training basic (nx power_lite)_india_20111115 (2)

Shoe Adhesive Training

- Basic group

Henkel

C·O·N·T·E·N·T·S

The Theory of Adhesion

Classification of Shoe Adhesive

Various Types of Bonding Failure

Standard Operation Procedures for Stockfit

Standard Operation Procedures for Assembly

2






3

Definition

Adhesive Substance(s) to be applied to surfaces with a view

to producing either a temporary attachment or a permanent

bond between component part of a footwear

Adhesive joint An assembly made by the use of an

adhesive

Adherends (substrate)

Solids materials in the adhesive

joint, other than the adhesive

Adhesion (bond)

The phenomenon, which allows A

the adhesive to transfer a load B

AB

CB

A

Adherend

Adhesion betweensubstrate and adhesive

from the adherend to the C Adhesive

adhesive joint4

Terminology

POT LIFE

- The time for which the adhesive, prepared for application

including the incorporation of any curing agent or other

additive, remains usable.

- Factors affecting pot life

• 1-component: Tendency of the adhesive to dry out and

lose solvent

• 2-component:

• Type and amount of additive(curing agent or additive)

• Pot life tends to be shorter at higher temperatures

which speed up the chemical reaction.

5

Terminology

SHELF LIFE (STORAGE LIFE)

- The time for which an adhesive can be stored, under the

conditions recommended by the manufacturer, and still

remain usable.

- Normally specified for unopened containers

- Users should store adhesives at the correct temperature.

• Too low temp : irreversible phase separation

• Too high temp: accelerate solvent loss or premature

reaction of constituents

• The temperature for water-based type is somewhat

higher than for solvent-based type.

6

Terminology

VISCOSITY

- The resistance of a liquid to flow

- The more difficult it is to stir a liquid adhesive, the

higher viscosity.

- Viscosity can be controlled for improving workability

and penetrating property and adjusting coating weight.

- Viscosity depends on,

• Solvent-based: Type of solvent, solids content

• Water-based: Solids content, presence of thickening

agents

• Hot-melt: Melt temperature

7

Terminology

SOLIDS CONTENT

- The proportion of the adhesive which remains as solid

material in the bond area once any volatile substances have

been lost.

- Usually expressed as percentage by mass.

COATING WEIGHT (COVERAGE)

- The amount of adhesive applied per unit area

- It depends on solids content, viscosity, application method

and nature of the surface.

8

Terminology

DRYING TIME

- The time taken for the volatile solvents or water to

evaporate from an applied coating.

- Factors affecting DRYING TIME

• Solvent blend, water to be lost

• Temperature, relative humidity

• Rate of air flow over the coating

Air movement and increased temperature speed up

drying, whereas high humidity may retard drying

especially with water-based adhesive.

9

Terminology

OPEN TIME

- The time between adhesive application and assembling the

bond.

- There is a recommended minimum-to ensure sufficient

drying, and a maximum-to ensure that the tack life is not

exceeded, for a satisfactory bonding result.

- Therefore, the open time is longer than the drying time but

shorter than the tack life.

10

Terminology

TACK

- An empirical property of an adhesive-coated surface which

is to a great extent assessed subjectively by the feeling of

stickiness to touch and which up to a point is an indication

that the adhesive film is still active.

- Pressure sensitive adhesive may be permanently tacky.

GREEN STRENGTH (INITIAL STRENGTH)

- The bond strength immediately on release from the bonding

press.

- Green strength varies with time from bonding.

11

Terminology

HEAT RESISTANCE

- Shoes must resist exposure to heat during the service life.

- Heat sources: Warm conditions during storage, transport or

display in shop windows, warm climates, and heaters and

hot conditions in the home or workplace.

AGEING

- The change of properties of an adhesive bond with time,

especially under the influence of heat, moisture and

chemicals.

12

How Adhesive Work?

By wetting the surface of substrate, gaps are filled up

with adhesive and through Chemical/Physical bond

and cohesive force of adhesive, adhesion is formed.

Moisture, oil, dust,

other contaminants

Substrate

Attaching

Cleaning the surface

Cementing

Roughing

Priming

13

How Adhesive Work?

1 Low viscosity adhesive/primer permeates

into the holes on substrate after that

mechanical interlocking occurs.

(Mechanical interlocking theory)

2 As molecules of adhesive and substrate

near toward each other, molecular

interactions are built. (Adsorption theory)

3 By mechanical interlocking and absorption,

adhesive and substrate are empowered

with enough force needed for maximum

adhesion.

14

How Adhesive Work?

