Adhesives & Sealants Industry February 2012

February 2012 • Volume 19, Issue 2 • www.adhesivesmag.com

❯ Understanding Flammability ❯ Composites 2012 Pre-Event Guide

Page 7

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“With resin and carbon fiber, we can build a New Economy.” New technologies are powering the drive to develop renewable energy. Spacecraft that are commercially viable. Airliners that leave a smaller carbon footprint. And cars that can cruise all day long without burning a drop of gasoline. From syntactic foams and other lightweight structural composites to the new generation of adhesives and batteries, Ross mixers are helping to create the materials necessary to build the New Economy. We’d like to help you succeed, too. Call 1-800-243-ROSS Or visit mixers.com

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IN THIS ISSUE ADHESIVES & SEALANTS INDUSTRY, VOLUME 19, NUMBER 2

DEPARTMENTS

NEXT-GENERATION COMPOSITE ADHESIVES

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6

Editor’s Memo

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Company News

10

People

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Calendar

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Advancing Adhesives: SEAL-KRETE

13

Advancing Adhesives: Henkel

41

Literature Showcase

MEASURING AND REGULATING FLAMMABILITY

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What’s New

Adhesives manufacturers support the aviation industry with new flame-retardant materials for composite aircraft.

43

Services Marketplace

45

Classifieds

46

Ask Dr. Dave

46

Ad Index

Adhesive technologies are quickly advancing to accommodate customer needs.

COMPOSITE CHALLENGES

17

Innovative solutions are needed to bond composite structures.

STRUCTURALLY GREEN

20

Structural adhesives can reduce emissions and assist in the recycling of plastics to minimize waste and VOCs.

OPPORTUNITIES ABOUND AT COMPOSITES 2012

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17

COMPOSITES 2012 is scheduled to take place February 21-23 in Las Vegas.

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ASSEMBLY LINE FASTENING SOLUTIONS

29

Engineered pressure-sensitive laminates deliver unmatched efficiencies when compared to other more traditional methods.

OVERCOMING CHALLENGES

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25

A variety of cavity baffle designs exist for water management within auto body pillar structures.

THE NEXT PHASE

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February 2012 • Volume 19, Issue 2 • www.adhesivesmag.com

Chemsultants’ Joe Mausar retires after 37 years in the industry.

A VISION OF QUALITY

37

One company’s reputation for product excellence results in regular investments in state-ofthe-art inspection equipment.

❯ Understanding Flammability ❯ Composites 2012 Pre-Event Guide

PROFESSIONAL LEARNING SOLUTIONS

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Page 7

New trends in learning reflect a changing workforce.

Wednesday, May 2, 2012 8:30am – 3:30pm EDT www.TechManufactureXPO.com

Cover-A.indd 1

ON THE COVER:

1/16/12 9:13 AM

Image courtesy of Dow Automotive Systems.

FOR SUBSCRIPTION INFORMATION OR QUESTIONS, CONTACT: Customer Service: (847) 763-9534 ADHESIVES & SEALANTS INDUSTRY (ISSN 1070-9592) is published 12 times annually, monthly, by BNP Media, 2401 W. Big Beaver Rd., Suite 700, Troy, MI 48084-3333. Telephone: (248) 362-3700, Fax: (248) 362-0317. No charge for subscriptions to qualified individuals. Annual rate for subscriptions to nonqualified individuals in the U.S.A.: $178.00 USD. Annual rate for subscriptions to nonqualified individuals in Canada: $216.00 USD (includes GST & postage); all other countries: $228.00 (Int’l mail) payable in U.S. funds. Printed in the U.S.A. Copyright 2012, by BNP Media. All rights reserved. The contents of this publication may not be reproduced in whole or in part without the consent of the publisher. The publisher is not responsible for product claims and representations. Periodicals Postage Paid at Troy, MI and at additional mailing offices. POSTMASTER: Send address changes to: ADHESIVES & SEALANTS INDUSTRY, P.O. Box 2148, Skokie, IL 60076. Canada Post: Publications Mail Agreement #40612608. GST account: 131263923. Send returns (Canada) to Pitney Bowes, P.O. Box 25542, London, ON, N6C 6B2.Change of address: Send old address label along with new address to ADHESIVES & SEALANTS INDUSTRY, P.O. Box 2148, Skokie, IL 60076. For single copies or back issues: contact Ann Kalb at (248) 244-6499 or [email protected].

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Audited by BPA Worldwide.

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EDITOR'S MEMO www.adhesivesmag.com

COMPOSITE GROWTH The use of composites as a substitute for steel and other heavy materials has skyrocketed in multiple markets. In the automotive industry, for example, lightweight composite materials are helping provide what represents the Holy Grail for those manufacturers: reduced fuel consumption. In fact, according to BCC Research, “an estimated 75% of the average motor vehicle’s fuel consumption is directly related to factors associated with vehicle weight.”* The composites sector offers multiple benefits for adhesives manufacturers. “As various materials interface, traditional joining technologies aren’t always sufficient under the required performance extremes,” writes Dow Automotive Systems’ Frank Billotto in this issue. “Adhesives, however, are being formulated to accommodate the bonding of these diverse, dissimilar substrates…” Read “NextGeneration Composite Adhesives” on pp. 15-16 to learn more. According to Brandon Willis of Uniseal, Inc., “With many of these substrates, mechanical fasteners have been abandoned in favor of adhesives, which provide a two-fold advantage. First, they provide a process and design flexibility that mechanical fasteners simply do not. Second, the adhesives themselves are lighter in weight than mechanical fasteners such as rivets, especially in large-quantity uses such as trailer sidewalls.” Willis discusses “Composite Challenges” on pp. 17-19. Safety is a vital concern in aviation, and adhesives manufacturers are supporting the industry with flame-retardant materials. Regulatory inconsistencies are a problem, however, and a Flammability Task Group has been formed to work with the Federal Aviation Administration. Todd Holder of Huntsman Advanced Materials provides details regarding “Measuring and Regulating Flammability” on pp. 25-27. The American Composites Manufacturers Association’s annual COMPOSITES 2012 Exhibition and Convention will be held this month in Las Vegas. (Our pre-event guide can be found on pp. 23-24 of this issue.) I’m looking forward to seeing the many new materials, technologies and opportunities that the composites sector has to offer. Hope to see you there! *Lightweight Materials in Transportation, www.bccresearch.com.

THIS MONTH ON www.adhesivesmag.com... Spotlight on Composites We’re excited to announce the launch of a new series of free quarterly e-newsletters that provide our regular ASI E-News subscribers with detailed information on specific sectors of the industry. The first edition will focus on composites. Visitors to the website can subscribe or access e-newsletter archives. Adhesives in the News Discover some of the latest applications and opportunities for adhesives and sealants around the world. Digital Edition ASI’s digital editions are easy to read, search and download. This month’s edition is sponsored by Mettler-Toledo Inc.

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

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BNP Media Helps People Succeed in Business with Superior Information February 2012

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COMPANY NEWS ACQUISITIONS

APPLAUSE

AV E RY D E N N I S O N C O R P. r e c e n t l y announced it has signed a definitive agreement to sell its Office and Consumer Products business (OCP) to 3M CO. for $550 million in cash. Avery Dennison reportedly intends to use the proceeds from the transaction primarily to reduce debt, make additional pension contributions and repurchase shares. The transaction is expected to be completed in the second half of this year. For more details, visit www.averydennison.com or www.3m.com.

OMNOVA SOLUTIONS REDUCES 2010 ENERGY USAGE BY 5.8%

CELANESE CORP. recently announced it has completed the acquisition of certain assets from ASHLAND INC., including two product lines, Vinac ® and Flexbond ® , which will reportedly support the strategic growth of the Celanese Emulsion Polymers business. For additional information, visit www.celanese.com. H.B. FULLER CO. recently signed an agreement to purchase the global industrial adhesives business of FORBO GROUP . The business to be acquired represents about 80% by revenue of the Forbo Bonding Systems division of Forbo Group. This business was expected to generate approximately $580 million in revenue for the fiscal year ending December 31, 2011. It operates 17 manufacturing facilities in 10 countries and employs more than 1,100 people globally. The purchase price for the transaction is CHF 370 million on a debt- and cash-free basis, or about $394 million at current exchange rates. Visit www.hbfuller.com or www.forbo.com for additional details. ROYAL ADHESIVES & SEALANTS , a portfolio company of Arsenal Capital Partners, and Vertis Communications recently announced that Royal will acquire substantially all of the assets of Vertis’ indirect wholly owned subsidiary, Webcraft Chemicals, which operates under the name CRAIG ADHESIVES & COATINGS. Based in Newark, NJ, Craig supplies UV light-cured and water-based adhesives and coatings to the printing and graphic arts markets. For additional details, visit www.royaladhesives.com or www.arsenalcapital.com. 8

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OMNOVA Solutions recently announced it received a letter of commendation from the U.S. Department of Energy (DOE) for the company’s achievement of a 5.8% reduction in energy usage for 2010. As a partner in the DOE’s Better Buildings, Better Plants program, OMNOVA voluntarily developed internal targets to reduce its energy consumption by 25% over a 10-year period for all of its U.S.-based manufacturing locations. “OMNOVA Solutions’ most recent annual report showed a 5.8% reduction in energy intensity in 2010, placing the company well on its way to meeting the pledge target,” wrote Leo Christodoulou, Ph.D., program manager, U.S. DOE. “We specifically acknowledge Mr. Doug Fox of OMNOVA’s LEAN SixSigma organization, who has worked closely with the department on this pubic/private partnership initiative.” For more information, visit www.omnova.com.

COMPANY NEWS CREATIVE MATERIALS recently completed its move to a new facility in Ayer, MA. The new site, reportedly more than three times the size of the previous location, will allow the company to expand to accommodate future growth. The newly renovated corporate center includes expanded office and meeting space, as well as custom-designed manufacturing facilities, a R&D laboratory, and a quality assurance area. For further details, visit www.creativematerials.com. EMERALD KALAMA CHEMICAL , a division of Emerald Performance Materials LLC, has expanded its distribution agreement with Connell Brothers, a division of Wilbur-Ellis Co., to support growth of its K-FLEX® products in Asia. Connell Brothers was originally appointed as distributor in 2007 for KALAMA ® sodium benzoate in Indonesia, Thailand, Vietnam, Malaysia, Singapore and the Philippines. The company will now also manage and develop sales for K-FLEX products in Australia, Hong Kong, China, India, Japan, Korea, New Zealand and Taiwan. Emerald Kalama Chemical has also entered into an agreement with CRITERION Representação, Participações e Consultoria Ltda. to support the growth of its K-FLEX® products in South America, with a focus on the Mercosur region. For more information, visit www.emeraldmaterials.com. GABRIEL PERFORMANCE PRODUCTS recently announced it has surpassed 500,000 hours worked without a lost-time injury at its Ashtabula, Ohio, plant. The company says it

reached this milestone after more than four years of working safely. For additional details, visit www.gabepro.com. L I N T E C H I N T E R N AT I O N A L L L C h a s announced a new partnership with Clariant Corp. As of January 1, Lintech has become the strategic distribution partner for the company’s Additives and Clariant Pigments business units. Lintech will cover the entire southeast, southwest and western U.S. for both Clariant product lines. For more information, visit www.lintechinternational. com or www.clariant.com. 3M and SHALE-INLAND recently announced they have entered into a fiveyear commercialization agreement to offer new product solutions for advancing the development of protective and decorative films in the global primary metal and metal fabrication markets. 3M’s expertise in material science technology platforms reportedly combines to drive disruptive innovation in the marketplace, while Shale-Inland brings expertise in steel and aluminum distribution, stainless steel polishing, stamping, and fabrication. Visit www.shale-inland.com or www.3m.com for additional details.

The Dow Chemical Co. recently announced that the SCG-DOW GROUP , a joint venture between Dow and Siam Cement Group, has finalized the startup of its new propylene oxide (PO) facility in Thailand. The world-scale plant, has a nameplate capacity of 390 kilotons per year (KTA) of PO via the hydrogen peroxide to propylene oxide (HPPO) technology. For more information, visit www.dow.com. February 2012

Learning opportunities include: Dynamic speakers and specialized sessions focus on a broader range of functional expertise.

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COMPANY NEWS ANNOUNCEMENT CHARLES D. MILLER PASSES AWAY Avery Dennison recently announced the death of Charles D. Miller, who served as chairman and CEO from 1977 to 1998 and was instrumental in transforming the company from a U.S.-based manufacturer into a global Fortune 500 market leader in pressure-sensitive labeling materials and office products. Miller, 83, died at his home in Pasadena, CA, on November 23, 2011, due to complications from emphysema. “Chuck Miller’s impact on Avery Dennison was immeasurable,” said Dean A. Scarborough, chairman, president and CEO. “Every aspect of our business, from vision to strategy to execution to culture, has been shaped for the better by his passion and imagination. Numerous organizations in southern California benefited from his tireless and wide-ranging philanthropic leadership over the past four decades. I will miss him as a leader, a mentor and a friend.” Miller began his 47-year association with Avery Dennison in 1964 when he joined Avery Products Corp., the precursor of Avery Dennison. Over the next 10 years, he held a series of operating and executive roles in the U.S. and Europe, and was named president and COO in 1976. In 1977, he was elected CEO, and, in 1983, chairman of the board. He served as CEO for 21 years, as chairman of the board for 17 years and as a member of the board of directors for over 30 years. He continued to serve the company as a director emeritus until his death. Under Miller’s leadership, Avery Dennison grew dramatically, with annual net sales increasing during his tenure as CEO from $423 million to $3.3 billion in 1998. Investing in research and development to introduce innovative products, the company established itself as a global leader in pressure-sensitive materials and finished labels. Miller also led the company into other lines of business, the most prominent of which was office products. Through a series of acquisitions culminating with the 1990 merger with Dennison Manufacturing Co., Miller established the Avery brand and the company as a global office products leader as well. Miller was born in Hartford, CT, and grew up in Old Greenwich. He is survived by his wife of 29 years, Carolyn, and their two daughters; three daughters from his previous marriage; and seven grandchildren. A memorial website is located at www.CharlesDMiller.org.

