Project Background Problem Statement Final Concept Operational ...
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Project Background Problem Statement Final Concept Operational ...
Sample Test Bed. Pressure Sensitive. Adhesive. Lockdown Fixture. Final
Concept. Operational Procedure. Project Transition. Our validation consists of
two parts ...
Team 6:
Di Ena M. Davis , Mark Deaver, Julia Levinson, Amanda Long
Sponsors: Chris Polizzi, Rob Carlozzi, Tom Cooper, Steve Stark Advisor:
Project Background The filter products that W.L. Gore produces consist of a combination of a backing material and expanded polytetrafluoroethylene (ePTFE) membrane. Bond integrity testing is an important step in the quality assurance of this manufactured product because it quantifies that the laminate bond is up to industry standards.
Final Concept
Stud
Hot Roller
Pressure Sensitive Adhesive
•Distinguishes source of variability
Problem Statement
To design and validate a process to quantify the bond strength between components of a membrane-backer laminate.
Benchmarking Not effective; Grips fail before membrane Membrane
ASTM Standard
Time consuming procedure
1 Cut Samples Take two right, center and left samples each from the material.
2 Adhere Samples to Plate Backer
Hydraulic Pressure
Design Specs Need new process to meet the following desires not met by current quality assurance testing methods:
Adhere all 6 samples to single testing plate.
Value Reflecting Bond Strength
•
Operator Steps
•
Operator Variability
•
Cycle Time
•
Other
Y
Right
Center
Left
Down-Web
Samples are taken in the cross-web direction from the right, center, and left locations. 180 Peel vs. Stud Pull
Correlation Study •Distinguishes level of Resolution •Determines Relationship (linear, exponential, etc.)
3 Secure Plate in Lockdown Fixture Align plate and rotate screw dials fully to lock the plate down.
4 Prepare Stud
180 Peel (units of Force)
Place adhesive on stud and attach stud to arm.
5 Begin Automated Test Click “begin a test” and then wait to collect data.
6 Remove Stud and Slide Plate Down The plate will be advanced by one testing unit each time.
•
C
A stud of which the end is covered with pressure sensitive adhesive is attached to the crosshead of the forcing machine. The machine then applies a compressive force to the sample for a specified dwell time. It then retracts from the sample separating the membrane from the backer and records the maximum force required; the maximum force corresponds to the bond strength of the sample.
Operational Procedure
Water Pressure Removal •
Lockdown Fixture
Sample Test Bed
R
Stud Pull (units of Force)
Recent product innovations have created more robust membranes. The current method is not always useful, therefore a new method is necessary.
•
EMP Study
eb W s s o r C
Soft Roller
180° Peel Test
Our validation consists of two parts. One is analyzing variability of the test by performing an Evaluation of the Measurement Process (EMP) study. The other is a correlation study to determine the relationship between our test method and the benchmark.
•Determines usefulness of measurement
Backer
End Product
Backer
Validation
The chosen concept uses an automated Texture Analyzer to “muscle” the membrane away from the backer by applying force in the z-direction.
Membrane Membrane
Jim Glancey
7 Repeat Steps 4 through 6 Repeat above steps until all samples have been tested.
8 Reset Testing Apparatus
Remove the stud and plate from device. The samples and adhesive must be removed from the plate. The adhesive on the stud must also be removed.
Project Transition •Adhesive Research •Membrane or Adhesive Yielding •Statistical Study on Bond Ranges
