UV Cured Silicone Elastomers:
A New Approach To Silicone Rubber Fabrication
Mel Toub
Presented To:
Medical Silicone Conference
Framingham, Massachusetts
October 5, 2011
The New Momentive
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Momentive Business Overview
Momentive Specialty Chemicals Inc.
(MSC)
Epoxy, Phenolic & Coating Resins
•! Adhesive & Structural Applications
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Epoxy Resins and Intermediates
Phenolic Encapsulated Substrates
Composite Resins
Phenolic Specialty Resins
•! Coating Applications
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Epoxy Coating Resins
Versatic Acids & Derivatives
Polyester Resin
Alkyd Resins
Acrylic Resins
Momentive Performance Materials Inc.
(MPM)
Forest Products
•! Adhesive & Structural Application
Products
–! Forest Product Resins
–! Formaldehyde & Derivatives
–! Specialty Waxes & Emulsions
–! Adhesives
Silicones & Quartz
•! Silicones
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Elastomers
Engineered Materials
Specialty Fluids
Silanes
Urethane Additives
•! Sealants
–! Silicone and Acrylic Sealants
•! Quartz & Ceramics
–! High-Purity Fused Quartz
–! Ceramic Materials
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Combined Technology Platform
Brings Growth Opportunities
Momentive Specialty Chemicals (MSC)
Fluids
Silanes
Elastomers
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Graphic Arts
Repair/Remodel
Electronics/Electrical
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Oil Field E&P
Construction
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Architectural
Wind Energy
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Healthcare/Personal Care
Furniture
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Quartz
UPR
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Sealants
Polyester
Resins
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Urethane
Additives
Acrylic
Monomers
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Engineered
Materials
Formaldehyde
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New Home Construction
Automotive
Vinyl & Acrylic
Lattices
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Amino Resins
Consumer/Durable Goods
Phenolics
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Versatics
Epoxy
Industrial/Marine
Momentive Performance Materials (MPM)
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Silicone Rubber Extrusion Using UV Cure
•! Silicone Elastomers In Healthcare
•! Silicone Rubber Tubing
•! Conventional Thermal Cure for Silicone Elastomers
•! UV Cure Technology
•! Pilot Scale Extrusion Trial
•! Wound Drain Extrusion Trial At Specialty Silicones Fabricators (SSF)
•! Peristaltic Pump Tubing Trial At Medical Elastomer Development, Inc.
(Med-Inc)
•! Pigmentable Silicone For UV Cure
•! Summary
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Silicone elastomers are particularly suitable for (Bio-) Pharmaceutical/
Healthcare applications
Main Features
SiO backbone
Inert material & surface
Durability, Compression set
Benefits
•! High thermal stability
•! Sterilizable with steam, ethylene oxide and
gamma radiation and cleanability
•! Highly transparent vulcanizates
•! USP Class VI and ISO 10993 compliance
possible
•! Compatibility with drugs and bodily fluids
possible
•! Neutral odor and taste
•! Resiliency, high recovery after flexing
•! Long service life under dynamic stress
•! Reduced material fatigue
Low modulus, Durometer
•! Minimal insertion force, smooth operation
•! Ergonomics and comfort
•! No plasticizers
Ease of fabrication
•! Design versatility and low tolerances
•! Excellent processability
•! Easily pigmented
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Market Segmentation
•!IV & Infusion Therapy: Needleless IV, Delivery Tubing
•!Urological: Incontinence Devices, Catheters
•!Wound Drains: Bulbs, Drain, Catheters
•!Gastroenterolgy / Nutrition Systems: Tubing, Feeding Devices, Balloons
•!Dialysis: Bag caps, Seals, O-rings, Catheters, Tubing
•!Drug Delivery: Tubing, Needleless Valves
•!Pharmaceutical: Tubing
•!Dental: Instruments, Sterilization Mats
•!Respiratory / Anesthesia: Masks, Tubing, Seals, O-rings, Valves
•!Surgical: Instruments, Sterilization Mats
•!Orthopedics / Prosthetics: Kneepads, Distal Pads, Prosthetic Sleeves
•!Diagnostics / Imaging: Seals, O-rings, Valves, Keypads
•!Ophthalmic: Contact Lenses, Nose Pads
•!Laboratory Products: Septa
•!In Vitro Diagnostics: Closures, Covers
•!Wound Care: Scar Therapy Pads
•!Hearing Devices: Ear Pads, Ear Plugs
•!Neonatal Devices: Baby Bottle Nipples, Pacifiers
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Features and Benefits Of Silicone Tubing
Feature
Benefit!
