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Schaumstoffprüfung - Markt-Stärke-Normen-Praxis
Helmut Fahrenholz
Stand: September 2004 2
Soft foams
Polyurethanes (PU or PUR)
Polyurethanes are formed by reacting a polyol (an alcohol)
with a diisocyanate or a polymeric isocyanate in the
presence of suitable catalysts and additives. The process
has first been patented 1937 by Otto Bayer and has
significantly been developed since.
Polyurethanes are real universal plastics having a lot of future potential. They are
known with many different faces, i.e. as foam, but also as rigid plastic, as synthetic
rubber (Elastan), as adhesives or varnish.
Latex foams are mainly used for mattresses. Unlike PU mattresses, which are
produced as a bloc foam and then cut, the Latex mattresses are directly molded.
Schaumstoffprüfung - Markt-Stärke-Normen-Praxis
Helmut Fahrenholz
Stand: September 2004 4
Soft foams
Foam rubber Moosgummi
can be produced from many rubber types. Accordingly variable are
their characteristics. They have an open cell structure. Produced
are molded parts, slab, profiles ...
Foam rubber
(open cells)
Cellular rubber
(closed cells)
Schaumstoffprüfung - Markt-Stärke-Normen-Praxis
Helmut Fahrenholz
Stand: September 2004 5
Soft foams
Typical supply chains within the foam
Industry
Schaumstoffprüfung - Markt-Stärke-Normen-Praxis
Helmut Fahrenholz
Stand: September 2004 6
Supply chains PUR foam
The supply chain Furniture
Floor coverings (sports
facilities)
Compound foam Gymnastic mats
producers Acoustic
Footwear
Furniture, Upholstery
Mattresses
Building industry
Bloc foam producers Textile (i.e. carpets)
Housewares
Hygiene, i.e. sponge
Raw material
producers
Automotive ( OEM) Vehicle seats
Insulation in vehicles
Molded foam Furniture, Upholstery
producers Mattresses
Medical
others
Schaumstoffprüfung - Markt-Stärke-Normen-Praxis
Helmut Fahrenholz
Stand: September 2004 7
Supply chains PUR foam
Raw material producers
Examples:
Schaumstoffprüfung - Markt-Stärke-Normen-Praxis
Helmut Fahrenholz
Stand: September 2004 8
Supply chains PUR foam
Molded foam producers (Automotive)
Produce finished PU-components , such as seat cushions
dashboards, molded parts to be used in cars for thermal
insulation or acoustic damping.
Examples:
Schaumstoffprüfung - Markt-Stärke-Normen-Praxis
Helmut Fahrenholz
Stand: September 2004 9
Supply chains PUR foam
Molded foam producers ( continued)
Schaumstoffprüfung - Markt-Stärke-Normen-Praxis
Helmut Fahrenholz
Stand: September 2004 10
Supply chains PUR foam
Bloc foam producers
Schaumstoffprüfung - Markt-Stärke-Normen-Praxis
Helmut Fahrenholz
Stand: September 2004 11
Supply chains PUR foam
Automotive industry
Schaumstoffprüfung - Markt-Stärke-Normen-Praxis
Helmut Fahrenholz
Stand: September 2004 12
Supply chains PUR foam
Overview of test methods
Schaumstoffprüfung - Markt-Stärke-Normen-Praxis
Helmut Fahrenholz
Stand: September 2004 13
Test methods
Type of test Standards Principle Specimen Significance / Application
example
Provides hardness values for cut specimen, i.e. from bloc foam
Indentation force deflection Specimen
ISO 2439 of for molded foam which can be tested on a flat support.
test (Indentation hardness) 380 x 380 mm
Known als ILD-test or IFD-test.
Cube
Creep in compression ISO 10066 This result is mainly applied in testing of packaging foams.
50 x 50
Schaumstoffprüfung - Markt-Stärke-Normen-Praxis
Helmut Fahrenholz
Stand: September 2004
Overview
14
of test methods - cut specimen
Type of test Standards Principle Specimen Significance / Application
example
Descibes an indentation characteristic as a hardness value
Indentation hardness and
Molded foam which is not directly compareable to the compressoin
respectively residual DIN 53579-1
(seat cushion) characteristics. many different shapes and dimensions of
thickness under load.
indentors are standardized.
several standards
Molded foam
Hysteresis of automotive Provides results for damping, toghness and the "comfort value".
(seat cushion)
OEM
Schaumstoffprüfung - Markt-Stärke-Normen-Praxis
Helmut Fahrenholz
Stand: September 2004
Overview
15
of test methods - molded foam
Type of test Standard Significance / Application
Density ISO 845 The appearant density is one of the most basic characteristics
of a foam. To be determined by dimension measurement and
weighing
Rebound resilience ISO 8307 Gives an indication about the shock absorption properties.
