Title of Invention	AN ASBESTOS FREE SEALANT AND A PROCESS FOR PREPARATION OF AN ASBESTOS FREE SEALANT MATERIAL FOR USE AS SEALANT AT JOINTS IN FUEL INJECTION PUMPS-DRY METHOD
Abstract	An Asbestos Free Sealant material suitable for use of the fuel injection pumps. A process for preparation of an Asbestos Free Sealant material! wherein said process, comprises of the steps in sequence :- a. Dry Mixing (Dry Proces) b. Hot Calendering Process (Dry Process) A process as claimed in Claim 2 for preparation of an Asbestos Free Sealant material suitable for use of the fuel Injection pumps, comprising the steps of, in sequence. a. subjecting the polymers to mixing and milling process b. subjecting pulp and fillers to mixing, c. said mixtures of Step 2(a) and 2(b) being combined and mixed

Title of Invention

AN ASBESTOS FREE SEALANT AND A PROCESS FOR PREPARATION OF AN ASBESTOS FREE SEALANT MATERIAL FOR USE AS SEALANT AT JOINTS IN FUEL INJECTION PUMPS-DRY METHOD

Abstract

An Asbestos Free Sealant material suitable for use of the fuel injection pumps. A process for preparation of an Asbestos Free Sealant material! wherein said process, comprises of the steps in sequence :- a. Dry Mixing (Dry Proces) b. Hot Calendering Process (Dry Process) A process as claimed in Claim 2 for preparation of an Asbestos Free Sealant material suitable for use of the fuel Injection pumps, comprising the steps of, in sequence. a. subjecting the polymers to mixing and milling process b. subjecting pulp and fillers to mixing, c. said mixtures of Step 2(a) and 2(b) being combined and mixed

