Neopolen. Contents. 1. Product 1.1 Description 1.2 Forms supplied 1.3 Delivery, Conveying, Storage

Transcription

1 = registered trademark of BASF SE General Technical Information Neopolen Contents 1. Product 1.1 Description 1.2 Forms supplied 1.3 Delivery, Conveying, Storage 2. Processing 2.1 Filling the mold cavity 2.2 Molding 2.3 Cooling 2.4 Demolding 2.5 Conditioning 3. Properties, Applications 3.1 Properties of Neopolen 3.2 Flammability 3.3 Applications 4. Product Safety and Environment

2 TI G-PM/PF September 2016 page 2 of 10 Neopolen 1. Product 1.1 Description Neopolen is expanded polypropylene (EPP) in the form of beads. The cells are largely closed Forms supplied 1.3 Delivery, Conveying, Storage Neopolen is supplied as expanded polypropylene (EPP) beads. Neopolen is delivered in bulk by road in large-capacity hopper vehicles. The silo volume available for storage must be about 150 m 3. Neopolen is transferred to the silos pneumatically at a rate determined mainly by the performance of the blower (dependent on type, speed of rotation, and drive power) as well as the cross-sections and lengths of the duct on both the suction and pressure sides. The loading of Neopolen in the air stream should not exceed 30 %. Experience has shown that for fast unloading the duct diameter must be at least 200 mm on the suction side and 150 mm on the pressure side. The radius of bends must be at least five times the duct diameter. To avoid abrasion of the product, all surfaces it comes in contact with must be smooth, and there should be no obstructions (e. g. edges at joints). This applies as well to the blower, whose rotor in particular needs to be carefully constructed. Neopolen needs to be protected both from the weather (rain and snow, frost, direct sunlight) and excessive mechanical stress. For storage bins higher than 4 m measures should be taken to minimize pressure on material at the bottom. 2. Processing Neopolen is molded on machines whose steam chambers are designed for excess pressures of at least 5 bar (cf. fig. 1). There are five distinct stages in the process. Fig. 1: Equipment for molding Neopolen

3 TI G-PM/PF September 2016 page 3 of 10 Neopolen 2.1 Filling the mold cavity The expanded beads are introduced into the mold cavity via injectors, which are fed from a pressurized vessel. Since Neopolen contains no expanding agent, the beads in the cavity must be compressed at the start. This can be achieved in one of two ways: a) Pressure filling: The beads are forced in by compressed air until back-pressure stops the flow. b) Crack-press-filling: The beads, driven by low excess pressure, enter the larger cavity formed by opening the mold slightly, and then the mold closes, compressing the beads. Prepressurizing Prepressurizing the beads increases the pressure of the air within the cells, which leads into higher volume expansion capability of the material. During processing, the range of material density can be scaled down. It is carried out by immersing the beads in hot compressed air for several hours before they are molded. The filling techniques given above are also used with prepressurized beads. 2.2 Molding The beads packed into the molds are heated with steam, which makes them swell and fuse. For the Neopolen, the inlet pressure of saturated steam must be at least 7-8 bar. The maximum pressure in the steam chambers should be bar. 2.3 Cooling The moldings are cooled until there is no risk of swelling and splitting when demolded. The time taken depends largely on the density and wall-thickness of the moldings. 2.4 Demolding The moldings are removed by means of mechanical ejectors, compressed air or a combination of both. 2.5 Conditioning The moldings must be conditioned for at least 6 h in warm air (preferably at 80 C), to partially restore their volume and remove any interstitial water. Good air circulation is required around the moldings, so the oven should not be overfilled. 3. Properties, Applications 3.1 Properties of Neopolen Neopolen is characterised by very good cushioning and recovery properties, as well as high energy absorption. Its heat resistance is good, and it is chemically inert. The low water absorption and easy cleaning of the beads, the good thermal insulation and environment-friendly properties (free of gas and other chemical blowing agent) are further advantages of Neopolen. The values of physical quantities given in tables 1-3 and fig. 2-7 should serve as guideline for properly processed Neopolen.

4 TI G-PM/PF September 2016 page 4 of 10 Neopolen Table 1: Physical properties of Neopolen (guideline values) Fig. 2: Recovery of compressed Neopolen P 9230 K molded test piece, density 60 [ kg/m 3 ] Property Method Unit Material Density as ISO 845 [ kg/m 3 ] (Core density) Tensile strength DIN EN ISO 1798 [ kpa] Elongation at break DIN EN ISO 1798 [%] Compressive stress according to [ kpa] at 10 % Strain ISO at 25 % Strain at 50 % Strain Residual compressive strain DIN EN ISO 1856 [%] (50%, 22 h, 23 C) (Method C) 24 h after stress release Compression hardness DIN EN ISO 3386 [ kpa] Cushion factor (optimum value) ISO Specific Energy ISO 4651 [ knm m -3 ] at h / d = 10 Static area loading DIN [ kpa] %, 100 d Dimensional stability at heat according to [%] < 2 < 2 < 2 < 2 < 2 Linear size alteration DIN ISO 2796 (after 4 d, 110 C) Thermal conductivity 2) DIN [ W m -1 K -1 ] Water uptake according to 1 day DIN [ Vol.-% ] < 1 < 1 < 1 <1 < 1 Surface resistance 1) DIN IEC (23 C, r.h., 50 %) [Ohm] ) divergent at Neopolen P 9230 ESD 2) divergent at Neopolen P 9335 MG and Neopolen P reflam

