20 4 3 did es 20 4 4 LER T IT TTL 21 4 5 Inade quate purgilig uscire tea Feo Rae Cete Rege Ee E NER EE FUR eR EXR UR ER ee chess ERR UE LERRA RET RE NECARE vaavelvavast 22 4 6 Ula le Er 22 Di EIwsrpe siedendscaptecenicts Eeer Naa EEEa E EEE ERE eE E ENa EREA RES NEE EE 23 6 Repairs troublshooting and faq ccccccessceessecsseceessecscccseecssscecssecsscecseecesseeseecssececesecsaececseecsaececetecaeeeeeeess 24 6 1 Product repairs troubleshooting esses eere nennen enne enne trennen entran enne traten nennen 24 ENI Particles iarten a E NA EE NEE aS aE ETN TINEA EE 24 Sra D MN Pao M SIE PRDLTEI DD E a E E E AA EE E aE 24 61 3 Bu bbleorlarge cells rente eap eh nto ron aa eee e tns eoe a gea hah Sdscoarseiesdennagdavesy sands 25 6 1 4 Poor incorrect transfer moulding cceccccssseessecsseceeseecsseceeseecsaecesseecsaeceseecsaecessecsaeceeseeeaeeeestess 25 6 1 5 Poorappearance of the gasket wiccscc cscssssccnccasccsvesecnacadscsveonacatacsssaosescnaceasseasensneanad scoavedsecneaaccessanvsends 26 61 6 Waves inth2. 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 Dynafoa m Demoulding is difficult The temperature in the mould or of the material is too high The quantity of release agent is not appropriate The transfer mould is dirty The density is too high The quantity of DYNAFOAM is insufficient DYNAFOAM is a proud member of the NORSEAL family Technical Guide Reduce the mould temperature Increase the cycle time Adjust the quantity Adjust the spray trajectory check the distance from the substrate Clean the mould using a soft brush and acetone Purge Adjust the quantity Check the density SPE5231E pdf March 2014 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 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 Cesme Mah Oz Sok No 19 Kat 3 34843 Maltepe Istanbul Turkey foams saint gobain com www foams saint gobain com eth 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 Don
3. 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 amp QUALITY OF THE GASKET 4 1 TEMPERATURE e Excessive temperatures harm the appearance of the skin e Temperatures that are too low can affect the density 4 2 THE PERCENTAGE OF GAS e Agasratio that is too low creates a higher density than required e Agasratio that is too high exceeding the permissible level creates a poor quality foam spitting coarser cells and open cells 4 3 PRESSURE e 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 e 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 ONT j DYNAFOAM is a proud member of the NORSEAL family Dynafoam SAINT GOBAIN Technical Guide 4 4 THE MIXER e The mixer s speed must relate to material throughput and the production cycle e Material throughput must not exceed the machine s capacity 6kg h e The mixer must not operate continuously in order to avoid over foaming the DYNAFOAM e Once the applicator gun has stopped the mixer s rotation falls sharply to 5 rpm approximately e lt is necessary to adjust the mixer s rotation optimum speed in order t
4. 702 spuoj syeyoes 8612602 C00 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 efft Dynafoam SAINT GOBAIN Technical Guide 3 3 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 amp 32 Between 35 amp 4596 Target density Between 350 kg m amp Between 220 kg m amp 450 kg m 240 kg m Gas pressure 6 bar 6 bar Product pressure Between 60 amp 80 bars Between 60 amp 80 bars Mixer speed Application T Between 60 amp 80 rpm Between 70 amp 80 C Between 60 amp 80 rpm Between 30 amp 40 C Table 2 Principal foaming parameters These figures are provided for information only The parameters need t
5. 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
6. aide d un couteau 3 Enlever le disque d coup et veiller ne pas laisser de bavures 4 Positionner le f t sous le plateau chauffant de votre vide f t Purger et d marrer le systeme suivant les instruc tions de la pompe 5 La temp rature d utilisation est indiqu e sur l tiquette code barres 6 Lorsque le f t est vide enlever le sac compress et le laisser expos a l humidit ambiante afin de permettre une r ticulation complete Le produit r sultant est inerte et peut tre limin suivant les lois locales 1 Nur 20 L F sser DYNAFOAM aus Kunstoffmehrwegbeh lter in das Metallfass umpst lpen 2 Feuchtigkeitsemfindliches Material Den inneren Folien beh lter erst unmittelbar vor Gebrauch ffnen Hierzu ein Loch oder einen X von 10cm 16cm Durchmesser in die Folie schneiden siehe Skizze 3 Ausgeschnittenes Folien st ck entfernen Auf eine glat te Schnittkante achten 4 Beh lter unter die Heizplat te des Fassschmelzers stellen Anlage entsprechend den Betriebsanweisungen f r Ihre Pumpe reiningen und anfahreni 5 Die Verarbeitungstempe ratur ist auf dem Strichcode Etikett vermerkt 6 Sobald der Beh lter leer ist zerdr ckten Foliensack ent fernen und bei Raumfeuch tigkeit zu einem unschad lichen Kunststoff vernetzen lassen Entsprechend den g ltigen Bestimmungen entsorgen mtm SAINT GOBAIN 1 S lo 20 litros Traspasar el DYNAFOAM del cubo de pl st
