FKM-USA, founded in 2000 by Dr. Ulrich Freudenberg, is the North American division of FKM- Walzentechnik (Duisburg, Germany). Its core business is the coating of high-quality polyurethane, lightweight and non-woven fabric rolls and rollers for a variety of industries, but especially automotive and steel processing. The company has strong ties to the Freudenberg Works, where formulation of fabrics designed specifically for cleaning, deoiling and tensioning steel strip and blanks was pioneered.
Relying upon its 25+ years experience in the roll coating business, FKM in Germany, designed and built the new Rotary Casting Machine. The machine consists of a chemical delivery system that feeds a robotic armature to deliver reactive components for the manufacture of polyurethanes. The system can handle multiple part chemistry that is pumped individually to the mixing head. The chemicals mix together just prior to application on the roll and the high reactivity of the chemicals cures as the coating is being built up along the roll face.
A multiple-axis robot is used to apply the chemical mixture by moving laterally back and forth along the roll form. Key to this rotary casting machine is FKM's custom-designed software. It receives and connects all information from the rotational roll stand, pumps, and robotics. The operator inputs various parameters such as roll size and desired roll hardness configuration, including layering of different hardnesses. FKM utilizes a variety of formulations for creating polyester polyurethanes and polyether polyurethanes, which are highly sophisticated and, in many respects, superior to competing chemistries.
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