4 For compatible polymers, molecular chain

extending on the interface, hydrogen

bond and ionic bond collaborate to

achieve the adhesion force. By this stage,

interfaces disappear and even formation

is formed. (Diffusion theory)

So cleaning, surface treatment, priming and

cementing all play an important role in achieving

the necessary adhesion!

15

Importance of Cleaning

What the most important in bonding process is to keep

the surface of substrate clean.

Rubber O/S : W/B Detergent Degreasing

Cleaning the

surfacePhylon M/S : Warm Water Wash

PU M/S : W/B Cleaning

Plastics, Synthetics : S/B Cleaning

Leather : Mechanical Roughing

16

Requirements for Good Shoe Adhesives

• Flexible and Strong

• Resistance to heat, water, weather, solvent, etc.

• Workability

• Proper price

• Discoloration resistance against contaminants and

sunlight

• Resistance to plasticizer

• Being curable at room temp or quick curing type

• Good grab(=Setting) after pressing

• Low hazards

• Stable property and appearance during storage andtransportation.

17






18

Classification of Shoe Adhesives

- Main bonding items

Edge foldingTPR counter

Padding

Sockliner

Mid sole / Out sole

Accessories, Logo

PU sole / Air bag

19

Basic Process

Bonding Process

Check the bonding property and information ofSubstrate

Pretreatment

Priming

Cementing

substrate, ingredient & composition

Choose the most efficient way to remove

bonding disturbing factor from the adherend

Choose the best Primer according to the substrate

Choose the best Adhesive according to the

property and environment

20


Adhesive

Primer

Cleaner

Curing agent

• Solvent-based PU & CR

• Water-based PU & CR

• Water-based acrylic emulsion

• Thermoplastic & PU reactive hot-melt

adhesive

• Solvent-based / Water-based

• Solvent-based / Water-based

• For solvent-based adhesives

• For water-based adhesives

21

Development of Shoe Adhesive

W/B PU& HMA

S/B PU

S/B Tol-free

S/B CR

S/B NR

1950 1960 1970 1980 1990 2000

22


CR(Chloroprene Rubber) based adhesive- The main component is Polychloroprene rubber, a kind of

synthetic rubber called as Neoprene rubber. It is classified into

two types, general solution and modified reaction type.

- Along with the development of shoe industry, most of CR based

adhesives have been replaced with PU based adhesives and

Hot-melt adhesive.

- Henkel Product

D-TAC: S/B CR Solution type

D-PLY, BUFFNON: S/B Modified CR type

AQUACE C- series : W/B CR adhesives

23


PU(Polyurethane) based adhesive- The main components of PU adhesive RM are

polyisocyanates

and polyester polyol and the using areas are stock-fitting and

assembly line.

- With characteristic of good Anti-discoloration,good green

bonding

strength , good green heat resistance etc, the using PU

Adhesive

is very common.- Toluene-free type adhesives are currently being converted

with

WB PU product.

- Henkel Product

BONDACE series : S/B PU adhesives

AQUACE W- series : W/B PU adhesives24


Hot Melt Adhesive- Hot melt adhesive is defined as an adhesive applied from the

melter, gaining strength upon solidification and crystallization

- 100% Solid & Simplification working process, productivity

improvement and PDS reduction.

- Temporary bonding before upper stitching,adhesion of padding

and liner,fixing back counter, lamination of sockliner, attaching

accessory and making shoe box.

- Henkel Product

MELTACE series : Thermoplastic HMA

MELTACE R- series : Reactive HMA

25


z W/B Acryl adhesive

- Adhesive made by Polymerization with acrylate monomer

- For lamination & sticker on upper material

- Good to water resistance , washing , anti-discoloration and

adhesion

- Good to continuous working with using of lamination machine.

- Henkel Product

z AQUACE L- series : For lamination

z AQUACE S- series : For sticker

26






27

Types of Bonding Failure

Adhesive peeling from material

x Unsuitable primer or/and adhesive used.

x Poor pretreatment of material before

applying an adhesive.

Poor coalescence of adhesive film

x Over drying time.

x Over cooling time and/or temperature.

x Poor compatibility between adhesives

28


Material breakdown

x The best result in peeling test.

Material breakdown - a shallow layer

of material separate

x Insufficient roughing against leather skin.

x Not enough penetration of adhesive into the

surface of a material.

29


Cohesive failure of adhesive

x Insufficient drying.

x Insufficient cohesive force & green strength.

x Migration of plasticizer, if contained.

x Insufficient curing due to lack of amount

and poor quality of hardener.