7. 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 e 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 Dynafoam SAINT GOBAIN 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 i
8. ri en EVER Eee RE Toe ER EEEE ENEE ea 21 Figure 9 Density that is too higli iiisae terii trei etn rano thuat err on Le ERR Fee LR nh Fio tsia Una nn Ee EE Ta 21 Figure 10 nozzle too far from the substrate sssssssssssseseseseeenenee enne nnne tnnn then rn sn nes enne enne enne 22 Figure 11 Gas injection valve eere ieoi nhe tbt Rae e P bake a RETE E Papa EE RE are e a rn Re roa 23 Figure 12 Assembly prior to complete curing sssseeseeseeeeeeneenneenneen nnne nennen en nennen nennen enne 24 Figure 13 Humidity damaging the skin eerte ette erben E pe raiekin Eanes rS ERR X ER in Eksis K EUER ce 26 Table 1 General aspects of these thermoplastic products nnne 9 Table 2 Principal foaming parameters eese tentent hene then ni Ei etta eee te bane Ene Ei re Fine ERR 15 Table 3 Viscosity and nozzle diameter nennen enne ennnen tentent senes 16 Table 4 Summary for all products ironic eee tire rep acer Rura Ernie tae eR dr Ey eene Fue ESE ona ako ree e K NE 19 Table 5 Application temperat res eret eee rre kart ee Yarro sehe e MERE ER eee e eaae hee ERR Vase bh EEEa EE iE an 24 DYNAFOAM is a proud member of the NORSEAL family Dynafoam SAINT GOBAIN Technical Guide INTRODUCTION The aim of this application manual is to guide partners and customers through the use of Saint Gobain s Dynafoam solution It is designed to provide general as well as precise informatio
9. ATTIM SAINT GOBAIN i j F 4 y DYNAFOAM W TECHNICA GV DE f P DYNAFOAM is a proud member of the NORSEAL family er ffitr Dynafoam SAINT GOBAIN Technical Guide CONTENT enWJgs PT 3 Eist oF I stratiOls er ie aa ERREUR PR EFRENIS AERREPRENRE EAR andes cng E PR RERE iene E E E AEE 5 aids To LU js To REP 6 EE LSU A M 7 1 1 arsit ENA 7 1 2 Packaging storage shelflife oce re ERREUR REESE RI dengue eese epe Ae Reuben 7 2 Principal implementation properties eene en nennen tense AEAEE enters rennen 8 2 1 Sensitivity t MEAL EM 8 2 2 Mono component and thermoplastic eseessseeeeenennen eene nnne en nnne en nnn en nnne enne 9 2 3 Curing in response to temperature and relative humidity eese 10 2 4 Density determines some of the gasket properties ssessssssseseseeeneeeeneeneen nennen enne nns 10 2 5 fa dier Dd rem shed esnnten ote aaa Aa ae Eeoa aaae eai aaa a EAA AAA EAE 11 2 6 Viscosity according to temperature sssssesessseeeeeeeeeneeen nennen en nnne en nnne en nnne nnne en nnne nnne 12 3 Jmplemintation iiiter rente thc eee Enn itaq inge Fan ku oa Lacu toidate sini gaiean eiee s E eiro R Eun aa eR au a ERR Ren E da BR RE RE 12 3 1 Nordson machine ge
10. LLS e Bubbles may have different causes O Adropin 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 6 1 4 POOR INCORRECT TRANSFER MOULDING e 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 e j DYNAFOAM is a proud member of the NORSEAL family Dynafoam SAINT GOBAIN Technical Guide 6 1 5 POOR APPEARANCE OF THE GASKET e This could be caused by various factors o High temperatures O Poor purging o The product s viscosity is too high o Amachine problem o Anincorrect quantity of water O Incorrect oven settings HHB Figure 13 Humidity damaging the skin 6 1 6 WAVES IN THE SKIN e Itis essential to check the nozzle s position in relation to the substrate too high 6 1 7 STRETCH MARKS ON THE SKIN e This could be caused by various factors o Inadequate adhesion too high in a deep groove etc O Density that is too high 6 1 8 UNEVEN GASKET HEIGHT e This could be caused by various factors o Trajecto
11. 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 Themaximum application temperature which must never be exceeded DYNAFOAM is a proud member of the NORSEAL family Dynafoam SAINT GOBAIN 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
