MIDTERM PROJECT

PLASTICS TECHNOLOGY

AQUINO, JUSTIN GIOHANN G.

 The Challenge of a Heavy Truck: Equipment Failure in Extreme Temperatures
Heavy trucks are designed to be tough, and what’s going on under the hood should be a top
priority for engineers. Polymer Technologies, Inc (PTI) was approached by an original
equipment manufacturer (OEM) of diesel engines for heavy trucks that were having engine
trouble.
The existing design inside the engine compartment was prone to freezing when condensation in
the system was exposed to extremely low temperatures. The components most susceptible to
freezing (leading to engine failure) were those inside the plastic crankcase cover and the inlet
and outlet tubes.
After the initial assessment of engine performance and understanding of the extreme conditions
in which the heavy trucks were intended to operate, we determined the OEM needed thermal
materials to insulate the engine’s crankcase ventilation system. A die-cut solution consisting of
closed-cell foam was developed for each component of the engine: the cover, the inlet tube, and
the outlet tube. The three 2D die-cut pieces of foam were applied flat with adhesive and
assembled by installers on the OEM’s assembly line. The additional assembly time to add the
three pieces of foam to the components was approximately 5 minutes which, at the initial low
volume, was acceptable.
We were able to help the OEM meet their initial requirements with a cost-effective, lightweight
solution. The manufacturer was pleased with the results and started to consider the development
and lifespan of their product in a new light. The OEM realized that trucks in warm climates
could potentially end up in one of the extremely low-temperature environments that caused the
freezing issue.
o start developing a new solution, Polymer Molded Products (PMP), our manufacturing division
for custom molded foam, was tasked with determining if the flexible hoses and rigid plastic
cover could be over-molded with Polyform® High Density Molded - Integral Skin (PHDM-IS).
In doing so, the molded material would provide a precise, one-piece thermal solution.
PHDM-IS is commonly used in over-molding applications because of its durable, attractive
outer skin and excellent adhesion to a variety of substrates. Through prototyping, we determined
both the flexible hoses as well as the plastic cover could be effectively over-molded. The OEM
had limitations on size and configuration of the foam part. Through experimenting with pour
patterns and mold articulation, we were able to meet the OEM’s requirements.

Reflection
Not only did the over-molded engine parts meet the required assembly time, thermal
performance, and other durability and wear requirements of the OEM, they were also
more aesthetically pleasing than the die-cut solutions. By switching from a die-cut foam
solution to custom molded foam, the OEM was able to reap cost-saving benefits they hadn’t
thought were possible.
 Vibration Isolation Solutions On-Demand Shorter Lead Times Provided with HVAC
Manufacturer
A leading commercial manufacturer of heating, ventilating, and air conditioning unit (HVAC)
came to Polymer Technologies with a problem: their supplier wasn't able to deliver isolation
mounts on time. While disruptions in the supply chain can happen, the HVAC manufacturer was
completely caught off guard because their supplier didn’t let them know ahead of time that the
isolation mounts they needed would no longer be in stock.
Polymer met one-on-one with the client to explore comparable solutions in regards to durability
and pricing that could be delivered quickly.
When the HVAC manufacturer contacted Polymer Technologies, they needed an equivalent
solution to their previous vibration isolation mounts. The mounts would be used for vibration
isolation in HVAC units for mobile offices and classrooms, so they had to be suitable for heavy-
duty applications to mitigate excess vibration and noise. Additional noise from shaky HVAC
units would disrupt users while excess vibration would compromise the integrity of the HVAC’s
blower motor assembly.
The manufacturer needed a new vibration isolation mount that was able to not only perform but
be delivered on time.The disruption caused by their previous supplier made lead times extend
between 8 to 16 weeks for the HVAC manufacturer.
Polymer listened to the manufacturer, understood their requirements and need for a speedy
turnaround, and quickly provided them with an isolation mount for testing that met their
manufacturing needs.
By understanding the HVAC manufacturer's specifications for isolation vibration, Polymer was
able to provide them with a comparable alternative: SquishyFlex® Anti-Vibration Mounts.
Developed by Polymer’s Technologies Elastomeric Solutions Division (ESD), SquishyFlex®
mounts are easy-to-install and suitable for use with blower motors in HVAC units. The three
different spring rates provided by SquishyFlex®, coupled with its fail-safe, drip-proof design,
gave the HVAC manufacturer a suitable and less expensive isolation mount alternative.
To cut down on extended lead times, Polymer was able to do what the competition couldn’t:
provide local warehousing and fast turnaround times on parts. Polymer Technologies was able to
cut down the excessive 8 to 16 week lead time to just one week! To help meet deadlines,
Polymer also provided the HVAC manufacturer with a 48-hour turnaround on orders with
emergency overnight deliveries if needed.