PEOPLE Univar recently announced it has appointed ABDERRAHIM ANASSE country manager of its Moroccan business. Anasse will concentrate on building a sustainable and profitable business in Morocco, with a particular focus on the food, pharmaceutical, household, and personal-care sectors. He will also be responsible for recruiting a skilled team of professionals and developing long-term relationships with new suppliers. Dow Coating Materials, a global business unit of The Dow Chemical Co., has named JOSE MARIA BERMUDEZ its new general manager for North America. Bermudez will lead all aspects of Dow Coating Materials’ business in North America, including sales, manufacturing and engineering, technical services, supply chain, customer service, and marketing. 10

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Brookfield Engineering Laboratories recently announced the appointment of ERIC CHIANG to the position of product manager, texture analyzers. Chiang takes the place of LEN THIBODEAU, who recently announced his retirement. Thibodeau has served as product manager since 2005. Plasticolors Inc. recently named LISA COLLETTE technical service applications representative and SARA WISCHHUSEN color match technician. Collette will provide direct technical support to customers in the polyurethane RIM, slabstock foam and elastomer marketplace, as well as to internal technical programs. Wi s c h h u s e n w i l l f o r m u l a t e c u s tom color matches for SMC/BMC, pultrusion, epoxy and urethane customers in the thermoset composites marketplace.

Emerald Performance Materials has named ROBERT L. CULP JR. its new vice president of Procurement and CHRIS O’NEIL vice president of Information Technology. Culp will have responsibility for Emerald’s global purchasing and logistics operations across the company’s four business groups. O’Neil will be responsible for Information Technology (IT) services for all of Emerald’s four business groups. Ellsworth Adhesives recently announced three leadership promotions: ROGER LEE has been promoted to vice president and general manager, Specialty Chemicals Division; JAY RICHARDSON has been named director, Sales–Engineering Sales Representative (ESR) Group; and ANDRE RIVARD has been appointed general Sales manager, Eastern Region. Sika’s Automotive Division recently announced a new personnel appointment in the Program Management function. BRETT RICHARDSON has joined the company as program manager, Domestics Group. His responsibilities include management of key programs for Ford and other domestic customers covering functional design, testing, and validation of new products. Richardson joins Sika from Tata Technologies/Ford Motor Co. Michelman has expanded its Chemical Specialties team with the addition of three professionals with extensive experience in key markets. DAVE RUPP has been hired as the company’s new regional business development manager for Chemical Specialties. He will focus on the western U.S., and have responsibility for growth and development of the company’s additives for wood product applications. MIKE SELBY has joined the company as a regional sales manager for Chemical Specialties. He will be responsible for managing the company’s Americas Chemical Specialties sales team, in addition to supporting regional customers with application and market expertise. CHAD FORSTHOEFEL has been hired as a research chemist, and will focus on developing new water-based formulations for the company’s burgeoning construction and wood coatings industry segments. In addition to his lab work, he will work closely with customers and provide technical support regarding the use of Michelman products. February 2012

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ADVANCING ADHESIVES

Artist John H. White applies SEAL-KRETE Clear-Seal to his storm drain mural, titled “Fragile Swan.”

SEAL-KRETE Clear-Grip was applied to this mural’s surface to provide a non-skid surface without changing the vibrant colors of the artwork, "Open Mouth Fish" by artist Laura Lynch.

SEAL-KRETE CONCRETE SEALER HELPS PROTECT PUBLIC MURALS Storm drain artwork raises water quality awareness. EAL-KRETE® partnered with James River Basin Partnership (JRBP) and the City of Springfield (MO) Storm Water Services Division on Storm Drain Reveal, a project designed to raise awareness that soapy water, litter, yard waste, and other pollutants that end up in storm drains lead directly to rivers, creeks, and other waterways. Ten downtown storm drains in Springfield were transformed into public murals as reminders of their connection to waterways. Each work of art was protected with SEAL-KRETE Clear-Seal, a premium lowgloss concrete sealer that seals and protects painted, stained or bare concrete. SEALKRETE Clear-Grip, a durable polymeric aggregate, was added to the sealant to ensure a non-slip concrete texture.

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“We were honored to partner with James River Basin Partnership to help raise public awareness of how stormwater drains lead directly to our waterways,” says Kevin Corcoran, marketing manager for SEAL-KRETE. “The Clear-Seal used by each artist will serve to protect their beautiful works of art that transformed ordinary storm drains into a daily reminder of our connection to our waterways.” SEAL-KRETE Clear-Seal is a durable urethane-fortified acrylic sealer with low odor and low volatile organic compounds (VOCs), making it easy to work with and safe for the environment. It goes on milky white and dries to a low-gloss finish, enhancing the natural character of the concrete surface. Clear-Seal resists chlorine, salt, chemicals and UV rays, and repels stains and spills, allowing it to be

used to protect and beautify painted, stained or bare concrete. “The artists were enthusiastic about protecting their murals with Clear-Seal,” says Tiffany Frey, project manager at JRBP. “They appreciated how easy the product was to use and they loved the low gloss finish. The artists were also impressed by the performance of SEAL-KRETE’s Clear-Grip—it added a great non-skid surface to the murals’ surfaces without changing the color of the artwork.” Developed for use as an anti-skid additive to floor paint or sealers, Clear-Grip is a durable, micronized polymeric aggregate that will not soften under normal heat exposure. It adds a slight texture to finishes without changing the color, and is chemical and solvent resistant. Clear-Grip can be used in water-based, solvent-based alkyd, urethane or epoxy coatings.

ABOUT SEAL-KRETE SEAL-KRETE is a Convenience Products brand, headquartered in St. Louis, MO. A leading manufacturer of waterproofing and decorative coatings for concrete, SEAL-KRETE has offered weatherproofing protection for concrete and masonry for more than 20 years. Serving both professional contractors and do-it-yourselfers, SEAL-KRETE manufactures products developed for surface protection and beautification. For more information, call (800) 323-7357 or visit www. SEAL-KRETE.com.

February 2012

ADVANCING ADHESIVES

Winners of the special award for the best use of adhesive: the Bayreuth University team pose at the Henkel stand.

Bonding of an aluminum part for a drive shaft with Loctite 648.

HENKEL INVESTS IN YOUTH WITH ENGINEERING CONTEST Formula Student contest includes special award for best use of adhesive. n addition to offering numerous training programs, participation in the annual Formula Student contest for engineering students at the Hockenheimring race track in BadenWürttemberg, Germany, has become a central component of Henkel’s commitment in this area. In 2011, the team from Bayreuth University received the special award for best use of adhesive, which Henkel instituted in 2009.

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The design competition attracts a great deal of interest internationally, with teams from colleges and universities from all over the world taking part. It ranks as a sort of unofficial Olympics for engineering students. Competing against all other entrants, the teams have to design and build the prototype of a new racing car from scratch, present it as a business case, and test its performance in various trials and a final race. The final round included

78 teams in the Combustion category and 31 in the Electric category. The five-day event is one of the highlights every year for the General Industry business of Henkel, which serves as one of the main sponsors. Up to eight Henkel adhesives experts were available at any time to give the contestants advice or lend a helping hand—in the pits, working on the cars themselves, or at the Henkel stand. The latter was not only stocked with high-performance repair and maintenance products from Henkel’s Loctite® and Teroson® brands, but also featured workbenches and even a heating cabinet to accelerate the curing of different adhesives.

AWARD FOR BEST USE OF ADHESIVE In order to inspire students to become even more creative, Henkel established a special award for the best use of adhesive throughout the entire contest. Submissions are judged on the attractiveness and creativity of the bonding application, the way the adhesive was selected and verified, the presentation made to the jury, and the students’ knowledge about bonding technologies. Seven teams made it through to the final round, and the award was given to Bayreuth University. The previous year’s winner, Zwickau University, received second place, and Coburg University came in third. “Last year, the entries were already of a very high standard,” says Rudolf N e u m a y e r, H e a d o f A p p l i c a t i o n Adhesives & Sealants Industry

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ADVANCING ADHESIVES Te c h n o l o g y, I n d u s t r i a l A d h e s i v e s , Europe. “But this year, they raised the bar several notches further. This trend shows that we are definitely moving in the right direction with our educational approach.” Henkel’s level of engagement in the entire contest earned high praise, not only from the contestants themselves but also from the organizer. “Henkel was present with a large team and

often performed last-minute rescue jobs,” said Ludwig Vollrath of VDI (the Association of German Engineers), who is in charge of the event. “People were highly impressed by that.”

MULTIPLIER EFFECT AND GREATER BRANDS AWARENESS Henkel acknowledges that the company and industry profit from the event as well. “The five-day finale of the con-

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test was itself attended by around 2,500 students, professors and design specialists,” says Patricia Silva, Marketing manager, General Industry. “No other event throughout the year draws so many highly interested people with a will to experiment. Having such a representative target group all in one place means that we can achieve important multiplier effects and heightened awareness of our brands.” “Bonding is simply the most dependable solution,” said Moritz Berard, a 23-year-old student from Karlsruhe University who participated in the contest. “For me, bonding is one of the best solutions there is, and easily the simplest and most dependable one. It opens up whole new worlds and gives an immense amount of design freedom.” Henkel says its engagement is actually a medium- to long-term investment that not many companies take the trouble to make. But the benefits can already be estimated, thinks Alfred Kaltenbach, Area Sales manager for BadenWürttemberg of Henkel’s General Industry business. “In Germany alone, about 2,200 young engineering graduates start their careers by going straight from university into private enterprise, where sooner or later they will occupy key positions,” he explains. “When engineers who have previously learned about our adhesives and sealants then design new components, they will already be familiar with all the advantages of adhesive bonding technologies and will include this joining technique in their design considerations right from the beginning. This way, adhesive bonding, which was unfortunately often regarded as a last resort in the past, will gain the status it deserves. And we intend to make sure that the young engineers’ experiences with Henkel have been entirely positive.”

ABOUT HENKEL Henkel operates worldwide with leading brands and

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Founded in 1876, Henkel holds globally leading market positions both in the consumer and industrial businesses with well-known brands such as Persil, Schwarzkopf and Loctite. Henkel’s preferred shares are listed in the German stock index DAX, and the company ranks

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among the Fortune Global 500. For more information, visit www.henkel.com.

February 2012

Epoxy adhesives play an important role in the fabrication, performance and durability of wind turbine blades.

NEXT-GENERATION COMPOSITE ADHESIVES Adhesive technologies are quickly advancing to accommodate customer needs. By Frank Billotto, Market Development Manager, Dow Automotive Systems any industries are experiencing regulatory and pricing pressures that have resulted in changes to their traditional materials and processes. As this happens, adhesive technologies are quickly advancing to accommodate customer needs by enabling the use of a wider variety of materials and new manufacturing and product assembly processes. In some cases, adhesive technologies are even ahead of the game. In the transportation industry, for example, market shifts are being driven by manufacturers’ need for increased weight savings to achieve better fuel efficiency and reduced carbon dioxide emissions. Manufacturers are moving away from allsteel vehicles and using reliable lighter weight materials like aluminum, magnesium, and sheet molding compound (SMC). Advanced lightweight materials like carbon fiber composites, glass fiber-reinforced polyamide (GFPA), glass fiber-reinforced polypropylene (GFPP), polycarbonate acrylonitrile butadiene styrene (PC-ABS) and polyurethane reaction injection molding (PUR-RIM) are also being used more often to accommodate evolving vehicle designs. Design changes have also been significant, especially in commercial transportation markets as those manufacturers strive to develop and produce vehicles that are lighter weight and more fuel efficient. Longer adhesive open times are also an important consideration in this market, since large modules or multi-piece assemblies may have to be joined before the adhesive starts to cure. As various materials interface, traditional joining technologies aren’t always sufficient under the required

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performance extremes. Adhesives, however, are being formulated to accommodate the bonding of these diverse, dissimilar substrates and manage differences in thermal expansion properties. The new adhesives offer high modulus, optimized elongation and broad service life temperature properties. Manufacturing processes can also benefit from a greater use of adhesives in terms of joining costs and cycle times. Adhesives also can help reduce the risk of repetitive task injury to the workforce, especially where mechanical fastening methods are commonly used. A range of solutions are coming to market as next-generation adhesives, all with some degree of customization options to better meet customer and market needs.

TWO-PART POLYURETHANE ADHESIVES A new two-part polyurethane (PU) adhesive is now being applied in full structural bonding applications for automotive and commercial vehicle manufacturing. It provides ultrafast curing, excellent temperature stability behavior, a broad range of mechanical properties, high modulus and elongation, a 1:1 (by volume) mixing ratio, and very good bead stability during applications. Typical bonded applications include automotive roof and hatchback bonding, as well as commercial transportation driver cabins. As material choices continue to diversify, this adhesive solution is addressing market concerns that focus on cost efficiencies, weight reduction, styling and design options, and environmental issues centered around fuel efficiency. Adhesives & Sealants Industry

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NEXT-GENERATION COMPOSITE ADHESIVES The continual bondline of the adhesive provides additional benefits, including improved durability, corrosion resistance, acoustical improvements and better crash performance.

MMA AND MMA/EPOXY HYBRID STRUCTURAL ADHESIVES Methyl methacrylate (MMA) and MMA/epoxy hybrid structural adhesives provide fast, simplified joining operations with minimal surface preparation. They can be used to bond composite body panels, bumpers and exterior trim, cockpit structures, door extensions, and tail and lift gates. Greater design flexibility is enabled by primerless adhesion to a variety of substrates, including lightweight composites that also help manufacturers develop more fuel-efficient vehicles. These nextgeneration adhesives also provide fast room-temperature cure with lower fixture time-to-open time ratios. In addition, they exhibit high tensile modulus, stiffness and impact strength, and are e-coat compatible to accommodate systems requiring that treatment.

ADDITIONAL ADHESIVE SOLUTIONS Composite adhesives are being used for a growing number of applications outside the automotive industry as well. For example, Dow Formulated Systems recently developed a foam core system for wind blades that is bonded by epoxy adhesives. The new system offers long-term dynamic behavior and shear strength properties that deliver the excellent mechanical strength and fatigue resistance necessary to achieve blade durability. Epoxy adhesives play an important role in the fabrication, performance and durability of wind turbine blades, where large substructures are bonded together to create the finished blades. 16

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Specialized properties are needed for adhesive mixing and application during the fabrication process, and cured adhesives must exhibit high levels of toughness and durability to withstand the extreme loads a wind turbine will face throughout its service life. In addition to wind energy solutions, adhesive formulation and application expertise is being leveraged into industries such as residential and commercial construction, infrastructure repair, oil and gas, appliance, furniture, shoe soles, decorative molding, and athletic equipment.