12. e 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 e Hardness and compression force e Curing speed which is inversely proportional to density e The size of the gasket e Compression set A 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 offa 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 ONT j DYNAFOAM is a proud member of the NORSEAL family Dynafoam SAINT GOBAIN Technical Guide 5 Dip the lead weight and the needle into the water without touching the wa
13. e 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 3 5 4 CURING TIME Bead Height 5 mm 6 mm Curing Conditions Curing Time mi 55 C 85 RH e 40 C 6096 RH E 30 C 5096 RH 60 60 NA NA NA NA 20 C 4096 RH NA NA NA NA NA NA 55 C 8596 RH 12 15 15 20 NT NT g 40 C 60 RH 30 35 40 50 NT NT R 30 C 50 RH 50 60 NA NA NT Nr 20 C 4096 RH NA NA NA NA NT NT 55 C 8596 RH 9 9 10 NT ENT O u 40 C 6096 RH 15 15 20 20 NT NT S 30 C 50 RH 25 30 30 35 NT NT 20 C 4096 RH 50 60 NA NA NT NT NA Above 1h test stoped NT Not tested max height 7mm Table 4 Summary for all products e j DYNAFOAM is a proud member of the NORSEAL family Dynafoam SAINT GOBAIN Technical Guide 3 6 RECOMMENDATIONS e t 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 9 e t 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
14. e skiri er reo Erde PAR aE E QR RR EEE Oaa ESEE Mesh EE DEC ERRR Fa cn 26 6 1 7 Stretch marks onthieskipi roe rre PEE Per enne e erint eg eap EE AR E EES r AR aR 26 6 1 8 Uneven gasket helght cs cccrcedsccescaseenvsdvennevewedcets cose codbsranncdecechbesdannactecsshercduadacededesvenscesdberteseah deters 26 6 1 9 Other repairs troubleShOOting ccsccesssecssecesseecsecesseccsseceseseceaecesseecsaeceeeeecsaeceeeecsaeceeeeeesseceetess 27 6 2 AG cC stecsaunenvesixcavagsnensdicecetessstneten anaeeesndsmesaech in A TEET EA 28 DYNAFOAM is a proud member of the NORSEAL family Dynafoam SAINT GOBAIN Technical Guide LIST OF ILLUSTRATIONS Figure 1 Density measurment test method 20 0 eee eseeeeeecseceeeeecaeceeeeeesaeceeeeecsaeceeeeeaaeceeeesaaeseeeeeeaeeseeeereaaeeeee 11 Figure 2 Nordson MACIIN R X 12 Figure 3 Instruction label for changing a drum cecececcesecssecseecseeeseeeeeeeeeeenceseceaeceaeceaeceaesaeesaeeeaeeeeeeeeseerseetensees 14 Figure E Nordson M Tol oT RR 15 Figure 5 PIT ced2ddd i ME h 17 Figure 6 Transfer Mouldinig nece terere eeetete Eee an Ene ERO aee rea EErEE Eara ea Ee E aee REESE No Een FERRE PERS 17 Figure 7 Example of a high humidity drying OVEN ee ceeeeeseeeeseceeeeecneeceeeeeeeaeceeeeessaeseeeeesaaeseneeesaeseeeeesaeeeeeeees 18 Figure 8 Exc ss foamlhg i eee re erster en eee pene ele esses bis ceccud cs RE ee RR KE IRR
15. eived 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 Saint Gobain will not bear the costs of drums damaged by the carrier DYNAFOAM is a proud member of the NORSEAL family Dynafoa m SAINT GOBAIN er ffitr Technical Guide To change a DYNAFOAM drum simply follow the instructions appearing on the label affixed to the lid of each drum solo 207 UK 1 In case of 20lit pails turn over plastic drum and insert DYNAFOAN into metal drum 2 Moisture sensitive material Open inner foil just before use Cut a 10cm 16cm hole or an X in the center of the top film 3 Remove film 4 Position the drum under the heated platen of the bulk Purge and initiate the system according to the instruction for your pump 5 System temperature is given on the bar code label 6 When container is empty remove compressed foil bag and allow it to re main exposed to am bient humidity to fully cure to an innocuous plastic Dispose in accordance with government state and lo cal regu lations F 1 Pour les f ts de 20 lit trans vaser le DYNAFOAM en retournant le f t plastique dans le f t m tallique 2 Mati re r active a l humi dit Ouvrir le sac juste avant l utilisation en d coupant un rond ou un X de 10cm 16cm au centre du f t l
16. gshin 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 amp 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 amp 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
17. hnical Guide 2 2 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 Density kg m With a high humidity Between 350 amp 400 Between 220 amp 280 drying oven Thixotropy Very high High Height width ratio 0 9 0 65 Application Temperature Between 70 amp 80 Between 30 amp 40 3D application yes yes Table 1 General aspects of these thermoplastic products DYNAFOAM is a proud member of the NORSEAL family Dynafoam CAIN C AIN Technical Guide 2 3 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 e initial density close to 1 100 kg m e the diameter and shape of the gasket e physical configuration presence of a groove or not e curing conditions temperature and relativ