Flexibility
Easy installation and routing
Translucency
Visual confirmation of flow
High Temperature Resistance
Autoclavable with long service life
High Resilience and Elastic Memory
Delivery accuracy and pump life
Biocompatibility
Nonallergenic, nonthrombogenic
Chemical Resistance
Compatible With CIP (Clean In Place)
Processability
Conducive to clean-room manufacturing
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Peroxide Cure Chemistry
(Free Radical Mechanism)
CH3
CH3
~O1/2 - Si - O - Si - CH = CH2 +
CH3
ROOR ---> 2RO*
RO*
CH3
CH3
~O1/2 - Si - O - Si - C*H -CH2OR
CH3
CH3
CH3
+ CH3- Si - O - Si - O -~
CH3
CH3
CH3
CH3
~~O1/2 - Si - O - Si - CH2 - CH2 - CH2 - Si - O - Si - O -~~
CH3
CH3
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Addition Cure Mechanism…Platinum Cure
Polysiloxane
Crosslinker
Crosslinked Polysiloxane
Pt Catalyst
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Advantages of Platinum Cure Over Peroxide Cure
•!Tight Surface Cure, Low Surface Tack
•!Lower Coefficient Of Friction
•!Fast cure Rate
•!No catalyst decomposition by-products
•!Non-blooming extrusion
•!Does not require postbake
•!Many grades compliant with USP class VI, ISO, FDA
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Curing Methods For Extrusion
•!
Hot Air Vulcanization (HAV)
–! Horizontal Tunnel, 25 – 30 Feet Long
•! High Temp Shock Box for quick surface cure
•! Convection or radiant heat, 600F – 1200F
•! Moving conveyor belt to support extrudate
•! Fresh air circulation to promote heat transfer
–! Vertical Tunnel, 3 – 10 feet long
•! Occupies smaller footprint than horizontal HAV
•! Conveyor unnecessary…No marking on extrudate
•! Forced air circulation unnecessary due to natural convection
•! Stretching a potential issue with thickwall profiles
–! Must use DCBP-50 or platinum cure to achieve rapid cure and avoid
porosity
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Conventional Thermal Cure…Vertical HAV
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UV Cure Silicone Elastomers for Extrusion
•! Material composition
–! Silicone base elastomer
•!
–! UV activated catalyst
•!
•! Process - Cure with a UV lamp at low
•!
temperature
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Value Proposition
Fast and on-demand cure
Fast extrusion of high quality thick
wall tubing or profiles
Co-extrusion with low temperature
substrates (elastomers and plastics)
Lower energy consumption
Lower capital investment
"! Less space needed
"! Lower equipment cost
Lower operation cost
Silicone
compound
UV
station
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UV Cure Process Overview
Milling!
Thermal!
•! Pot Life – 1-2 hrs!
Extrusion!
•! Cold Extruder!
Curing!
•! Heat – IR!
•! 800F – 1200F!
UV Cure!
•! Pot Life – 1-2 hrs!
•! Preheat For
Optimized Cure Rate!
•! UV Cure – Variable!
•!600 Watts/Inch Max!
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Basic Formulation For UV Cure Silicone Extrusion
UV HCE Starting Formula:!
Milling Guidelines:!
•! UV Base Rubber – 100 parts!
•! Similar to thermal system!
•! UV Catalyst MB – 0.5 – 1.0 parts!
•! Shield from daylight!
•! UV Stabilizer MB – Optional,
Depends on pot life requirements!