30






31

Standard Operating Procedures

Adhesive Production Flowchart

33

Warehousing

Ideal Storage Condition

SBA WBA HMA HMMC

5~40 5~35 5~40 5~40Temp.

40±20% 40±20% 40±20% 40±20%Humidity

Avoid Avoid Avoid AvoidSunlight

RequiredVentilation

Not Notrequired required

Required

34

How to Use Adhesive

Water-based PU adhesive / primer / fluid

• Subdivide W/B primer and adhesive product preferably into 3Kg PE

beaker.(Fig. 1) - Maximum weight of adhesive for hardener mixing

should not exceed 5Kg,

• Add suitable hardener with proper quantity/percentage.(Fig. 2)

Water Based Cement

• AQUACE W-06 : ARF-40 : ARF-45 = 100 : 5 : 1

• AQUACE W-08 : ARF-40 = 100 : 5

Water Based Primer

• AQUACE W-104/105 : ARF-40 = 100 : 5

• AQUACE PR-651: ARF-45 = 100 : 3

• Mix them using electric agitator at 200~300RPM for over 8 minutes.(Fig.

3)

• Recommended Pot Life : 2 hrs maximum

1

2

3

35

How to Use Adhesive

Solvent-based adhesive / primer

• Subdivide S/B primer and adhesive product preferably into 3Kg PE

beaker.(Fig. 1) - Maximum weight of adhesive for hardener mixing should

not exceed 5Kg,

• Add the suitable hardener with proper quantity/percentage.(Fig. 2)

• Influence by relative humidity is not significant to primer and adhesive

properties but following changes are recommended for extreme humidity

condition.

• When RH is 80% and above,

: Solvent Based Cement

Desmodur RFE = 100 : 5, ARF 1000 = 100 : 6

: Solvent Based Primer

Desmodur RFE = 100 : 4, ARF 1000 = 100 : 5

• When RH is below 80%,

: Solvent Based Cement

Desmodur RFE = 100 : 4, ARF 1000 = 100 : 5

: Solvent Based Primer

Desmodur RFE = 100 : 3, ARF 1000 = 100 : 4

• Mix them using electric agitator at 200~300RPM for over 3 minutes.(Fig.

3)

• Recommended Pot Life : 1 hr maximum

• For special purpose primer (e.g. primer for difficult to bond material), please

1

2

3

36

How to Use Adhesive

Water-based chlorinating primer for rubber

• Slightly shake the container of base solution 3-4 times before

putting in the powder.

• Put the powder into the container of base solution.(Fig. 1)

• Record the powder mixing time. Pot life is max 1 hour for WB O/S

primer and max 3 hours for TFA O/S primer.

• Shake the container manually for 5 minutes or by shaking machine

at the rate of 60 times/min until complete dissolution.(Fig. 2)

• While shaking the container, the color of the mixture will turn to

colorless transparent.

• Leave the solution at room temp for 20 minutes.

• Make visual confirmation of the complete dissolution of the powder

before use.

• Pour 200~300g of the solution into a proper glass or ceramic

bowl.(Fig 3)

• The rest of the solution in the PE container should be kept tightly

sealed.

• Use lid to cover the upper part of the bowl to prevent thinner from

the evaporation into the work place which results in the

condensation of the solution and contamination of the air.(Fig. 4)

1 2

3

437

Production

Stockfit

Material Pretreatment

Assembly


Priming Cementing

Priming Cementing

Pressing

& Cooling

Pressing

& CoolingFinishing

38

Stockfit


Rubber

Phylon

Die-cut EVA

TPU

Pebax

Nylon

Priming CementingPressing

& Cooling

39

Stockfit

Rubber Degreasing Priming Cementing

1 Prepare rubber

• Prevent the generation of blooming on rubber surface.

• Rubber should be degreased using Ultrasonic Machine within 14

days after pressing. (Within 7 days if possible)

• More intensive care in rubber compounding is needed to reduce

failure bonding, adhesive peeling from the rubber surface.

• There should be no change in rubber compounding formulation.

• Rubber scrap should be max.25%

• Rubber should be optimally cured. (not over / under cure)

• Minimize usage of mold release agent.

Pressing& Cooling

40

Stockfit


2 Degrease with CL-800A ˧ Dehydrate

• Dilute CL-800A with water. Water : CL-800A = 25:1

• Immerse rubber sole in CL-800A solution for above 50 seconds.

• Dehydrate rubber by air blow for 5~10 seconds.

• Tips!

- Keep the pH value of the solution at >10.5

- Check pH every hour.