18. ico al bid n met lico 2 Material reactivo a la hume dad Abrir la bolsa justo antes de su uso mediante un corte en forma de X en el centro y de unos 10cm 16cm 3 Quitar el pl stico cortado evitando dejar residuos 4 Colocar el cubo debajo del plato caliente de su equipo Purgar y arrancar el sistema segun las instrucciones de su bomba 5 La temperatura de trabajo est en la etiqueta c digo de barras 6 Una vez el cubo est vac o sacar la bolsa y exponerla a la humedad ambiente para con seguir que el material se con vierta en un pl stico inerte Eliminar conforme a las regu laciones vigentes de las autoridades locales PERFORMANCE PLASTICS Figure 3 Instruction label for changing a drum 1 Rimuovere il DYNAFOAM 20 lit dal fusto in plastica a quello metallico 2 Materiale sensibile all umidit Aprire il sacco e praticare con un coltello una X di circa 10 16cm al centro del film protettivo solo al momento dell utilizzo 3 Togliete il cerchio ottenuto e controllate che non ci siano sba vature residue 4 Posizionate il fusto sotto la piastra riscaldante della pompa Spurgate ed av viate il sistema secondo le is truzioni 5 La temperatura di utilizzo si trova sull etichet ta codice a sbarre 6 Quando il fusto vuoto rimuovere il sacco e las ciare reticolare il mate riale all umidit am biente diviene plas tica innocua trat tabile secondo le vigenti norme 2
19. lls 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 CO which makes the gasket swell to its final size The extent of post foaming also depends on various parameters e The diameter of the initial gasket e Curing speed e Relative humidity e 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 Dynafoam SAINT GOBAIN Technical Guide 2 6 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 AN In the event of too much shear specifically in terms of the mixer the temperature will rise but the
20. 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 amp 85 e DYNAFOAM is reactive to humidity e Hygrometry and temperature are the main factors influencing curing speed e The higher the humidity the faster the curing process e DYNAFOAM will not cure without humidity moisture 3 5 2 TEMPERATURE BETWEEN 40 C amp 55 C e The higher the temperature the faster the curing process e However there are limits beyond which temperature has a negative effect on the quality of the foam and its skin e 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 e 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 Dynafoam 3 AIN Technical Guide 3 5 3 AMBIENT TEMPERATURE ROOM TEMPERATURE e Curing at an ambient temperature results in o Ahigher density o A harder foam o A longer curing time O Possibly exceeding the gasket s dimensional tolerances e Any change in relativ
21. n 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 Dynafoam SAINT GOBAIN 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 e Amono component product PUR 1K e Thermoplastic e Physically foamed with nitrogen humidity moisture must be below 5 ppm e Applied in place e Cured by its reaction with the humidity moisture in ambient air e Vacuum packed in a contamination free multilayer bag e
22. n 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 Dynafoam SAINT GOBAIN Technical Guide 4 Do not exceed the recommended application temperature Product 512 7440 Series Application T Between 70 amp 80 C Between 30 amp 40 C 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 o From cured DYNAFOAM within the system o Askin on the drum s surface o The heating platen was not properly cleaned when the drum was changed 6 1 2 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 T DYNAFOAM is a proud member of the NORSEAL family Dynafoam SAINT GOBAIN Technical Guide 6 1 3 BUBBLE OR LARGE CE
23. neral information essen nennen enne nne nre 12 3 2 Changing dynafoam dir ms ertet ttr eire ee ERES ikek R E Fete eR the HERE nie NiE 13 3 3 FOAMING INSERUCTIOMN e top 15 3 3 1 Nordson MAaChiNnG MERE 15 3 3 2 JGeneralinforimation urere redet sates uti Hs Pe kai E REX FEET eaa aae Ve Ma ota EE ESTEA 16 3 4 APPLICATION ss secede cisdicesscpevecneiogeesve a EE 16 34 1 Dispensing Nad iaic c cd cscaceiiendedsiieeesseed ceatariivciensivasteonssecdaanaaaeioneendddesiutevantavestechanivaadamidessnads 16 39 4 2 Application metliods rr rrr t rH Ea ne HERE RIP EU ARA REPE MERE EEERM BAR REP FUE sees SEE dun 17 3 5 up c 18 3 5 1 Humidity moisture between 4596 amp 8596 cccccccsccssscssscssecseecseecsessssesessessseeseceeecssecsaeeeecseesseeeeeees 18 3 5 2 Temperature between 40 C amp 55 C oc ceesecsssssecssscssseecssscseseeceseeseeeeceseeseaeeceeeeseaeeceeeeseseecseeeseneess 18 3 5 3 Ambient temperature room temperature esseesssesee eene enne nnne enne nnns 19 DYNAFOAM is a proud member of the NORSEAL family Dynafoam CA NI COR AIN Technical Guide SA CUIR ME siog endoa a eae eiea ae o es e aa een aa aa o suhavteesteatacteunectes 19 3 6 RECOMMENGALIONS EE 20 4 Parameters affecting the appearance amp quality of the gasket
