月: 2023年2月

What Is an Epoxy Resin Paint?

An epoxy resin paint is a paint whose main ingredient is epoxy resin.

It is characterized by the reticular cross-linking that occurs when the main ingredient, epoxy resin, reacts with a hardener. Epoxy resin coatings reflect the characteristics of epoxy resins and have excellent water and corrosion resistance.

Uses of Epoxy Resin Paints

Taking advantage of the characteristics of epoxy resin paints, which have high insulating properties and excellent chemical and water resistance, epoxy resin coatings are used as coatings for printed circuit boards, memories, CPUs, and other electronic components of many electronic devices and appliances, as well as for parts that do not conduct electricity.

In addition, its high corrosion resistance makes it suitable as a coating material for paints and can interior walls of automobiles and ships, and as an industrial adhesive. Recently, it is also used as a material for optical modeling, a type of 3D printer.

Principle of Epoxy Resin Paints

Epoxy resin, the main component of epoxy resin paints, is a generic term for compounds with reactive epoxy groups at their ends. Typical examples include bisphenol A and epoxy resins.

By adding a curing agent to this resin, a network of cross-links is formed and cured, resulting in a cured resin with a variety of properties. In general, the properties of epoxy resin paints can be adjusted by changing the type of curing agent, mixing ratio, and curing conditions.

Types of Epoxy Resin Paints

Epoxy resin coatings come in two types: two-component types, in which the base resin and hardener are mixed immediately before use, and one-component types, in which the base resin and hardener are pre-mixed and heated to harden.

1. Two-Component Epoxy Resin Paints

Two-component epoxy resin paints form a strong coating film when cured, and are characterized by their strong waterproofing and dustproofing properties. They also have excellent chemical resistance and abrasion resistance. Therefore, they are suitable for use under severe conditions.

Two-component epoxy resin paints have different applications depending on the type of hardener used in the mixture. The main types are polyamide amine effect type with water and alkali resistance, and modified polyamine type with water, alkali, acid, and solvent resistance.

Two-component modified epoxy resin primers and tar epoxy resin paints using modified epoxy resin are also suitable as rust inhibitors. To improve rust-preventive properties, a mixture of specially modified epoxy resin and aluminum phosphate pigment is also available, sold as an easy-to-handle spray.

2. One-Component Epoxy Resin Paints

One-component epoxy resin paints have excellent corrosion resistance and adhesion. One-component types are often used for repair spraying of wood, iron, steel, and other materials.

Other Information on Epoxy Resin Paints

1. Reaction of Epoxy Resin Paints (Epoxy Resins)

Epoxy resins contain functional groups called epoxy groups, and when mixed with a hardener, a ring-opening polymerization reaction of epoxy groups occurs, forming a three-dimensional cross-linked structure that cures. The high mechanical properties and chemical resistance of epoxy resins are the result of curing.

The curing reaction of epoxy resins and curing agents requires heat, but some resins and curing agents can cure at room temperature, depending on the combination of the resin and curing agent. The curing speed depends on temperature, with higher temperatures resulting in faster curing and lower temperatures resulting in slower curing.

Since the curing reaction is an exothermic reaction, the resin itself tends to become hot when the outside temperature is high, such as in summer, and may solidify in an instant, so care should be taken. Conversely, in winter, the curing reaction may stop at around 40F.

2. Cautions When Using Epoxy Resin Paints

Epoxy resin paints are expected to deteriorate at a rate of about 10㎛ per year outdoors, with the surface deteriorating and turning white due to ultraviolet rays. To ensure long-term performance, protection by coating with polyurethane or fluoro resin is necessary.

What Is an Etching Process?

An etching process is a technology to form various patterns by partially dissolving or cutting a specified portion of a metal sheet, which is the material to be processed, to hollow out the specified portion of the sheet, or to make the sheet thinner to a specified thickness.

Features of Etching Processes

Etching processes can process complex patterns on extremely thin or small metal sheets with high precision. It is widely used in the manufacture of electronic components, such as semiconductors and medical devices.

In addition to stainless steel, copper, and iron, molybdenum, and titanium are among the materials that can be handled in the etching processes.

The advantage of the etching process is that it can be performed quickly and at a low cost, but it also has the disadvantage of not being suitable for mass production.