- Keep the solution temperature between 60~70.

- Clean the tank every week.

3 Rinse with water

• Rinse with water for over 35 seconds.

• Tips!

- Water should be kept clean.

Pressing& Cooling

41

Stockfit


4 Rinse with CL-800B ˧ Dehydrate

• Dilute CL-800B with water. Water : CL-800B = 25:1

• Immerse rubber sole in CL-800B solution over 35 seconds.

• Dehydrate rubber by air blow for 5~10 seconds.

• Tips!

- Keep the pH value of the solution as 2~3.



- Clean the tank every week.

5 Heat dry

• Dry by heat chamber at 60×3minutes.

Pressing& Cooling

42

Stockfit


6 Preheat the surface of rubber

• Preheating is not a mandatory process but is recommendable before

priming because it improves workability and bond strength.

• Preheating condition is 50(surface temp)×2 min 30 sec ~3 min.

7 Apply rubber primer on rubber

• Prepare WB Rubber primer. See page 33 for details.

• Apply WB Rubber primer on rubber thinly and evenly using cotton

cloth.

• Tips!

- Apply primer within 5 hours after sole degreasing. Max is 24

hours

- Change used cotton cloth every 1 hour.

- Residual solution and extracted powder on the bowl should be

removed before re-filling the solution. Provide 2 bowls per one

operator.

Pressing& Cooling

43

Stockfit


8 Dry

• Dry completely at 50(surface temp)×3min ~ 3 min 30 sec.

• The drying condition might change depending on the process or

material applied.

• Tips!

- Constantly check the inner chamber temperature to avoid

sudden temperature increase

- Insufficient drying causes adhesive failures and over drying

causes interface separating between adhesives.

Pressing& Cooling

44

Stockfit


9 Apply adhesive ˧ Dry

• Prepare AQUACE W-08, a water-based PU adhesive. See page 33 for

details.

• Apply AQUACE W-08 evenly and thinly by brush.

• Dry at 55~60× 3 min.

• Tips!

- Apply adhesive within 18 hours after priming.

- Change application tool regularly.

- The drying condition might change depending on the process or

material applied.

Pressing& Cooling

45

Stockfit


10 Attach ˧ Press ˧ Cooling (Chilling)

• Attach each cemented material as soon as possible.

• Pressing condition

- Assure steady, even pressure and sufficient pressing time

- Required pressure: 30 kg/cm2, 8~10 seconds minimum

• Cooling condition

- Proper cooling helps to achieve better initial bond strength

- Recommended cooling condition: Perform enough chilling to

lower the surface temp of center part of M/S to below 40

Pressing& Cooling

46

Stockfit


Rubber

Phylon

Die-cut EVA

TPU

Pebax

Nylon


& Cooling

47

Stockfit

Phylon Degreasing Priming Cementing

1 Degrease with CL-800B ˧ Dehydrate

• Dilute CL-800B with water. Water : CL-800B = 30:1

• Immerse phylon in CL-800B solution for 4 minutes.

• Dehydrate phylon by air blow for 5~10 seconds.

• Tips!

- Keep the pH value of the solution as 2~3.



- Clean and refresh the tank every week.

2 Rinse with water ˧ Dehydrate

• Rinse with water for 2 minutes.

• Dehydrate phylon by air blow for 5~10 seconds.

• Tips!

- Water should be kept clean.

- Keep the water temperature between 52~58.

Pressing& Cooling

48

Stockfit


3 Heat dry

• Dry at 50×above 90 seconds.

The alternative

• Rubber degreasing process can be applied for phylon cleaning.

Pressing& Cooling

49

Stockfit


4 Preheat the surface of phylon

• Preheating is not a mandatory process but is recommendable

before priming because it improves bond strength.

• Preheating condition is 40~50(surface temp)×2min 30sec ~ 3min.

5 Apply UV primer on phylon

• Apply UV Primer on phylon evenly using cotton cloth or brush.

• Tips!

- Apply an UV primer within 24 hours after sole washing.

Pressing& Cooling

50

Stockfit


6 Dry

• Dry completely at 45~50(surface temp)×2 minutes.


material applied.

7 Apply UV

• UV Treatment Condition:

- Regular Phylon-Black: 0.50 ~ 0.55 J/cm2

- Regular Phylon-White: 0.54 ~ 0.59 J/cm2

- LS-3 Phylon-Black: 0.60 ~ 0.70 J/cm2

- LS-3 Phylon-White: 0.65 ~ 0.75 J/cm2

Pressing& Cooling

51

Stockfit


8 Stamping ˧ Keeping

• After UV irradiation, mark irradiation date on the surface of the sole.