•! Compatible Pigments!
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Momentive UV HCE for Vertical Extrusion
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The Family of Products
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UV “V” Galium Lamp Output
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“D” (Iron) Bulb Spectral Output
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Comparison Of Physical Properties…Thermal Vs. UV Cure
Durometer
Shore A
Tensile
Elongation, %
Strength, psi
Tear B, ppi
50 Durometer
Thermal Cure
52
1566
573
194
50 Durometer
UV Cure
50
1552
562
182
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UV Extruded Tape Trial…50 Durometer
•! Dimensions: 1.27 mm x 19 mm
–!Extrusion conditions and set up
»!UV power: 20% (47 w/cm)
»!Material temperature (extruder barrel temperature) 50C
»!Extrusion speed: 60 ft/mim (18.3 m/min)
–!Mechanical properties
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SSF / Momentive UV Extrusion Trial Setup
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SSF / Momentive UV Extrusion Trial Samples
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Med-Inc. UV Extrusion Trial #1…Pump Tubing
•! Setup Parameters
–!Silicone Compound…Momentive 50 Durometer UV Base
–!Catalyst…UV Photosensitive Platinum Complex
–!Base/Catalyst Mix Ratio…99 / 1
–!Nominal tubing Size…0.200” OD
–!UV Lamp…10” D (Iron) Bulb
–!UV Power Equipment and Fixture…Nordson Coolwave2
–!Power Setting…30% max
–!Barrel Preheat…55°C
•! Results
–!3X+ increase in line speed compared to thermal cure (max extruder
RPM)
–!Excellent dimensional control within tolerance limits
–!High quality product…no porosity, no surface tack, exceptional
elasticity
–!Mixed shelf life > 4 hours
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Figure 4…Med-Inc Extruder With Nordson UV Lamp Fixture
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Med-Inc. UV Extrusion Trial #2…Solid Rod
•! Setup Parameters
–!Silicone Compound…Momentive 50 Durometer UV Base
–!Catalyst…UV Photosensitive Platinum Complex
–!Base/Catalyst Mix Ratio…99 / 1
–!Nominal Rod Diameter…3/4”
–!UV Lamp…10” D (Iron) Bulb
–!UV Power Equipment and Fixture…Nordson Coolwave2
–!Power Setting…30% max
–!Barrel Preheat…55°C
•! Results
–!Achieved 8 feet/minute extrusion rate at max screw speed
–!High quality product…no internal porosity, no surface tack
–!Unifiorm cure from outer skin to inner core
–!No cool down time required
allows immediate packaging
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UV Cured Pump Tubing And Solid Rod
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Can Pigments Be Used With UV Cure?
•! Intensity Dependent…Works best with low level of “Transparent” colors
•! Pigment Dependent…Must be compatible with platinum cured silicones
•! Bright, vivid transparent colors are possible
•! Some opaque colors may work
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Silicone Rubber Extrusion UV Cure Summary
•!Potential Benefits
–!3X increase in productivity
–!Lower energy consumption
–!Reduced footprint for production equipment
–!Improved Quality…Elimination/Reduction of Porosity
–!Compatibility with temperature sensitive products
–!Enables innovative product design
–!Possible translation to calendered and molded goods
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(collectively “SUPPLIERS”), ARE SOLD BY THE RESPECTIVE LEGAL ENTITY OF THE SUPPLIER SUBJECT TO SUPPLIERS’ STANDARD CONDITIONS
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UWM 3 Day Silicone Technology Course…Nov. 30 – Dec. 2
Silicone Elastomers Technology and Fabrication
This course is designed to provide a comprehensive overview of silicone
elastomers, including basic silicone chemistry, types of silicone elastomers,
manufacturing processes, fabrication techniques, problem solving, and
application areas. Emphasis is on liquid injection molding (LIM / LSR) with
detailed information in the areas of material selection, dispensing methods,
injection molding process, tool design, and bonding alternatives. This
course is presented by a panel of experts in the silicones field, and time is
allotted for discussion of specific projects of interest.
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Thank You
Questions?
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