Determination by means of a falling ball. Formerly in DIN 53573
also standardized with a pendulum rebound tester.
Tension test ISO 1798 relavant mainly for foams which will be submitted to tensile
forces in practical use. This method gives values for the
resistance to destruction.
Tear resistance test ISO 8067 Gives the characteristic of a pre damaged foam.. The result is
subject to very big scutter.
Shore 00 Hardness ASTM D 2240 Sometimes used to characterize local hardness, i.e. for
compound foams.
Schaumstoffprüfung - Markt-Stärke-Normen-Praxis
Helmut Fahrenholz
Stand: September 2004 16
Overview of test methods - others
Selected tests in detail
Schaumstoffprüfung - Markt-Stärke-Normen-Praxis
Helmut Fahrenholz
Stand: September 2004 17
Tests in detail
Determination of compression stress-strain properties
(Compression-load-deflection , CLD)
Editor Designation Notes
ISO ISO 3386 - 1 Low density materials
ISO 3386 - 2 High density materials
ANSI ASTM D 3574 - Specimen shapes same as in ISO, but different
Test C test method.
DaimlerChrysler DBL 5452, section refers to ISO 3386
4.6
BMW QV 52009-1 refers to ISO 3386-1
section 2.2.3
Volkswagen PV 3410, section Refers to ISO 3386-1 but pre-set cycles only to
3.5 60 % compression strain. Result in cycle 4 at
40%.
Test set-up to ISO 3386 -1 PSA D41 1003 flexible foams
D41 1541 flexible and semi-rigid foams
Specific test method
Renault N° 1003 Identical to PSA
N° 1541
Toyota TSM 7100 G Specific test method
section 4.2
Schaumstoffprüfung - Markt-Stärke-Normen-Praxis
Helmut Fahrenholz
Stand: September 2004 18
Tests in detail
Method ISO 3386 Conditioning
ISO 3386-1
23 °C / 50 %
ISO 3386-2
23 °C / 50 %
Specimen
27 °C / 65 % 27 °C / 65 %
Storage / conditioning 72 h / 16 h 72 h / 16 h
Dimensions Surface = 2500 mm² Parallelepiped ≥ 40 x
(≥ 50 x 50 mm, Ǿ ≥ 57 mm ) 40 mm
Force measurement ± 2% of measurement ± 2% of measurement
machine
Testing
Travel measurement ± 0.2 mm ± 0.1 mm
Support platen larger than specimen, vented larger than specimen
with holes
Compression platen larger than specimen larger than specimen
Determination of acc. ISO 1923 (no contact acc. ISO 1923 (no
initial heigth, t0 force defined) contact force defined)
Pre-set cycles
Zéro point (origin) at initial heigth at initial heigth
of travel
Number 3 3
Charge point (load +5 +5
70 % compression strain 70 % compression
locus)
Decharge point Initial heigth Initial heigth
Test speed 100 ± 20 mm/min 5 ± 1 mm/min
Recovery time 0 0
Zéro point (origin) at initial heigth, t0 at initial heigth, t0
Measurement cycle
of travel
Charge point 70 +5 % compression strain 70 +5 % compression
strain
Decharge point - -
Time at measurement 0 0
Test speed 100 ± 20 mm/min 5 ± 1 mm/min
Results CV at XX% CV at XX%
(Example XX = 40 %) (usual XX = 25, 40 50,
65 %)
Schaumstoffprüfung - Markt-Stärke-Normen-Praxis
Helmut Fahrenholz
Stand: September 2004 19
Tests in detail
Requirements to the test equipment:
Particular points:
Schaumstoffprüfung - Markt-Stärke-Normen-Praxis
Helmut Fahrenholz
Stand: September 2004 20
Tests in detail
Method ASTM D 3574 test C ASTM D 3574 - test C
Specimen
Conditioning 23 °C / 50 %
Storage / conditioning (7 days) / 12 h
Dimensions Surface ≥ 2500 mm²
(≥ 50 x 50 mm, Ǿ ≥ 57 mm )
Force measurement no indication
machine
Testing
Travel measurement no indication
Support platen larger specimen, vented
Compression platen no indication
Determination of 170 ± 35 Pa
initial heigth, t0 (70 Pa)
Pre-set cycles
Zéro point (origin) at initial height
of travel
Number 2
Charge point (load 75 - 80 % compression strain
locus)
Decharge point no indication
Test speed 240 ± 24 mm/min
Recovery time 6 ± 1 min
Measurement cycle
Zéro point (origin) to be re-determined
of travel at 140 Pa (70Pa)
Charge point 50 % compression strain
Decharge point -
Time at measurement 60 ± 3 s
Test speed 49.8 ± 4.8 mm/min
Results Specimen height t1 in mm
Compression stress CFD in Pa
Schaumstoffprüfung - Markt-Stärke-Normen-Praxis
Helmut Fahrenholz
Stand: September 2004 21
Tests in detail
Requirements to the test equipment:
Particular points:
– Initial height has to re-determined in the last cycle ( measurement cycle)
– Dwell time between pre-set cycles and measurement cycle.