• UV treated phylon should be kept in a black poly-bag immediately

after irradiation.

• Shelf life after UV irradiation is max 2 weeks.(3 days preferred)

• Tips!

- Time from UV irradiation to stockfit and assembly should be

minimized.

- It is important to follow the time constraints in accordance with

stamped date on the sole.

- “First-in, First-out guide line should be followed at all times to

make sure it does not exceed the time constraints.

Pressing& Cooling

52

Stockfit



• Prepare AQUACE W-08. See page 33 for details.


• Dry at 55~60(surface temp)× 3 min.

• Tips!




material applied.

Pressing& Cooling

53

Stockfit


10 Attach ˧ Press ˧ Cooling(Chilling)

• Attach cemented material as soon as possible.






- Recommended cooling condition: Perform enough chilling to lower

the surface temp of center part of M/S to below 40

Pressing& Cooling

54

Stockfit


Rubber

Phylon

Die-cut EVA

TPU

Pebax

Nylon


& Cooling

55

Stockfit

Die-cutEVA

Roughing Priming CementingPressing& Cooling

1 Roughing

• Rough the bonding area of EVA after skiving.

• Remove residual dust on the surface by air blow.

• Tips!

- Since residual dust on the surface after roughing can cause

bonding problem, it should be removed completely.

2 Priming ˧ Dry

• Apply EVA Primer )to the whole surface of EVA using cotton cloth.

• Dry completely at 45~50(surface temp)×3min ~ 3min 30sec.

• Tips!

- Sufficient amount of primer should be applied.

- Divide primer into 500~600g unit and fill in a bowl with a lid in order

to prevent the solution from evaporating into the air during use.


material applied.

56

Stockfit

Die-cut

EVARoughing Priming

PressingCementing

& Cooling





• Tips!




material applied.

57

Stockfit

Die-cut

EVARoughing Priming Cementing

Pressing

& Cooling

4 Attach ˧ Pressing ˧ Cooling ( Chilling )









5

Stockfit


Rubber

Phylon

Die-cut EVA

TPU

Pebax

Nylon


& Cooling

59

Stockfit

TPUSolvent

PrimingCleaning

PressingCementing

& Cooling

1 Solvent Cleaning

• Wipe the surface of TPU with cotton cloth soaked with solvent(MEK) or solvent-based

cleaner(233seires).

• Dry completely at room temp.×10min or 45~50(surface temp)×2min.

• Tips!

- Refresh the bowl/container with solvent or cleaner on a regular basis to prevent solvent or

cleaner from contamination.

2 Priming

• Apply BONDACE 232-2 or 232HF-2 onto TPU with cotton cloth or brush.

• Tips!

- Sufficient amount of primer should be applied.

- Divide primer into 500~600g unit and fill in a bowl having a lid in order to prevent the solution from

evaporating into the air during use.

60

Stockfit

TPU

3 Dry

SolventCleaning

Priming CementingPressing& Cooling

• Dry completely at 50(surface temp)×3min ~ 3min 30sec.

• Tips!

- The drying condition might change depending on the process or material applied.





• Tips!




61

Stockfit

TPUSolvent

PrimingCleaning

PressingCementing

& Cooling

5 Attach ˧ Pressing ˧ Cooling (Chilling)









62

Stockfit


Rubber

Phylon

Die-cut EVA

TPU

Pebax

Nylon


& Cooling

63

Stockfit

PebaxSolvent

PrimingCleaning

PressingCementing

& Cooling

1 Solvent Cleaning

• Wipe the surface of Pebax with cotton cloth soaked with

solvent(MEK) or solvent-based cleaner(233series).

• Dry completely at room temp.×10min or 45~50(surface

temp)×2min.

• Tips!

- Refresh the bowl/container with solvent or cleaner on a regular

basis to prevent solvent or cleaner from contamination.

2 Priming

• Mix Pebax primer with hardener(Desmodur RFE, 5~7% by primer weight)

and apply to the whole surface of Pebax with cotton cloth.

• Tips!

- Pot life is 3 hrs max.(1 hour preferred)

- Divide primer into 500~600g unit and fill in a bowl having a lid in

order to prevent the solution from evaporating into the air during use.

64

Stockfit

Pebax

3 Dry

SolventCleaning


• Dry completely at 70(surface temp)×above 5min.

• Tips!

- Insufficient drying may result in defective bonding.


material applied.





• Tips!


- Change application tool regularly.(Usually every 30 minutes)


material applied.