Uses of Etching Processes

The etching processes can be used to process fine patterns that cannot be handled by press working and to process thin work materials with extremely high precision. For this reason, it is used in the manufacture of integrated circuits that make up the aforementioned electronic components, such as semiconductors and medical devices, as well as in the patterning of heater wires (SUS foil) for thin heaters.

Of course, many etched parts are incorporated into products that combine many components, such as electronic devices and automobiles. It is also suitable for the production of products that require precision, such as general household goods, interior design items, and clothing.

Principle and Process of Etching Processes

Principle of Etching Processes

In the etching processes, a protective film is formed on a metal plate as the work material, onto which the patterned shape to be fabricated is transferred, and the portions of the metal plate without the protective film are dissolved or cut. The metal sheet is then hollowed out or thinned to a specified thickness to create various pattern shapes.

Etching Processes

The actual process includes the following steps:

1. Plate Making Process
Two base plates are created according to the desired pattern shape using CAD. This is to sandwich the material to be processed between the two base plates. At this point, precision is required in the creation of the base plates because any discrepancy in the dimensions of the base plates will greatly affect the quality of the finished product.

2. Laminating Process
This is the process of attaching photoresists to form a protective film on a metal plate, which is the material to be processed. Photoresist is a photosensitive substance that is used in later processes to “transfer the pattern shape to the metal sheet to be processed” and “protect the parts of the metal sheet not to be removed from etching.”

Since the degree of adhesion between the metal plate and photoresist greatly affects the quality after processing, the photoresist is generally applied after degreasing and cleaning the metal plate to be processed.

3. Pattern Shape Transfer Process
A metal plate to which photoresist is applied is sandwiched between base plates and irradiated with UV light. The photoresist on the area not shaded by the base plate is then photosensitized, resulting in the pattern shape of the base plate being transferred to the metal plate to be processed.

4. Etching Processes
First, the photoresist is removed from the area to be removed by etching along the pattern that appears on the surface of the workpiece. Then, an etchant that dissolves metal is sprayed on the area, which dissolves only the area where the photoresist has been removed from the metal plate, leaving only the pattern shape. Finally, the photoresist is removed from the entire material to be processed.

Types of Etching Processes

There are two types of etching processes: wet etching, which uses etchant as described above, and dry etching, which uses reactive ion gas or plasma gas.

1. Wet Etching

Wet etching is a processing method to obtain a pattern shape by reacting to a chemical solution to a workpiece to which the photoresist has been transferred in a predetermined pattern shape as described above. This method is used in semiconductor manufacturing processes, etc. Wet etching with a badge method, in which multiple workpieces are immersed in a chemical solution, is widely used.

It has the advantage of high productivity because multiple workpieces can be processed simultaneously, but it is not suitable for processing ultra-fine pattern shapes because, in principle, it also erodes and dissolves the underside of the photoresist.

2. Dry Etching

Dry etching is a method of obtaining a predetermined pattern shape by cutting the areas without a photoresist by applying reactive ion gas or plasma gas to a workpiece on which the photoresist has been transferred in a predetermined pattern shape. In dry etching, reactive ion gas or plasma gas is applied perpendicularly to the photoresist to cut the workpiece.

In other words, while wet etching is an isotropic etching process, dry etching is an anisotropic etching process. In principle, the gas erodes perpendicularly to the photoresist, so in dry etching, the gas does not reach the underside of the photoresist as in wet etching, making it more suitable for processing ultra-fine pattern shapes than wet etching.

Other Information on Etching Processes

Integrated Circuits and Etching Processes

Etching is often used in the fabrication process of integrated circuits, where three-dimensional structures are deposited in layers. Since the three-dimensional structures that make up integrated circuits have extremely delicate pattern shapes, not only wet etching but also dry etching is used to enable more delicate processing.

It is important to select the appropriate wet etching processes or dry etching processes according to the required productivity and the level of integration (fineness of patterning).

What Is an Energy Monitor?

An energy monitor is a product that visualizes energy status by reflecting it on a monitor screen.

It is often used to refer to devices that measure electricity usage, mainly in homes and buildings. They are widely used from industrial to household products. Typical examples of use include checking the usage status of motors and engines of hybrid cars and displaying the power usage status of facilities with power generation systems such as solar power generation systems.