Reflection
Solutions using polymers has successfully met the goals of the HVAC manufacturer.
Ultimately, a great manufacturer needs a great supplier to be their partner to deliver
results on-demand. By working one-on-one with the manufacturer, Polymer was able to get
to the crux of the problem and provide a durable HVAC vibration isolation solution that is
locally warehoused and consistently delivered on time, every time.
 Noise Reducing Molded Foam for Oxygen Concentration

While the functionality of electronic medical equipment is of the utmost importance to

manufacturers, it is also necessary to consider the experience of patients using the equipment.
Noisy medical devices can have a negative impact on the patient's quality of life.

A manufacturer approached Polymer Technologies because their oxygen concentrator produced

too much noise during operation. They expressed their need to reduce noise in existing models
because developing a redesign of the product’s exterior wasn’t feasible.

We worked with them to devise the best solution to absorb sound waves and increase patient
comfort by thinking forward with an innovative material solution.

When the manufacturer contacted Polymer, they had just completed the design and build of their
first production models of the oxygen concentrator. The manufacturer was concerned about the
feedback the units received. Patients disliked how loud the oxygen concentrator was during
operation, which severely impacted user experience as patients often have their device with them
throughout the day.

Noise was a primary concern for the manufacturer, and not only because users were unhappy
with its performance. They were up against tough noise reduction requirements. While the
manufacturer was located in the United States, they planned to distribute to the European Union,
which has stricter requirements for noise levels emanating from devices such as oxygen
concentrators.

Since the oxygen concentrator was already a finished product, the tools for developing the unit
were already designed. A redesign of the unit was not an option, so this gave us a specific
direction and a set of restrictions to think inside the box to find the best solution.

A custom molded foam was chosen to simplify the assembly of the product and improve the
quality of the damping effect.

Molded polyurethane foam is ideal for reducing sound and filling space inside of devices with
soft material. We were able to develop a two-piece mold out of POLYFORM® High Density
Non-Skinned foam that absorbed noise and reduced the number of parts.

The 3D foam solution reduced the decibel level of the oxygen concentrator significantly, which
resulted in a better experience for the end user and passed EU requirements. The molded foam
solution also provided additional cost savings.

Reflection
The manufacturer was able to replace multiple expensive mountings and airflow brackets
inside the oxygen concentrators with the two pieces of molded foam, as well as drastically
reducing production cost and assembly time. The two molded foam pieces fit perfectly into
the side of the oxygen concentrator and were specifically designed to allow air to pass
through, creating a snake-like path that produced minimal noise.
 Improved Foam Cushion for Medical Equipment
In addition to the electronic functions of medical equipment, patient comfort is also a concern
when designing a device for home use. Polymer Technologies worked with a medical
manufacturer of a heart monitoring device that consisted of two components: a device placed
inside the patient’s heart, and the foam cushion containing electronics that read the information
from the device. Because the patient needed to lie down on the foam cushion, the client came to
Polymer in order to perfect its design in terms of both comfort and cost-effectiveness when
developing a new and improved generation of the product.

The medical manufacturer required an update to the foam cushion component of their product

The customer contacted Polymer because they were working on launching the second generation
of their product. They were not satisfied with the foam used in the first generation’s cushion and
wanted to use a more cost effective material. The design of the customer’s product was made for
comfort by encasing the electronics inside the foam cushion rather than exposing them. In
keeping with the design goal, they wanted the foam to be firm enough for a patient to lie down
on comfortably. The foam cushion consisted of three parts: a bottom, a top, and a pillow.

Additionally, the customer needed a way to block electromagnetic interference from hindering
the function of the electronics inside the foam.

PLDM-HR Polyurethane Foam for Comfort

The customer had a particular firmness in mind that would be just right for comfort, and they
wanted to use molded urethane. They specified the desired firmness according to the Indentation
Force Deflection (IFD) standard, and Polymer sent them a few sample formulations that fit the
specifications. The customer then chose the formulation that they felt best suited their needs,
which was POLYFORM® Low Density Molded—High Resilient (PLDM-HR) polyurethane
foam.
EMI RFI shielding material
While the POLYFORM® foam cushion solved the issue of patient comfort, there was still a risk
of electromagnetic interference preventing the device from functioning properly. The customer
required an addition to the design that would stop this problem; therefore, Polymer created a
fabric shield assembled on the back of the cushion.

