The composite industry is highly competitive and wrestles with a number of variables in production. Examples are long exotherms and surface roll-out times. In post - production part fabrication, machinability issues can occur with cracking from brittle parts along with constant blade wear. Polymeric microspheres address these issues along with reducing part weight and costs.
In 1994, Fischer Industrial Coatings of Westchester, Ohio, developed a unique water-based polyurethane dispersion (PUD) to dip coat baseball bats in production at Hillerich & Bradsby (HB) in Louisville, Kentucky, for Hall of Famer Ken Griffey of the Seattle Mariners. Griffey cited* "his new bat as a crucial contributor to his success in April, May and, June of 1994, including 32 home runs, 64 RBIs, and a .318 batting average". The PUD coating applied during the manufacturing process at HB utilized a 37% solids aliphatic PUD resin featuring low VOC 182 grams per liter, rapid cure, high film build and great depth of image. In addition, the bat coating exhibited extraordinary adhesion, along with resistance to abrasion, water, perspiration, and impact, proving its ability to stand up to major league punishment.
Most people are aware that polymeric microspheres can dramatically reduce the cost and weight of their formulas/products. In addition to cost and weight improvements (Image 1), there are several other benefits you can obtain when using polymeric microspheres.
Are very low Volatile Organic Compound (VOC) projects challenging your need for the correct cost performance balance? Do you want to build coating durability with polyurethane resins? Fortunately, high molecular weight waterborne polyurethane dispersions can build durable coatings and can meet your low VOC needs as well as your budgetary demands.
There are several types of low-density hollow microspheres to consider when choosing a microsphere for your application. Thermoplastic, glass, ceramic and phenolic beads represent the main family of microspheres from which to choose.
The challenge is determining which type will be the best choice for your application. This will depend on your process and the goal of your product characteristics.
For the following comparison, we are going to focus on Dualite thermoplastic microspheres vs. hollow glass microspheres:
Do you formulate coatings or adhesives for industrial or consumer products that require high durability and low Volatile Organic Compounds (VOC)? Are regulations increasing costs and delaying your process? Increasingly stringent low VOC regulations and a friendly Safety Data Sheet (SDS) make the correct decision concerning a resin essential.
Fortunately, water base polyurethane dispersions (PUDS) contain low or zero VOC, offering a wide range of properties that can be formulated to a product meeting performance and VOC requirements plus an attractive SDS. PUDS come with the challenge of customizing a coating or adhesive for low VOC end use applications however formulators can employ several additives supplied by Chemical industry partners to assist during product development phase.
We are all used to buying things such as gas and milk by the gallon. Have you ever wondered what the costs for these products would be if you paid by the pound? For milk at $2.00 per gallon, you’d pay around $18.00 per pound. Gas at $3.00 per gallon would cost around $21.00 per pound. Such high prices might have you rethinking your dairy consumption. They’d definitely push you toward purchasing one of those all-electric cars.
The market for adhesives is very competitive. It is difficult to reduce the density/cost of your adhesive without affecting the adhesives quality and performance. Using glass microspheres is an option, but low-density glass microspheres are not sprayable and can break during mixing, resulting in increased density and cost. Other rigid lightweight fillers can have a negative effect on your adhesive’s physical properties.
Dualite Microspheres have an organic thermoplastic shell which encapsulates a low boiling point hydrocarbon. The Dualite Microspheres are available in both expanded and unexpanded grades.
There are several reasons why you should consider the Dualite Microspheres in your current or future adhesive application.