LOOKING AHEAD Industrial applications for adhesive technology are certain to grow as the need for innovative manufacturing and assembly practices evolves. Adhesives suppliers can be on the leading edge of this evolution by creating adhesive solutions that will enable these new practices. Dow Automotive Systems is off to a good start by combining several technologies for adhesively bonded composite structures, thereby laying the foundation to address long-lasting improvements in energy efficiency by mastering lightweight solutions with next-generation composites. This experience can then be shared across multiple industries to benefit customers and end users around the world. For more information, contact the author at Dow Automotive Systems, 1250 Harmon Rd., Auburn Hills, MI 48326; call (248) 391-6300; email [email protected]; or visit www. dowautomotive.com.

February 2012

Innovative solutions are needed to bond composite structures.

dhesive. Bonding agent. Glue. These terms commonly refer to a material that is used to affix two surfaces (i.e., substrates) together for some duration of time. Specialized substrate bonding has become a ubiquitous operation in both personal and business applications, and bond quality has evolved to such a degree that industrial adhesives are now used in place of the mechanical fasteners of the past. Many consumers may be astounded to know that the car they drive or the airplane they fly on is held together in no small part by “glue.” But as products have evolved in key industries, the bonding surfaces have also changed, posing new challenges to adhesive suppliers. Metal is one of the most common substrates associated with adhesives in

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the industrial market. Automobiles, heavy trucks, freight trailers, agricultural, and heavy equipment have all traditionally been major users of steel, aluminum, and other metals and alloys. As the requirements of these vehicles have grown over time, however, the metals in many applications are slowly being replaced by composite structures. This trend, in turn, affects the adhesives industry.

By Brandon Willis, Director of Marketing and Business Development, Uniseal, Inc.

in the automotive and heavy truck/ trailer industry) to reduce emissions and improve vehicle gas mileage. These efforts have led to the use of unique substrates, specifically composites, to help decrease vehicle weight and therefore improve gas mileage. With many of these substrates, mechanical fasteners have been abandoned in favor of adhesives, which provide a two-fold advantage. First, they provide a process and design flexibility that mechanical fasteners simply do not. Second, the adhesives themselves are lighter in weight than mechanical fasteners such as rivets, especially in large-quantity uses such as trailer sidewalls. In addition, adhesives can provide a cost savings over mechanical fasteners. Composites are used extensively in vehicle and trailer manufacturing. Some applications include: • Automotive hoods, doors and deck lids • Heavy truck hood, roof and door assemblies • Trailer and storage box sidewalls and roofs As the use of composites has expanded, so too has the variety of composite materials and their production processes. These variations present multiple adhesive challenges for adhesive bonding.

ENVIRONMENTAL PRESSURES AND COMPOSITES

SURFACE VARIATION

As the focus on environmental awareness and preservation intensifies, the transportation industry is increasingly affected by government regulation and general public sentiment. The result of these pressures has been a significant effort by OEMs (especially those

Each composite surface can vary in terms of roughness, porosity or surface energy. In some cases, a coating may have been applied prior to bonding that completely changes the chemistry of the part surface. The physical and chemical attributes of the bonding surface have a Adhesives & Sealants Industry

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COMPOSITE CHALLENGES Figure 1. Stress Caused by Differing Coefficients of Thermal Expansion

The use of innovative adhesive technologies allows manufacturers to capitalize on the advantages that composites offer.

Composites are used extensively in trailer manufacturing.

huge influence on the adhesion strength of the bond. In general, high surface area substrates are easier to bond to. However, extremely porous materials can be a problem if the adhesive is forced into a non-continuous form. Surface energy is even more critical to the successful bonding of a set of substrates. For optimum adhesion, an adhesive must be able to fully “wet” the substrate surface. This occurs when the adhesive is lower in surface energy than the substrate. Table 1 contains surface energies of several common substrates and related materials. The information in the table shows that metals are significantly higher in surface energy than plastics. But the line between what is generally considered “high surface energy” and “low surface energy” is fairly narrow—about 10 mJ/m 3 . Developing an adhesive that bonds to these very different surfaces (metal vs. plastic) can require significantly different approaches and materials. To complicate matters further, in situ mold release is commonly used to prevent molded composite parts from “sticking” in the mold. The mold release is formulated to migrate to the surface of the part during molding, where it can prevent the part from 18

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adhering to the mold. This mold release is still present on the surface of the composite part to varying degrees when it is bonded. Adhesive manufacturers must formulate a product that is able to adhere to the surface of the part when it contains a mold release specifically designed to prevent adhesion. Formulating an adhesive to overcome this scenario is no small task. The use of a selective wetting agent based on the specific chemistries involved provides the best opportunity to adequately bond the part, especially if the application calls for environmental cycling resistance. However, it is critical to note that each application is different, and one solution may not work for every part or process. Further surface variation can come from parts that experience deviations in the molding process. Differences in mold time, temperature and pressure can affect the porosity of the part, as well as the surface energy. Parts can also be molded in color, which requires that a part contains a color pigment. One common issue with molded in color parts is marring. To avoid this problem, substrate manufacturers include an anti-marring agent such as PTFE wax. This wax orients at the surface and acts like a low-surfaceenergy coating that the adhesive must penetrate to gain adhesion. Adhesion difficulties due to surface effects and treatments can be present in initial adhesion testing such as lap shear or T-peel. However, it may also be hidden in these tests only to resurface during more demanding adhesion tests, such as hot water immersion (90-100°C) or environmental cycling. When bonding composites in combination with more traditional substrates, it is important to perform a variety of tests to verify results.

BONDING DISSIMILAR SUBSTRATES Bonding two surfaces made from the same material is straightforward. Bonding two parts made from disparate materials, however, can be a challenge. First, the aforementioned factors affect the longevity of the bond. The more the two surfaces vary, the more difficult it can be to bond them together, as the adhesive must have a broad enough set of adhesion properties to be able to match up with both parts. The coefficient of thermal expansion (the degree to which a substrate expands and contracts with heat or cold) is also of critical importance when bonding dissimilar substrates. This is particularly true with bonding composites to rigid substrates like metals. Metals are typically higher in coefficient of thermal expansion than composites, and this difference can be February 2012

Table 1. Surface Energy of Various Substrates and Materials Material

Material Class

Surface Energy

Aluminum

High-surface-energy metal

840 mJ/m2

Stainless steel

High-surface-energy metal

> 700 mJ/m2

High-surface-energy ceramic

> 250 mJ/m2

Kapton® industrial film

High-surface-energy plastic

50 mJ/m2

Rigid PVC

High-surface-energy plastic

39 mJ/m2

Polyester

High-surface-energy plastic

43 mJ/m2

Nylon

High-surface-energy plastic

46 mJ/m2

Epoxy paint

High-surface-energy coating

43 mJ/m2

Polyurethane paint

High-surface-energy coating

43 mJ/m2

Polyethylene

Low-surface-energy plastic

31 mJ/m2

Tedlar® polyvinyl fluoride film

Low-surface-energy plastic

28 mJ/m2

Teflon® fluoropolymer

Low-surface-energy coating

18 mJ/m2

PVA mold release

Low-surface-energy coating

33 mJ/m2

Glass

significant. When a metal substrate expands or contracts at a higher rate than the more thermally stable composite, it creates a stress in the adhesive bond as it “stretches.” In the worst case, the bond, unable to tolerate the stretching effect, will break and the adhesive will pull free from the metal, causing adhesive failure. In less dramatic situations, the adhesive may not break away immediately, but constant fluctuations in temperature may cause repeated stresses in the bond and potentially result in fatigue and adhesion loss. It is critical that the adhesive is formulated to take these cyclical stresses into account and tested to verify efficacy. Figure 1 illustrates the stresses created when one substrate has a higher thermal expansion coefficient. In the illustration, substrate 1 is the more thermally stable substrate (composite), and substrate 2 has the higher coefficient of thermal expansion, resulting in a higher degree of expansion or contraction. In addition to the stresses caused by expansion and contraction, fracture toughness must be considered. Impact is a serious concern, especially in the transportation industry. The bond must be able to survive substantial stress from impact without fracture, which would result in adhesive failure. Fracture tests are commonly performed at ambient conditions as well as in extreme cold (e.g., from -20°C to as cold as -40°C). At these extreme temperatures, many adhesives February 2012

fracture upon impact. The root issue in this scenario is that the adhesive becomes too brittle to absorb and efficiently displace the energy of the impact. Adhesive manufacturers have made significant efforts over the last several years to develop toughened systems that can pass these cold impact tests. The first step toward meeting this requirement is fine-tuning the curing process of the adhesive to avoid brittleness and improve fracture toughness. The use of specially formulated accelerators can help adjust the cure rate and improve toughness. A second critical formulation area is the use of selective, reactive tougheners in combination with thermoset polymers, which results in a highly toughened adhesive that does not sacrifice mechanical properties. These avenues are far superior to the traditional method of “softening” the polymer matrix with thermoplastic materials that will degrade mechanical properties. Further development in this area continues.

OVERCOMING OBSTACLES It is critical to spend early development time using failure mode and effects analysis (FMEA) and establishing a design plan that minimizes or eliminates the potential failure modes identified as part of the design FMEA. Using multiple tests to evaluate failure modes is also a key component to success. Once design and test strategies are established, development can begin. Optimizing polymer type and

f u n c t i o n a l i t y, a d d i t i v e l e v e l s a n d toughening levels are critical components to reaching the best formulation possible. However, consideration of the customer’s manufacturing process must be given as well. Pairing the adhesive and the application process, including optimum cure parameters, provides the greatest chance of long-term success. Composites provide significant advantages in various applications, especially in the transportation industry. The use of innovative adhesive technologies allows manufacturers to capitalize on the advantages that composites offer. However, composite applications are among the most challenging developments an adhesives manufacturer can undertake. Many obstacles to product success exist, and the developer must be cognizant of the potential issues related to surface profile and energy, variations in molding process, surface coatings, or contaminants. When bonding dissimilar substrates, consideration must be given to the differences in the substrates, including coefficient of thermal expansion and fracture toughness. Finally, pairing the adhesive with the manufacturing process helps ensure the most optimum results possible. For more information, contact the author at Uniseal, Inc., 1014 Uhlhorn St., Evansville, IN; phone (812) 425-1361; email [email protected]; or visit www.uniseal.com. The author would like to thank Thanikaivelan Veeraraghavan, Ph.D., for his contributions.

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Structural adhesives can reduce emissions and assist in the recycling of plastics to minimize waste and VOCs. By Sally Sinai, Technical Support Manager, ITW Plexus ecause recent trends in the marketplace emphasize green, manufacturers are looking for new and innovative ways to reduce emissions and volatile organic compounds (VOCs). This is particularly true in the automotive industry, where there is a real drive to design lighter cars that are less thirsty for fuel and consequently produce fewer emissions. Alternative materials such as plastics, fiberglass and aluminum are being used more often. Since 1990, some reports suggest that the replacement of automotive steel has avoided burning more than 22.2 billion gallons of fuel globally. In addition, it has been estimated that the automotive industry’s ongoing move to lighter materials will cut the world’s greenhouse gas emissions by 20%. In order to facilitate this shift toward lighter materials, designers have had to identify an appropriate method of joining new and dissimilar materials. The joining method must be fast and easy to achieve, and the resultant joints need to be strong and durable (at least on a par with the performance of welding and other traditional methods of joining steel components). This is where structural adhesives have helped to make a big difference.

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STRUCTURAL BASICS Five different joining methods are currently used with alternative materials: glass tabbing, putties, bolts, rivets and structural adhesives. Structural adhesives are used either as single-part moisture cure or as two-part reactive cure systems; both offer designers and manufacturers key benefits, such as continued advances in technology and cost savings in labor and capital investment. Structural adhesives also distribute stress and load over a wider area. Because structural adhesives allow the joining of dissimilar materials, many design options that reduce the overall weight and VOC emissions of the final component can be created. 20

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February 2012

Structural integrity is vital in the marine industry.

Structural adhesives can add value to finished products in applications such as metal bonding in locker doors on coaches and rub rails on buses, where both aesthetic appearance and bond strength are critical. Structural integrity is also vital in the marine industry; the overall weight of the boat is reduced by bonding in systems such as stringer grids. VOC emissions can be reduced as well. Today’s new engineered composites provide designers with a wealth of options and challenges. Many structural adhesives are currently available, and the correct adhesive choice is crucial. Factors to consider include VOC content, surface preparation, working and fixture times, requirements of the application, and dynamic fatigue resistance. A green adhesive is one that eliminates toxins to the greatest extent possible. These products, which focus as much on human health as performance, can be developed by reducing off-gassing to nearly undetectable levels in order to prevent indoor and outdoor air quality problems. Another important green February 2012

quality is the ability to recycle or regrind the finished product. Some companies believe that adhesive manufacturers have an obligation to develop products that focus on human health and recyclability. However, it is up to the customer who is using the product to determine which adhesive provides the safest option for their operators while ensuring the best performance for their product. Independent organizations and industry bodies, such as the HSE (UK) or AFSSET in France, and industry groups like BASA in the UK and FEICA in Europe, are also constantly monitoring green issues by looking at current and future legislation.

ADHESIVE TYPES A variety of structural adhesive types exists in the market today; each type offers users a different level of “greenness.” Some structural adhesive types include epoxies, urethanes and methyl methacrylates. Reactive two-component epoxies are typically 100% solids with little or

no VOC emissions. For example, some activator systems contain butyl acetate, which releases less than 25 g/L of VOC. Additional factors to consider include the amine content and the sensitivity of being mixed off-ratio, which can increase the possibility of off-gassing. One- and two-component urethane systems are typically 100% solids with little or no VOC emissions. However, solvents can sometimes be used as carriers in non-structural versions, which can release VOCs at around < 25 g/L. The isocyanate content and the potential for off-gassing (if mixing off-ratio) must also be considered. Tw o - p a r t r e a c t i v e m e t h y l methacrylate adhesives (MMAs) vary depending on formulation but typically have between 40-60% reactive VOC components, which results in greater than 99.5% conversion. Therefore, VOC emissions are typically less than 0.5%. These products are off-ratio tolerant compared to other systems and have no off-gassing issues. These products do have a distinct odor. Adhesives & Sealants Industry

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STRUCTURALLY GREEN was the customer’s need to regrind and recycle waste material. Adhesive would therefore remain both on the bonded part and cut-offs. A Plexus two-component reactive MMA adhesive system was able to resolve the problem for the OEM. The nature of the MMA adhesive means it is compatible with many types of thermoplastic regrind materials, and the adhesive does not need to be cut from the bonded part. Test data clearly showed that there were minimal effects on the injection molding parameters of the plastic and that there was minimal loss of properties when compared to the virgin material (see Figures 1 and 2).