Schaumstoffprüfung - Markt-Stärke-Normen-Praxis
Helmut Fahrenholz
Stand: September 2004 22
Tests in detail
Method PSA / Renault Conditioning
D41 1003
23 °C / 50 %
Specimen
Storage / conditioning - / 16 h
machine
Travel measurement ISO 5893 (no indication of class)
Testing
Support platen larger specimen, vented
Compression platen larger than specimen, vented
(without holes for skinless specimen )
Determination of Contact force 1 N
initial heigth, t0
Pre-set cycles
Zéro point (origin) at initial height
of travel
Number 0 or 4 (acc. to specification)
Charge point (load 75 % compression strain
locus)
Decharge point initial height
Test speed 100 ± 10 mm/min
Recovery time 0s
Measurement cycle
Zéro point (origin) at initial height, t0
of travel
Charge point 75 % compression strain
Decharge point at initial height, t0
Time at measurement 0s
Test speed 100 ± 10 mm/min
Results 1. cycle: P25/1, P50/1, P65/1
5. cycle: P25/5, P50/5, P65/5
Schaumstoffprüfung - Markt-Stärke-Normen-Praxis
Helmut Fahrenholz
Stand: September 2004 23
Tests in detail
Requirements to the test equipment:
Particular points:
– Upper and lower compression platen has to be vented with holes. Only for foams
without skin (slab foam which is cut from the internal portion of a larger bun) it is
allowed to use platens without holes.
– The test can consist of 5 cycles where the first and the fifth is a measurement
cycle.
Schaumstoffprüfung - Markt-Stärke-Normen-Praxis
Helmut Fahrenholz
Stand: September 2004 24
Tests in detail
Determination of indentation properties on standard
specimen (Indentation hardness, IFD)
Schaumstoffprüfung - Markt-Stärke-Normen-Praxis
Helmut Fahrenholz
Stand: September 2004 25
Tests in detail
ISO 2439 - A ISO 2439 - B ISO 2439 - C
Indentation hardness to Conditioning 23 °C / 50 %
Specime
27 °C / 65 %
ISO 2439
n
Storage / conditioning 72 h / 16 h
Dimensions 380 +20 mm
Force measurement ± 1% or 1 N (largest value)
machine
Testing
Travel measurement ± 0.25 mm
Support platen larger specimen, vented with holes
Compression platen Diameter. 200 +3 mm (swivel joint)
Determination of 5 -2 N
initial heigth, t0
Pre-set cycles
Zéro point (origin) at initial height
of travel
Number 3
Method A Charge point (load 70 ± 2.5 % Indentation
locus)
Decharge point completely discharged
Test speed 100 ± 20 mm/min
Recovery time - - -
Zéro point (origin) Initial height Initial height Initial height
Measurement cycle of travel
Charge point 40 ± 1 % Indentation 25 ± 1% / 40 ± 1% / 40 ± 1 %
65 ± 1% Indentation Indentation
Decharge point - - -
Time at measurement 30 ± 1 s 30 ± 1 s 0s
Test speed 100 ± 20 mm/min 100 ± 20 mm/min 100 ± 20
mm/min
Results Indentation Indentation hardness Indentation
hardness index as characteristic as hardness as
force at 40 % force at 25 / 40 / 65 force at 40 %
indentation % indentation
Schaumstoffprüfung - Markt-Stärke-Normen-Praxis
Helmut Fahrenholz
Stand: September 2004 26
Tests in detail
Indentation hardness to ISO 2439 Method B
Method A
Method C
Schaumstoffprüfung - Markt-Stärke-Normen-Praxis
Helmut Fahrenholz
Stand: September 2004 27
Tests in detail
Requirements to the test equipment:
Particular points:
Schaumstoffprüfung - Markt-Stärke-Normen-Praxis
Helmut Fahrenholz
Stand: September 2004 28
Tests in detail
Fatigue by constant load pounding
Editor Designation Notes
ISO ISO 3385 80000 Cycles
Schaumstoffprüfung - Markt-Stärke-Normen-Praxis
Helmut Fahrenholz
Stand: September 2004 29
Tests in detail
ISO 3385 Constant load pounding ISO 3385
23 °C / 50 %
en
Storage/ conditioning 72 h / 16 h
Dimensions Parallelepiped 380 x 380 mm
-1
Frequency 70 min
machine
Load apply 750 ± 20 N
Load apply time max. 25% of cycle time
Support platen larger specimen, vented
measure
Determination of acc. ISO 2439 prior first pre-set cycle at
First
initial height, d1 5N
Determination of acc. ISO 2439 - A, agreed indentation, i.e.
