Selection & Application Support
From material and process information to a controlled trial and a documented production window.
Seven areas of application support
| Area | Source-described work |
|---|---|
| Grade selection | Screen AC/modified AC, NC, OBSH/OBSH-1/TSH, masterbatch, microsphere and functional-additive candidates from actual material and process requirements. |
| Formulation diagnosis | Consider agent, resin, activation/cure system, thermal history, dispersion and cooling together. |
| Controlled sample trials | Compare baseline, direct substitution, permitted optimisation and a second/compound route. |
| Process-window review | Align softening/melting, cure, gas generation, gas retention and cell fixing. |
| Odour/formamide evaluation | Separate odour, ammonia, VOC and formamide tests; assess grade/additive/process and ageing. |
| Lightweighting/microfoaming | Assess density/part weight alongside appearance, sinks, warpage, mechanics and dimensions. |
| Scale-up | Recheck material batches, mixing/feeding, actual temperatures, pressure/speed, mould/die, cooling/ageing and continuous variability. |
Problems to describe clearly
- Insufficient expansion or high density.
- Coarse/merged/broken cells, collapse, shrinkage or unstable dimensions.
- Silver streaks, flow marks, pinholes, yellowing or reduced whiteness.
- Ammonia/combined odours, high formamide results, deposits or die build-up.
- Mechanical-property loss after lightweighting or variation between batches.
What to bring to the discussion
- Exact base material and grade; process and equipment.
- Actual material temperature, residence time, pressure/speed and product thickness.
- Current blowing agent and dose; activation, crosslinking or cure system.
- Current/target density, cells, surface and colour; the principal issue.
- Required odour/VOC/formamide or restricted-substance test, destination and test method.
- Which equipment or formulation conditions cannot be adjusted.
Four controlled comparisons
- A · Baseline. Current compound, agent, dose and process, with the current result recorded.
- B · Direct replacement. Change the candidate agent while holding other conditions steady.
- C · Process optimisation. Evaluate permitted adjustments to actual temperature, time, speed, pressure and cooling.
- D · Alternative. Compare a second candidate or a reviewed compound route.
For each group record model, batch, dose, mixing order, equipment settings, actual material temperature, pressure, speed, residence time, mould/die, cooling and sample time.
Measure the complete result
| Evaluation | Record |
|---|---|
| Foaming | Apparent density, part weight, expansion and thickness. |
| Cells | Size distribution, open/closed cells, merging, breakage and skin. |
| Dimensions | Appearance, shrinkage and immediate / 24-hour / 7-day / 28-day change, where appropriate. |
| Mechanics | Hardness, rebound, tensile/tear and compression properties required by the customer. |
| Chemical requirements | Odour, VOC, ammonia and formamide are distinct tests; use the specified methods. |
Pending confirmation No customer-specific baseline, trial results or project report has been supplied. This table is a proposed recording framework, not a results claim.
From a small trial to the production line
A small-trial result does not establish production stability. Record model, batch, addition level, mixing order, actual equipment and material temperatures, pressure, speed, residence time, mould/die, cooling and sample time.
Use the production trial to define a model, addition range, process window and acceptance criteria. No fixed response time or guaranteed outcome has been supplied.
Information and responsibility
Depending on the model/project, request TDS, SDS, batch/recent COA, application directions, sample recording sheets, packaging/storage/shelf-life information and available third-party reports. Reports apply only to their named sample, batch and tests.
Technical suggestions do not replace the customer’s formulation responsibility, production validation, finished-product testing or applicable requirements.
Start with what you already know
If a full formulation cannot be shared, begin with the material system, actual process temperature, existing agent and main issue. Further technical information may still be needed.
Discuss selection or a trial