Applications of Energy Monitors

Energy Monitors can be used to monitor infrastructure energy usage, such as electricity and gas. This makes it possible to monitor usage by time of day and by device, which is useful for energy conservation.

It contributes to lower running costs by limiting the use of equipment with high power consumption and introducing energy-saving equipment. Companies may also reduce CO2 emissions to improve their image. It also has advantages such as early detection of abnormal usage.

Principle of Energy Monitor

Energy monitors, like electricity meters, are often designed based on accuracy class 1 electricity measurement technology. Accuracy class is a standard defined by the International Electrotechnical Commission (IEC) and is divided into five levels, from Class 0.1 to Class 3. Class 0.1 is the most accurate, and Class 3 is the least accurate.

For power-related monitors, power consumption is calculated based on current and voltage measurements. Therefore, it consists of a voltage sensor for measuring AC power supply voltage and a current sensor for measuring AC power supply current. These sensors are attached to the equipment’s mains power cable for measurement. The voltage sensor measures the supply voltage from the charging unit with an alligator clip or similar, while the current sensor often measures the current through the cable sheath with a clamp or similar.

The measured current and voltage are calculated by an internal microcomputer board or other control unit. Models with communication functions will also have a communication module.

The above calculated values are used to calculate power consumption, which is displayed on a monitor in real time or stored in a data log. In large factories, the ON/OFF status of various connected machines may be displayed, and real-time power details may be displayed numerically.

Types of Energy Monitors

Various types of Energy Monitors are available for different applications. The following are examples of types of Energy Monitors:

1. Stand-Alone Type

Stand-alone Energy Monitors are energy monitors that can be used by themselves. These monitors have built-in voltage and current sensors to measure power consumption. However, a separate power supply for driving the Energy Monitor is often required. 

2. Smart Meter Type

These Energy Monitors are installed as meters provided by the power company, just like regular electricity meters. It is compatible with the smart grid and real-time communication, and can provide real-time notification of electricity usage. This type may be used when a solar system or internal combustion private power generation equipment is present.

When installed in a solar system, it is used to measure power generation and power consumption. It is also used to monitor electric power consumption of lighting equipment, air conditioners, etc.

3. In-Line Type

Energy Monitors can be mounted directly on a switchboard or control panel. These monitors are typically used for industrial or commercial energy management. Because the products are linked to control equipment, they are often sold by instrumentation manufacturers.

4. Portable Type

These Energy Monitors are designed as small portable devices. They are used to measure energy use locally or for short periods of time. Products with built-in batteries, etc., are also available, in which case measurements can be made without the need for a power supply. They can also be used to measure the power consumption of household appliances and office equipment.

What Is an Air Respirator?

An Air Respirator is a device that removes dust from the outside of an oil tank while maintaining the tank’s internal pressure.

It is a type of hydraulic equipment mainly installed above oil-filled tanks such as reservoir tanks and hydraulic oil tanks.

It has a built-in filter to remove dust from the outside. The cap is made of alloy or resin, which has excellent durability and other properties. The cap can be removed with a thumbscrew, and many products have a simple structure for easy maintenance.

Uses of Air Respirator

Air Respirators are mainly used in industrial applications. They are used in industrial equipment, such as tanks that contain oil.

The following are examples of air respirator applications:

• Electrical equipment such as generators and oil-filled transformers
• Large reduction gears with oil circulation
• Hydraulic tanks in hydraulic units

As mentioned above, air respirators are used in tanks and equipment that incorporate large volumes of oil. Generators and oil-filled transformers that handle voltages higher than high voltage incorporate insulating oil for internal winding insulation. Insulating oil for electrical equipment may also contain silica gel for moisture absorption, since moisture contamination can cause insulation deterioration.

Large reduction gears, for example, generally incorporate a large volume of oil and use it to lubricate gears. Since the temperature of the lubricating oil gradually increases with rotational motion, it may be cooled through a heat exchanger or similar device. Thus, air respirators are used in a wide range of fields such as machine tools and power generation and substation.

Principle of Air Respirators

Air respirators are mounted on top of a hydraulic oil tank or reservoir tank. Since the oil volume in an oil filled tank expands and contracts with temperature changes and other factors, sealing the tank can lead to deformation of the tank and damage to the extraction pump. Therefore, in order to maintain a constant pressure inside the tank, it is common to attach an opening to allow suction and exhaust.