Reflection
Polymer’s solution was more comfortable and also less expensive while better meeting the
quality requirements. Polymer also offered a more competitive price than the first
generation’s supplier. The second generation of the device will hit the market with
improvements provided by Polymer’s molded solution. Most importantly, the patients will
be able to benefit from the heart-monitoring data collected by the electronics as well as
comfort while using the device.
 Noise and vibration Reduction for a high-end manufacturer of blenders

A high end manufacturer of blenders for home as well as commercial use contacted Polymer
Technologies, Inc. for help with reducing the noise and vibration their blenders create. Polymer
consulted with the customer on various improvements to the product and also developed a
custom foam insertion, enabling the manufacturer to be confident that their blenders are as quiet
as possible.

In food service establishments, such as cafes that serve frozen drinks like frozen coffee and
smoothies, it’s important to create a welcoming environment for customers without any harsh or
disruptive noise.

However, there are two factors that work against noise control in food service. One is the icy
drinks served at these establishments—crushing ice in a blender makes a lot of noise. The second
is the acoustics. Any establishment that serves food is designed to be easy to clean—this means
lots of hard, reflective surfaces such as granite, tile, or laminate countertops and backsplashes.

Polymer consulted with the manufacturer on creating an enclosure for the blenders. The result
was a see-through enclosure that surrounds the blender and minimizes the amount of airborne
noise while keeping the contents visible. Additionally, the customer used damped rubber isolated
feet for the blender’s base. Without damped rubber feet, the product would ―walk‖ around the
counter and amplify the vibration causing more noise.

Much of the noise and vibration comes from the ice-crushing mechanism, but there is also noise
from the blender’s motor. The motor requires airflow for cooling, so the noisy motor cannot be
sealed up entirely, and without a tortuous path, sound escapes directly from openings in the base
and is loud. Polymer recommended a sound baffle so the sound would have to bounce around
foam lined interior before escaping, thereby reducing the sound energy.

In many projects, Polymer takes flat sheets of foam and cuts it into the desired shape, similar to a
cookie cutter, and the shape’s thickness is uniform. In this case, Polymer contour-cut the foam at
a 45-degree angle into a funnel-like shape to create clearance for the sound baffle.

Polymer provides non-flammable and self-extinguishing UL-94V0 POLYDAMP® Melamine

foam, which allowed the manufacturer to advertise that their equipment was high-quality and
safe for home and commercial use.

Reflection
The combination of the custom contour cut foam, damped rubber feet, and the sound
enclosure allowed the manufacturer to produce a blender that operated at the lowest sound
level possible. As a result, the blenders can be used in commercial food service
environments with minimal disruption to the customer experience while ordering and
enjoying their food and drink.
 HMMWV Cab Liner Program to Protect Troops

In the process of up-armoring the military HMMWV (Humvee) for combat missions in Iraq and
Afghanistan, enough heavy armor plating was added to the base vehicle that each crew door now
weighed in excess of 400 lbs. This helped protect the troops from rocket-propelled grenades but
when the vehicle was upended by an IED (Improvised Explosive Device) planted in the road, it
became difficult for soldiers to quickly extricate themselves from the vehicle, given the weight
of the doors, now overhead.

In some cases, the blast would result in a fire that involved the acoustical/thermal cab liner
insulation. While these common automotive products met the normal flammability criteria for
passenger cars and trucks (FMVSS 302), that standard assumes that most vehicle operators and
passengers have ample time to exit the vehicle. As such, it allows for the dripping of molten
foam residue, as the material slowly burns, prior to self-extinguishing.

Army hospitals in Germany were reporting a higher than normal incidence of soldiers suffering
from burns on the face, neck, head and arms as a result of contact with the dripping molten
foams.

TACOM (U.S. Army Tank Automotive Command) challenged is prime HMMWV manufacturer
to develop an
acoustical/thermal cab liner that would pass a much more stringent flammability standard; one
that does not allow for the dripping of molten foam when the material is involved in a fire. The
standard chosen was UL 94-V0. This is a burn test whereby the sample burned is in a vertical
orientation.

 PTI, along with seven other materials companies, was invited to participate in this
developmental challenge to help protect U.S. combat troops. Contending composites
would need to not only pass UL 94-V0, but would have to be very durable and watertight,
as the HMMWV is capable of fording deep streams. Anti-fungal capabilities were also a
must.
 PTI developed a rugged closed-cell foam base and introduced a tough aerospace-oriented
woven facing for added long-term endurance in a military setting. Its unique through-
foam perforating technique allows air to escape from behind the closed cell foam during
installation. This, in addition to a very aggressive adhesive system, provides for a most
secure and lasting bond.
 PTI’s superior cab liner composite was chosen over the other contenders and is now in
production on the HMMWV. Other military vehicle OEMs as well as commercial vehicle
manufacturers have shown a keen interest in this new Non-Burning cab liner composite.