Figure 1. Tensile Shear (MPa)

CONCLUSION

Figure 2. Melt Flow Index (g/10 minutes)

Structural adhesives can and do provide an excellent alternative to traditional assembly methods. Various structural systems can offer low VOC emissions, which, in turn, can reduce the overall emissions for the customer. Many products can offer little or no offgassing, which makes them safer to use in both indoor and closed environments. The choice of adhesive is critical, and a balance between performance and human health will often be determined by the customer. Adhesive manufacturers are looking to develop products that can address this balance and make the customer’s choice an easy one—with no compromise on product performance or employee welfare.

OTHER JOINING METHODS

ABOUT ITW PLEXUS

More traditional methods of joining composite materials include the use of glass tabbing or polyester putties, but drawbacks are associated with both of these technologies. The application method used for glass tabbing can greatly affect VOC emissions. A closed-mold application will suppress emissions. Older technology can be 40-50% styrene, with new technology reducing this level to < 35% styrene. VOC emissions can reach up to 15%. Off-gassing is also a matter of concern with this bonding technique. Polyester putty emissions are again application- and technique-related, and they are typically very high in VOC emissions (around 224 g/L). New, lower VOC technologies are available, but the levels are still not reduced considerably. The use of these materials is very application-dependent, and off-gassing is also a matter of concern.

ITW Plexus, a division of Performance Polymers Europe, is part of ITW (Illinois Tool Works), which was established in 1912 and today employs 60,000 people worldwide. The Performance Polymers Europe division has more than 25 years of experience in the design, development and production of polyurethane, epoxy, and methacrylate bonding agents. The company has an extensive and ongoing adhesive R&D program centered at its modern UK and Eire laboratory facilities. Technical service is particularly important to the company, and it offers its customers free professional advice, substrate and bond strength testing, as well as ideas on dispens-

CASE IN POINT The automotive industry is committed to plastic recovery and re-use programs. Problems often arise regarding the incompatibility of the structural adhesive with the plastic recycle recovery process. The intrinsic nature of most structural adhesives poses a serious regrind problem, and therefore the adhesive must be cut out of 22

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parts and disposed of in a non-recyclable waste stream. This process is both laborintensive and wasteful, since a large portion of plastic is often cut out with the adhesive. One particular application was a thermoplastic bumper that needed to be structurally joined. The main challenge during the production process

ing equipment and process improvement. The company is accredited to the ISO 9001:2000 quality certification, and its Shannon manufacturing facility in Ireland has ISO 14001:2004 Environmental certification. ITW Plexus specializes in the design and manufacture of sophisticated structural adhesives for the bonding of materials used in markets such as transportation, marine, wind energy, automotive, engineering and construction. For more information, visit www.itwplexus.eu.

February 2012

COMPOSITES 2012 is scheduled to take place February 21-23 in Las Vegas.

F

or professionals involved with the composites industry, Las Vegas is the place to be this month. The COMPOSITES 2012 Exhibition and Convention, which is produced by the American Composites Manufacturers Association (ACMA), will be held February 21-23 at the Mandalay Bay Hotel in Las Vegas. More than 3,000 attendees from a variety of market segments are expected to attend. Markets represented at the show will include aerospace, architectural, automotive, civil structure, construction, corrosion, energy, kitchen and bath, marine, mass transportation, military, sports and leisure, and truck/RV.

and sports commentator Rusty Wallace will be featured as the general session’s keynote speaker on February 21. He will provide insights about teamwork in business, as well as the increasingly common use of composites in the automotive industry. More than 100 45-minute educational sessions and 25-minute technical papers will be presented during the show as well. A university poster session, opening welcome reception, awards luncheon and specialized networking events are also on the agenda.

THE COMPOSITES EXHIBITION 2012 KEYNOTE SPEAKER: RUSTY WALLACE Attendees at COMPOSITES 2012 will have access to an array of educational opportunities. NASCAR champion

SCHEDULE AT A GLANCE Tuesday, February 21 9:00 a.m.-12:00 p.m. 12:00-1:30 p.m. 1:30-3:30 p.m. 3:45-5:00 p.m. 5:15-6:45 p.m. Wednesday, February 22 8:00-9:15 a.m. 9:30 a.m.-5:30 p.m. 12:00-1:30 p.m. 2:00-5:00 p.m. 5:15-6:45 p.m. Thursday, February 23 8:30 a.m.-12:00 p.m. 9:30 a.m.-3:30 p.m. 1:30-3:30 p.m.

Education Sessions and Technical Papers University Poster Session General Session—Open to All Education Sessions and Technical Papers Opening Welcome Reception

On February 22 and 23, more than 220 exhibitors will represent their products and services on the show floor (see sidebar on p. 24). Exhibiting companies from every state and more than 40 countries will be in attendance. These exhibitors will be showcasing emerging technologies, new green industry trends, and advancements in materials and market applications. The Adhesive and Sealant Council (ASC) will again be partnering with ACMA to provide the 600-sq-ft Adhesive and Sealant Pavilion at this year’s event. The Pavilion will be prominently displayed on the show floor and will accommodate five exhibitors from the adhesives and sealants sector. Exhibitors will include raw materials suppliers and manufacturers of adhesive and sealant solutions for the composites market.

NETWORKING AND ADDITIONAL OPPORTUNITIES General Session — Open to All Exhibit Hall Open Awards Luncheon Education Sessions and Technical Papers Specialized Networking Sessions

Education Sessions and Technical Papers Exhibit Hall Open Education Sessions and Technical Papers

COMPOSITES 2012 will offer a number of networking opportunities beyond the educational sessions and the exhibition. The opening welcome reception, which usually has more than 1,000 attendees, will kick off the three-day event. An awards luncheon will be held on February 22 to honor companies and individuals for innovative contributions to the industry. During the luncheon, the Award for Composite Excellence (ACE) and the Pinnacle Awards will be given in design, manufacturing and market growth categories. In addition, ACMA will host a number of committee meetings during COMPOSITES, and a handful of specialized industry networking receptions will take place as well. For additional details, visit www.acmanet.org.

February 2012

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OPPORTUNITIES ABOUND AT COMPOSITES 2012 EXHIBITOR LIST* Company

Booth

A.P.C.M. Manufacturing 1142 ACMA Central 665 ACS International 920 The Adhesive & Sealant Council 656, 657, 661 Advanced Plastics, Inc. 914 Airtech International 823 AkzoNobel 807 Albion Engineering Co. 659A Allied Custom Gypsum 541 AOC 605 Arkema Inc. 837 Ashland 1153 ATC Formulated Polymers 1023 Auburn University 1164 AXEL 407 B/E Aerospace 454 Baltek, Inc. 747 Bayer MaterialScience 757 Beijing Partnerworld Int’l 649, 651, 653, 750, 752 BYK USA, Inc. 841 CCP Composites 329 Cerex Advanced Fabrics, Inc. 758 Changzhou Topweaving 332 Chem-Trend LP 819 Chemique Adhesives 564 China National Building 213 CHOMARAT North America 737 Chongqing Polycomp Int’l Corp. 559 CMS North America, Inc. 315 Colbond, Inc. 328 Composites Europe Lounge 461 Composites One 528, 629 Composites World 956 Continental Diamond Tool 1139 Controx – Neuhauser 1057 Crane Composites, Inc. 740 Creative Pultrusions, Inc. 539 CTG International Inc. 551 Cutting Edge Composites 1264 Dassault Systems Americas 447 De-Comp Composites, Inc. 1115 DIAB Sales, Inc. 664 Diatrim Tools Ltd. 1154 Diversified Machine Systems 206 Dixie Chemical Co. 1270 DuraPlate Products Group 738 Eastman Machine Co. 929 Elliott Co. of Indianapolis, Inc. 646 Endurance Technologies 1050 Engineered Fillers International 918 Entec Composite Machines 347 Eurovac Inc. 925 Fiber Glass Industries 836

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Company

Booth

Fiber-Line, Inc. 547 Fiberlay 753 Flow International Corp. 247 Frees, Inc. 412 Freudenberg Nonwovens 928 Geis Companies 359 General Plastics Manufacturing 951 Gibco Flex-Mold Inc. 1034 Gruber Systems 840 GS Manufacturing 450 Hawkeye Industries, Inc. 815 Henkel Corp. 907 Hennecke Inc. 1007 HK Research Corp. 421 Hodogaya Chemical (USA) 851 Hollingsworth & Vose Co. 1128 Horn 314 Huber Engineered Materials 715 INOAC Corp. 959 Interplastic Corp./NAC 619 Intertek 349 IPS Weld-On Corp. 615 ITW Finishing Equipment 935 ITW Insulation Systems 107 ITW Plexus 955 ITW Spray Core 1037 ITW Wind Group 859 Jensen Industries, Inc. 313 Jiaxing Sunny FRP Industries 1054 JRL Ventures, Inc. 847 Jushi USA 915 Kenrich Petrochemicals, Inc. 1015 KMT Robotic Solutions 338 KNF FLEXPAK Corp. 1124 Knowlton Technologies LLC 1041 Krauss Maffei Corp. 453/2 Lindau Chemicals, Inc. 1114 Litek Composites Corp. 947 Magnum Venus Plastech 229, 523 Martin Pultrusion Group 316 MCC Equipment & Service Ctr. 965 McLube/McGee Industries 1019 MDC Mould & Plastic Co., Ltd. 934 Mektech Composites Inc. 1146 METYX Composites 557 Micro Air 1012 MIT-RCF 334 Momentive Specialty Chemicals 307 MultiCam, Inc. 746 Myers Engineering, Inc. 756 Nantong Power Plastic/Rubber 964 Nederman Inc. 855 Nexeo Solutions 207 Norton 339 Olympus 440

Company

Booth

Owens Corning 321 Parabeam BV 1165 Performance Minerals Corp. 916 Plascore, Inc. 1053 Plasticolors, Inc. 941 PPG Industries, Inc. 441 PPG-Devold 853 Precision Quincy Corp. 1047 Pro-Set, Inc. 438 The R.J. Marshall Co. 517 Reichhold 506 Rexco Mold Care Products 516 RS Hughes Co. 659B SAERTEX USA, LLC 415 Saint-Gobain ADFORS 741 Scott Bader, Inc. 446 Sika Corp. 1029 Smart Tooling 1046 Sogel Inc. 865 SP-High Modulus 852 Specialty Products Co. 946 Spheretex America, Inc. 453 Stiles Machinery Inc. 1013 Structural Composites, Inc. 330 Sworl 642 Syrgis Performance Initiators 641 System Three Resins, Inc. 243 Taconic 1246 TCR Composites, Inc. 930 Tech Systems, LLC 1059 Teijin Aramid USA, Inc. 340 Tiodize Co., Inc. 1127 Toho Tenax America, Inc. 546 TR Industries 543 Tricel Honeycomb Corp. 909 Unicomposite Technology Co. 341 United Soybean Board 647 Universal Star Group Ltd. 223 University of Alabama 1065 University of Mississippi 1170 University Pavilion 1064 Valspar 637 Vectorply Corp. 638 Ventilation Solutions 1156 Virginia Economic Dev. 1006 Warm Industrial Nonwovens 416 Watkins & Associates, Inc. 413 Westech Aerosol Corp. 565 Winona State University 1071 Wisconsin Oven Corp. 1147 Wm. T. Burnett & Co. 1033 Xamax Industries, Inc. 320 *as of 12/8/11

February 2012

Next-generation epoxy adhesives are formulated to not propagate fire even when exposed to open flame.

Measuring and Regulating Flammability Adhesives manufacturers support the aviation industry with new flame-retardant materials for composite aircraft. By Todd Holder, Aerospace Adhesives Marketing Manager, Huntsman Advanced Materials he introduction of commercial aircraft built with increasingly complex composite materials and configurations has led aircraft manufacturers, their suppliers and the Federal Aviation Administration (FAA) to review the test methods used to determine fire safety. A particular focus has been placed on reexamining the flammability performance criteria established by FAA 14 CFR 25.853, which governs materials used in aircraft interiors. These efforts began in 2009, when industry leaders recognized that some of the existing regulations did not directly measure the flammability of newly designed composite components built with new-generation materials and technologically advanced construction methods. Compounding the dilemma was the broad interpretation of required testing used by various aircraft manufacturers to determine whether assembled structures met the requirements of the 14 CFR 25.853 flammability regulations. Several of the regulation methods at issue included the testing of adhesives, insert potting compounds, and edge fills used in bonded structures and honeycomb core composite panels for aircraft interiors. Closely defined parameters for sample material, size, and configuration were also lacking from combustion and flammability tests. Conversely, some testing was perhaps being conducted unnecessarily when, for certain materials, years of collective flammability data already existed.

T

February 2012

STANDARDIZATION TASK GROUP The Flammability Standardization Task Group (FSTG) was formed to work with the FAA and make recommendations to address some of these inconsistencies. The group is comprised of approximately 80 companies and more than 200 individuals representing global aircraft materials suppliers and manufacturers. Task group members conduct in-depth studies on substrates, adhesives/syntactics, and “details” such as texture and color of decorative laminates, plastics, and paints. Input from the FSTG is expected to support greater test standardization backed by a thorough understanding of the most effective methods for evaluating aircraft interior components of all sizes fabricated with a variety of materials and construction techniques. “We’re trying to determine which flammability tests and test combinations are needed to obtain accurate and repeatable results,” says Panade Sattayatam, engineering manager at C&D Zodiac and a team leader on the FSTG. “As the task group evaluates the findings, members are working together to apply years of experience in materials and manufacturing to recommend alternate methods of compliance (MOC) that maximize efficiency by trying to eliminate non-value added testing without compromising safety.” Based on the findings of the FSTG, as well as testing performed by aircraft manufacturers and government agencies, Adhesives & Sealants Industry

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the FAA is expected to issue a new policy memo covering flammability MOCs during the first quarter of this year. These MOCs can be used by aircraft manufacturers to ensure that consistent methods are used to evaluate the flammability, as well as the heat and smoke release performance of materials and components fabricated throughout the world.

