Scientific Study on Tension Reel Poly Urethane

Sleeve

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 Use of sleeve in tension reel

• To grip sheet during head TR operation but without paint peel off from coil ID or
surface Impression (initial wrapping of coil winding).
• Slippage when necessary (during coil out from mandrel), abrasion resistance.
• Takes shape of mandrel, when expand or collapse.
• To avoid paint surface defect while rewinding /removal from TR.
• Constant volume deformation to regain its original shape and size
Rubber Sleeve in
Tension sleeve

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Reason for Replacement of tension reel sleeve in every three month
• Life cycle decided by OEM is 5 to 6 months.
• But after completion of 3 to 3.5 month of Rubber sleeve in tension reel.
• Prime coils get struck from the ID of coil due to sleeve get loose by designed while removing coil
from tension Reel .

Reason

Mandrel sleeve getting loose (permanent deformation) between 3 to 3.5

month in tension reel because of rubber characteristic

Permanent deformation due to-

• Frequent expand and collapse (low stress relaxing time),
• High temperature from finished coil (45 degree C).
• Loaded for long time during coil winding causing creep effect.
• Hoop stress due to sudden expansion 3
 Study on Tension Reel Mandrel Sleeve
TYPES OF RUBBER MATERIALS / ELASTOMER TYPES OF POLYURETHANE
• Natural Rubber (Poly isoprene) • Flexible Polyurethane Foam. ...
• SBR (Styrene-Butadiene-Rubber) • Rigid Polyurethane Foam. ...
• EPDM(EPDM ETHYLENE PROPYLENE ) • Coatings, Adhesives, Sealants and Elastomers (CASE)
• Butyl rubber • Thermoplastic polyurethane (TPU)
• Polyurethane (AU, EU) • Reaction Injection Molding (RIM)
• Neoprene CR (Poly chloroprene) • Binders
• Hydrogenated Nitrile (Hnbr Hsn ) • Waterborne Polyurethane Dispersions (PUDs)
• HYPALON Chloro sulphonated Polyethylene ( CSM )
• NITRILE ( NBR ) Specific Property Improver:-
• Acrylic ACM (Alkyl Acrylate Copolymer) Type of TPU:-
• Polyester TPU •Impact Modifiers
• VAMAC •Carbon Fibers
• SILICONE RUBBER • Polyether TPU
• Flame Retardant •Heat Stabilizers
• VITON •Compatibilizers
• Fluoro silicone ( FVMQ) •Flame Retardants
• FLUOROCARBON (FKM ) •Melt Flow Enhancers
• AFLAS ( Tetrafluoro ethylene-Propylene ) •Scratch Resistance Additives
• Water Council Approved Compounds
Polyurethane polymers are traditionally and most commonly Courtesy:- https://www.meadex.co.uk/material-data-content
https://polyurethane.americanchemistry.com/Applications/
formed by reacting a di- or tri poly-isocyanate with a polyol
http://www.calsak.com/polymers-additives/additives/
 How idea generated
Structure and Shape Memory Properties of Polyurethane Copolymers Having Urethane Chains as
Soft Segments
Shape memory polyurethanes are usually fabricated with low-molecular weight polyols
through a two-step copolymerization, which often results in difficulty attaining both
desired shape memory switch temperature and optimal thermomechanical properties.

Low polarity segments which are rather long (called soft segments),
alternating with shorter, high polarity segments (called hard
segments). Both types of segments are linked together by covalent
links, so that they actually form block-copolymers.

The crystalline or pseudo crystalline areas act as

Courtesy:- Article in Journal of Macromolecular Science Part B · December 2011
https://www.researchgate.net/publication/232921728
Journal of Macromolecular Science R , Part B: Physics, 50:2290–2306, 2011
physical cross-links, which account for the high
elasticity level of TPU, whereas the flexible chains
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will
impart the elongation characteristics to the polymer.
 Study on Tension Reel Mandrel Sleeve
• Rubber sleeve made of poly Urethane.
• After discussion with vendor came to know material is thermoset poly
urethane but detail composition is secret.

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 Study on Tension Reel Mandrel Sleeve
• We had put a discarded sleeve in Exit pulpit and kept it for 20 to 30 days
in horizontal position and it was found that sleeve becomes more loose
on horizontal side but sleeve which we had put in open area nothing were
changed in size.
This was a breaking point for thinking ,why its happen
and then we thought for re using of sleeve & how

• We searched & study phenomenon about rubber characteristic on net

and found behavior changed over period of time under proper condition
and if we put in open area rubber characteristic breaks
Why Do Rubber Bands Lose Their Elasticity? » Science ABC
https://www.scienceabc.com › Eye Openers

Based on study we changed the time cycle ( Before achieving break point ) of sleeve to used at a time and kept it
at dark place to regain on its actual size.

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 How sleeve made applicable for Re use

From the month of Jun-17 we had started measurement after keeping OLD sleeve
in vertical position
• 1. Old sleeve diameter checked in 15 days and it was found diameter getting less
by 5 to 2 mm.

• 2. Diameter of sleeve checked in the slot of 15 ,20,25 & 30 days and it was found
there is continuous reduction in diameter of sleeve

• 2. After keeping sleeve in vertical condition with wrapping of plastic for three
month its was found sleeve diameter came to its actual diameter on which its
was supplied to us.

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Re use of Rubber sleeve in TR

Picture of coil removal after 2

month while use of re used
rubber sleeve

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 Saving calculation

• One sleeve price 1.5 lac

• Total consumption of sleeve without using of old sleeve-
4/year
• Cost 4 sleeve -6 lac
• Cost saving by making sleeve re usable by reduction in sleeve
consumption by 3 No's /year – 1.5 lac

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