5 TI G-PM/PF September 2016 page 5 of 10 Neopolen Table 2: Effects of various substances on Neopolen (according to DIN 53428) Substance Effect 1 Hydrochloric acid, 10 % + 2 Hydrochloric acid, conc. + 3 Sulfuric acid, 3 % + 4 Sulfuric acid, 30 % + 5 Nitric acid, 10 % + 6 Distilled water + 7 Seawater + 8 Hydrogen peroxide, 10 % + 9 Alkaline flux + 10 Acid flux + 11 Hydrofluoric acid, 5 % + 12 Sodium hydroxide soln + 13 Sodium chloride soln + 14 Diethyl ether 15 Acetic acid, 3 % + 16 Acetic acid, conc Ethanol + 18 Mineral solvent Diesel fuel + 20 Gasoline + 21 Turpentine + 22 Olive oil + 23 Mineral solvent + benzene + 24 Benzene + 25 Tetrahydronaphthalene 26 Decahydronaphthalene + 27 Acetone + 28 Tetrahydrofuran 29 Ethyl acetate + 30 Trichlorethylene + 31 Formaldehyde soln + + Unaffected + Prolonged contact may cause shrinking or swelling Unstable

6 TI G-PM/PF September 2016 page 6 of 10 Neopolen 3.2 Flammability Table 3: Fire Behavior of Neopolen Standard-Grades (divergent at Neopolen P reflam) Material Density according ISO 845 [ kg/m 3 ] (Core Density) Method Thickness DIN EN ISO ) 10 mm 2) E E 20 mm 2) E E E E 30 mm E E E E E E DIN mm B3 B3 B3 B3/B2 3) B2 B2 20 mm B3 B3/B2 3) B2 B2 B2 B2 30 mm B3/B2 3) B2 B2 B2 B2 B2 FMVSS mm fulfilled fulfilled fulfilled fulfilled fulfilled UL mm HBF HBF 13 mm HBF HBF HBF 1) Edge exposure, classification according to EN ) Edge exposure failed, surface exposure passed with E 3) B3 (easily flammable), the classification B2 (flammable) applies if the edges of the plate are covered 3.3 Applications Neopolen is ideal for lightweight articles providing excellent shock-absorption and good thermal insulation. Its applications include: automotive components, e. g. shock-absorbing elements in bumpers and side-impact systems, head supports, sun visors, tool boxes, etc.; packaging, e. g. protective packaging for shock-sensitive goods such as measuring instruments and computers, returnable packaging; transport containers, e. g. crates and pallets; components of apparatus and appliances, e. g. multifunctional components protecting against vibration and shock, reducing weight, simplifying assembly, or insulating; safety equipment, e. g. children s safety seats, helmets.

7 TI G-PM/PF September 2016 page 7 of 10 Neopolen Fig. 3: Stress-strain-diagram Fig. 4: 100-d Compressive creep of Neopolen

8 TI G-PM/PF September 2016 page 8 of 10 Neopolen Fig. 5: Cushioning curves for Neopolen density 20 [kg/m 3 ] Fig. 6: Cushioning curves for Neopolen density 30 [kg/m 3 ]

9 TI G-PM/PF September 2016 page 9 of 10 Neopolen 4. Product Safety and Environment Neopolen is produced without the use of halogenated hydrocarbons or compounds containing heavy metals. It contains no materials that require declaration under the GADSL (Global Automotive Declarable Substance List, Version 3,0, 1) At the time of delivery, the product contains no blowing agent and is not classified under dangerous goods regulations. Neopolen presents no danger to water (VwVws Germany , App. 1) 1) Neopolen is recyclable. When using this product, the information and advice given in our Safety Data Sheet should be observed. Necessary attention should also be given to the precautions necessary for handling chemicals. Fig. 7: EPP life-cycle Note The data contained in this publication are based on our current knowledge and experience. In view of the many factors that may affect processing and application of our product, these data do not relieve processors from carrying out their own investigations and tests; neither do these data imply any guarantee of certain properties, nor the suitability of the product for a specific purpose. Any descriptions, drawings, photographs, data, proportions, weights etc. given herein may change without prior information and do not constitute the agreed contractual quality of the product. It is the responsibility of the recipient of our products to ensure that any proprietary rights and existing laws and legislation are observed. 1) except Neopolen P reflam

10 TI G-PM/PF September 2016 page 10 of 10 Neopolen BASF SE GBM Specialty Plastics Ludwigshafen Germany