AIRCRAFT MATERIALS APPLICATIONS In the past 20 years, aircraft OEMs have started to replace metal parts with composite materials to reduce weight and thereby realize significant fuel savings and increased payload capacity. Today, major airframe manufacturers utilize a broad range of lightweight, high-strength composite materials, including advanced thermoplastics and honeycomb core/phenolic prepreg composite sandwich constructions. The primary aircraft interior applications for fabricated composites include galleys, lavatory areas, overhead baggage bins, bulkheads, wall and floor panels, window reveals, and tray tables. Epoxy adhesives and potting compounds, along with low-density void- and edge-filling syntactics, have long been the “workhorse” materials in manufacturing interior aircraft components. Newer to the field are nano-toughened epoxies that provide high-temperature performance after a room-temperature cure and flameretardant polyurethane adhesives that are ideal for use on hard-to-join engineering thermoplastics. Accompanying the proliferation of nonmetallic products used in building aircraft has been a growing base of information about how different materials can affect passenger and crew survivability in the event of an on-board fire or crash. For example, FAA 14 CFR 25.853-compliant adhesives and syntactics do not propagate flame when exposed to the 60- or 12-second vertical Bunsen burner test (see sidebar on p. 28).

Polyurethane adhesives are ideal for repairing thermoplastic cabin components.

Figure 1. Aircraft Composite Components Applications

ADHESIVES AND SYNTACTICS OVERVIEW Adhesives as a class of materials are designed to hold substrates together by surface attachment. The products distribute a load over an entire bondline rather than concentrating stress at specific points like mechanical fasteners. Adhesive bonding also can significantly reduce part weight and assembly time compared to mechanical fasteners. 26

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Epoxy paste adhesives are typically favored for use on metal, as well as composite primary structural parts that require good mechanical strength and performance at elevated temperatures (350°F dry/250°F wet). Epoxy adhesives feature high lap shear strengths, retain

adhesion when exposed to vibration and thermal cycling, and exhibit excellent chemical/solvent and fatigue resistance. Epoxy adhesive pastes are also ideal as potting compounds used to install attachments and inserts in composite panels. February 2012

Tabbed inserts in overhead stowage bins are held securely in place using epoxy syntactic.

Polyurethane adhesives are typically more flexible than epoxies, with good shear and high peel strengths on metals and engineering thermoplastics. These types of adhesives are particularly wellsuited for joining substrates with dissimilar coefficients of thermal expansion and for securing various types of inserts in composite panels. Lightweight syntactics are produced by modifying epoxy resin systems with special fillers such as high-performance glass microspheres to produce lowdensity materials that can reduce weight while maintaining compression strength. These products exhibit good mechanical properties, along with the ability to resist fluid absorption and chemical attack. Syntactics are widely used for reinforcing honeycomb core, insert potting and edge-

sealing composite panels against moisture incursion (see Figure 1).

FLAME RETARDANT ADHESIVES AND SYNTACTICS As FAA flammability requirements have changed in the past, both epoxy and polyurethane materials have been reformulated to comply with new regulatory standards and individual OEM aircraft demands. For example, the first flame-retardant epoxies included halogenated compounds and antimony oxide to reduce flammability. However, the presence of bromines generated high levels of smoke, making the products inappropriate for many cabin interior applications. Today, adhesives manufacturers are working closely with the FSTG to develop next-generation systems. The challenge in developing these new products is obtaining

the needed flammability characteristics without sacrificing peel and/or shear strength, which would result in brittle bonds. In addition, new formulations must be TSCA registered, REACH compliant, UV stable, easy to handle and economical. Color is also important. Some very effective flame retardants produce dark-colored adhesives and syntactics that are not acceptable for use on light-colored aircraft interior components. As chemists work to formulate new flame-retardant adhesives and syntactics, they also seek to improve the performance of properties such as strength and elevated temperature capabilities. At the same time, they are exploring the production of materials with ever-lower densities. At Huntsman, we are developing nextgeneration adhesives that maintain or exceed the mechanical strength of existing flame-retardant epoxies while significantly improving self-extinguishing characteristics. A new syntactic system being explored meets current flammability standards and performs at higher temperatures than previous formulations (see Table 1).

NEW FLAMMABILITY STANDARDS In-depth physical examinations of new composite component designs for aircraft interiors have contributed to the need for improved materials, as well as upgraded flammability testing. For example, the standard Bunsen burner test did not adequately determine the flammability characteristics of medium-sized composite parts when exposed to a hidden heat source that might represent an in-flight fire threat. Industry leaders are working with the FAA to develop foam

Table 1. Comparison of Flame-Retardant Adhesives and Syntactics Adhesives-Epoxy

Adhesives-Polyurethane

Syntatics-Epoxy

Properties

Epoxy Formula 1

Epoxy NextGeneration 1

Epoxy NextGeneration 2

PUR Formula 1

PUR Formula 2

Syntactic Formula 1

Syntactic Formula 2

Syntactic NextGeneration 1

Viscosity, cP at 77ºF

semi-paste

paste

non-flow paste

paste

semi-paste

paste

soft paste

paste

Gel time min. at 77ºF

4 - 10 (50 g mass)

140 (100 g mass)

90 (20 g mass)

4-8 (100 g mass)

15-25 (100 g mass)

60-90 (50 g mass)

70 (100 g mass)

15 (56.5 g mass)

Density, g/cc

1.20

1.30

1.35

1.20

1.16

0.70

0.90

0.68

Service temperature, ºF

180

180

180

180

180

180

350

200

Compressive strength, psi

N/A

N/A

N/A

N/A

N/A

5,500

8,800

5,200

2,700

2,600

3,900

700

2,200

1,000

1,200

1,700

400

~2,400

300

1,300

N/A

N/A

23 (roller)

10 (T-peel)

35 (T-peel)

N/A

N/A

2

0

<10

self extinguishing

<2

5

1.6

<1

5

<7

Lap shear strength, psi at 77ºF at 180ºF Peel strength, pli Flammability (60 sec. ignition, vertical self-extinguishing) time, seconds Burn length, in.

February 2012

1,300

self extinguishing burn rate 1 in./min

N/A

<1 <1

Adhesives & Sealants Industry

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FLAMMABILITY TESTING: VERTICAL BURN TEST

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Vertical burner test subjects are vertically mounted over an open Bunsen burner flame to determine a material’s flame propagation and self-extinguishing characteristics. The FAA’s 14CFR 25.853(a) defines two vertical Bunsen burner flammability standards (60-second and 12-second flame applications) based on materials and end-use applications. Materials and components such as commercial aircraft ceiling panels, partitions, galley structures, cabin walls, structural flooring and overhead baggage bins must meet the more severe 60-second test [14CFR 25.853(a) Appendix F Part 1 (a) (1) (i)]. In order to pass this test, a specimen must have an average burn length of no greater than 6 in. and an average flame time after removal of the flame source not exceeding 15 seconds. (This standard may change to specify “average flame time after removal of the flame source must self-extinguish within 15 seconds.”) Materials used in floor coverings and textiles, seat cushions, trays and galleys, and electrical and ducting equipment must meet the 12-second test [14CFR 25.853(a) Appendix F Part 1 (a) (1) (ii)]. In order to pass this test, the average burn length of the materials may not exceed 8 in.; the average flame time after removal from the flame source may not exceed 15 seconds.

block tests designed to validate that structural adhesive and potting compound configurations do not propagate fire. At the same time, the FSTG has been investigating flammability test results based on composite parts of varied materials, size, thickness and construction. Among the test specimens are honeycomb core sandwich 1:54:51 PM panels and composite laminates. The flammability performance of single components is also being studied. These specimens include different types, densities, and thicknesses of honeycomb core, unpainted panels, and panels coated with a variety of paint and ink colors, as well as panels that have been bonded, potted and/or edge sealed. Several of the recommendations under consideration by the FSTG to help standardize flammability testing on adhesive and syntacticcontaining composite components include: • Testing adhesive, detail and substrate separately or bonded to a “worst case” substrate • Testing a fabricated, potted or edge-filled panel section or potting/edge sealing compound alone • Testing an adhesive or syntactic used for insert reinforcement alone to a 12-second vertical test The FAA is reviewing the group’s recommendations to determine its final policy.

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Raw Materials, Chemicals & Additives Handbook • Search by product category or company name • Downloadable product spec sheets • Alpha company listings • Live web & email links

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CONCLUSION Stronger partnerships with materials suppliers are developing as OEMs take significant time and dedicate substantial resources toward research into the flammability performance of composite materials. It is through the commitment of all sections of the aviation industry that new products will come, leading the way to safer, lighter and more durable aircraft.

CONNECT

For more information, contact the author at Huntsman Advanced Materials, 10003 Woodloch Forest Dr., The Woodlands, TX 77380; phone (281) 719-4859; fax (281) 719-

Start your search today!

4011; email [email protected]; or visit www.huntsman.com.

(www.adhesivesmag.com/materialshandbook) 28

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February 2012 1/3/12 11:38 AM

ASSEMBLY LINE FASTENING SOLUTIONS By Kurt Schramer, Strategic Business Development Director, MACtac®

rom the early 1900s, when the f i r s t p o w e r- d r i v e n a s s e m b l y line for vehicle production was introduced, manufacturers have sought ways to decrease labor costs, increase safety, improve turnaround times and implement efficient processes in an effort to positively impact their bottom line. The first assembly lines commonly included materials such as screws, bolts, nails and wet adhesives. Today’s assembly lines have been transformed; engineered pressuresensitive laminates have displaced other conventional fastening devices like rivets and wet adhesives to become a preferred fastening method. One of the more significant time and cost savers in assembly line production has been driven by the implementation of engineered pressure-sensitive laminates as alternative fastening solutions.

F

THE BASICS Engineered laminates require only a slight initial external pressure to hold two surfaces together solely by surface contact. Depending on manufacturer specifications and end-use application, engineered laminate solutions can withstand adverse temperatures ranging from -40°F to more than 400°F. They are also capable of adhering to a variety of substrates and surfaces, including metal, wood, fiber, glass, rubber, and plastic, and they will often last or outlast a product’s lifecycle. Another advantage of engineered laminates is their ability to fasten dissimilar surfaces together. Manufacturers have discovered that they can realize greater efficiency in assembly line production with engineered laminates because these alternative fasteners can be customized February 2012

Engineered pressure-sensitive laminates deliver unmatched efficiencies when compared to other more traditional methods.

Figure 1. Engineered Laminate Layers

for specific market segments. In other words, the same amount, size and thickness of laminate is used in applications in a specific segment each time, which offers better consistency without compromising the integrity of the substrate or end product. Engineered laminates that are formulated specifically to work with manufacturers’ assembly lines bond quickly and help shorten the average assembly process. As a result, manufacturers can become more efficient and launch their products to market faster and at a better price. As a comprehensive bonding solution, the engineered pressuresensitive laminate is made up of multiple layers. Depending on the application, the engineered laminate could include a release liner, adhesive and carrier—all working together as one engineered solution that ensures product performance and value (see Figure 1).

Release liners protect and position the adhesive. Although the liner is discarded during installation, it needs to be right from the beginning for effective processing. Release liners should have good holdout, be heat resistant, and possess a consistent caliper for consistent die cutting. The carrier, which could be in the form of paper, film, foam or another specialty material, is the middle layer that must be compatible with the adhesive to ensure the best product performance. Engineered pressure-sensitive laminates are formulated to adhere to specific substrates and can either be permanent or removable, depending on the end-use application. Permanent adhesives possess high ultimate adhesion to a variety of surfaces and are intended to last the lifecycle of the end-use product. Removable adhesives, on the other hand, are characterized by low ultimate adhesion to surfaces and are intended for applications that require Adhesives & Sealants Industry

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ASSEMBLY LINE FASTENING SOLUTIONS removal of the adhesive without residues, stains or ghosting within the expected lifecycle of the end application. Engineered laminates are produced as either single- or double-coated adhesive constructions in a free-film or supported system. All layers of an engineered laminate work together to give manufacturers an assembly solution that meets their specific needs. The benefits of working with engineered laminates far outweigh those of using mechanical or liquid fasteners. The ability to customize and pre-apply the laminate is one major benefit, but there are several other advantages to working with these fastening solutions.

ENGINEERED LAMINATES VS. TRADITIONAL MECHANICAL FASTENERS Compared to mechanical fastening solutions, engineered laminates offer manufacturers the opportunity to work with fewer fastening components, thereby creating the ability to manufacture products with a more consistent quality in less time. In addition, engineered laminate-fastened solutions usually weigh less than finished products composed of mechanical fasteners.

For example, prior to the incorporation of engineered laminates in cell phone applications, one cell phone contained more than 20 different non-pressure-sensitive fastening components. As cell phones gained popularity and began downsizing, manufacturers began to transition to engineered laminates. With this transition, the number of required components drastically decreased, which reduced labor, manufacturing costs, and the overall weight of the product while simultaneously enhancing the product’s design aesthetics to create a more appealing end-use product. The same can be said about many other electronic, automotive and appliance applications. Engineered laminates also allow manufacturers to achieve enhanced structural integrity for finished products by eliminating unwanted holes or openings associated with mechanical fastening solutions and preventing potential rusting that metal-on-metal fasteners could cause. These engineered fasteners easily reduce stress on product joints, which can minimize product underperformance or failure. With the ability to increase flexibility in product development, engineered laminate solutions can be used to bond incompatible

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

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

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

www.adhesivesmag.com

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

surfaces that would not be able to bond with traditional mechanical fastening solutions. Unlike mechanical fasteners, engineered laminates form an insulating seal that prevents dust, liquids and in some cases unwanted sound and vibration from intruding. The convenience of working with engineered laminates also benefits today’s assembly lines. Because no elaborate equipment is required, manufacturers save money and can pass on these savings to consumers.