Full Text	Background of the invention A sealant is a substance used to sea! joints the commonly known type is the asbestos Seaia nt. This invention relates to an Asbestos Free Sealant and a process for preparation of an asbestos free sealant material suitable for the use of Fuel injection pumps, to enhance the seating effect in ait critical points. Known Prior Art Currently in fuel injection pumps. Asbestos sealants are being used to seal the critical joints. The sealing agent is expected to hold the lubricating oil inside the pump and possess adequate compression strength, high and low temperature resistance and temperature shock, controlled swelling behaviour in oil, vibration resistance, fuel resistance, etc The asbestos is carcinogenic. The disadvantage is that It has adverse effect on human skin and is health hazardous. Object of the invention The object of this invention is to provide a new sealant, wherein use of Asbestos is eliminated and to make it environment friendly. It is another object of the invention to arrive at an end product whose quality is better than currently available. It is another object of the invention, in the context of present trend in the international arena towards elimination of Asbestos in sealant preparation, to prepare Asbestos free sealant. According to the invention, the enhanced quality of the sealant originates from the composition and also from the controlled process which has been developed by the inventors. Summary of the invention According to the invention, the sheet for sealant is formed by Mixing (Dry Process) and Hot Calendering process. During the process, the necessary ingredients are added in required quantity and sequence while maintaining the process parameters to the specified values. Description of the invention The sealant, according to invention carried out for resolving the aforementioned disadvantages, involves the said process comprising of steps :- a. Dry mixing (Dry Process), b. Hot Calendering Process (Dry Process) The process is now described herein below in its broadest scopes and aspect and the possible variant features and characteristics of the invention are described along with equivalent features and characteristics in the preferred embodiment Step 1: Mixing & Milling Process In this Process, the natural rubber is masticated by which the material is permanently softened for further mixing with the nitrite rubber in the required ratio. The mastication is carried out at 45 - 50 rpm and pressure 2.3 - 3 bar. With this, the binder, which is a combination of natural and nitrite rubber is ready for use. Step 2: Chopping and Mixing process The synthetic pulp fe chopped to shorten the length by chopping after the fillers are mixed in the required ratio in a mixer for uniform mixing to avoid agglomeration of the pulp which is essential for the smooth, uniform surface finish of the end product. The binder (a mixture of nitrite and natural rubber ds ly4 - pofyisoprene.) & other vulcanising chemicals are mixed and the mixing ts continued for 10 mins at low rpm mode to ensure that a uniform distribution is achieved. In this process, 2 different compositions are prepared for the manufacture of the sheet as a 3 layer system termed as w XYX" layers where in the * X & X" are the outer layers having the same composition and the " Y" layer, middle layer or body layer which contributes the major portion of the required thickness in having a different composition. Each mix is prepared separately and made into a dough form by adding Toulene (375 - 400 ml.) and the mixing is continued for 2 - 3 mins for uniform mix. Care is be token that the temperature does not exceed beyond 35° C to avoid premature reaction of the vulcanising chemicals. Step 2 A Outer layer - Composition The outer layer in the manufacture of sheet is having the following compositions. As per the invention, an Asbestos Free Sealant and a process for preparation of an asbestos free sealant material for use as sealant at all critical joints in fuel injection pumps, wherein said process the operating temperature is below 35°C and comprises of the following steps In sequence : a. subjecting the synthetic pulp to dry mixing process with binders and vulcanizing chemicals to form plurality of outer and inner compositions with different ratio of binders, b. forming a triple layer with single inner composition sandwiched with outer composition on its two sides by means of calendering at a temperature of 120C-125C. The said process for preparation of an asbestos free sealant material for use as sealant at all critical joints in fuel injection pumps, wherein the said dry mixing process comprises of steps : - a. synthetic pulp is chopped under continuous churning to shorten the length, b. adding fillers to synthetic pulp to form a smooth pulp, c masticating natural rubber at pressure 2-3 bar at 25-rpm to form a binder, d. adding binder to the synthetic pulp under continuous stirring in two different ratio to form a plurality of first outer composition and second inner composition, e. adding vulcanizing chemical under continuous stirring, f. adding toluene (375-400ml) to form a dough, g. stirring is continued for further 10 minutes under 1000 rpm, h. stirring is continued for further 10 minutes, i. coaling off and maturing the two compositions at room temperature for 24 hours. The said process for preparation of an asbestos free sealant material for use as sealant at ail critical joints in fuel injection pumps, wherein said calendering process, comprising the steps of: a. preparing a triple layer tubular form with single inner composition sandwiched with outer composition on its two sides, such the first outer composition thickness is 40-50 urn, built up thickness of first outer composition and inside composition is 0.45 mm and total thickness of first outer composition, inside composition and said outer composition is 0.50 mm by means of a roller at a roller pressure 34- 36 bar, roller speed 14-15 M/min and at a roller temperature 120°C- 125PC, cut open the tubular open to form a sheet, b. allowing the sheet to cool off in room temperature. Physical and Mechanical Properties Achieved 1 Appeara nee Pale brown yellowish sheet in single layer, glossy finish, smooth and without any fibrous cut edges. 