indentation hardness 40 %
Recovery time 10 ± 5 min
measuremt.
Determination of acc. ISO 2439 prior first pre-set cycle at
Second
initial height, d2 5N
Reference point for
initial height , d1
travel
Determination of acc. ISO 2439 - A, agreed indentation, i.e.
indentation hardness 40 %
Schaumstoffprüfung - Markt-Stärke-Normen-Praxis
Helmut Fahrenholz
Stand: September 2004 30
Tests in detail
ISO 3385 Constant load pounding
Schaumstoffprüfung - Markt-Stärke-Normen-Praxis
Helmut Fahrenholz
Stand: September 2004 31
Tests in detail
Requirements to the test equipment: :
Particular points:
Schaumstoffprüfung - Markt-Stärke-Normen-Praxis
Helmut Fahrenholz
Stand: September 2004 32
Tests in detail
Type of test Standards Principle Specimen Significance / Application
example
Descibes an indentation characteristic as a hardness value
Indentation hardness and
Molded foam which is not directly compareable to the compressoin
respectively residual DIN 53579-1
(seat cushion) characteristics. many different shapes and dimensions of
thickness under load.
indentors are standardized.
several standards
Molded foam
Hysteresis of automotive Provides results for damping, toghness and the "comfort value".
(seat cushion)
OEM
Schaumstoffprüfung - Markt-Stärke-Normen-Praxis
Helmut Fahrenholz
Stand: September 2004
Overview
33
of test methods - molded foam
Indentation hardness / residual thickness under load
(Seat testing)
Editor Designation Notes
ISO no standard
DIN DIN 53579-1 Measurement at specified indentation
deflection or under specified load
ANSI ASTM D 3574 Measurement at specified indentation
test B1
ANSI ASTM D 3574 Measurement at specified load / Method for seat
test B2 testing
DaimlerChrysler DBL 5452, refers to DIN 53579-1
Abschnitt 4.7
BMW QV 52009, part 1 refers to DIN 53579-1, pre-set at 300 mm/min,
measurement cycle at 100 mm/min
Test set-up to DIN 53579-1 Volkswagen PV 3410, section Measurement under specified load. Result is the
3.8 indentation deflection
PSA D41 1427 Measurement under specified load. Result is the
indentation deflection. Specific indenter.
General Motors GMI 60283 - part 7 Measurement at specified deflection, but specific
procedure B test methods acc. to the type of component to be
measured.
Toyota TS F6223G Measurement at specified deflections.
Schaumstoffprüfung - Markt-Stärke-Normen-Praxis
Helmut Fahrenholz
Stand: September 2004 34
Tests in detail
DIN 53579-1
Method DIN 53579-1 Conditioning 23 °C / 50 %
Specim
en
Storage / conditioning 72 h / 16 h
Dimensions molded foam
Force measurement ± 1% of measured value (class 1)
machine
Travel measurement ± 0.1 mm
Testing
Support platen Support for contoured molded parts
Compression platen 9 different Indenter shapes and
dimensions
Determination of not foreseen
initial heigth, t0
Pre-set cycles
Zéro point (origin) In each cycles at the preload given for
of travel the inderter
Number 3
Charge point (load Indentation travel corresponding to
locus) 70% of deflection
Decharge point no indication
Test speed 100 / 50 / 20 mm/min
Recovery time 0
Zéro point (origin) not foreseen
Measurement cycle
of travel
Charge point Indentation travel or load, value to be
aggreed upon
Decharge point no indication
Time at measurement 0 or 30 s
Test speed 100 / 50 / 20 mm/min
Results Indentation force or indentation travel
(depending of the pre-set)
Schaumstoffprüfung - Markt-Stärke-Normen-Praxis
Helmut Fahrenholz
Stand: September 2004 35
Tests in detail
Requirements to the test equipment:
Particular points:
– In seat testing we find many company standards from the automotive industry.
These standards define many different indenters, deflections, indentations travels,
settings times etc. according to the type of part to be tested (seat cushion, back
rest pads, headrest, armrest ...)
