release agents and processing aids for rubber molding

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Release Agents and Processing Aids for Rubber MoldingChem-Trend Technology

Rubber in Automotive Conference- Troy, MIJune 13, 2017

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Chem-TrendRelease Agents for a Wide Variety of Global Customers

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Freudenberg Chemical Specialties

Business Units• High degree of specialization and strong brands• Focus on innovation • Global reach with simultaneous local support

capabilities

• Focus on distribution

• Standardized products

• Global indirect sales

• Maintenance/repair

• Focus on operators

• Industry application specific

• Global direct sales

• Consumables

• Focus on operators

• System dependent


• Process components

• Focus on OEM

• Customer specific


• Components High-PerformanceLubricants

Special Release Agents

Specialty Lubricants

Surface and Electro-Plating Technologies

Confectionary Coatings

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Main Products:• Semi-Permanent

Release Agents• Mold Cleaners and

Sealers

Key Applications:• Advanced Composites• Fiber-Reinforced

Plastics

Composites

Main Products:• Purge Compounds• Mold Maintenance

Products

Key Applications:• Injection Molding• Extrusion• Rotational Molding

Main Products:• Release Agents• Plate/Platen/Screen

Sealers and Primers

Key Applications:• OSB• MDF• Particle Board

Main Products:• Tire Paints• Bladder Coatings• Mold Treatments

Key Applications:• Pneumatic Tire

Manufacturing and Retreading

Main Products:• Semi-Permanent

Release Agents

Key Applications:• General Rubber• Rubber to Metal

Bonding• Belts and Hoses

Main Products:• Mold Release Agents• Mold Cleaners and

Sealers

Key Applications:• HR Foam• Footwear• Integral Skin

Main Products:• Die Lubricants• Plunger Lubricants

Key Applications:• High Pressure Die

Casting• Squeeze Casting

Polyurethane RubberDie Cast

Industry Segments

Tire Wood CompositeThermoplastics

5

Global Footprint

Manufacturing facilitiesOffices Distributors

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Manufacturing Near Our Customers

Valinhos, Brazil

Howell, USA (MP) Norderstedt, Germany

Qingpu, China

Anseong, S. Korea

Howell, USA (GR) Mysore, India

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The Rubber IndustryA wide variety of parts and customer needs

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Rubber Parts We’re Talking About Today

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Chem-Trend ReleaseTechnology Platforms

Multiple products and technologies to meet ALL rubber molding requirements

Semi-permanent Technology

Si-free Technology

Water-based Products

Mold Primers

Conventional Technology

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Rubber Release AgentsHow do they work?

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What is Rubber Mold Release Agent?

A coating applied to a mold surface that:1. Acts as a barrier between the mold and molded part2. Imparts a film that allows the molded part to be removed easily from the mold

BarrierProtects the mold –

Chemical

SlipHelps the part slide out –

Mechanical

Release Agent

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Release Agent Technologies

Type Advantages Disadvantages

Permanent Technology

No transfer to partLong lastingNo release agents in plant

Very expensive processMolds need to be sent awayCoating easily damagedFixed “release-ease”

Semi-permanent Technology

Very low transfer to partRenewable in-situVariable release propertiesMolds stay very cleanInfrequent applicationMolds clean very easily

Need good spray equipmentNeed discipline in application

Conventional or Sacrificial Technology

Low material costEasy to applyHigh lubricity

Always transfer to partLabor intensiveNeed dilution equipmentHigh mold fouling

Internal release agents Part of the compound

Can affect physical propertiesCan affect bonding capabilityOften needs external RA help

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Semi-Permanent Mono-Coat® Release TechnologyHow does it work and key development factors

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Chemistry – Mono-Coat®

MONO-COAT® Release Agent

Mold Substrate

FGFGFG FG

Active Functional Groups – This is what bonds together to create semi-permanence

Additional slip component is added when more lubricity is need for complex geometries

FG FG FG FG

MONO-COAT® Release Agent

Mold Substrate

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Development factors – details to consider

• Geometry

• Mold substrate (steel, chromed, etc.)

