tremco illbruck has taken a holistic approach in developing the new JS910 hybrid sealant for insulating glazing. The new secondary sealant is user and process-friendly, whilst at the same time being compatible with workplace safety and environmental requirements. The new technology not only optimises the features of the insulating glass and offers practical benefits in the production process, it also dispenses with substances which are hazardous to people or the environment.
Water-based and free from hazardous substances
In technical terms, JS910 is an innovative polymer which integrates the organic chemistry of carbon with the inorganic chemistry of silicon. The result is a product which combines the key application and performance benefits of silicon, polyurethane and polysulphide. At the same time JS910 dispenses with hazardous substances from the existing technologies (such as isocynate, chlorinated paraffins, heavy metals etc.). Instead, JS910 is water-based and therefore requires no hazard pictograms.
Flexible curing in all circumstances
In this case, the progress in the production process for manufacturing insulating glass is primarily an advance in the curing process. JS910 A is an one-component product with a booster component B. The product is ideally used in the standard 10:1 (100:10) volume mixing ratio. However, the mixing tolerance is exponentially higher. The curing process of all established 2C sealants is affected by fluctuations in dosage, however JS910 also cures completely without the B-component. This means that curing will always take place, even if an incorrect mixing ratio is used, and there will be no residual soft spots in the edge seal.
Using a standard mixing ratio of 100:10, the curing will occur faster than with PU or PS, but with analogue Shore A Hardness. Consequently, mechanical strength is achieved quickly, at the same time as long-term flexibility of the edge seal. The completed insulating glass units can therefore be transported quickly, whilst also being durable. The additional benefits of JS910:
- Reduced contamination of the mixer – lower set up and cleaning times and fewer exchanges of parts
- Can be disposed of as residual waste – reduced disposal costs for rinsing material and end product
- No risk to employees working on the equipment – improved working conditions and minimised health risk
- Guaranteed availability of raw materials – the components of JS910 are available long-term.
Sales force present during changeover
The changeover of the manufacturing process to JS910 requires no more extra effort or expense than a change between PU and PS, for example. Parts which wear, such as seals and hoses, need to be replaced (in part) and the production facility washed down carefully. tremco illbruck's technical support is available to assist with any stage of the process. Experts will support the start-up and fine-tuning of the machines, working together with the equipment manufacturer’s engineers, where necessary.
Comprehensive testing and documentation
JS910 can be used with all established spacer systems – rigid and flexible, metal and warm edge. The wide adhesion spectrum allows for use with all commercially available types of glass. tremco illbruck tests the application of products and their compatibility with other products using the DI-01/1 and VE-05/1 ift guidelines and also in accordance with DIN 18545 and other standards, as required. Due to the absence of aggressive substances in JS910, a higher level of compatibility can generally be expected. However, in any case, the usual individual testing is still required. The manufacturer documents all product combinations which have already been tested and make the test results available, on demand. Where necessary, further testing will be carried out.
Apart from the obligatory system tests according to EN1279, JS910 is already tested by CEKAL and the respective production facilities audited. tremco illbruck has supplemented the climatic chamber system checks specified by EN and CEKAL with additional internal long-term testing. The results do not show any negative deviation compared to existing sealant technologies. As regards UV resistance, a significant improvement in durability has been determined.