Reflection

PTI engineering and applications specialists considered all parameters that might
prove important in a military vehicle setting, calling on its past experience in
providing cab liners for such military stalwarts which in my opinion is a genius idea.
 Environmentally Conscious Electric Cooling and Heating System with Closed-Cell Foam

A high profile company was looking to create a brand new, high-end residential cooling and
heating system. As an industry leader, they needed cutting edge design that was also
environmentally conscious. While fiberglass is normally used for insulation within these types
of systems, the material presents certain environmental and health hazards that this company was
looking to avoid. Often times when handling and installing fiberglass, small fibers can escape
into the air and cause skin irritation.

This health hazard to workers, along with the environmental implications of using fiberglass, led
our client to request an alternative material. While it seems simple on paper to replace the
fiberglass, finding a material that insulates as well as fiberglass can be a complex task.
Complicating the process is the fact that insulation materials must meet certain regulations.

The Solution: Polymer’s PLFS Closed-Cell Foam

When this client approached Polymer Technologies, they had very specific demands. They
needed insulation foam that:

 Passed ASTM E-84 flame spread and smoke development specifications of 25/50 or less
 Was non-water absorbing
 Featured closed-cell material
 Met the R-value of 4.2 at a minimum

Faced with this long list of specifications, Polymer proceeded to create a handful of material
options that met our client’s requirements. Polymer sent the different test materials, with
documentation of material characteristics, to the client, and the client did in-house testing on
each of the materials at their headquarters and put the test materials into action via field tests.

After three extensive field tests, it was clear that Polymer had provided the best solution
compared to the competition; the chosen material was Polymer PLFS-CC – a specially designed
Low flame spread and smoke generating closed-cell foam that provides insulation properties
similar to fiberglass, but with a variety of added advantages including:

 Easier and more efficient fabrication of materials

 Easier and more efficient installation process
 Safer working environment for employees
 Is non-moisture absorbing

Reflection
PLFS closed-cell foam, they were able to maintain their environmentally conscious
attitude while still providing a superior heating and cooling product.
 Truck Cab Insulation Customization

A cab and chassis manufacturer from the Midwest approached Polymer Technologies with an
aesthetic issue with their interior. The cab’s metal frame is covered with a layer of insulation to
protect passengers from uncomfortable temperatures and noise. To create a clean-cab look, the
manufacturer covered the insulation with a Masonite board which was then covered by a gray,
interior fabric for visual appeal and comfort. Initially, this construction would create a nice, clean
appearance inside the cab; however, due to the effects of heat and humidity, the Masonite board
would warp over time, causing the ceiling and walls of the cab to appear contorted or deformed.
The warping detracted from the overall appearance and comfort of the cab.

The Solution: Customized Corrugated Plastic

Wanting to increase the lifetime of the cab interiors while also maintaining the high-quality
aesthetic of the cab, the manufacturer turned to Polymer for a solution. Polymer’s engineering
team provided alternative sample materials for the client to test in their cabs. Testing of the
material focused on two key requirements: rigidity and durability.

The client selected a material commonly used in Polymer’s military applications: a 4 millimeter
thick customized corrugated waterproof plastic. Using corrugated plastic was key as it allowed
the client to move away from wood-based material. Initially, the corrugated plastic was slightly
more expensive than the Masonite board, but after making adjustments to the manufacturing
process, Polymer was able to reduce the cost of the plastic, making it less than the Masonite.

Polymer Technologies was able to create custom pieces to fit within the cabs. Polymer provided
the parts prefabricated, so the client didn’t have to spend additional funds and time to
manufacture the piece themselves.

The Results: Quality Interior & Cost Savings

The new custom, corrugated plastic was an improvement over the previous Masonite board as it
provided:

 The correct rigidity

 Increased durability which results in no warping
 A small decrease in weight of materials
 More dimensional stability
 Reduced cost

Reflection
With this new solution in place, the cab manufacturer can now create cabs that maintain a
clean, comfortable look and feel with the added benefit of durability. With the warping
issue eliminated, the manufacturer can promote longer-lasting interiors while also saving
money on the materials associated with the cab production.
 Improved Look & Reduced Costs for Boiler Cover Wrap

A manufacturer of industrial tank-less boiler systems approached Polymer Technologies with a

problem related to their manufacturing and installation process. The client was constantly
experiencing unacceptable results and poor aesthetics due to current installation procedures and
material choice.