However, if outside air is introduced as it is, dust and other particles will be sucked into the oil-in-oil tank. To prevent deterioration of the oil and damage to peripheral equipment caused by dust, an air respirator is attached to the opening for filtering. This removes dust and foreign matter from the outside air when the air is sucked in.

Air respirators are mainly composed of a filter element, lid, and body. The filter element filters dust and foreign matter from the outside air. Filter paper or metal mesh is used.

The body and lid play the role of guiding the outside air to the filter element while the air respirator is attached to the tank. Screw-in installation is the most common method. The material is a robust substance such as metal or hard resin, and the filter element is secured with rubber packing inside.

How to Select an Air Respirator

Air respirator selection is based on the mounting method and diameter, air flow rate, and material.

1. Mounting Method

The most common mounting method is the screw-in type. If flange mounting is desired, a flange with a callout can be manufactured. The mounting diameter is the diameter of the screw to which the air respirator is attached, and is selected according to the size of the opening screw. 

2. Air Flow Rate

The air flow rate is the amount of air that the air respirator can allow. The airflow rate is determined by the product. Select a product with a permissible value greater than the expected airflow rate.

3. Material

Material is the material of the body and filter element. The material and coarseness of the filter element determines the coarseness of the dust to be separated, so select a product with the required filtering capacity. The material of the main body and filter also directly affects the allowable temperature, so metal products are preferable when the operating temperature is high.

Other Information on Air Respirators

Cleaning Air Respirators

If the element of an air respirator is used without cleaning, it will become dirty and clogged. As a result, the tank will be sealed and the internal pressure will rise, directly leading to damage to the oil-filled tank.

In addition, if the tank’s internal pressure becomes lower than atmospheric pressure, it is likely to cause excessive air to flow into the oil and cause bubbles to form. If air bubbles in the oil flow into the inside of the extraction pump, cavitation can cause damage to the pump. If debris or other substances are mixed into the oil due to pump damage, it can cause malfunctions in various hydraulic equipment.

Therefore, maintenance such as periodic cleaning or periodic replacement of filter elements and caps of air breathers is very important.

What Is an Air Blow Nozzle?

An Air Blow Nozzle is a nozzle that uses compressed air or gas to blow air at high speed.

By blowing air intensively, it can remove dirt and dust from the surface of an object or dry it. Air Blow Nozzles consume air efficiently and can sometimes be expected to save energy for compressors and other equipment.

Uses of Air Blow Nozzles

Air Blow Nozzles are widely used in industrial applications. They are used in a wide range of fields from the automotive industry to the food industry.

1. Maintenance

When used for maintenance and cleaning, air blow nozzles remove dust and dirt from machine and product surfaces. It is sometimes used to remove dust from human bodies.

2. Cooling of Objects

Air may be used to cool objects. This is installed in lines that require rapid cooling, such as resin processing and molding lines and cast product transfer lines. It is also used to repel foreign substances by air pressure.

3. Automotive Industry

Air Blow Nozzles are used in the automotive industry to dry painted surfaces quickly. Air Blow Nozzles are used in the food processing industry to dry fruits and vegetables. They are also used to dry banknotes and clothing.

Principle of Air Blow Nozzles

Air Blow Nozzles are typically designed so that compressed air or gas flows from a narrow tube into which it is injected to a wide opening. This narrow tube section is called the nozzle throat, where the compressed air is accelerated to a higher velocity. The tip of the nozzle that extends from the nozzle throat is called the nozzle diffuser, where the air is slowed down and the pressure is reduced.

This change in velocity causes the air blown out of the Air Blow Nozzle to flow at a high velocity. Air Blow Nozzles are used for the above applications by utilizing this air flow.

Some Air Blow Nozzles can be adjusted to blow air in any direction. By adjusting the moving parts, the flow of air blown out of the Air Blow Nozzle can be adjusted.

How to Select an Air Blow Nozzle

When selecting an Air Blow Nozzle, it is important to pay attention to the following points:

1. Shape

The shape of the Air Blow Nozzle should be selected according to its intended use. Thin tubular products can enter and operate in narrow crevices. On the other hand, wide fan-shaped products can cover large areas. 