ENGINEERED LAMINATES VS. LIQUID ADHESIVES Engineered laminates are also advantageous to manufacturers who usually work with wet adhesives as a fastening method. These manufacturers often experience less downtime with engineered laminates, because engineered fasteners do not require any drying or curing time, or extensive clean-up of the assembly area. In addition, engineered laminates emit little to no volatile organic compounds (VOCs), which reduces health risks to workers and improves sustainability. Because of the pre-applied concept, manufacturers can also ensure product consistency and performance with engineered laminates because the exact amount is applied each time. Assembly engineers find that line workers need minimal training and skill to work with engineered laminates. Because they can be engineered and die cut for specific assembly lines and surfaces, fewer hands are required to join product parts. This results in reduced labor costs, which could in turn affect price point competitiveness. This customizable characteristic of an engineered laminate ensures quality, consistency, precision and faster production time. Engineered laminate fastening solutions also assure engineers that even the most delicate products will be protected during the assembly process because they are free of harmful solvents and do not require heat to activate— two things that can easily damage more sensitive products and lead to increased waste. Because engineered laminates offer immediate adhesion, assembly lines operate continuously without interruptions. There is no need to wait for long cure times, which means finished products can be handled or used immediately.

CONCLUSION For today’s manufacturing industry, engineered pressure-sensitive laminates have the ability to streamline assembly processes, shorten lead times, reduce operational risks and increase profitability. For more information, visit www.mactac.com.

February 2012

A variety of cavity baffle designs exists for water management within auto body pillar structures. By Ray Helferty, New Domestic Group Manager; Walid Omar, Senior Market Field Manager, Automotive; and Philip Weber, Director-Technical Service, Sika Corp. xpandable cavity sealers have become a critical component of the overall acoustic package that has contributed to the documented noise reduction in passenger car applications over the past 20 years. Solutions encompass a variety of technologies, some of which are highly engineered parts and assemblies. As the market for smaller and more fuel-efficient vehicles expands, design architectures of the vehicle platforms are evolving to include body designs with smaller spaces between adjacent layers of sheet metal. As this space, or cavity, between adjacent layers of sheet metal shrinks, the complexity of components that must be integrated into the space increases. Sophisticated arrays of airbags, corresponding wire harnesses, and water management tools are now standard requirements in the design process. To manage the complexity of these lightweight, fuel-efficient vehicle architectures, new engineering design solutions are required to meet ever-increasing and stringent acoustic requirements. The supply base of acoustic products to the OEMs has also matured, creating a very competitive environment, both regionally and globally. Design solutions that go beyond the basic functionality of a cavity filler are becoming more common. In one recent example, a design challenge presented by an OEM required improved visibility for the driver. Here, the hardware to direct water drainage is moved from outside the windshield pillar cavity body metal to inside the cavity metal. A new cavity filler solution is conceptualized to manage this unique packaging and acoustic performance need. Although it is in its infancy, the innovative solution, along with other means of water management, have been measured for insertion loss, compared and presented.

E

AN EVOLVING MARKET As consumer and testing demands for performance grow, vehicle designs continue to drastically improve to meet new safety and fuel economy regulations. These regulations put pressure on OEMs to streamline vehicle design. Innovative automotive body design and assembly practices result in a complex arrangement of interconnected channels and cavities. These channels become efficient paths for noise to propagate around the February 2012

perimeter of the passenger compartment once it is introduced into the body.1 Acoustic baffles are used to reduce the transmission of this noise into sensitive areas, including the upper body structure, where acoustical breakout (noise penetration) through drain and access holes in the body are attenuated only by the acoustical properties of the interior trim components. The variety of potential paths by which sound is propagated throughout the upper body structure requires the baffle package design be evaluated as a system for acoustic and water management. As automakers continuously refine their cars, trucks and SUVs, design capabilities and material science technologies of acoustic baffles become an engineering challenge to fulfill these refinements. Early part designs were cumbersome, bulky and not very efficient in overall performance. A full layer of expanding material was often assembled onto a metal or plastic bracket that functioned as a shelf to span the cavity section to be sealed. These parts were often welded or clipped to the body structure with plastic pins. As material know-how evolved and chemical companies explored, developed and gained experience in part manufacturing, design and cost optimization of the acoustic baffle began. 2-4 Extruded rubber-based chemistries that required labor-intense die-cutting and assembly were augmented with automated injection moldable thermoplastic chemistries, resulting in lower labor costs, higher flexibility and more freedom in design. As the competitive push in the baffle market began and automakers continued the cycle of cost reduction with model changeover, the simple full-layer baffle evolved into a race track baffle (see Figure 1, p. 32). The full layer of the expanding material was replaced with a perimeter seal of expandable material and a core of thermoplastic. Since vehicle styling and safety technologies continue to advance, the need for smaller, stronger pillar sections that offer the driver more visibility and increased occupant safety are the norm. Using improved cavity section designs and high-strength steels, as well as relocating sunroof drain tubes into the cavity, will provide the automaker the advantage they anticipate. With the design freedom created by these moldable Adhesives & Sealants Industry

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OVERCOMING CHALLENGES Figure 1. Evolution of the Acoustic Baffle

thermoplastic baffles, they could now be considered in these areas of the vehicle structure that historically were untreated.

A UNIQUE SOLUTION

Figure 2. Acoustic Drain and Flap Assembly Baffle

Figure 3. Acoustic Performance Comparison

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Routing a soft, pliable sunroof drain tube through a body pillar section with an expanded cavity sealer in the way presents a formidable challenge. After assembly, the cavity section “seal” needs to be maintained in order to gain the benefit for which the sealer is installed.5 To add to the difficulty, not all vehicles get a sunroof drain tube installed, so the specific baffle must perform even if a drain tube is not present. Although assembly processes by the OEMs are rigorously developed, errors in the physical assembly of the vehicle are always possible. If a tube is installed by mistake and needs to be removed, the baffle should maintain its performance. After careful review of existing treatments and solutions, none provided the needs of managing both the installation and removal of the drain tube. They did, however, provide a good basis for benchmarking baffle performance limits where water management treatment is required. These existing treatments, along with a unique solution that meets both needs of tube installation and removal, will be comparison tested against race track design baffles and against each other for acoustic performance. The race track design baffle, while providing outstanding acoustic performance, does not provide any means for water management. The two existing treatments identified and developed were the acoustic drain and the flap assembly baffle. Figure 2 illustrates these designs in terms of their functionality. The acoustic drain is an insert plug with a series of offset holes that facilitates water drainage while providing a tortuous path for noise.7 This plug is robust and can be readily applied in many application areas and parts. The limitation, however, is that the drain tube carrying the water must terminate above the baffle itself. In this case, water simply drains onto the insert and passes through. Management of water coming out the other end must then be considered. If the tube needs to pass through the section, the second existing treatment methodology would have to be used. The flap assembly baffle integrates a trap door and release mechanism that is deployed when the tube is installed. If no tube is present, the door remains February 2012

closed and the baffle is sealed. If a tube is installed, the door is released and the tube passes through with the sealing functionality maintained between the tube outer surface and inner wall of the funnel, optimized by the shape of the funnel to best match the tube. In the case where the tube may need to be removed, the door would remain open and the acoustic benefit compromised.

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RACE TRACK BAFFLE VS. EXISTING BAFFLE DESIGNS Figure 3 compares the noise-blocking performance of the existing solutions for water management to the typical race track baffle design. Sound insertion loss (IL) measured in accordance with SAE J2846 is plotted from 800 to 16,000 Hz. It should be repeated for clarity that the race track baffle design has no provisions for water management, while the design solutions investigated were selected for this very reason. Clearly, the overall performance of the acoustic drain solution remains favorable despite the added complexity in its design. Note that only water can pass through; no accommodations for a drain tube itself are made. In comparing the flap assembly baffle to the acoustic drain baffle design, it is possible to see that, while an acoustic benefit is still shown, the performance has necessarily diminished. The flap assembly design was originally developed to address vehicle platforms with sunroofs and required the drain tube as an optional accessory in the manufacture of a vehicle (i.e., some cars would have a drain tube installed, others would not). Creating more complexity in design and function clearly shows an impact on performance, as demonstrated by the results.

A SELF-CLOSING BAFFLE DESIGN The new challenge presented in recent customer specifications is to consider the removal of the drain tube if installed in a vehicle that does not require the tube. After many concepts and design iterations, an innovative, spring-mechanized, self-closing trap door funnel baffle was developed. On the open end of the funnel is a trap door connected through two thin membranes that act as hinges. Between the hinges is a specifically shaped plastic strap that allows for the tube to pass through unencumbered, but provides a return force on the door that closes itself if the tube is removed. February 2012

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OVERCOMING CHALLENGES Figure 4. Relative Acoustic Performance of Self-Closing Baffle

Figure 5. Design Complexity vs. Functional Performance

complexity and performance. Tested design solutions included: • Typical race track baffle—no water management is required • Acoustic drain baffle—simple water management is needed, but no drain tube accommodations • Flap assembly baffle— accommodations are now made for water drain tube installation • Self-closing baffle—an additional need to be able to remove the water drain tube is imposed The alternative solution presented adds more value than traditional solutions that are currently available on the market. This claim is based on the acceptance of the conceptual design solution by the OEM on a vehicle-level basis (prototype components were fabricated and tested by the target OEM). Factors considered by the OEM included cost, weight, overall vehicle-level performance, and compatibility with the automobile manufacturing and assembly process. While the component-level test data presented herein still show a slight performance gap to current marketplace solutions, the added challenges of innovative water management techniques managed by the concepts as proposed are illustrated as viable. The self-closing design solution continues to evolve, and design iterations are in process to drive total performance in line with current production solutions. For more information, contact Sika Corp. at 30800 Stephenson Highway, Madison Heights, MI 48071; phone

In conceptual form, it has been tooled and molded, tested for tube installation effort and initially tested against the flap assembly baffle for IL performance. Figure 4 shows the basic workings of this solution, as well as documented relative acoustic performance. Although there is currently a gap in performance between this and the flap assembly, the self-closing baffle solution presents great potential for design refinements that offer performance improvements. Ongoing design iterations on the self-closing baffle will drive product functionality and performance equivalents associated to the flap assembly design while maintaining current costs. This no-cost added value to the customer is an attractive solution due to ever-increasing demands for improved safety, enhanced styling and advanced technology. Figure 5 illustrates the relationship between the baffle solutions presented as they 34

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are designed to accommo date the various degrees of complex requirements imposed on them for water and hardware management.

WHAT DOES THE FUTURE HOLD? As the need for enhanced safety features, better styling, and improved technology is placed on OEMs, continual pressure is exerted on the packaging space available for hardware, trim and available space in the auto body structure. Design-flexible materials like baffles and seals are targeted for change. Accommodation for water management is now placed on parts that historically have not been expected to handle them. As resultant flexibility requirements are increased on baffles, the design complexity is increased and the acoustic performance is diminished. The collected data clearly show this relationship between design

(248) 577-0020; or visit www.sikausa.com.

REFERENCES 1. Weber, P. E., Hopton, G. W., “Characterizing the In Vehicle Performance of Expandable Sealants Used As Acoustic Baffles,” SAE Technical Paper 1999-01-1687,1999. 2. Chang, R.J., Dawes, K., Schwartz, L. D., “Expandable Foams with Programmed Expansion as Body Cavity Filler,” SAE Technical Paper 980590, 1998. 3. Visintainer, A. P., Saha, P., “Acoustic Study of Cavity Fillers Vehicle Applications,” SAE Technical Paper 971931, 1997. 4. Chang, R.J., Biche, B., Chiotis, A., “Design and Acoustic Performance of Baffles Based on Programmed Heatactivated Foams,” SAE Technical Paper 1999-01-1673, 1999. 5. Saha, P., Myers, R.D., “Importance of Sealants for Interior Noise Control of Automobiles,” SAE Technical Paper 920412, 1992. 6. SAE International Surface Vehicle Recommended Practice, “Laboratory Measurement of the Acoustical Performance of Body Cavity Filler Materials,” SAE Standard J2846, Issued 2010-05. 7. Saha, P., Jones, D., “Acoustical Drain Plugs in Body Cavity Sealer ‘Baffles,’” SAE Technical Paper 971908, 1997.

February 2012

The Next Phase Joe Mausar retires after 37 years in the industry. By Susan Sutton, Editor-in-Chief, Integrated Media oe Mausar earned a bachelor’s degree in industrial design from the Kansas City Art Institute in 1970, and his first job involved designing graphic signage systems for large architectural complexes. Little did he know that he would actually spend the majority of his career working with tapes, labels and glues. Mausar will retire this year after 37 years in the adhesives industry. I recently had the opportunity to speak with him about his career, the changes he’s seen over the years and his plans for the future.

J

I transferred to Fasson’s Painesville, Ohio, headquarters and from 1977-1987, I was involved in a number of market areas. During the period I was with Fasson, I also earned my MBA from Baldwin-Wallace College in Cleveland. I joined Chemsultants in 1999 as Marketing manager. I was responsible for identifying new business opportunities, both for markets they were already involved in (like pressuresensitive tapes, labels, base materials) and looking at other markets where there might be business opportunities. Like everyone else in the world, we were interested in medical and electronics.