2 Material structure Organic fibrous material with inorganic filters and a blend of NR - NBR as binder. 3 Thickness 0,45 to 0,55mm 4 Density 1.65 to 1.75 gm/cm3 (DIN 53479) 5 Ignition toss 27 - 30% (DIN 52911) 6 Shear Resistance Along the fiber : 27 to 29 N/mm2 (DIN 52910) Across the fiber: 12 to 13 N/mm2 7 Deformation Compression : 16..18% Characteristics Recovery : 55...60% (ASTM-F36PartA) 8 Resistance +17.5 to +24.5 (Volume change ) toASTM OHNo2atl0r/C-24h 9 Shear Resistance after Along the fiber: 23.25N/mm2 storage in ASTM Oil No Across the fiber : 10...11N/mm2 2 at 150°C - 24h Test Procedure - Moisturize the test specimen and measure the initial thickness within 5s. - Place the specimen ewer the table of thickness gauge and lift me measurement base. - Measure volume change after 30s (within 5s) - Record 10 readings after every 30s on an approximate curve (graph) - Report thickness change at 180s (Reported value should be the average of 5 samples) Important functional properties achieved - Pressure Tightness : The material developed has shown excellent pressure tightness property as a sealant of fuel injection pump at the critical joints upto a pressure of L 5 bar under adverse assembly conditions. - Torque properties : The specified ratio of initial tightening torque to further tightening torque is minimum 0.45. The material developed has always exhibited a ratio higher than 0.8 in all trials with different and severe test conditions ( vibtration, temperature etc.,) - Temperature resistance : The material possesses good temperature resistance between - 40°C and + 140°C without affecting the pressure tightness. - Vibration resistance : The material developed is able to function without any leakage under conditions of vibration specified for fuel injection pump coupled with elevated temperature upto 10O°C Illustration of the Invention Figure 1 illustrates the sequential processes as per the invention wherein the six steps of process involved in preparation of asbestos free sealant by dry method. In the step(l), the binder is prepared by mixing and milling process wherein the natural fiber is masticated with the nitrite rubber in required ratio and then in step(2), the synthetic pulp is chopped under continuous churning to shorten the length and then it is mixed with filters, binders, under continuous stirring in two different ratio to form a plurality of first outer composition and second inner composition. Then the mixture is mixed with vulcanizing chemicals and toulene under continuous stirring to form a dough. Then in step(3) the mixture prepared for the outer layer and inner layer is allowed for maturation process at room temperature for 24 hours. Then a triple layer tubular form with single inner composition sandwiched with outer composition on its two sides is prepared by calendering process in step(4) by means of a roller at a temperature of 120°C- 123°C and at a pressure 34-36 bar with a speed 14-15 M/min and resulting in the formation of a sheet. Then the sheet formed is allowed to cool off in room temperature in step(5) and then it is tested in step(6). WE CLAIM : - 1. An Asbestos free sealant and a process for preparation of an asbestos free sealant material for use as sealant at alt critical joints in fuel injection pumps, wherein said process the operating temperature is below 35°C and comprises of the following steps in sequence : - subjecting the synthetic pulp to dry mixing process with binders and vulcanizing chemicals to form plurality of outer and inner compositions with different ratio of binders, and - forming a triple layer with single inner composition sandwiched with outer composition on its two sides by means of calendering at a temperature of 120°C- 125°C 2. A process for preparation of an asbestos free sealant material for use as sealant at all critical joints in fuel injection pumps as claimed in claim 1, wherein the said dry mixing process, comprising the steps of: a. synthetic pulp is chopped under continuous churning to shorten the length, b. adding fillers to synthetic pulp to form a smooth pulp, c masticating natural rubber at pressure 2-3 bar at 25-rpm to form a binder, d. adding binder to the synthetic pulp under continuous stirring in two different ratio to form a plurality of first outer composition and second inner composition, e. adding vulcanizing chemical under continuous stirring, f. adding toluene (375-400ml) to form a dough, g. stirring is continued for further 10 minutes under 1000 rpm, h. stirring is continued for further 10 minutes, i. cooling off and maturing the two compositions at room temperature for 24 hours. 3. A process for preparation of an asbestos free sealant material for use as sealant at all critical joints in fuel injection pumps as claimed in claim 1, wherein said calendering process, comprising the steps of: - preparing a triple layer tubular form with single inner composition sandwiched with outer composition on its two sides, such the first outer composition thickness is 40-50 urn, built up thickness of first outer composition and inside composition is 0.45 mm and total thickness of first outer composition, inside composition and said outer composition is 050 mm by means of a roller at a roller pressure 34- 36 bar, roller speed 14-15 NVmin and at a roller temperature 120°C- 125°C, cut open the tubular open to form a sheets - allowing the sheet to cool off in room temperature. 4. A process for preparation of an asbestos free sealant material for use as sealant at aH critical joints in fuel injection pumps as claimed in claim 1, 2 & 3, wherein Step 2d, the first outer composition has the following ingredients and composition.' Torque properties : Initial tightening torque to further tightening torque ratio higher than 0.8 under different and severe test conditions ( vibration, temperature etc,) Temperature resistance : Good temperature resistance between - 40°C and 4- 140°C without affecting the pressure tightness. Vibration resistance : The material developed is able to function without any leakage under conditions of vibration specified for fuel injection pump coupled with elevated temperature upto 100°C.

