Polyurethane Foam Systems

1 Polyurethane foam Systems Zelu is the one-stop manufacturer of high-grade adhesives and Polyurethane foam Systems , pro- viding you with quality made in Germany wherever you may be in the world, coupled with prompt delivery, reliability and expertise. We have an in-depth knowledge of the manufacturing of customised solutions each and every one of which is guaranteed to be optimally tailored to suit the desired application. From large-volume orders to special formulations, we can make it happen. PUR foams are incredibly versatile and the manufacturing requires a high level of expertise. Zelu offers you tailor-made solutions from soft to hard. Individually adjustable system parameters such as good flowability, high process stability and fast reaction enable short cycle times. Ensuring ease of use and efficient production for a huge range of applications in the automotive & transport, sport & leisure, filtration, furniture and industry & construction.

2 Zelu has the solution. 02 PUR foam Systems Flexible / Viscoelastic foams Flexible / Visco- Composition Processing Properties and benefits For our flexible and viscoelastic Mixing the two liquid foam compo- good ease of flow and high foams we develop water- nents polyol (Zelupur HR ) and process stability blown Systems based on poly- isocyanate (Zelunat ) triggers highly open-cell structure for air elastic Foams ether polyol and methylene polymerisation to create foam . permeability ( breathable ). diphenyl diisocyanate (MDI) for Foaming is a result of the chemical high elasticity and low loss of processes using the low- conversion of water to carbon hardness over long wear times energy cold-moulding foam dioxide and therefore does not choice of resilience from springy method. release foaming agents that to viscoelastic are harmful to the environment. good stability under stress from They are processed with foaming heat and moisture zelupur HR machines using both a low-pres- low odour and emissions.

3 Sure and high-pressure method. flame-retardant versions available Products based on our flexible foam Systems Zelupur HR are . exceptional in their outstanding elasticity while still main- taining good resistance to ageing, even under the sustained influence of heat and cold. This makes the Zelupur HR - . Systems well-suited to a vast range of products. From foam lacquering rolls, highly durable rail car seats, motorcycle Zelupur HR . Zelupur HR Zelupur HR . Zelupur HR . Product for furniture for cars for rail car seats viscoelastic seats and office chairs through to flake composite foam . We customise our foam Systems to suit every product and Density [kg/m ]. DIN EN ISO 845. > 40 > 40 > 80 > 50. every production process. Hardness [kPa] 2 to 10 4 to 15 8 to 12 1 to 10. DIN EN ISO 3386. Tensile strength [kPa] > 85 > 100 > 100 > 70. DIN EN ISO 1798. Distension [%] > 80 > 90 > 60 > 80. DIN EN ISO 1798. Compression set <5 <7 <5 < 20. (22 hrs, 70 C, 50 %).

4 [%] DIN EN ISO 1856. Meets the requirements BS 5852 Crib 5, VDA 270, VDA 278, DIN 5510-2, DIN 5510-2, of the following tests EN 1021-1 and -2 ECE R-118-02 VI EN 45545 HL2 EN 45545 HL2. (selection). 04 PUR foam Systems Integral Foams / Semi-Rigid Foams Integral /. Composition Processing Properties and benefits We develop our integral foam The compacted surface zone of outstanding abrasion resistance Systems on a polyether polyol and our Zelupur SI -integral foams is surface hardness in the range methylene diphenyl diisocyanate created by using low-boiling of 10 to 90 Shore A. Semi-Rigid (MDI) basis using physical foaming liquids (so-called physical foaming flame-retardant versions agents for processes using agents) that vaporise and then available the cold-moulding foam method. condense on the inside of the mould resistant against a wide range during the foaming process. For of chemicals, low-maintenance our semi-rigid Zelupur SF -foams, and easy to clean Foams we dispense entirely with physical low water absorption foaming agents and use water unrestricted colour design using instead.

5 In this case the effect of in-mould coating an integral skin is controlled good ease of flow and high by process additives. They are process stability processed with foaming machines using both a low-pressure and high-pressure method. zelupur SI zelupur SF . With their outstanding abrasion resistance, products based on our Zelupur SI integral foam Systems are especially . suited to applications where the material is subject to high wear. For example as impact-absorbing protective sports gear, handles, knobs or office chair armrests. Integral soft Product . Zelupur SI -integral foams . Zelupur SI flame retardant Zelupur SF . foams are composed of a compact, elastic skin and a Density [kg/m ] > 250 > 250 > 150. flexible, open-cell foam core. Depending on the application, DIN EN ISO 845. we adapt our material to suit your specific production process. Surface hardness [Shore A] 10 to 90 20 to 90 10 to 90. DIN 53505A. Water is the only foaming agent we use for our semi-rigid Tensile strength [kPa] > 800 > 800 > 200.