2. Outlet Size

Vent size should be selected according to the air pressure and blowing volume to be used. Generally, the outlet inner diameter should be selected so that it is proportional to the air pressure value to be used. Air Blow Nozzle manufacturers may provide a diagram showing the relationship between the inside diameter of the outlet and the air pressure.

In some sectors, such as electronics manufacturers and the automotive industry, the air outlet size may be very small.

3. Air Pressure

Selection should be based on the air pressure to be used. Air Blow Nozzles can quickly deteriorate depending on the frequency of use and the environment in which they are used.

Using an Air Blow Nozzle designed for the appropriate air pressure will extend the life of the Air Blow Nozzle itself. It is also important to choose Air Blow Nozzles made of durable materials and designs.

4. Piping Connection

The connection port of the Air Blow Nozzle to the air source piping must also be selected. The connection port should be selected according to the diameter of the piping. It is also necessary to select a fitting and connection method according to the air source pressure.

Ease of connection must also be considered. Selecting a connection port that can be easily connected, such as a one-touch fitting, can reduce work time.

5. Options

Air Blow Nozzles blow air at high speed, which can cause injury if used improperly. Safety can be ensured by selecting an Air Blow Nozzle equipped with an appropriate safety device.

There are also Air Blow Nozzles that can control the amount of air, and whether it is sprayed or stopped. Products with the necessary options should be selected.

What Is an Air Balancer?

An air balancer, utilized extensively in industrial and manufacturing settings, is a sophisticated load-handling device. It leverages air pressure to assist operators in lifting, maneuvering, and precisely positioning heavy loads or tools with minimal effort. By making the load seemingly lighter, air balancers enhance both safety and efficiency in the workplace.

Uses for Air Balancers

Air balancers are integral to various tasks, including:

1. Assembly Work

They simplify the lifting of large parts, aiding in accurate placement during the assembly process.

2. Transportation and Moving

Utilized for moving heavy loads within the work area, air balancers minimize physical strain and heighten operational efficiency.

3. Installation and Removal of Equipment

These devices are crucial during the installation or removal of heavy industrial equipment, enabling precise handling and positioning.

4. Painting and Finishing Operations

In painting and finishing tasks, air balancers ensure the steady operation of tools for consistent application.

5. Inspection and Maintenance

They facilitate the handling of tools and equipment during the maintenance and inspection of machinery, enhancing accessibility and ease of work.

6. Product Transportation and Loading/Unloading

Efficiently used in loading and unloading materials, air balancers streamline the transfer process into and out of transport vehicles.

7. Work in Confined Spaces

They support operations in tight or elevated spaces, improving maneuverability and safety for the operator.

Principle of Air Balancers

Air balancers operate on the principle of buoyancy adjustment through internal air pressure regulation. This mechanism allows the device to counterbalance the weight of a load, making it easy to lift and position. By maintaining constant air pressure, the device ensures the load remains buoyant, significantly reducing the manual effort required from the operator for lifting.

Types of Air Balancers

Diverse models of air balancers cater to specific application needs:

1. Rope-Type Air Balancer

Utilizes a rope or cable to suspend loads, ideal for a range of general applications.

2. Hose-Type Air Balancer

Features a flexible hose for load suspension, offering an extensive working range suitable for confined spaces.

3. Balancer Arm Type Air Balancer

Equipped with a long arm for load suspension, this type allows for adjustable working range and accessibility.

4. Air Bag Type Air Balancer

Supports loads with an airbag, adaptable to the load’s shape, perfect for handling uniquely shaped items.

5. Suction Cup Type Air Balancer

Employs suction cups for holding flat-surfaced materials like glass or metal plates, ensuring secure handling.

6. Air Balancer for Multiple Work Stations

Designed to operate across multiple workstations from a single unit, enhancing operational flexibility.

7. Highly Efficient Air Balancer

Offers rapid lifting speeds and precise control, suited for swift and accurate handling of heavy loads across various tasks.

 

What Is an Air Shaft?

An air shaft, also known as an inflation shaft or expansion shaft, is a winding shaft designed for winding paper, cloth, or other materials. It plays a crucial role in maintaining the correct tension during the winding or feeding process, thanks to an internal air fill or drain valve. This valve enables the shaft to expand and exert a force that securely holds the material, facilitating uniform tension throughout the operation.