65

Stockfit

PebaxSolvent

PrimingCleaning

PressingCementing

& Cooling

5 Attaching ˧ Pressing ˧ Cooling









• Tips!

- If the outsole is Pebax (high hardness property), then the required

pressure is >40 kg/cm2, 8~10 seconds minimum.

66

Stockfit


Rubber

Phylon

Die-cut EVA

TPU

Pebax

Nylon


& Cooling

67

Stockfit

NylonSolvent

PrimingCleaning

PressingCementing

& Cooling

1 Solvent Cleaning

• Wipe the surface of Nylon with cotton cloth soaked with solvent(MEK) or solvent-based

cleaner(233series).


• Tips!

- Refresh the bowl/container with solvent or cleaner on a regular basis to prevent solvent or

cleaner from contamination.

2 Priming

• Mix Nylon primer with hardener(Desmodur RFE, 5~7% by primer weight) and apply to the whole surface

of Nylon with cotton cloth.

• Tips!

- Pot life is 3 hrs max.(1 hour preferred)

- Divide primer into 500~600g unit and fill in a bowl having a lid in order to prevent the solution from

evaporating into the air during use.

68

Stockfit

Nylon

3 Dry

SolventCleaning



• Tips!

- Insufficient drying may result in defective bonding.






• Tips!




69

Stockfit

NylonSolvent

PrimingCleaning

PressingCementing

& Cooling

5 Attach ˧ Pressing ˧ Cooling









70

Assembly


Synthetic leather

F/G leatherA/C leather

Nubuck

Oily leather

Oily nubuck

Nylon mesh

Leathers need Fluid


& Cooling

71

Assembly

Synthetic Solventleather Cleaning

1 Solvent Cleaning


• Wipe the surface of leather with cotton cloth soaked with MEK or

water-based cleaner.


2 Priming

• Apply BONDACE 232HF-2*(SB) or AQUACE W-104*(WB) evenly using

cotton cloth(only for SB primer) or brush. See page 33 for details of

preparation of W-106.

• Tips!

- Mixing with hardener completely prior to application.

• BONDACE 232HF-2: Desmodur RFE=100: 3~5

• AQUACE W-104 : ARF-40 = 100 : 5


order to prevent the solution from evaporating into the air during use.72

Assembly

Synthetic Solventleather Wiping

3 Dry




material applied.





• Tips!




material applied.

73

Assembly

Synthetic Solvent

leather Wiping

5 Attach ˧ Press ˧ Cooling


& Cooling







- Recommended cooling condition: Last temperature measured on the

heel base of the last immediately after de-lasting is below 40

74

Assembly


Synthetic leather


Nubuck

Oily leather

Oily nubuck

Nylon mesh

Leathers need Fluid


& Cooling

75

Assembly

F/G, A/CNubuck

1 Roughing


• Remove the grain layer of leather completely by roughing with wire

roughing M/C or hand roughing M/C.

• Remove residual dust or other contaminants on the surface

completely after roughing by air blow or brush.

• Tips!

- If a sand paper is used for roughing, a proper sand paper should

be selected after considering the thickness of leather surface

layer.2 Priming

• Apply BONDACE 232HF-2*(SB) or AQUACE W-104* or W-105*(WB)

evenly using cotton cloth(only for SB primer) or brush. See page 33 for

details on preparation of W-105 and W-106.

• Tips!


• BONDACE 232HF-2: Desmodur RFE =100:3~5



Assembly

F/G, A/CNubuck

3 Dry


• Dry completely at 50(surface temp)×3’~3’30”.

• Tips!

- The drying condition might change depending on the process

or material applied.





• Tips!




material applied.

77

Assembly

F/G, A/C

NubuckRoughing Priming

PressingCementing

& Cooling








- Recommended cooling condition: Last temperature measured on the

heel base of the last immediately after de-lasting is below 40

7

Assembly


Synthetic leather


Nubuck

Oily leather

Oily nubuck

Nylon mesh

Leathers need Fluid


& Cooling

79

Assembly

Oily leather

Oily nubuck

1 Roughing


• Remove the grain layer having high content of oil completely by roughing

with wire roughing M/C or hand roughing M/C.

• Remove residual dust or other contaminants on the surface completely

after roughing by air blow or brush.

• Tips!

- If a sand paper is used for roughing, a proper sand paper should be

selected after considering the thickness of leather surface layer.

2 Priming

• Apply BONDACE 224-2*(SB) evenly using cotton cloth or brush.

• Tips!