HOW DID YOU GET INTO THE ADHESIVES INDUSTRY? In 1974, I joined the Fasson division of Avery International (now Avery Dennison) in Chicago. I joined them as a national accounts manager. In that position, I was responsible (along with five other guys) for developing new business opportunities for pressure-sensitive materials. Our main focus was transitioning existing label applications that were either glue-applied labels or direct product decoration technologies over to PSA labels. February 2012

HOW HAS THE INDUSTRY CHANGED OVER THE YEARS? When I joined Chemsultants, we were heavily involved with the PSA industry—probably 75% of our business back then was directly related to pressure-sensitive adhesives. Most of the work we did was on PSA tapes and labels. Today, only about 25% of our business involves PSAs. Much the same as today, product performance testing was really key back at that time. Our clients were interested in Adhesives & Sealants Industry

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THE NEXT PHASE Mausar, then (inset) and now.

ongoing performance of their existing products, as well as new replacement adhesive technologies. We were doing a lot of comparison work between solventbased emulsion, water-based and hot-melt adhesives, comparing and contrasting performance differences. Even when I joined Chemsultants back in ’99, there was a strong drive to move away from solventbased adhesives. That had been going on since I was with Fasson in the mid-70s. We also did a fair amount of QA/QC testing for clients, both for incoming materials that customers were going to convert into tapes or labels, and also for end-use customers who would actually buy converted pressure-sensitive products. We did a lot of QA/QC testing for both of them, helping them to ensure that what they were getting in the door would satisfy the end customers’ needs. It’s interesting that, even in ’99 when I started, most of the testing was limited (in the pressure-sensitive industry anyway) as far as who was doing it. There were just a few labs like us. Obviously, the large PSA manufacturers did a lot of testing. But label and tape converters did very little testing back then. We did a lot of testing for them. Interestingly enough, a lot of them today have their own internal testing capabilities. We’ve helped a lot of them set up QC/QA labs; many of them have actually bought testing equipment from our sister division, Cheminstruments, so things have changed over the years. A lot of people were moving away from the solvent adhesives that they were used to and had a history with, to water-based adhesives or hot melts. There was always a caveat from the mid-70s to the mid-90s that you couldn’t make a permanent hotmelt adhesive that would perform as well as a solvent-based adhesive. So there was 36

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some hesitancy. People wanted to get away from solvents and hazardous materials, but they wanted to make sure that the new adhesives would perform for them. And since they didn’t have a way to evaluate that, we were used in a lot of cases to do that for them. Most of the testing we did early on was pretty simple. There are three basic properties of all pressure-sensitive adhesives: peel, tack and shear. Most of the testing we did was pretty limited to peel adhesion tests, tack tests and shear tests. We weren’t doing a lot of application-related testing. Testing was done in lab conditions on stainless steel test panels, and customers were trying to translate that information into whether the adhesive would actually perform on their specific substrate. Today, we do a lot of testing on customerspecific substrates and on other test panel materials. We do elevated- and lowtemperature testing. We’re actually getting into some significant ultra-slow-rate de-bonding tests for clients to see how adhesives are really going to work over time. Testing has really changed. A dozen, 15 years ago, we might take a look at the viscosity of an adhesive. Today, we look at rheological properties. It’s a lot more in depth, more extensive.

HOW HAS GOVERNMENT REGULATION AFFECTED THE INDUSTRY? Everyone’s familiar with the EPA [U.S. Environmental Protection Agency]. We’ve all lived with them for the almost 40 years. Obviously, the EPA and TSCA [Toxic Substances Control Act] in the U.S. have had an impact, and so have the recent REACH [Regulation, Evaluation, Authorization and Restriction of Chemicals] legislation and regulations in Europe. For the last couple of decades, the adhesives industry had to look at meeting regulations almost on an individual state basis with regard to VOCs. We started out with some general EPA regulations and guidance, and by the time we get to TSCA 15 years later, we’re looking at, “What can I produce in this plant in this state, and what can I sell in that state?” It’s gotten a lot more complex. I know that there’s some change in the regulations happening with regard to TSCA, which will hopefully be a little bit clearer and less restrictive. The industry has become global in scope, so even though you might be a U.S. manufacturer of adhesives or sealants, REACH is going to affect you if you want

to send those products into Europe. If you’re a manufacturer in Europe or you have an operation in Europe, REACH is going to affect what solvents and chemicals you bring in. We’ve seen big, big changes over the last 20-30 years due to regulations. G r e e n i s n o t j u s t a c o l o r, a n d sustainability is not just how long an adhesive is going to last. There’s a big movement to look at bio-based adhesives. Everyone knows what the volatility— in prices, in supply—has been with petroleum-based raw materials. Bio-based is going to give us a chance to move away from some of those issues. Moving to lowor no-VOC raw materials will enable us to address biodegradability issues, as well as compostability, pulpability and recycling. Everyone expects that there will be significant costs savings in feed stocks and raw materials as bio-based adhesives really replace, to a large extent, petro-based.

WHAT ADVICE DO YOU HAVE FOR INDUSTRY NEWCOMERS? They’re going to be entering a really dynamic and exciting industry. One of the really big changes is that the industry has truly become global in scope since I’ve become involved. Because change is constant, I’d suggest that they make sure that they keep current on what’s happening in the industry, particularly from a knowledge standpoint. Things change so fast, I think you need to be integrally involved in the industry. You can’t just have a job and work in the adhesives industry. You have to really understand what’s happening.

WHAT ARE YOUR PLANS AFTER RETIREMENT? I’m going to take a very long nap! But seriously, it’s going to be very interesting because I’ve been in this particular industry for 37 years. It’s going to be different not being involved all day, every day. It may be a little tough to completely walk away. I might try to find some way to keep in touch in some kind of capacity. I think I’m going to enjoy having a little bit more time to myself. I’ve been riding a Harley-Davidson motorcycle for the last 10 years, so I hope to be able to take some longer trips on that. I was introduced to fly fishing a number of years ago and never seemed to have enough time to do that. I’m hoping to spend some time standing in a stream somewhere, fishing for trout. Chemsultants’ website is located at www.chemsultants.com.

February 2012

One company’s reputation for product excellence results in regular investments in state-of-the-art inspection equipment. TL, formerly known as Ad Tape & Label Co., was established in 1951 as a small, family-owned printer in Menomonee Falls, WI. Manufacturing its products from tabletop presses, the company was named after its original product line of advertising tape. In 1963, ATL incorporated and was officially recognized as Ad Tape & Label Co., Inc. At that time, ATL focused on the production of labels for industrial and direct mail markets. Following the sale of the company to an employee in 1987, ATL continued to expand its markets and product lines, specializing in producing customized labels for large printers and direct mail companies. Twenty years ago, ATL formed a second division that focused on servicing the medical industry by converting foams and tapes into disposable medical devices. The company developed a relationship with 3M and became one of 14 “3M Medical Preferred Converters” in the U.S. ATL’s ability to achieve and surpass the strict quality standards required by the medical industry led to a natural transition into the pharmaceutical industry in 2001, when the company developed an in-line booklet label from 3-19 pages. Since then, ATL has manufactured more than 120 million pharmaceutical booklet labels in over 80 languages for more than 1,700 clinical trials. In 2003, ATL earned its cGMP (current good manufacturing practice) acceptance as a result of strict compliance to 21 CFR

A

February 2012

(Code of Federal Regulations) Part 820, for the manufacture, packaging and storage of disposable medical devices. In 2007, ATL became a private brand manufacturer of medical devices and began direct shipment from its Wisconsin plant to worldwide stores/distribution centers. ATL also follows cGMP 21 CFR Parts 210 and 211 for the manufacturing, processing and packaging of all pharmaceutical label manufacturing. ATL Security Label Systems™ was established in 2007 to provide an advanced new line of labels, offering security and anti-counterfeiting features such as invisible digital forensic marking, track and trace, mass serialization, custom codes, 2-D barcodes, color shifting authentication, covert “machine readable” markers, and anti-microbial labels and packaging. The nature of the customers served by ATL means that the quality of the company’s output is of paramount importance. In addition to strict adherence to approved organizational and procedural regulations, ATL’s products undergo rigorous quality checks at each stage of design and production. To help maintain the company’s reputation for product excellence, regular investments are made in state-of-the-art inspection equipment. This commitment to upholding the company’s high quality standards can be illustrated by the recent purchase of an advanced Kestrel 200 optical measuring microscope from Vision Engineering. Adhesives & Sealants Industry

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A VISION OF QUALITY A NECESSARY UPGRADE “Although we were previously able to adequately measure die cuts and spacing, along with the location of prints with our existing technology, we felt that this was an area for potential upgrading,” explains Greg Gilanyi, ATL’s quality manager. “Having researched the alternative optical measuring microscopes and viewing demonstrations of the most applicable units, we chose Vision Engineering’s Kestrel 200. Our new Vision Engineering microscope delivers fast and accurate two-axis measurements aiding our precision and speed of operation. The very sharp, high-contrast images also provided by the Kestrel’s advanced optics enable our staff to examine work in greater detail. The superior optical image of the unit even allows difficult-to-view features to be measured on low-contrast items, such as black or transparent labels.” According to Donald Dobert, president of ATL, “We were looking for a unit that would allow us to expand our FDA cGMP compliance. The Kestrel allows us to measure critical die cuts down to .0001 in. We constantly perform IQ-OQ-PQ (installa-

tion/operational/performance qualifications) in our Systems Validation Protocol, and the Kestrel unit provides us with accurate and precise measurement. From this we can determine process Cpk and quantify to our customers our quality in terms of defects per million. “We perform instrument Repeatability and Reproducibility studies so we can prove that measurement error does not induce false readings into our validations or Cpk (capability) data. I can tell you from my background of more than 30 years in quality that the Kestrel unit is one of the best devices I’ve ever used.”

SIMPLIFYING PRODUCTION With data processing performed by a QC-200 multi-function microprocessor, the Kestrel 200 was designed to be simple and easy to use, making it ideal for offline quality control routines performed by production staff. Perfect for measuring 2-D features of small, intricate parts, with a high-precision measuring stage of 6 x 4 in., the Kestrel 200 is the smallest member of Vision Engineering’s optical measurement range.

Kestrel uses Vision Engineering’s patented Dynascope™ technology to provide enhanced surface definition for fast and simple measurement. Outstanding optical clarity also allows detailed visual inspection to be performed simultaneously. Unlike video systems that digitize captured optical information, Kestrel employs a pure optical image, meaning that there is no image processing before the measurement. The result is that component parts can be measured with confidence. The Kestrel’s surface and sub-stage illumination options enable adjustment of lighting to suit any application. Semicoaxial spot lamps (power x2) provide surface illumination, with the option for an LED ring light or an episcopic (through the lens) illumination for viewing blind bores or deep surface features. With x20 magnification fitted as standard, further quick-change magnification options of x10, x20 and x50 are available. For more information, contact Vision Engineering at 570 Danbury Rd., New Milford, CT 06776; phone (860) 3553776; or visit www.visioneng.us. ATL’s website is located at www.atlco.com.

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February 2012 1/3/12 11:33 AM

New trends in learning reflect a changing workforce. By Laurie Keyser Brunner, Senior Vice President of Global Client Services, ESI International

ith sluggish growth, reduced resources and tightening budgets as the order of the day, the economy continues to create uncertainty in commercial and government organizations. Even as we await more favorable market conditions, one thing is clear: The makeup of today’s workforce is forever changed. Human resource (HR) professionals must operate with a leaner workforce in which employees, regardless of level, have the capability to lead and execute work in cross-functional teams. People are now the primary investment within organizations. As such, professional development initiatives must keep pace. Learning programs need to be more agile, adaptive and occur as quickly as possible to maximize the productivity of employees and adjust to a tech-savvy, global workforce with different learning styles.

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HR’S NEW ROLE With blended learning, human resource practitioners now have a range of delivery modalities to meet various learning styles within an organization. But that is not enough. HR needs to match learning modalities (e.g., instructor-led, February 2012

e-training, virtual, peer-to-peer, mentoring, social media) to desired business outcomes and the skills and behaviors needed on the job across a diverse workforce demographic. In this sense, HR is now a true “broker of capability.” The ESI 2011 Learning Trends Report, a global learning survey directed at a cross-section of commercial and government leaders, confirms that best-in-class organizations need learning methods that: • Align to an individual’s “moment of need.” • Develop leadership and other “soft” skills, such as critical thinking and business acumen. • Translate into tangible and measurable business impact.

BLENDED LEARNING Blended learning contrasts with more traditional commodity training that is focused on obtaining credentials. Although credential training is a good starting point, it focuses exclusively on learning content to achieve a certification, rather than on-the-job application. Just-in-time tools, learning-on-demand and self-paced online learning are just a few methods that organizations are using to ensure learning events are immediately relAdhesives & Sealants Industry

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PROFESSIONAL LEARNING SOLUTIONS evant—with the added bonus of cost savings and flexibility by reducing travel and keeping people on the job. The difficulty, however, lies in the fact that more training choices do not necessarily translate into better results. A blended training approach needs to provide the right information at the point of need to enable an employee to perform effectively. For example, learners who simply need more information on a topic or are seeking to recall information may require a different learning experience than those seeking to apply content to specific on-the-job challenges or organizational changes. The blending of learning solutions is not simply offering a choice of modalities; it must also take into account content, learning styles, teaching techniques, and learning environments and align to specific learning objectives. A multi-touch, blended learning program therefore must: • Support the learner’s ability to recall and repeatedly apply content in their work environment. • Follow and complement the individual’s workflow. • Reflect and be tailored to support organizational methodologies, culture and technical readiness in order to ensure an engaged and productive workforce.

als. Leadership training can move the entire organization forward by: • Equipping the workforce with skills in critical thinking and business acumen to identify organizational priorities and design the appropriate responses within a business context. • Supporting a culture of individual accountability to speed decision making, ensure successful project outcomes and, ultimately, ensure organizational effectiveness. • Rapidly developing the capabilities of less tenured employees to manage and lead successfully to ensure continuity and productivity. • Achieving a new level of team dynamics to create more integration and cohesion on projects and programs, resulting in greater workforce productivity.

Organizations report an increasing need to develop leadership capabilities in their employees and cite a growing priority to improve skills. TRAINING’S VALUE

LEADERSHIP SKILLS DEVELOPMENT An aging and changing workforce means that organizations must plan for a wave of retiring employees while building new talent. To meet this challenge, organizations report an increasing need to develop leadership capabilities in their employees and cite a growing priority to improve skills in stakeholder management, interactive communication, and effectiveness in a cross-functional team environment. Specifically, the ESI Learning Trends Report shows that 53% of organizations indicate that fostering and encouraging leadership skills in employees is an important area of training investment, coupled with a strong requirement to allocate funds and build business skills/ acumen (40%) for technical profession40

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With training and development budgets under strain and scrutiny, HR recognizes the need to move beyond “smile sheets” to post-assessments that track learning transfer and business impact. Learning can and should be a critical business process, enhancing not only individual or team performance, but also having a significant impact on the strategic and financial goals of an organization. If you can measure the business impact of learning, then you are better able to determine how effectively your organization achieves true learning transfer. The first step is to define the key business impact areas for measurement. Some of these might include increasing quality, increasing productivity, increasing employee engagement, decreasing costs, increasing revenue, increasing

customer satisfaction, decreasing cycle time, decreasing risk and increasing effective communication. Then, set expectations with a measurement strategy. This would include course evaluations completed immediately after training by both the trainee and manager. Another round of measurement 90 days and even six months after the training would help to substantiate behavior change and, ultimately, the business impact of the learning investment. Quantification is the last—but most critical—step in validating the business case for learning. Producing quantitative and qualitative reports and other highlevel output can help prioritize training investments based on real, tangible data showing job impact. Measuring, of course, assumes that training translates into an actual transfer of learning in the classroom to changed on-the-job performance. For this to happen, organizations must develop a supportive and complementary workplace environment in which management, business processes, and supporting tools all permit the learner to apply new knowledge and skills immediately upon return to work. Organizations often fail to establish success criteria or identify expectations for learning engagements. This is a key pre-training strategy in order to measure trainee performance against agreed-upon standards.