Full Text

Background of the invention
A sealant is a substance used to sea! joints the commonly known type is the asbestos Seaia nt.
This invention relates to an Asbestos Free Sealant and a process for preparation of an asbestos free sealant material suitable for the use of Fuel injection pumps, to enhance the seating effect in ait critical points.
Known Prior Art
Currently in fuel injection pumps. Asbestos sealants are being used to seal the critical joints. The sealing agent is expected to hold the lubricating oil inside the pump and possess adequate compression strength, high and low temperature resistance and temperature shock, controlled swelling behaviour in oil, vibration resistance, fuel resistance, etc
The asbestos is carcinogenic. The disadvantage is that It has adverse effect on human skin and is health hazardous.
Object of the invention
The object of this invention is to provide a new sealant, wherein use of Asbestos is eliminated and to make it environment friendly.
It is another object of the invention to arrive at an end product whose quality is better than currently available.
It is another object of the invention, in the context of present trend in the international arena towards elimination of Asbestos in sealant preparation, to prepare Asbestos free sealant.

According to the invention, the enhanced quality of the sealant originates from the composition and also from the controlled process which has been developed by the inventors.
Summary of the invention
According to the invention, the sheet for sealant is formed by Mixing (Dry Process) and Hot Calendering process. During the process, the necessary ingredients are added in required quantity and sequence while maintaining the process parameters to the specified values.
Description of the invention
The sealant, according to invention carried out for resolving the aforementioned disadvantages, involves the said process comprising of steps :-
a. Dry mixing (Dry Process),
b. Hot Calendering Process (Dry Process)
The process is now described herein below in its broadest scopes and aspect and the possible variant features and characteristics of the invention are described along with equivalent features and characteristics in the preferred embodiment
Step 1: Mixing & Milling Process
In this Process, the natural rubber is masticated by which the material is permanently softened for further mixing with the nitrite rubber in the required ratio. The mastication is carried out at 45 - 50 rpm and pressure 2.3 - 3 bar. With this, the binder, which is a combination of natural and nitrite rubber is ready for use.

Step 2: Chopping and Mixing process
The synthetic pulp fe chopped to shorten the length by chopping after the fillers are mixed in the required ratio in a mixer for uniform mixing to avoid agglomeration of the pulp which is essential for the smooth, uniform surface finish of the end product. The binder (a mixture of nitrite and natural rubber ds ly4 - pofyisoprene.) & other vulcanising chemicals are mixed and the mixing ts continued for 10 mins at low rpm mode to ensure that a uniform distribution is achieved.
In this process, 2 different compositions are prepared for the manufacture of the sheet as a 3 layer system termed as w XYX" layers where in the * X & X" are the outer layers having the same composition and the " Y" layer, middle layer or body layer which contributes the major portion of the required thickness in having a different composition.
Each mix is prepared separately and made into a dough form by adding Toulene (375 - 400 ml.) and the mixing is continued for 2 - 3 mins for uniform mix. Care is be token that the temperature does not exceed beyond 35° C to avoid premature reaction of the vulcanising chemicals.
Step 2 A Outer layer - Composition
The outer layer in the manufacture of sheet is having the following compositions.

As per the invention, an Asbestos Free Sealant and a process for preparation of an asbestos free sealant material for use as sealant at all critical joints in fuel injection pumps, wherein said process the operating temperature is below 35°C and comprises of the following steps In sequence :
a. subjecting the synthetic pulp to dry mixing process with binders and
vulcanizing chemicals to form plurality of outer and inner compositions
with different ratio of binders,
b. forming a triple layer with single inner composition sandwiched with outer
composition on its two sides by means of calendering at a temperature of
120C-125C.
The said process for preparation of an asbestos free sealant material for use as sealant at all critical joints in fuel injection pumps, wherein the said dry mixing process comprises of steps : -
a. synthetic pulp is chopped under continuous churning to shorten the
length,
b. adding fillers to synthetic pulp to form a smooth pulp,
c masticating natural rubber at pressure 2-3 bar at 25-rpm to form a binder,
d. adding binder to the synthetic pulp under continuous stirring in two
different ratio to form a plurality of first outer composition and second
inner composition,
e. adding vulcanizing chemical under continuous stirring,
f. adding toluene (375-400ml) to form a dough,
g. stirring is continued for further 10 minutes under 1000 rpm,
h. stirring is continued for further 10 minutes,
i. coaling off and maturing the two compositions at room temperature for 24 hours.
The said process for preparation of an asbestos free sealant material for use as sealant at ail critical joints in fuel injection pumps, wherein said calendering process, comprising the steps of:

a. preparing a triple layer tubular form with single inner composition
sandwiched with outer composition on its two sides, such the first
outer composition thickness is 40-50 urn, built up thickness of first
outer composition and inside composition is 0.45 mm and total
thickness of first outer composition, inside composition and said outer
composition is 0.50 mm by means of a roller at a roller pressure 34-
36 bar, roller speed 14-15 M/min and at a roller temperature 120°C-
125PC, cut open the tubular open to form a sheet,
b. allowing the sheet to cool off in room temperature.
Physical and Mechanical Properties Achieved
1 Appeara nee Pale brown yellowish sheet in single layer,
glossy finish, smooth and without any fibrous cut edges.
2 Material structure Organic fibrous material with inorganic filters
and a blend of NR - NBR as binder.
3 Thickness 0,45 to 0,55mm
4 Density 1.65 to 1.75 gm/cm3 (DIN 53479)
5 Ignition toss 27 - 30% (DIN 52911)
6 Shear Resistance Along the fiber : 27 to 29 N/mm2 (DIN 52910) Across the fiber: 12 to 13 N/mm2
7 Deformation Compression : 16..18% Characteristics Recovery : 55...60% (ASTM-F36PartA)
8 Resistance +17.5 to +24.5 (Volume change ) toASTM
OHNo2atl0r/C-24h
9 Shear Resistance after Along the fiber: 23.25N/mm2
storage in ASTM Oil No Across the fiber : 10...11N/mm2
2 at 150°C - 24h

Test Procedure
- Moisturize the test specimen and measure the initial thickness within 5s.
- Place the specimen ewer the table of thickness gauge and lift me measurement base.
- Measure volume change after 30s (within 5s)
- Record 10 readings after every 30s on an approximate curve (graph)
- Report thickness change at 180s (Reported value should be the average of 5
samples)
Important functional properties achieved
- Pressure Tightness : The material developed has shown excellent pressure
tightness
property as a sealant of fuel injection pump at the critical joints upto a pressure of L 5 bar under adverse assembly conditions.
- Torque properties : The specified ratio of initial tightening torque to further tightening torque is minimum 0.45. The material developed has always exhibited a ratio higher than 0.8 in all trials with different and severe test conditions ( vibtration, temperature etc.,)
- Temperature resistance : The material possesses good temperature resistance between - 40°C and + 140°C without affecting the pressure tightness.
- Vibration resistance : The material developed is able to function without any leakage under conditions of vibration specified for fuel injection pump coupled with elevated temperature upto 10O°C
Illustration of the Invention
Figure 1 illustrates the sequential processes as per the invention wherein the six steps of process involved in preparation of asbestos free sealant by dry method. In the step(l), the binder is prepared by mixing and milling process wherein the natural fiber is masticated with the nitrite rubber in required ratio and then in step(2), the synthetic pulp is chopped under continuous churning to shorten the length and then it is mixed with filters, binders, under continuous stirring in two different ratio to form a plurality of first outer composition and second inner composition. Then the mixture is mixed with vulcanizing chemicals

and toulene under continuous stirring to form a dough. Then in step(3) the mixture prepared for the outer layer and inner layer is allowed for maturation process at room temperature for 24 hours.
Then a triple layer tubular form with single inner composition sandwiched with outer composition on its two sides is prepared by calendering process in step(4) by means of a roller at a temperature of 120°C- 123°C and at a pressure 34-36 bar with a speed 14-15 M/min and resulting in the formation of a sheet. Then the sheet formed is allowed to cool off in room temperature in step(5) and then it is tested in step(6).

