Novel Formaldehyde Free Technology For Glass … Formaldehyde Free Technology For Glass Fibers:...
Transcript of Novel Formaldehyde Free Technology For Glass … Formaldehyde Free Technology For Glass Fibers:...
© The Lubrizol Corporation 2009, all rights reserved
Novel Formaldehyde Free Technology For Glass Fibers:
Hycar® FF 26920 & Hycar ® FF26921
Building and Industrial Mat Meeting 5/19-5/21Dennis P. Butcher – Technical Market Manager
Lubrizol Advanced Materials
© The Lubrizol Corporation 2009, all rights reserved2
Formaldehyde Free Technology For Glass FibersFormaldehyde Free Technology For Glass Fibers
Saturation ApplicationFiltration
Wet-laid Fiberglass/ Industrial MatsDuct LinerCarpet Tiles
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The Clean Air Act
California Proposition 65
ACGIH lists formaldehyde as suspected human carcinogenAmerican Conference of Governmental Industrial Hygienists
IARC Group 1 Human CarcinogenInternational Agency for Research on Cancer
Free formaldehyde level permissible is continuously being reduced by various regulations globally
European Union, California, New England States are forefront in reducing the limits on free formaldehyde on various substrates
California Air Resources Board – Wood Products
Reducing formaldehyde may allow potential of “Green Branding” for products using alternative technologies
US Green Building Council – LEED Certification
Drivers for Formaldehyde Free Technology
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What does a binder need to do in industrial mat applications?
• Bind fibers• Provide structural integrity
– Dimensional stability and strength• Initially during manufacturing of mat product• In final composite
• Provide processability and product integrity– Resistance to:
• Solvents• Plasticizers• Petroleum based materials
• Provide application appropriate feel– Stiffness– Flex
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How do we measure binder performance?
Dry Tensile Strength
Hot Dry Tensile Strength
Thermal Stability
Hot Wet Tensile Strength
Wet Strength
Plasticizer Resistance Tensile Strength
Mat Chemical Resistance
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Overall Physical Performance Targets
Achieve similar or improved properties of crosslinked industry leading acrylic with a formaldehyde free system.
Overall Performance of leading acrylic + 2.5 pph melamine formaldehyde
High Dry Tensile Strength Good Hot-Dry Tensile StrengthHot-Wet Tensile Strength
Good wet/dry ratioPlasticizer Resistance Tensile Strength
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ProductProduct TgTgooCC SolidsSolids pHpH ViscosityViscosity CommentComment
Leading Acrylic +29 49.0 5.5 60 cP
Can Modify with MF or UF Resin to Improve:
Hot Dry Tensile StrengthHot WetPlasticizer Resistance
Conventional Benchmark
Product commonly used in construction products alone and with crosslinking resins
Key Properties– Dry Tensile– Hot Dry Tensile Strength– Hot / Wet Tensile
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Procedures for Testing BindersSubstrate: Whatman® Microfiber GF/A
Test Conditions:• Target LOI: 25% • Dry/Cure Conditions: 2 minutes at 375°F• Sample Conditioning: Samples conditioned for 24 hours at 70±1°F and 50%±2% RH• Crosshead speed for tensiles- 1”/min.• Avg. of 4 specimens• Tensiles recorded in lbs./in.
Dry Tensile• 1x 6 Sample • Gauge length – 4”
Hot-Dry Tensile• 1"x9" Sample - die cut• Gauge length - 7"• Samples placed in hot slot and tested after 1 minute at 375°F
Hot-Wet Tensile• Samples immersed 10 minutes in H2O at 180°F• Tested using same parameters as dry tensile
Plasticizer Soak• Samples immersed 2 minutes in Diisononyl Phthalate (DINP) at RT• Tested using same parameters as dry tensile
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Glass Fiber Saturation Test Procedure• Substrate- Whatman Microfiber Grade:GF/A• Saturate substrate sheets with latex on Padder• Dry sheets in oven at 190°C/ 2 min.• Cut sample into strips and measure tensile properties
Padder Tensile Test
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Dry TensileSystem Summary on Whatman Microfiber GF/A
25% Binder Level
11.45 11.37 11.48 11.6011.91
8.0
8.5
9.0
9.5
10.0
10.5
11.0
11.5
12.0
12.5
Leading Acrylic Leading Acrylic +2.5 pph MF
Hycar® FF 26920 Hycar® FF 26921 Hycar® FF 26921+ 2K
Tens
ile (l
bs/in
.)
Dry Tensile
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Hot Dry TensileSystem Summary on Whatman Microfiber GF/A
25% Binder
3.9
5.25.8
6.7
5.5
0.0
1.0
2.0
3.0
4.0
5.0
6.0
7.0
8.0
Leading Acrylic Leading Acrylic +2.5 pph MF
Hycar® FF 26920 Hycar® FF 26921 Hycar® FF 26921+ 2K
Tens
ile (l
bs/in
.)
Hot Dry Tensile
28% Improvement
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Hot Wet TensileSystem Summary on Whatman Microfiber GF/A
25% Binder
2.2
2.9
2.3
4.8
5.8
0.0
1.0
2.0
3.0
4.0
5.0
6.0
7.0
Leading Acrylic Leading Acrylic +2.5 pph MF
Hycar® FF 26920 Hycar® FF 26921 Hycar® FF 26921+ 2K
Tens
ile (l
bs/in
.)