24. o 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 Dynafoam Technical Guide 3 3 2 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 Between 70 amp 160 Between 30 amp 80 Viscosi ty Pa s at 100 C Pa s at 40 C Nozzle diameter 1 2 mm 1 9 mm 1mm 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
25. o 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 T DYNAFOAM is a proud member of the NORSEAL family er ff itr Dynafoam SAINT GOBAIN Technical Guide 4 5 INADEQUATE PURGING e Inadequate purging continuously or intermittently o affects the density which is no longer controlled O causes spitting and affects the quality of the foam e Therefore it is preferable to use a purge cycle similar to the production cycle For example 7 secon 5 sec off e Material throughput must not exceed the machine s capacity 4 6 THE NOZZLE e The shear rate is the key factor influencing formation of the foam and its skin e 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 e Nozzle position o A
26. ry o Density o Adhesion O Inappropriate groove design T DYNAFOAM is a proud member of the NORSEAL family Dynafoam SAINT GOBAIN Technical Guide 6 1 9 OTHER REPAIRS TROUBLESHOOTING e t is imperative to adhere to the specified range of temperatures for the product in question e Excessive temperatures cause O A poor surface appearance O Acoarse cellular structure o Anincrease in the product s viscosity e A change in the vacuum drum s temperature has no effect on the foam s properties e Certain applications may require a specific configuration of the machine s temperatures settings e j DYNAFOAM is a proud member of the NORSEAL family Dynafoa m 6 2 FAQ S Symptoms Potential causes The material throughput is The pressure is too low insufficient The density is too high Cured product obstruction The temperature is too high The temperature is rising in the mixer The extruded strand is The nozzle is too far from swirling the substrate The quantity of DYNAFOAM is insufficient DYNAFOAM is a proud member of the NORSEAL family Technical Guide 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 Clean the machine Check the mixer s speed Adjust the mixer s rotation to
27. 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 Dynafoam SAINT GOBAIN Technical Guide 3 4 2 APPLICATION METHODS DYNAFOAM can be applied in two ways e 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 e By transfer moulding the process should be defined on a case by case basis wit 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 Dynafoam SAINT GOBAIN Technical Guide 3 5 CURING As Dynafoam is reactive to ambient humidity and heat it is of paramount importance to
28. 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 e j DYNAFOAM is a proud member of the NORSEAL family Dynafoam SAIN r GOBA IN 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 rec
29. suit the throughput Correct the application gun s trajectory Increase the quantity Dynafoa m The gasket has a poor The nozzle needle is closed appearance The gas is dispersing poorly The material pressure is too low The temperatures are too high or too low The and or relative humidity are not correct Foaming is excessive Technical Guide Check the air solenoid valve Increase the needle s stroke Adjust the mixer s speed Do not exceed the machine s capacity Check the pressure in the system Adjust the pressure Purge the machine Check the density Check the machine s heating Adjust the temperature Purge if necessary Check proper operation of the HHB Reduce the temperature and relative humidity if necessary only to check proper operation of the HHB Reduce the gas level DYNAFOAM is a proud member of the NORSEAL family Dynafoa m 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 The product s density is too The gas injection valve is high blocked The dynamic mixer is damaged or clogged DYNAFOAM is a proud member of the NORSEAL family Technical Guide Increase the temperature in the premises Use an air humidifier Check the HHB s operating parameters Check the temperature water and relative humidity
30. 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 se Dynafoam 3 AIN Tec
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