Schaumstoffprüfung - Markt-Stärke-Normen-Praxis
Helmut Fahrenholz
Stand: September 2004 36
Tests in detail
Type of test Standard Significance / Application
Density ISO 845 The appearant density is one of the most basic characteristics
of a foam. To be determined by dimension measurement and
weighing
Rebound resilience ISO 8307 Gives an indication about the shock absorption properties.
Determination by means of a falling ball. Formerly in DIN 53573
also standardized with a pendulum rebound tester.
Tension test ISO 1798 relavant mainly for foams which will be submitted to tensile
forces in practical use. This method gives values for the
resistance to destruction.
Tear resistance test ISO 8067 Gives the characteristic of a pre damaged foam.. The result is
subject to very big scutter.
Shore 00 Hardness ASTM D 2240 Sometimes used to characterize local hardness, i.e. for
compound foams.
Schaumstoffprüfung - Markt-Stärke-Normen-Praxis
Helmut Fahrenholz
Stand: September 2004 37
Overview of test methods - others
Tension and tear resistance
Schaumstoffprüfung - Markt-Stärke-Normen-Praxis
Helmut Fahrenholz
Stand: September 2004 38
Tests in detail
Requirements to the test equipment:
Schaumstoffprüfung - Markt-Stärke-Normen-Praxis
Helmut Fahrenholz
Stand: September 2004 39
Tests in detail
Zwick products for the soft foam industry
Schaumstoffprüfung - Markt-Stärke-Normen-Praxis
Helmut Fahrenholz
Stand: September 2004 40
Products
Products for compression load deflection characteristics on
cut specimen, i.e. to ISO 3386
ZwickiLine ProLine
Fmax: 1 kN or 2.5 kN Fmax: i.e. 5 kN
Schaumstoffprüfung - Markt-Stärke-Normen-Praxis
Helmut Fahrenholz
Stand: September 2004 42
Products
Robotized testing of PUR dampers
ZwickiLine ProLine
Fmax: 1 kN Fmax: 5 kN
Schaumstoffprüfung - Markt-Stärke-Normen-Praxis
Helmut Fahrenholz
Stand: September 2004 44
Products
Products to determine indentation hardness of molded foam parts, i.e.
to DIN 53579-1, ASTM D3574, automotive standards
Schaumstoffprüfung - Markt-Stärke-Normen-Praxis
Helmut Fahrenholz
Stand: September 2004 45
Products
Products for hardness testing on seats. , i.e. acc. to DIN
53579-1, ASTM D3574, automotive standards
C-frame machine
• Fmax: 5 kN or 10 kN
• hinged table for seat testing (1000 x 1450 mm)
• or with shifting table for testing of mattresses
(1000 x 2000 mm)
• particularly useful in production control
• Very good accessibility from 3 sides
• adaptation possibilities for long-stroke
extensometer
Schaumstoffprüfung - Markt-Stärke-Normen-Praxis
Helmut Fahrenholz
Stand: September 2004 46
Products
Products for determination of hardness ( IFD) on molded
foam, i.e. to 53579-1, ASTM D 3574, automotive standards
Schaumstoffprüfung - Markt-Stärke-Normen-Praxis
Helmut Fahrenholz
Stand: September 2004 48
Products
Constant load pounding machine. (Fatigue tester)
Fatigue tester
• robust Electro-mechanical drive
• Fmax: 1 kN (load measurement below support
platen)
• max. speed: 30 m/min
• max. travel: 200 mm
• Support: 400 x 400 mm, vented with holes
Schaumstoffprüfung - Markt-Stärke-Normen-Praxis
Helmut Fahrenholz
Stand: September 2004 49
Products
Fatigue tester for headrests
Schaumstoffprüfung - Markt-Stärke-Normen-Praxis
Helmut Fahrenholz
Stand: September 2004 50
Products
Products for tensile and tear tests.
Left picture:
Tensile test, ISO 1798
• zwickiLine or ProLine
• Longstroke extensometer
Center:
Tear test on trouser
specimen, ISO 8067
Schaumstoffprüfung - Markt-Stärke-Normen-Praxis
Helmut Fahrenholz
Stand: September 2004 51
Products
Rebound resilience tester to ISO 8307, ASTM D 3574 test H
Schaumstoffprüfung - Markt-Stärke-Normen-Praxis
Helmut Fahrenholz
Stand: September 2004 52
Products
Further products for testing of soft foam
Schaumstoffprüfung - Markt-Stärke-Normen-Praxis
Helmut Fahrenholz
Stand: September 2004 53
Products