WE CLAIM : -
1. An Asbestos free sealant and a process for preparation of an asbestos free
sealant material for use as sealant at alt critical joints in fuel injection pumps,
wherein said process the operating temperature is below 35°C and comprises of
the following steps in sequence :
- subjecting the synthetic pulp to dry mixing process with binders and vulcanizing chemicals to form plurality of outer and inner compositions with different ratio of binders, and
- forming a triple layer with single inner composition sandwiched with outer composition on its two sides by means of calendering at a temperature of 120°C- 125°C
2. A process for preparation of an asbestos free sealant material for use as
sealant at all critical joints in fuel injection pumps as claimed in claim 1, wherein
the said dry mixing process, comprising the steps of:
a. synthetic pulp is chopped under continuous churning to shorten the
length,
b. adding fillers to synthetic pulp to form a smooth pulp,
c masticating natural rubber at pressure 2-3 bar at 25-rpm to form a binder,
d. adding binder to the synthetic pulp under continuous stirring in two
different ratio to form a plurality of first outer composition and
second inner composition,
e. adding vulcanizing chemical under continuous stirring,
f. adding toluene (375-400ml) to form a dough,
g. stirring is continued for further 10 minutes under 1000 rpm,
h. stirring is continued for further 10 minutes,
i. cooling off and maturing the two compositions at room temperature for 24 hours.

3. A process for preparation of an asbestos free sealant material for use as
sealant at all critical joints in fuel injection pumps as claimed in claim 1, wherein
said calendering process, comprising the steps of:
- preparing a triple layer tubular form with single inner composition
sandwiched with outer composition on its two sides, such the first
outer composition thickness is 40-50 urn, built up thickness of first
outer composition and inside composition is 0.45 mm and total
thickness of first outer composition, inside composition and said outer
composition is 050 mm by means of a roller at a roller pressure 34-
36 bar, roller speed 14-15 NVmin and at a roller temperature 120°C-
125°C, cut open the tubular open to form a sheets
- allowing the sheet to cool off in room temperature.
4. A process for preparation of an asbestos free sealant material for use as
sealant at aH critical joints in fuel injection pumps as claimed in claim 1, 2 & 3,
wherein Step 2d, the first outer composition has the following ingredients and
composition.'

Torque properties : Initial tightening torque to further tightening torque ratio higher than 0.8 under different and severe test conditions ( vibration, temperature etc,)
Temperature resistance : Good temperature resistance between - 40°C and 4- 140°C without affecting the pressure tightness.
Vibration resistance : The material developed is able to function without any leakage under conditions of vibration specified for fuel injection pump coupled with elevated temperature upto 100°C.

Documents:

1071-mas-1999 claims duplicate.pdf

1071-mas-1999 claims.pdf

1071-mas-1999 correspondence others.pdf

1071-mas-1999 correspondence po.pdf

1071-mas-1999 description (complete) duplicate.pdf

1071-mas-1999 description (complete).pdf

1071-mas-1999 drawing duplicate.pdf

1071-mas-1999 form-1.pdf

1071-mas-1999 form-19.pdf

1071-mas-1999 form-26.pdf

1071-mas-1999 form-5.pdf

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Patent Number

220412

Indian Patent Application Number

1071/MAS/1999

PG Journal Number

30/2008

Publication Date

25-Jul-2008

Grant Date

28-May-2008

Date of Filing

05-Nov-1999

Name of Patentee

MOTOR INDUSTRIES COMPANY LIMITED

Applicant Address

Inventors:

#	Inventor's Name	Inventor's Address
1	KAYICKODATHU RAMACHANDRAN
2	VISHWANATH VISHNU HEDGE

PCT International Classification Number

F 16 J 15/10

PCT International Application Number

N/A

PCT International Filing date

PCT Conventions:

#	PCT Application Number	Date of Convention	Priority Country
1			NA