Uses of Air Shafts

Air shafts are indispensable in various printing applications, offering several benefits:

1. Material Retention

They ensure that paper, film, or other substrates are firmly held in place during printing, contributing to the accuracy and quality of the final product.

2. Maintaining Uniform Tension

The generated expansion force keeps the material tension consistent, allowing for precise handling without distortion in the printing press.

3. Speed and Efficiency

Quick expansion and contraction enabled by air pressure improve operational efficiency and allow tension adjustments to match printing speeds.

4. Applicable to Multiple Materials

Designed to accommodate various printing materials, air shafts enhance the versatility of printing operations.

Such characteristics make air shafts valuable for winding, feeding, positioning, laminating, and etching in printing processes.

Principle of Air Shafts

Air shafts rely on air pressure to expand and grip the material, facilitating precise tension regulation. They contain valves for air intake or release, enabling them to adjust their diameter for material engagement. The controlled expansion exerts an outward pressure, securing the material in place, while air release allows the shaft to contract for material release. This mechanism ensures uniform tension and accurate material positioning, essential for quality printing outcomes.

Types of Air Shafts

Diverse air shaft designs cater to specific operational needs:

1. Single-Grip Air Shaft

Featuring a single pneumatic valve for expansion and contraction, this shaft type is suited for winders and feeders, providing precise tension control.

2. Double Grip Air Shaft

With pneumatic valves on both ends, it offers balanced tension control, reducing material distortion during winding and feeding.

3. Expanding Air Shaft

Its expandable segments can be individually controlled, allowing for flexible tension adjustments based on material size and width.

4. Differential Tension Air Shaft

Enables the application of varying tensions to different material sides, balancing tension differentials for uniform print quality.

5. Rattock Type Air Shaft

Utilizes a ratchet mechanism for gradual contraction, ensuring stable material retention and pull during take-up.

6. Slip-Type Air Shaft

The shaft’s outer layer is coated with a slippery material, promoting smooth material movement and minimizing wear during winding and feeding.

What Is Urethane Insulation?

Urethane insulation is a heat-insulating material made primarily of polyurethane resin.

Urethane insulation is made by forming (foaming) polyurethane resin, which has many independent bubbles inside. Each of these bubbles is filled with a gas that conducts little heat and thus has high heat insulation properties.

Uses of Urethane Insulation

Urethane insulation is used in a wide variety of buildings. In addition to its high thermal insulation properties, urethane insulation is also suitable as a soundproofing material because of its soundproofing properties.

For this reason, it is also used in roofs, walls, and ceilings of agricultural and stockbreeding facilities, as well as in constant-temperature rooms for tobacco drying, which require high temperatures and long drying times. It is also used in ships, plants, and furniture.

Principle of Urethane Insulation

Polyurethane resin, the raw material for urethane insulation, contains both polyisocyanate and polyol that bond together to form a polymer. In urethane insulation, a foaming agent is added, and the heat from the reaction between the isocyanate and polyol vaporizes the foaming agent, creating many small independent bubbles.

Each of these bubbles is then filled with gas derived from the blowing agent, thus achieving a high heat-insulating effect. In addition, since there are many gas-filled bubbles, it is highly effective in absorbing sound, and a soundproofing effect can also be obtained.

Other Information on Urethane Insulation

1. Advantages of Urethane Insulation

The advantage of urethane insulation is that it is a self-adhesive, foam-like material that can penetrate complex shapes and structures, such as uneven surfaces in the construction area, without gaps, and form an insulation layer. Another advantage is that there is little deterioration, and the difference between initial insulation performance and insulation performance after aging is small, so it retains its insulation effect even when it is old.

Urethane insulation is also highly waterproof. This is because each air bubble inside urethane insulation has an independent structure, making it difficult for moisture to penetrate inside the urethane insulation. For this reason, urethane insulation does not lose its insulating effect, even when wet.

2. Disadvantages of Urethane Insulation

The biggest disadvantage of urethane insulation is its high price. There are two types of insulation materials: foam insulation materials such as urethane insulation and fiber insulation materials such as glass wool. The price of urethane insulation is about 1,900 to 2,700 yen per square meter for a sprayed type, and about 3,000 to 4,000 yen per square meter for a ceiling, more than twice the price of glass wool.

