The Two-Component Revolution

June 1, 2007
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New technology reduces maintenance downtime.

The MS-C at work.


A new two-component mixing head features a patented, servo-driven ceramic valve system. The RAMPF MS-C dynamic mixing system simplifies two-component meter, mix and dispensing operations by reducing downtime for cleaning and maintenance. This is accomplished by a ceramic valve disk system with no dynamic seals. Maintenance time is reduced because the ceramic valves do not require the frequent cleaning and rebuilding of needle valves. The ceramic valve and mixing sections are separate, allowing the mixing chamber and mixer to drop down with a quick coupler for a rapid change. Recirculation of the components through the mix head keeps the materials consistent from shot to shot. Temperature-control systems are available that stabilize the materials regardless of ambient conditions.

The process begins with gear pumps precisely metering the resin and catalyst entering the mixing head, ensuring that the correct mix ratio is held. The MS-C servo motor rotates the valve disks to the proper position, aligning the valve openings. The servo also turns the mixer up to 6,000 rpm to energize and thoroughly blend the materials. The shutoff valve is opened and the shot is made. The MS-C is capable of dispensing 2 g/sec. and up to 120 g/sec., and mixes two to three components at viscosities of 50-200,000 cps. A rinsing system of either solvent or high-pressure water automatically flushes the mixing chamber.

The RAMPF MS-C mixing head is available in two different sizes for output rates between 2 g/s and 120 g/s.

The mixing system is more robust with less dynamic seals wear items and required spare parts. Older, complex mix-head designs require a preventative maintenance schedule that keeps systems running if adhered to. However, if maintenance is neglected, problems result. This new design is significant because problems with resin dispensing systems usually aren’t noticed until hundreds of bad parts are produced.

Two-component reactive materials, such as polyurethane, silicone or epoxy, consist of a resin and a catalyst. The materials must be metered to the proper mix ratio, mixed and dispensed. Some materials, such as polyurethane and silicone foams, require dynamic mixing - blending the two components using a high-speed mixer. As the materials are continually metered and mixed, the system must be capable of maintaining an accurate mix ratio while dispensing multiple shots.

The servo-driven ceramic valve system combines precision, reliability and durability.

The RAMPF MS-C dynamic mixing head solves many problems associated with processing reactive resins.
  • Its internal ceramic valve system does not require frequent inspection, maintenance or cleaning.
  • High output rates to 120 grams per second are possible, as well as precise dispensing down to 2 g/sec.
  • Accurate mix ratios are consistently held.
  • Precise nucleation levels are monitored by a RAMPF nucleation controller.
In addition, the MS-C system features a clean, compact design, very few parts and one servo motor for the mixer and valve system.

The MS-C system replaces the needle valves used in a conventional dynamic mix head with the internal ceramic valve system, thereby reducing maintenance headaches for users. Older mix heads require one valve for the resin, another valve for the catalyst and valves for air and cleaning solvents. These valves must be cleaned and maintained in order to operate properly. Should a valve become restricted, the mixing ratios can become flawed. Preventative maintenance on the valves consists of frequent cleaning of the valve tip, as well as valve rebuilding, since dynamic seals are wear items. When this maintenance is neglected, the mix ratio can change and result in scrap parts. Older mix-head designs may be extraordinarily complex. Some dynamic, two-component mix heads may have as many as 360 parts and one material valve that consists of 100 parts by itself. These older designs are difficult to maintain and service. Material valves with this degree of complexity may have to be returned to the factory for rebuilding, requiring backup inventory of all valves.

The new RAMPF MS-C combines simple design with high-tech ceramic materials to reduce downtime and keep production up and running.

For more information, contact RAMPF Group Inc., 50714 Century Court, Wixom, MI 48393; phone (248) 295-0223; fax (248) 295-0224; e-mail info@rampf-group.com; or visit www.rampf-group.com.

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