ACHIEVING RESULTS Learning transfer also happens more effectively with an incentive program to motivate employees, full manager support along with executive sponsorship, and a systematic process to prepare individuals to apply what they have learned. In order to maintain a competitive edge, bestin-class organizations are adopting new approaches to learning, and HR is becoming a “broker” of these blended learning capabilities. In this way, HR adds real value, turning an organization’s workforce into a tangible return on investment by achieving higher quality output, even with fewer resources and lowered budgets. For more information, visit www.esi-intl.com.

February 2012

WHAT’S NEW RAW MATERIALS EMERALD POLYMER ADDITIVES ANTIOXIDANT

This company, a division of Emerald Performance Materials, has added GOODRITE® 3131 to its portfolio of antioxidants for lubricants. The low-DPA-containing liquid antioxidant reportedly decreases extractables and volatility, thereby improving antioxidant efficiency, scorch, and long-term stability, and reducing discoloration in applications. Based on an octyl butylated diphenylamine chemistry, GOOD-RITE 3131 is formulated to prevent discoloration/scorch by providing thermo-oxidative stabilization of polyols, elastomers and adhesives. The liquid can reportedly offer high activity at low use levels (less than 0.5%), allowing it to be used in automotive, aviation and industrial applications specifically related to the use of flexible polyurethane foams, hot-melt adhesives, and high-performance gear oils. Phone: (888) 889-9150 Web: www.emeraldmaterials.com

HENKEL CERAMIC COATING

A new two-part, sprayable ceramic coating designed to protect metal surfaces on industrial equipment from wear, abrasion and corrosion is now available. Packaged in a reusable dualcartridge dispenser, Loctite® Nordbak® 7255™ sprayable ceramic coating can be sprayed onto metal components to create smooth, low-friction surfaces that improve equipment efficiency. The coating can reportedly be quickly and evenly applied to large surfaces and complex or intricate areas that are difficult to coat. It can be used on tank linings, mixing vessels, pump housings, impellers, chutes, troughs and centrifuge components. The solvent-free, thixotropic formulation can be used in overhead applications, and reportedly adheres well to a range of metal surfaces. Web: www.henkelna.com/nordbak

medical, sporting goods, automotive, truck, and bus component dispensing applications. The valves are based on the company’s MicroKiss No-Drip® valve body design for low-flow fluid control using bayonet-style static mixers. The No-Drip design feature integrates carbide ball-end needles with carbide seats for long life dispensing of viscous and abrasive materials. Web: www.sealantequipment.com

TROY CORP. ADHESION PROMOTER

SIKA CORP.

Troysol™ PWA is a new wetting and adhesion promoter intended for dry-mix products. The material reportedly improves adhesion to substrates and enhances pull-off strength. Useful for cement-based adhesives, EIFS adhesives, mortar, gypsum board, tile adhesives, and other dry-mix products, the material can fill the need for a high-performance additive designed for building products. Web: www.troycorp.com

STRUCTURAL ADHESIVES

FORMULATED ADHESIVES CLEAN SEAL INC. EMI/RFI SEALS

EMI/RFI seals are available from this company for use in the electric vehicle and telecommunications industries. Fabric fits over the extruded and foam extruded seals to protect from disrupting radio frequencies and other electronic devices. The seals can also help shield from undesired energy radiating from the product. The fabric can be applied to almost any of the standard profiles, or a custom die can be made to customers’ specifications, according to Bill Dawson, vice president and general manager. Web: www.cleanseal.com February 2012

This company recently introduced its Body in White (BIW) SikaPower® product portfolio of structural adhesives for use in car and light truck body assembly. The products were developed to provide solutions to OEMs based on design challenges created by the stringent and increasing regulatory demands for safer, lighter and stronger vehicles; improved fuel efficiency; and reduced CO2 emission. The new products are advanced one-component, solvent- and PVC-free, warmapplied, heat-curing adhesive technologies that reportedly enhance crash-resistant structures, and bond to dissimilar and diverse materials. Web: www.sika-automotive.com

EQUIPMENT

NORDSON CORP. SPRAY GUN

The new Quattro automatic spray gun reportedly incorporates fast cycling, fine atomization,

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

Showcase METTLER TOLEDO offers many analytical solutions in the quality control of polyols and isocyanates, such as molecular weight, total acidity, specific gravity and water content.

SEALANT EQUIPMENT & ENGINEERING INC. MIX-DISPENSE VALVES

This company’s new 2600-093 Micro-Kiss™ series mix-dispense valves are designed for the low-flow mixing and dispensing of two-component adhesives and sealants such as silicones, epoxies, urethanes, and acrylics. The valves can be used to apply twopart adhesives and sealants for bonding, gasketing, potting and filling processes in aerospace, appliance, contractor, defense, electronics, filters, marine,

Contact: George McLean Marketing Manager-Lab Analytical Phone: 614-438-4853 E-mail: [email protected] www.mt.com/titration-excellence

Adhesives & Sealants Industry

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WHAT’S NEW and easy maintenance for higher productivity and improved finish quality in airless painting applications. The stainless steel gun can be used for general finishing in either non-circulating or circulating heated airless applications. The unit features a four-in-one valve design to enhance automatic color changing without having to reposition the spray gun. Up to four different colors can be used in the gun, or three colors and a flushing solvent. The guns can produce fine atomization and a soft, controllable spray with minimal overspray. Web: www.nordson.com

evaluate multiple products side-by-side with the product comparison feature, and can request a quote for quick and convenient product pricing. In addition, The Glue Doctor University offers access to all of the company’s Glue Doctor resources, including videos, white papers, podcasts and application guides. Web: www.EllsworthIberica.es

EVONIK TVM BUILDING PRODUCTS

POCKET GUIDE

NOZZLE TOP

The Pocket Tego Guide is a 144-page guide detailing the company’s line of additives, resins and cobinders. The guide includes information on topics such as formulas, measurements and standards, raw materials, color, and typical coating defects. Web: www.tego.us

This company’s new 360o turn-able silicone nozzle, Twisted Top, is now available for distribution within Canada, the U.S. and Mexico. The product, which was developed with the professional contractor and DIY consumer in mind, addresses the countless hard-to-reach areas that are often limited by a straight silicone top. It was designed to replace all removable sealant nozzles for caulks, silicones and adhesives. The all-in-one product can perform all the functions of a straight nozzle while also providing access to typically unreachable areas. Web: www.tvmi.com

CHARLES ROSS & SON CO. DUAL-SHAFT MIXERS

Dual-shaft mixers are available from this company to process pastes, gels, suspensions, slurries and other viscous formulations. Composed of two independently driven agitators working in tandem, this system is designed for heavyduty mixing with the capability of fine-tuning shear levels and flow patterns. The high-speed disperser draws powders into the liquid batch through a powerful vortex and can rapidly disperse any lumps and agglomerates. The lowspeed anchor agitator can promote bulk flow and uniform batch temperature, feeding the disperser blade with fresh product while constantly scraping the vessel surfaces. The following features are available on the fabricated vessels and reactors: • Offered in many sizes, from 1-4,000 gal capacity • Vacuum or pressure capability • Interchangeable mix vessels • Sanitary designs include special seals, polished wetted parts and sanitary connections • Heating/cooling jacket • Temperature probes, pressure transducers and other batch sensors • Discharge system • Temperature control unit, vacuum pump and other auxiliary equipment A range of control options can be supplied, from simple variable frequency drives to fully integrated PLC recipe systems. Phone: (800) 243-7677 Web: www.mixers.com 42

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RESOURCES BROOKFIELD ENGINEERING LABORATORIES INC. TEXTURE ANALYSIS WEBSITE

A new website from this company focuses on the science of texture analysis. The site reportedly features exclusive, in-depth interviews with experts in the texture analysis industry and a Q&A section with answers to specific customers’ questions. A library of educational articles examines food, packaging and pharmaceuticals, as well as more than two dozen application notes explaining established industry test procedures, methodology, test results, and more. The Resources tab features a texture glossary, a brief answer to the question “Why measure texture?” and useful links to additional texturerelated sites. Web: www.textureanalysis.com

ELLSWORTH ADHESIVES SPANISH LANGUAGE WEBSITE

This company has announced the launch of its new website in Spain, www.EllsworthIberica.es. The site features over 4,000 products from industry-leading manufacturers, including 3M, Lord Corp., Dow Corning and Dymax. Visitors to the site can drill through key product attributes to find the specifications they are seeking, such as brand name, physical and chemical properties, service temperature ranges, and mix ratio. Users can reportedly

IDI COMPOSITES INTERNATIONAL THERMOSETS MICROSITE

This company has posted product information for a new line of structural thermoset compounds on a new “microsite” in the Products section of its website. The new high-performance product line builds on the most popular properties of the company’s standard thermoset products, such as corrosion resistance and durability, and adds mechanical strength and exceptionally light weight. The new product postings provide detailed product information that allows design engineers to evaluate their use for current applications. Web: www.idicomposites.com

SIKA MOBILE APP

A new Sika product finder is now available in the Android Store. This tool can allow users to access the company’s product catalogs worldwide from mobile devices running on Android. Product or Material Safety Data Sheets can be accessed as well. Web: www.sikausa.com

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

February 2012

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February 2012

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ASK

AD INDEX

DR.DAVE

QUESTION: We manufacture high-value agricultural/industrial buildings using pre-cast concrete walls, and need to seal fairly large gaps between the wall sections to achieve rigidity, maximum weatherability, and water resistance. What sort of sealant would you recommend for this application? ANSWER: The usual type of sealant for this application is This type of epoxy a silicone, polyurethane or a silyl-terminated polyether sealant. However, I would also sugis commonly used gest that you consider a flexible two-component epoxy adhesive for sealing or sealant. Concrete does not expand or contract very much with temperature changes, and expansion joints in you do not really need a sealant with high flexibility. concrete floors. The advantage of using an epoxy would be very high adhesion to the concrete (usually exceeding the strength of the concrete), excellent gap filling and abrasion resistance, and outstanding weatherability (although you may see some fading of color due to UV light). This type of epoxy is commonly used for sealing expansion joints in concrete floors. QUESTION: We need to assemble a large quantity of a consumer product and need to bond an aluminum film to 3/8-in.-thick glass. Should we use an epoxy adhesive?

ASK

ANSWER: A two-component epoxy would probably work well for this application but would require equipment for mixing and clamping of the components until the adhesive has fixtured. A single-component, heat-cured epoxy is another alternative, but it would require ovens for curing. This type of application sounds ideal for a UV- or light-cured acrylic adhesive that can be cured by irradiating through the glass. Full bond strength can be achieved in a few seconds. These adhesives are expensive and require lamps for the irradiation, but the increase in productivity is tremendous.

DR.DAVE

Adhesive & Sealant Council, Inc.

www.ascouncil.org/industry/conventions

9

Albion Engineering Co.

www.albioneng.com

28

Applied Test Systems, Inc.

www.atspa.com

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Charles Ross & Son Co.

www.mixers.com

3

Conn & Co.

www.connblade.com

Evonik Industries

www.evonik.com

Kitpackers

www.kitpackers.com

NuSil

www.nusil.com

IFC

Sika Corp.

www.sika.com

BC

The Adhesion Society

www.adhesionsociety.org

IBC

14

5

11

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

Spend less time searching for information and more time using it www.adhesivesmag.com/materialshandbook

Raw Materials, Chemicals & Additives Handbook • Search by product category or company name • Downloadable product spec sheets • Alpha company listings • Live web & email links

Do You Have a Question for Dr. Dave?

Visit www.adhesivesmag.com and click on Ask Dr. Dave in the left-hand column. Dr. Dave Dunn is a former vice president and director of Loctite Corp. and has spent many years troubleshooting adhesive and sealant problems in the adhesives, sealants, specialty rubbers, and plastics fields. Questions for publication

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CONNECT

should be directed to him at 242 Trails End, Aurora, OH 44202; (330) 562-2930; FAX (330) 247-1690; email [email protected]; or visit www.fldenterprises.com.

Start your search today!

Any views or opinions expressed in this column are those of the author and do not represent those of Adhesives & Sealants Industry, its staff, Editorial Advisory Board or BNP Media.

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February 2012 DirectoriesA_QtrpgAd_2012.indd 1

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ADHESION SOCIETY 35th Annual Meeting and Exhibition Astor Crowne Plaza New Orleans, LA

February 26-29, 2012 Technical Meeting - The Annual Technical Meeting begins on Sunday, February 26. Over 150 technical presentations. Topics include: Structural Adhesives, Soft Adhesives, Particle Adhesion, Contact Mechanics, Mechanics of Failure, Bio-inspired and Green Adhesives, Single Molecule Adhesion, and many more. Short Course - The Adhesion Society Short Course, “Adhesion Science and Technology”, is on February 24 and 25. Each subject is taught by a world leader in his field. Exhibition - Show your products and services to 250+ adhesion scientists and engineers. All breaks, receptions and the Poster Session are held in the Exhibition Hall to provide interaction among the attendees and exhibitors.

The Adhesion Society, Inc. 2 Davidson Hall - 0201 Blacksburg, VA 24061 http://www.adhesionsociety.org phone: 540-231-7257, email: [email protected]

Sika - Your Global Partner Sika is a global specialty chemicals company supplying the building and construction industry as well as manufacturing industries; automotive, bus, truck, rail, marine, aftermarket, alternative energies and building components. Sika is a leader in processing materials used in our core competencies of sealing, bonding, damping, reinforcing and protecting load bearing structures. Our product lines feature high-quality concrete admixtures, specialty mortars, sealants and adhesives, silicones, damping and reinforcing materials, structural strengthening systems, industrial flooring, roofing and waterproofing systems. A worldwide presence in 77 countries and over 14,000 employees links customers directly to Sika and guarantees the success of your programs. Global reach with local presence provides a winning formula for your toughest engineered applications. Visit us today at sika.com, or sikausa.com for more information, or call (248) 577-1028 for direct contact.