Another disadvantage of urethane insulation is that it is difficult to peel off once it has been installed because of its high self-adhesiveness and the fact that it is installed without gaps. In addition, restoration after peeling is also costly.

3. Relationship Between Urethane Insulation and Fire

Because urethane insulation has low fire resistance, in recent years it has become a requirement to install insulation that meets fire resistance standards. Although there is an aspect that “urethane foam insulation is flammable,” it is very rare for urethane foam insulation to be the cause of a fire.

In actual cases of fires, most fires from urethane insulation occur at the construction site. During construction, remodeling, and demolition, there have been instances where sparks or welding burners have ignited due to the use of urethane insulation while various workers were entering and exiting the site.

To prevent fires involving urethane insulation, it is necessary to take firm precautions on site as well as by the occupants. It is important to have a correct knowledge of the material, such as “it is a heat insulator, not a heat-resistant material,” and “it burns even if it is flame retardant,” and to handle it safely.

What Is Urethane Paint?

To begin with, let us explain the characteristics of paint components: it is a mixture of pigments, resins, additives, and water or solvents as solvents. Resin plays an important role in determining the chemical properties of the paint and has a strong influence on the durability of the paint and the color and gloss of the finished product.

Urethane paint is paint that contains urethane resins as the resin component and can be produced at a low cost. The least expensive paint is acrylic paint, but it is the next most expensive.

This paint contains urethane paint as a resin component, which is highly flexible and thus provides high adhesion. It has also been used in a wide range of applications because of its beautiful gloss and luxurious appearance.

Currently, demand is on the decline as silicone-based paints with high durability are becoming mainstream, but they are still popular due to their low cost and high versatility.

Uses of Urethane Paints

Urethane paints are used to paint exterior walls, motorcycles, and furniture. While relatively inexpensive, they are known as highly convenient paints due to their superior gloss, elasticity, and adhesion. They are also used for DIY projects because they are easy for amateurs to handle. Recently, spray-type urethane paints have been sold at home centers and are readily available. Commercial urethane paints are often highly volatile oil-based paints, so rubber gloves and a mask are essential.

Characteristics of Urethane Paints

As explained at the beginning of this article, urethane paints contain urethane resin as its component. This resin component contributes greatly to the chemical properties of urethane paints, such as its durability and unique color and gloss after painting.

This material is synthesized by the polymerization reaction of the polyol with multiple hydroxyl groups and polyisocyanate. By changing the combination and mixing ratio of polyol and polyisocyanate, it is possible to develop paints with various properties.

In the application, the paint is dissolved in water or a solvent, diluted, and then applied. This dilution process not only makes the paint easier to handle but also increases its adhesion. Depending on the solution dissolved in the paint, the paints are broadly classified into water-based, oil-based, and elastic paints.

• Water-based Paint: Water-based paints are diluted with water and are highly convenient because they suppress the odor characteristic of paints. However, because it contains water, it is more susceptible to external factors such as temperature and humidity.
• Oil-based Paint: Diluted with solvent, oil-based paints are inexpensive and reduce the work process. However, there are some disadvantages, such as strong solvent odor and risk of ignition.
• Elastic Paints: Elastic paints use an elastic compound as a hardener to provide elasticity. Because of its high elasticity, it has the advantage of being less prone to cracking. However, care must be taken because if not used properly, heat dissipation will deteriorate and adhesion will decrease.

Difference Between One-Component Urethane Paints and Two-Component Urethane Paints

Two types of urethane paint exist: one-component and two-component. In one-component type, a hardener is added in advance to the main agent, and the coating can be applied by itself. They are classified into water-based and oil-based types based on differences in solvent solubility and are diluted with water or a solvent before use. On the other hand, two-component types are prepared separately with a base agent and a hardener, which must be mixed before use. Two-component types are also available in two types: water-based and oil-based, based on their solvent solubility, and are diluted with water or an appropriate solvent before use.

Advantages of Urethane Paints

The primary advantage of urethane paints is its high functionality. Compared with other paints, urethane coatings have a softer coating film and can accommodate changes in the shape of the wood over time. The unique glossy finish of urethane coatings also makes them ideal for use on high-end furniture and flooring.