• BONDACE 224-2: ARF-11 =100: 5

• BONDACE 224-2:Desmodur RFE = 100:2~3

- Divide 224-2 into 500~600g and fill in a bowl having a lid in order to

prevent the solution from evaporating into the air during use.

80

Assembly

Oily leather

Oily nubuck

3 Dry



• Tips!




• Apply SB PU adhesive* or AQUACE W-08*(WB) evenly and thinly by

brush.

• Dry completely at 50(surface temp)×min. 3mins for SBA or

55~60(surface temp)×min. 3mins for WBA .

• Tips!

- Mixing with hardener completely prior to application

• SB PU adhesive : Desmodur RFE=100:4~5

• AQUACE W-08 : ARF-40 = 100 : 5

- Divide adhesive into 500~1000g unit and fill in a bowl having a lid in


Assembly

Oily leather

Oily nubuckRoughing Priming Cementing

Pressing

& Cooling





- Required pressure

• For Assembling: 30 kg/cm2, 10~12 seconds minimum



- Recommended cooling condition: Last temperature measured on

the heel base of the last immediately after de-lasting is below

40

82

Assembly


Synthetic leather


Nubuck

Oily leather

Oily nubuck

Nylon mesh

Leathers need Fluid


& Cooling

83

Assembly

Nylon Solventmesh cleaning

1 Solvent cleaning


• Wipe the surface of Nylon with with solvent(MEK) or solvent-based

cleaner(233series).


• Tips!

- Slightly scratch the surface with sand paper(100~200) if necessary.

- Refresh the bowl/container with solvent or cleaner on a regular

basis to prevent solvent or cleaner from contamination.

2 Priming

• Apply a primer evenly using cotton cloth or brush.

• BONDACE 224-2, D-PLY 160-2 or D-PLY 167 can be applied.

• Tips!


• BONDACE 224-2 : Desmodur RFE =100 : 2~3

• D-PLY 160-2 or 167 : Desmodur RFE=100 : 5~7

84

Assembly

Nylon Solventmesh wiping

3 Dry



• Tips!







• Tips!




material applied.

85

Assembly

Nylon Solvent

mesh wiping



& Cooling




- Required pressure

• For Assembling: 30 kg/cm2, 10~12 seconds minimum



- Recommended cooling condition: Last temperature measured on

the heel base of the last immediately after de-lasting is below

40

86

Summary of Bonding Process

Material

Rubber

Phylon

Die-cut EVA

TPU

Pebax

Nylon

Pretreatment

CL-800A + Water &CL-800B + Water

CL-800B + Water

Roughing

MEK or 233 series

MEK or 233 series

MEK or 233 series

Priming

PR-505A or 505ID +Powder(2 wt%)

P-5-2 + UV or P-7-2

008-2

232F-2 + D-RFE(3-4wt%) or232HF-2 + D-RFE(3-4wt%)

167 + D-RFE(5-7wt%) or160-2 + D-RFE(5-7wt%)

167 + D-RFE(5-7wt%) or160-2 + D-RFE(5-7wt%)

Cementing

W-08

+ARF-40 (5 wt%)

WB SB

87

Summary of Bonding Process

Material

Synthetic leather

Full grain leatherAction leatherNubuck

Nylon mesh

Oily leatherOily nubuck

Pretreatment

MEK or

CL-811

Roughing

MEK or 233 series

Roughing

Priming

232HF-2+D-RFE(3-4wt%) or

W-106 + ARF-40(5wt%)

232HF-2+D-RFE(3-4wt%) or

W-105 + ARF-40(5wt%) orW-106 + ARF-40(5wt%)

224-2 + D-RFE(3-4wt%) or167 + D-RFE(5-7wt%) or160-2 + D-RFE(5-7wt%)

224-2 + ARF-11(5wt%)224-2 + D-RFE(3-4wt%)

Cementing

W-08

+

ARF-40 (5 wt%)

SB PU adhesive +D-RFE (4-5wt%)

W-08 +

ARF-40(5wt%)

WB SB

88

Troubleshooting

VOC evaporation

Trouble Solution

The workplace is contaminated with solvent which • Use a good bowl/dispenser which can reduce

evaporates from adhesive. evaporation of solvent.

• Install a local ventilation and wear necessary PPE.

• Consider the use of VOC-reduced adhesive such

as water-based type or hot-melt.

89

Troubleshooting

Fluorescent lamp

Trouble

Since fluorescent lamp is placed deep inside of the

chamber, workers may feel annoyed by confirming the

coverage of primer for each substrate through pushing

the primed substrate toward deep inside of the chamber.

