Since last 27 years, Ultraseal India offers complete solutions for impregnation requirements to our customers in India and Abroad.
Ultraseal India can offer full turnkey solutions for any impregnation requirements such as :
Ultraseal offers two types of autoclave with top-load equipment:
Vertical Transfer System (VTS):
Here, the workload is suspended in a basket during the vacuum phase before being lowered and immersed in the sealant. The vacuum is then released, forcing the sealant deep into the porosity. VTS-based impregnation machines are simple in design and have a relatively small footprint.
Sealant Transfer System (STS):
Here, the workload is loaded into the autoclave with the sealant in an adjacent tank. After the vacuum has been drawn on the autoclave, a valve is opened and the sealant transfers into the autoclave, immersing the components. The vacuum is then released, forcing the sealant into the porosity, after which unused sealant returns to its original tank under vacuum. STS machines are simpler to automate and benefit from well-conditioned sealant due to the length of time the sealant is held under vacuum. For critical applications, a pressure autoclave can be supplied, enabling a pressure cycle to be incorporated following the vacuum phase.
Rotational System Technology:
The limitations of traditional batch processing systems, in terms of long cycle times and potential for contamination of parts held in static tanks, led Ultraseal to develop a rotational processing system which is available as an option on all of its top loading systems. In tandem with rotational technology, Ultraseal pioneered the principle of cascade washing, whereby a copious volume of fluid is pumped through a manifold and over the rotating workload, providing a more aggressive and effective washing action than conventional systems.
The drain cycle involves removing excess sealant from the component after impregnation. Good draining is essential to reduce 'carry-over' to the cold wash tank and limit the amount of sealant lost as effluent. While a static drain is suitable in some applications, sealant may become trapped in pockets or features within more complex components. A rotational drain system physically rotates the components in their basket to maximize sealant removal. This is then collected and automatically returned to the autoclave.
After draining, the components are transferred to the cold wash tank for removal of surface sealant. For more complex components, a rotational system is recommended. The wash solution is pumped from the lower tank into the chamber, passing over and through the rotating workload, before returning to the tank. The workload is not immersed, as if the components were to remain in the water during washing, contamination in the wash solution would adhere to the components and cause potential cleanliness problems during curing. The weight and volume of washing media passing through the components effect a high level of cleanliness and the subsequent rotation drain minimises carry-over to the hot cure module.
This takes place in a separate tank with water controlled at a minimum of 90°C (195°F). For maximum productivity, a rotational system is recommended, where the hot cure solution is pumped from the tank to the manifold at the top of the chamber. The solution fills the chamber to a point where it automatically weirs back to the lower sump while the chamber is continually filled with filtered, reheated solution from the lower storage tank. This method not only cures the sealant within the porosity but provides a very effective final washing action.
Front Load Technology:
Ultraseal front-loading machines were from the beginning designed specifically to work with the company's acclaimed recycling sealants with all their associated environmental and health and safety benefits. They also have closed tanks, with process fluids remote and covered, minimising emissions into the work area, and so enabling them to be placed in the main part of the factory alongside other processes.
Each compact module offers all the productivity and quality advantages associated with rotational processing, while unlike top-loading machines, the rotational drain process takes place within the autoclave, reducing the number of modules required and so saving cost and floorspace.