This paint is also used as a base coat for exterior walls due to its high adhesion. The adherent coating film is effective in reducing the occurrence of cracks.

In addition, two-component urethane paints mixed with a hardener have been developed, resulting in a high degree of versatility. The two-component type is characterized by a dense coating film formed in a mesh structure.

Disadvantages of Urethane Paints

There are four disadvantages of urethane paints.

The first is that the durability is only 6 to 10 years, which is inferior to other paints. However, since it is a low-cost paint with good performance, it can be considered the best paint for a new paint job.

Second, there is a risk of discoloration. Urethane paints are prone to discoloration caused by ultraviolet rays. Exterior walls and roofs that are exposed to ultraviolet rays during the day are easily affected and may turn yellow.

Third, they are vulnerable to water. The curing agent in urethane paints reacts easily with water. Therefore, when painted in a humid environment, for example, the hardener reacts with moisture in the air, and the performance of the coating film may deteriorate. Therefore, it is necessary to be alert to the weather, humidity, and other environmental conditions at the time of use.

Fourth, there is a risk of expansion of the paint film. In the case of exterior walls with insulation, heat is trapped between the exterior wall and the paint film. As a result, there is a risk that the heat will cause the paint film to expand and peel off. This phenomenon is not only caused by heat but also by air that enters through rust, hand stains, or other foreign objects.

What Is an Insert Ring?

Insert rings are ring-shaped components utilized in hydraulic, pneumatic, water, and other fluid piping systems. They are specifically designed for insertion inside pipes and tubes to enhance the strength of seals or connections in piping and pipe connections. Insert rings play a crucial role in preventing shrinkage at the joints of tube fittings, which are components that connect tubing to fittings to ensure secure connections and prevent leakage.

These rings are versatile and come in various types tailored to their specific application within piping systems.

Uses of Insert Rings

Insert rings find their application across different joints in piping systems, primarily to prevent fluid leakage.

1. Liquid and Gas Piping Systems

These rings are integral in connecting diverse piping systems that transport liquids or gases, aiding in leak prevention.

2. Pressure Control Devices

In pressure control devices and valves, insert rings are employed at pipe connections to ensure precise pressure control and mitigate the risk of leakage or overpressurization.

3. Fuel Supply Systems

They are crucial in automotive and aircraft fuel delivery systems, preventing fuel leaks at fuel line connections.

4. Cooling Systems

Insert rings are also pivotal in cooling systems for circulating water and fluids, where their role in preventing leaks is essential for maintaining the cooling effect.

5. Chemical Processes

These rings are employed in piping systems for the safe mixing of chemicals and liquids in various manufacturing processes, preventing chemical leakage.

6. Medical Field

In medical equipment and devices that use piping for the supply and drainage of liquids and gases, insert rings ensure safe operation and maintain a hygienic environment by securing the joints.

Principle of Insert Rings

Insert rings are strategically placed between pipes or between a pipe and a fitting. Upon connecting the pipes, the fitting or compression ring secures the insert ring in place, applying pressure. This pressure deforms the insert ring’s material, ensuring it tightly conforms around the connection, filling any gaps and creating a leak-proof seal.

To effectively achieve this seal, insert rings are made from elastic materials capable of exerting the necessary pressure for a secure fit and adherence to the connection surfaces.

Additionally, to combat tubing shrinkage, insert rings are used, made from materials more rigid than the tubing itself, such as metal, providing an internal support structure.

Types of Insert Rings

Insert rings are categorized into the following main types:

1. Fitting Gasket

Used at pipe fitting connections, these gaskets ensure a secure link between pipes and fittings, preventing leaks.

2. Tube Seal Gasket

These gaskets are specifically designed for piping joints, particularly in environments with high pressure or temperature, safeguarding against gas and liquid leaks.

3. Valve Stem Packing

A gasket placed between the valve stem and the valve body to prevent leaks during valve operation and guarantee its proper function.

4. Tube End Cap

These caps seal the ends of pipes to protect them from contamination and damage, particularly useful for sealing unused piping sections.

5. Swaging Ring

A ring that increases the diameter of a pipe to facilitate connection to a fitting, ensuring a robust connection by clamping the pipe end into the fitting.