Conveyor

A cross-section of the chamber

Solution

Move fluorescent lamp to the outside so that workers

can confirm the coverage of primer quickly and easily.

Conveyor

90

Troubleshooting

UV dosage

Trouble

1. Different UV dosage (intensity) on side and center.

Especially on wall with high height, insufficient UV

is irradiated.

2. Not checking regularly for constant UV dosage.

Solution

1. Adjust the angle of a reflecting mirror to give

almost same UV dosage regardless of bonding

area, and clean the mirror regularly to increase

reflecting effect.

2. Check UV dosage every 2 hours with UV

radiometer.

UV radiometer

91

Troubleshooting

Hardener

Trouble

If open the cap of hardener opened frequently, moisture

in the air may penetrate into the hardener. Then the

quality of hardener deteriorates.

Solution

Use only required amount by pouring into an appropriate

dispenser having a cap. Residual hardener should be

capped tightly and stored in a cool and dry area.

92

Troubleshooting

Pot life

Trouble Solution

Workers could forget the time of changing adhesive (pot- Mark the time to change adhesive on the bowl or

life), for example, if they are busy. dispenser so that workers can recognize the time and

use adhesive properly.

93

Troubleshooting

Coating weight

Trouble

As workers get familiar with water-based adhesive, they

follow application method of water-based type, applying

thinly, even when applying solvent-based type. So

bonding problem may caused due to insufficient coating.

Solution

The solids content of water-based adhesive is much

higher than that of solvent-based type. For example,

water-based PU contains 50% of solids while solvent-

based type has 20%. Therefore, supervisors should train

their employees to differentiate coating amount of water-

based type from solvent-based type.

94

Troubleshooting

Application tool

Trouble Solution

Excessive amount of adhesive by using a thick brush Use an appropriate-thickness brush considering its

causes puddling on the surface of substrate and makes purpose.

brush hard.

95

Troubleshooting

Contamination

Trouble

If using a cleaner not refreshing or changing regularly, it

could be contaminated by the application tool which has

contacted with contaminated substrate. Then, certain

contaminants may concentrate in the cleaner.

Solution

• Refresh or change with new cleaner regularly to

minimize contamination of cleaner in use.

• Change an application tool regularly by marking

exchanging time on a deposit case.

96

Troubleshooting

HMA applicator

Trouble

When running HMA applicator with small amount of hot-

melt in the thank, or leaving the applicator heat at high

temperature, melted adhesive in the nozzle and hose

chars. Charred adhesive makes bonding area stained.

Solution

• Charge hot-melt in the tank at 50~70% of the tank

capacity.

• Reduce temperature when on standby.

• Clean the tank (once a week) and nozzles (once a

day) regularly.

97

PPE

Safety glasses

A. Safety glasses with side shield

Protect eyes against chemical splashes from

hot liquids, solvents or hazardous solutions.

B. UV-resistance glasses

Protect eyes against intense concentrations of UV.

Safety gloves

A. Chemical-resistant gloves

Protect hands against chemical splashes from

solvents or hazardous solutions.

B. Thermal-protection glovesProtect hands against chemical splashes from hot

liquids (hot-melt adhesive)

Protective clothingProtect body against chemicals, hot splashes or

physical hazards. Ensure that the protective clothing

selected will provide protection against the specific

hazard.

A B

A B

98

PPE

Local ventilation

Protect respiratory system against gas, vapor

Contaminants, particulate contaminants and other air

Contaminants. Ensure compliance with applicable

exposure limits.

Chemical mask

Protect respiratory system against gas, vapor

contaminants particulate contaminants and other air

contaminants,. Wear chemical mask whenever

engineering and work practice control measures are

not adequate to prevent atmospheric contamination at

the worksite. Ensure that the mask selected will

provide protection against the specific hazard.

Dust mask

Protect respiratory system against particulate

contaminants. Wear dust mask whenever

engineering and work practice control measures are

not adequate to prevent atmospheric contamination at

the worksite. Ensure that the mask selected will

provide protection against the specific hazard.

99

PPE

Employers should explore all possible engineering and work practice

controls to eliminate hazards and use PPE (Personal Protective

Equipment) to provide additional protection against hazards that cannot

be completely eliminated through other means.

- from “Personal Protective Equipment” established by OSHA

100

Q & A

101

training basic (nx power_lite)_india_20111115 (2)

Education

adhesive adhesion

adhesive application

c adhesive adhesive

liquid adhesive

footwear adhesive

waterbased adhesive

definition adhesive

terminology viscosity