• Journal of the Korean Society of Manufacturing Process Engineers
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• v.13 no.2
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• pp.81-88
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• 2014

Synthetic products such as casting tape and splints are rapidly replacing conventional plaster casts to treat orthopedic patients. Most synthetic products are produced through a polymerization process with related chemical agents. In this study, the effect of the process parameters on the residual NCO content within a prepolymer for casting tape and the hardening temperature for casting tape were experimentally evaluated. In order to verify the effects of the process parameters, an experimental method was adopted. From an S/N ratio analysis, optimal parameter combinations were determined to produce a pre-polymer with a suitable residual NCO content and alower hardening temperature. Prediction models for the NCO content and the hardening temperature were developed and confirmed.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.7 no.3
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• pp.61-66
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• 2008

For the production of urethane prepolymer, the effect of process parameters such as diisocyanate MDI and polyol TDI was tested. In this paper, design of experiments has been adopted for studying the effect of the process parameters on the improvement of NCO and viscosity of pre-polymer. As a result of comparison of different parameters, the effect of polyol was stronger than that of isocyanate in comparison of reactivity according to the amounts of isocyanate and polyol. Especially, NCO and viscosity of pre-polymer affected a product safety.

• Elastomers and Composites
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• v.52 no.4
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• pp.295-302
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• 2017

Polyurethane dispersion (PUD) polymers were synthesized by using polyether and polyester polyol. The effect of ionomeric centers, r(NCO / OH) values, chain extender process, and chain extender types on the adhesion properties was investigated. In the case of polyether-based PUD, the ionic center, r value, chain extension process and chain extender types were not adjusted even after adjustment. In the case of polyester-based PUD, when the ionic center content was more than 2.5%, the state of adhesive strength was $2.0kgf/cm^2$ or more. On the other hand, the initial adhesive strength was excellent at about $1kgf/cm^2$ when the ionic center content was over 3.5%. When the r value was 1.3 or more, it was found that the initial bonding strength and the state of bonding strength were excellent at about $1kgf/cm^2$ and $2.1kgf/cm^2$ or higher, respectively. An IR spectrum analysis of the synthesized PUD confirmed that PUD was composed of urethane based on the N-H characteristic peak at $3340cm^{-1}$ and the urethane characteristic peak at $1730cm^{-1}$. Moreover, the characteristic peaks of the isocyanate ($2260cm^{-1}$) used in the preparation of the prepolymer were not observed. As a result, the residual -NCO was not observed, and urethane was completely synthesized.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.18 no.2
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• pp.1-6
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• 2019

With the increase in number of the athletic population and elderly demographic, the demand for orthopedic splints, which are used to support a damaged body, has rapidly increased. Current splints mainly consist of inner and outer parts, which are multiple fabrics covered with polyurethane and nonwoven fabrics, respectively. However, the laminated materials with directly applied pre-polymer coating lead to a high defect rate because of the uneven thickness on the surface. Thus, this study proposes an indirect coating method using a precise clearance controller, which enables the even application of the coating material on multiple inner parts while maintaining a constant thickness. In addition, a roll-to-roll (R2R) technique is applied instead of the sewing mechanism to bond the inner and outer materials together and enhance the productivity in the final stage. In the advanced methods, there is a storage tank that contains polyurethane, a clearance controller, and pairs of rollers in the upper and lower rows. To improve the quality of the products and optimize the equipment, three controllable factors are determined: the viscosity of polyurethane, angle of the gap controller and number of pairs of rollers in the R2R system.