6 Zelupur SF -foams. These emission-optimised versions are DIN EN ISO 1798.. particularly suitable for use in car interiors, for example as Distension [%] > 150 > 120 > 100. centre armrests. DIN EN ISO 1798. Meets the requirements of ECE R-118-02 VI ABD 0031 7-1-2, VDA 270, VDA 278, the following tests DIN 4102-1 B2 ECE R-118-02 VI. (selection). 06 PUR foam Systems Filter Foams Filter Foams Composition Processing Properties and benefits Our Zelupur EL - products are They are processed with foaming exceptionally high resilience at liquid foam Systems on a polyether machines using both a low-pressure a low hardness range (13 to 30. basis which are processed with and high-pressure method. The Shore A) and at low and high Zelunat (MDI) using the cold foam mixed components are inserted into temperatures (-40 C to +120 C). method. Water is used as a foam - tempered plastic or metal foaming closed, high-density surface zelupur EL.. ing agent. moulds and demoulded after adapt- excellent distension and tensile able reaction times.

7 Strength to ensure long life high process safety allows the use of mineral fillers Our Zelupur EL - Systems are processed to lightly foamed, . elastic PUR foams. Their range of application extends from basic industrial filters to automotive filters up to specific filters used in the electronics industry. For decades soft filter foams have been used as sealing lips in air filter elements. The function of the flexible sealing lips is to seal off the folded filter materials from the air filter housing.. Zelupur EL Zelupur EL Product panel filter round filter Density [kg/m ] 350 to 550 400 to 800. DIN EN ISO 845. Surface hardness [Shore A] 13 to 30 15 to 50. Tensile strength [MPa] > 0,5 > 0,5. DIN 53504_S3A. Distension [%] > 150 > 150. DIN 53504_S3A. Compression set < 10 < 10. (22 hrs, 70 C, 40 %) [%]. Meets the requirements of Compression set Compression set the following tests (selection) (22 hrs, 100 C, 50 %): < 20 % (22 hrs, 100 C, 50 %): < 20 %.

8 08 PUR foam Systems Rigid Foams Rigid Foams Composition Processing Properties and benefits We develop our rigid foam Systems They are usually processed with long life thanks to high shape on a polyether or polyester polyol foaming machines using a high- and dimensional stability and methylene diphenyl diiso- pressure method. Special foam low heat conductivity cyanate (MDI) basis using physical Systems are also processed using good ease of flow and low cavity foaming agents or water. a spray method or on batchers pressure zelupur RD . with static mixing Systems . allow self-releasing formulations ( fire class DIN 4102-1 B2). can be coated following suitable pre-treatment flame-retardant versions available Rigid foams based on Zelupur RD are highly cross-linked . foams with a large proportion of closed foam cells. The resulting low heat conductivity makes rigid foam the perfect insulation material. This material is also resistant to bending and pressure and can therefore be used wherever high shape and dimensional stability is required: this includes the con- struction industry, cold insulation of refrigeration equipment and facilities, filling hollow bodies with foam for stabilisation purposes, in apparatus and casing construction or for cush- ioning components, for protective helmets.

9 Zelupur RD Zelupur RD Product for insulation and cavity filling for decorative elements Density [kg/m ] > 40 > 200. Heat conductivity [mW/(m K)] < 30 n. a. DIN 52612. Compressive strength [MPa] > 0,3 > 2,0. DIN 53421. Surface hardness [Shore A] > 20 > 35. DIN 53505A. Further properties DIN 4102-1 B2 Can be coated following suitable pretreatment 10 PUR foam Systems Casting Systems Casting Composition Processing Properties and benefits Our Zelumer - casting Systems are The liquid polyol and isocyanate resistant to a wide range of liquid solvent-free, non-foaming or lightly components are processed on and gaseous materials foaming two-component casting two-component batchers using a resistant to ageing Systems compounds on a Polyurethane low-pressure method (static or variable hardness in the range basis. The active component of our dynamic mixer). The flow charac- from Shore A to Shore D. Zelumer - Systems consists mainly teristics determine the processing customised processing parameters of polyether or polyester polyols time of these PUR Systems and (pot life, viscosity etc.)

10 And can be processed either with can be adapted to specific applica- good flow, wetting and adhesion or without fillers as required. tions via the so-called pot life. solvent-free Zelucure uses purely MDI-based temperature-resistant isocyanates as hardeners. zelumer . Our Zelumer -casting Systems involve reactive Polyurethane . resins with a broad range of properties. Thanks to their high resistance to temperature and ageing, they are mainly used as adhesive and sealing Systems for end plate bonding on air, Product . Zelumer (filled).. Zelumer (unfilled). oil or diesel filters. This also enables the production of filter Base PUR PUR. flanges or other moulded components that can be directly demoulded. Density [g/cm ] 1,2 to 1,7 approx. 1. Viscosity [mPas] to 400 to Filler content 20 to 70 0. Pot life [min.] 1 to 40 1 to 40. Chemical resistance Good Good Shore A/D (D30-90)D (A50-D80)A/D. Product category Adhesives from Zelu In addition to Polyurethane foam Systems , we can also provide you with a wide range of adhesives.