MONTBEL XL 105 - Questions & Answers
1. What is MONTBEL XL 105? It is polyurethane based product that improves the strength of the foam matrix. It improves the foam in compression i.e. hardness as well as in tension when used as an Isocyanate reducer.
2. What is it made out of? It is a mixture of PU based cross linkers.
3. How does it work? When MONTBEL XL105 is added to the formulation, part of the TDI reacts with Polyol and all the OH containing components of the XL 105, resulting in direct route to cross linked polymers. In the XL 105, due to their small size, the chain extenders and the cross linker polymers react first with the TDI before the base Polyol. The cross linking component of XL 105 has numerous OH terminals that will react with TDI creating bonds that act as “micro springs”. These multi bonds are allowing the XL 105 to attach to the TDI more effectively than to the less bonded Polyol. These numerous additional micro springs that are now added to the PU matrix will increase the load bearing and compression of the foam and, at the same time, the tensile and elongation. If the foamer chooses not to increase the hardness of his foam then he would need to reduce his TDI level in the formulation.
4. What can we achieve with MONTBEL XL 105? Maintain the hardness of the foam by reducing the TDI level or having a density reduction or both.
5. What TDI and polyol reduction can we expect using MONTBEL XL 105? Depending on the formulation, you can expect to achieve up to 2% chemicals saving, while simultaneously maintaining the set hardness of the foam and improving aspects of its quality.
6. What savings can we expect? As a TDI reducer, for every part of XL 105 used you can remove 1 part of polyol and up to 2.0 parts of TDI. The density savings depends on the Tin level in the formulation.
7. How much MONTBEL XL 105 is needed in the formulation? As a TDI reducer, the level will depend on your current formulation and process used. You can use 0.3 to 0.8 PPHP of XL 105
8. Why use MONTBEL XL 105 as opposed to increasing the solid content of the polyol? Or Increasing Tin.
To answer this, one needs to understand how the hardness from polymeric polyol is achieved. Polymeric polyol contains a percentage of Styrene Acrylonitrile (SAN) solid particles grafted in the polyol. These SAN particles, much smaller in size than organic fillers, end up incorporated in the struts (the side wall of the cell structures) and reinforce the PU matrix in compression strength only. However the SAN weakens the structure in elongation and tensile strength. The higher the solid content (SAN), the weaker the foam becomes in tensile and elongation. Contrary to polymeric polyol, XL 105 does not weaken the foam tensile and elongation, it actually improves it. Therefore it complements the polymeric Polyol or organically filled foam. Hardness always works in the contrary sense to Compression set and resiliency and Tin have far more the compression set and affects the resiliency as compared to XL.
9. How to apply MONTBEL XL 105? It is not used as an additive but rather as a substitute i.e. you do not add it to the Polyol but rather you replace the polyol with it. For every part of XL 105 used, you remove an equal part of polyol. Furthermore, it is pumped using any existing pump such as the color unit. XL 105 is miscible with polyol i.e. you can mix it with polyol or polyol based colorants.
10. What aspect should I be concerned with when applying MONTBEL XL 105? Used properly as per TDS, XL 105 is safe and like any component in the formulation? The usage level would affect the exotherm. As such the implementation should be in accordance with the TDS, ensuring at all times that the exotherm of the foam is below 170 degrees centigrade.
11. How do we verify the results? Montbelle is able to test your foam either by having your foam samples sent to us or our technical staff can conduct full physical properties tests on site with our mobile laboratory kit. Other than Density We can test the following aspects of your foam:
- Hardness in CLD (what the client cares for)
- Resilience ( bounciness is the essence of foam and a good measure of quality)
- Compression set. (an excellent measure of quality and durability of foam)
- Hysterisis (An excellent indication of the quality and longevity of the foam)
- Tear strength (another quality reference that is easy to measure and is important for furniture makers who always seek better tear strength)
