BAYER CORPORATION CONCLUDES THAT INCREASED CLAMPING PRODUCES BETTER MOLDED POLYURETHANE FOAMS

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BAYER CORPORATION CONCLUDES THAT INCREASED CLAMPING PRODUCES BETTER MOLDED POLYURETHANE FOAMS
14 October 2002 - Bayer MaterialScience AG

What began as a technical service project for a customer that molds seating revealed why processors may experience significant rates of rejected parts when working with molded polyurethane foams.

Bayer Corporation learned that composite molds (fiberglass and wood) will produce molded foam parts with fewer defects and improved physical properties if the processor uses four clamps rather than just two.

Eric Reinstadtler, technical service specialist for Bayer's Polyurethanes Division presented the results of a clamping study in a poster paper, 'Effects of Clamping on Molded Polyurethane Foams,' at the Alliance for the Polyurethanes Industry (API) Polyurethanes 2002 technical conference here this week

In this study, Bayer concluded that when processing molded polyurethane foam in common wood and fiberglass molds, the percentage of good parts can be increased by using four clamps rather than two and by placing these clamps in uniform positions on the mold lid. More significantly, these steps can increase the performance of the molded foam by maximizing the foam's indentation force of deflection (IFD) property.

Bayer conducted the study in response to a customer in the seating market that was experiencing a significant rate of defective parts. When Bayer conducted machine prototyping using the customer's mold, Reinstadtler observed that better quality parts resulted when four clamps, rather than two, reinforced the lid.

Bayer tested this phenomenon by molding numerous parts and varying only the number of clamps on the customer's mold. Density and index were held constant, while the number of clamps was alternated between two and four clamps. In all cases, increased clamping enhanced the quality and physical properties of the foam, said Reinstadtler.

'As result of this study, Bayer recommends the use of increased clamping for molded polyurethane foams because it minimizes the need for specific pour patterns to achieve good parts. It also maximizes foam performance and results in more usable foam in the part rather than in the flash,' he concluded.

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About: Bayer MaterialScience AG
Bayer Corporation, headquartered in Pittsburgh, is part of the worldwide Bayer Group, an international health care, nutrition and innovative materials group based in Leverkusen, Germany. Bayer employs 23,300 in North America with net North American sales of 8.8 billion euros in 2003. Bayer’s three operating business areas – HealthCare, CropScience and MaterialScience, improve people’s lives through a broad range of essential products that help diagnose and treat diseases, protect crops and advance automobile safety and durability.

Bayer MaterialScience AG is one of the world's largest producers of polymers and high-performance plastics. The main customers for Its innovative developments in coatings, adhesives, insulating materials and sealants, polycarbonates and polyurethanes are the automotive and construction industries, the electrical/electronics segment and manufacturers of sports and leisure goods, packaging, and medical devices.

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