• The rubber compound– Elastomer type– Compound hardness– Compound cure system– Compound fillers– Rubber to metal bonding

• Application equipment

• Post molding considerations

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Mono-Coat® Release TechnologyThe development of two new products

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Development of a Mono-Coat®

• Rubber to metal bonding application

• Customer wanted more durability low/no transfer, easier release to prevent defects, less mold fouling

• Customer items submitted for development:– Two natural rubber stocks for product development

• Compound A: 40 durometer• Compound B: 70-80 durometer

– Primer and adhesive– Current release agent as a control

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Mono-Coat® vs Control: Durability

Basic Release Screening on Flat Panelsto Baseline Performance

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Control

Mono-Coat® Sample A Mono-Coat® Sample B

NR Compound A –40 Durometer

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Control

Mono-Coat® Sample A

Mono-Coat® Sample B

NR Compound B –70-80 Durometer

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Control –After 4 releases film

degradation observed

Mono-Coat® Sample B –After 4 releases

no film degradation

NR Compound B 70-80 Durometer


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Mono-Coat® vs Control: Mold Fouling

Test Parameters• Cavity molding

• Metal coated with primer and adhesive

• Prebake coated metal in mold

• Mold part with coated metal

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NR Compound B – 70-80 Durometer

Control –After 5 releases



Adhesive staining and rubber fouling/build-up observed on the mold surface

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Mono-Coat® Sample A –After 5 releases



Light adhesive staining observed on the mold surface, some rubber build-up after 16 releases

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Adhesive staining observed, but little rubber fouling/build-up observed on the mold surface

Staining can be solved with a formulation modification

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Mold Fouling vs DurabilityNR Compound B – 70-80 Durometer

Cavity Molding Test

Easy

Difficult

ControlMono-Coat®

Sample A

Mono-Coat®

Sample B

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Film Formation and WettingControl Mono-Coat® Sample A Mono-Coat® Sample B

Mono-Coat B shows better wetting characteristics which is a variable for better product performance

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Results = Two New Products for the Market

Part geometry and rubber compound factor into product selection

• Sample A = Mono-Coat® 1589W– Good overall performance with regards to release, mold fouling and

staining– Softer polymer film, better for softer rubber compound and parts with

complex geometry that require more slip

• Sample B = Mono-Coat® C1892W– Superior durability and good resistance to mold fouling – Modified to improve staining with final formulation – Maximum durability for NVH applications and natural rubber molding– Provides mold protection for abrasive rubbers– Build-up in mold cavity is extremely low– Mold cleaning interval much higher

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Mono-Coat® Release TechnologyHow to use it to optimize performance

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2.5

3.0

3.5

4.0

4.5

5.0

5.5

0 10 20 30 40 50 60 70 80 90 100

REL

EASE

(5=e

xcel

lent

, 4=g

ood,

3=f

air,

2=po

or, 1

=loc

k)

Part Number

Mono-Coat® C1892WComparison of Touch-up Regimen on Release Ease

EPDM, Sulfur Cured Indicates when the mold was touched up.

Timely touch-up coats = Better release

Touch up before failure or difficult releasemaximizes release ease and durability

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Timely touch-up coats = Lower build-up

0

1

2

3

4

5

6

0 10 20 30 40 50 60 70 80 90 100

Bui

ld-U

p (0

=non

e, 5

=sev

ere)

Part Number

Mono-Coat® C1892WComparison of Touch-up Regimen on Build-up

on EPDM, Sulfur CureIndicates when the mold was touched up.

More frequent touch-ups minimizes mold build-up

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QUESTIONS?

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Other Chem-Trend Innovations

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Rubber Cleaning Compound

Chem-Trend® IPMC-1100co-formulated with FST

Cleans the mold without pulling the tool off-line

Extreme time saver for customers

Dirty Mold Cavities

Dirt and build-up on the used

Chem-Trend ® IPMC-1100

Clean Mold Cavities after Chem-Trend ® IPMC-1100

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Passivating, Si-Free Mono-Coat®

Mono-Coat® A1475WMono-Coat® A1555WMono-Coat® A1478WMono-Coat® A1509WMono-Coat® 1625WMono-Coat® A1469W

Less Slip/More Durability

More Slip/More Lubricity

Passivating chemistry offers semi-permanence but through a different mechanism

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How Passivating Semi-Permanents Work

Mold releases that passivate the mold surface

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“Semi” Semi-Permanence

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release agents and processing aids for rubber molding

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