Hot Wet Tensile
65-100%Improvement
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Plasticizer Soak TensileSystem Summary on Whatman Microfiber GF/A
25% Binder
10.911.9 11.9
12.5
7.7
0.0
2.0
4.0
6.0
8.0
10.0
12.0
14.0
16.0
Leading Acrylic Leading Acrylic +2.5 pph MF
Hycar® FF 26920 Hycar® FF 26921 Hycar® FF 26921+ 2K
Tens
ile (l
bs/in
.)
Plasticizer Tensile
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Composite Tensile ResultsSystem Summary on Whatman Microfiber GF/A
25% Binder
0.0
2.0
4.0
6.0
8.0
10.0
12.0
14.0
Dry Tensile Hot Dry Tensile Hot Wet Tensile Plasticizer
Tens
ile (l
bs/in
.)
Leading Acrylic
Leading Acrylic + 2.5 pph MF
Hycar® FF 26920
Hycar® FF 26921
Hycar® FF 26921 + 2K
Performance equaled or exceeded control in all cases
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Based upon initial development work, additional studies were performed to better understand application properties and property development
1. Attempt to better quantify wet tensile improvement2. Examine wet tensile strength development as a function
of time3. Examine tensile strength development as a function of
temperature
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Wet and Dry Tensile – 2 min cure @ 190ºC
Dry and Wet Tensile with % Retention
0.0
2.0
4.0
6.0
8.0
10.0
12.0
14.0
16.0
Leading Acrylic +2.5 MF
Hycar® FF 26920 Hycar® FF 26921 Hycar® FF 26921FF Xlink #1
Hycar® FF 26921FF Xlink #2
Sample ID
lbs/
in
0%
10%
20%
30%
40%
50%
60%
% re
tent
ion
wet
/dry
Dry TensileWet Tensile% Retention
35-60% improvement in wet/dry tensile ratio
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Cure Rate Study - 190º
Cure Rate Study-Wet TensileWhatman Microfiber GF/A 25% LOI
0
1
2
3
4
5
6
7
0.5 1.0 2.0 3.0min.
lbs.
/in.
Leading Acrylic + 2.5 MF
Hycar® FF 26920
Hycar® FF 26921
Hycar® FF 26921-FFXlink #1
Hycar® FF 26921-FFXlink #2
ControlBetter wet tensile properties at equal or lower curing duration
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Cure Temperature Study – 2 min.CURE STUDY - Wet Tensile on Whatman GF/A 25%LOI
0
1
2
3
4
5
6
7
100 125 150 191°C
lbs/
in.
Leading Acrylic + 2.5 MF
Hycar® FF 26920
Hycar® FF 26921
Hycar® 26921-FFXlink #1
Hycar® 26921-FFXlink #2
Control
Wet tensile strength improved under normal comparable drying conditions
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Findings ………1. Formaldehyde free products showing improved tensile
properties on microglass over MF crosslinked Leading Acrylic system– Hycar® FF 26920 compared to control– Hycar® FF 26921 shows improved hot and wet tensiles
compared to control
2. Hycar® FF 26921 demonstrates improved cure response compared to control– Opportunity for energy savings?
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Total Formaldehyde (ppm)
0
500
1000
1500
2000
2500
3000
3500
4000
4500
5000
Leading Acrylic Leading Acrylic+
2.5 pph MF
Hycar®26920 Hycar® 26921 Hycar® 26921 -2K
Product ID
ppm
HC
HO
Total Formaldehyde (ppm)
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HYCARHYCAR®® FFFF--26920 Formaldehyde Free System 26920 Formaldehyde Free System
Unique Benefits:Unique Benefits:• Formaldehyde Free System• Unsurpassed Hot Dry Tensile Strength• Self Cross-linking• 1K solution to a typical 2K system
Tg: +29°CViscosity: 105 cps (#2 @ 60rpm)pH: 8 – 9Solids: 44%
Solution Description:Solution Description:
Hycar FF-26920 is a one component system replacing the use of traditionalacrylic emulsion binder and melamine-formaldehyde cross-linker for a non-yellowing binder for most industrial use fiberglass nonwovens.
General SpecsGeneral Specs
Potential Applications:Potential Applications:
• Wet-laid • Fiberglass/ Industrial Mats• Duct Liner• Carpet Tiles• High Tech Filtration
Value Creation:Value Creation:• “Green” implications because of Formaldehyde Free system• Reduced emissions at substrate manufacturing process• Extended durability and usage life of substrate because enhanced hot
dry tensile strength
FiberglassFiberglassBuilding MatBuilding Mat
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HYCARHYCAR®® FFFF--26921 Formaldehyde Free System 26921 Formaldehyde Free System
Unique Benefits:Unique Benefits:• Formaldehyde Free System• Unsurpassed Hot Wet Tensile Strength• Self Cross-linking
Tg: +29°CViscosity: 65 cps (#2 @ 60rpm)pH: 8 – 9Solids: 44%
Solution Description:Solution Description:
• Hycar FF-26921 is a one component system replacing the use of traditional acrylic emulsion binder and melamine-formaldehyde cross-linker to be used as a binder for most industrial use fiberglass nonwovens.
• For unsurpassed performance, additional non-formaldehyde component can be added
General SpecsGeneral Specs
Potential Applications:Potential Applications:
• Wet-laid • Fiberglass/ Industrial Mats• Duct Liner• Carpet Tiles• High Tech Filtration
Value Creation:Value Creation:• “Green” implications because of Formaldehyde Free system• Reduced emissions at substrate manufacturing process• Extended durability and usage life of substrate because enhanced hot
wet tensile strength
FiberglassFiberglassBuilding MatBuilding Mat
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Thank You!
AcknowledgementsAshok Makati
Jamel LawrenceMatt Sciulli
Prachur BhargavaGary Anderle