The client’s material vendor provided presized and precut boiler cover wrap material but due to
an inferior edge-wrapped sealing system, the material would frequently tear apart when installed.
This caused the end product to look displeasing and increased project costs due to scrappage of
damaged materials. The vendor was unable to improve their product, leading the boiler
manufacturer to approach Polymer for support.

After discussing the goals of the project with our client’s manufacturing team, it was decided that
Polymer would create a similar material to the one the client was using; however, Polymer’s
material would include a custom facing that was aesthetically pleasing.

The chosen material was a closed cell foam of 0.5’’ thickness covered on one side with the
PLFS-CC-050-BRV Facing. To aid installation, the foam would adhere to the tanks using a 3’’
wide, easy-install, edge seal tape.

PTI resolved all aspects of the Issue in the following ways:

1. Engineered a more rugged, yet aesthetic facing

2. Designed and engineered an aesthetic and easy to install edge seal tape
 Manufactured a unique 3" wide Edge Sealing Tape - Utilizing the facing and
PSA, 1/2 of the back of the tape had release liner and the other 1/2 was applied to
the wrap's facing
 Once the composite was wrapped and edges matched the release, the liner was
pulled off and the tape was sealed to the facing, giving it a positive seal that was
also aesthetically pleasing.
3. Polymer’s design lowered the material and labor cost significantly

Reflection

Polymer is now trusted due to the ability to proactively respond with innovative methods
and materials. Polymer is now working on other projects with the client that will produce
greater savings and therefore, more market share.
Natural Gas Compression/Pump: Increased Acoustical Performance, Decreased Costs, and
Improved Employee Health & Safety

A leading manufacturer of natural gas compression and delivery (pumping) systems knew they
needed to redesign the insulation and enclosure of their systems. They approached Polymer
Technologies with a three-fold request:
Improve the acoustical performance : Similar in look to regular gas station pumps, these
compression/ pumping systems require substantially larger mechanical parts (resulting in the
entire system being at least 8ft x 8ft x 8ft), which create significantly more noise.
Reduce the cost of materials and installation: They were using mineral wool as a noise insulator.
Sheets of mineral wool needed to be cut and sized manually. The hands-on installation incurred
high labor and required too much manufacturing floor space. In addition, hundreds of stud
welds had to be spot-welded onto the pre-painted enclosure at great cost and time loss.
Increase employee safety during installation: The hands-on installation also put the installers at
risk of skin irritation and inhalation of mineral wool particles.
Polymer's Process:

Polymer had to determine which parts of the mineral wool were working to perform which
specific acoustical functions. Figuring out if the mineral wool was reducing noise because of its
mass or because of its other inherent properties was crucial in honing in on an appropriate
solution. Polymer worked closely with the client’s engineering team in a series of field tests to
zero in on the ideal composite.
After the completion of the field tests, Polymer’s engineering team noted that the mineral wool
was acting primarily as a sound barrier/vibration damper, and less as a sound absorber. This
information was critical in helping Polymer focus on the characteristics of their chosen material,
making sure that the end composite was an effective sound barrier/ vibration damper as well as
providing necessary sound absorption. . In the end, Polymer determined that a custom Melamine
Foam/Sound Barrier composite would be the ideal solution for the client’s problems.
Polymer’s production team was able to design a streamlined production process whereby they
would provide the composite in kit form, fully ready for installation. By producing, shaping, and
cutting the materials for the customer, there would be a dramatic reduction in the client’s cost of
labor and a relief of manufacturing floor space for core operations. This service also eliminated
the hazardous conditions their installers had been exposed to with the mineral wool.

Polymer Technologies exceeded the capabilities and characteristics of mineral wool.

1. POLYDAMP® Melamine Foam has a high resistance to flammability and smoke, a
characteristic extremely important for this application.
2. In this case, POLYDAMP® Hydrophobic Melamine Foam was chosen to provide a very
high resistance to water absorption—as these are all out-door installations - something
the mineral wool lacked.
3. Polymer used a micro-perforated Reinforced Aluminum Foil facing on the surface of the
foam in order to protect it from outside contaminants, enhance durability, and add
longevity to its performance.
4. The micro-perforation also gives the foam better acoustical absorption characteristics;
especially in the frequency range of importance in these systems.
5. With Polymer’s engineering team having developed an excellent material composite, the
next step was to delve further into additional options to reduce costs.

6. Adding a pressure sensitive adhesive on the backside of the composite reduced the
number of stud welds needed to secure the insulation—the mineral wool required
hundreds of stud welds whereas the melamine foam needed 90% fewer stud welds.
7. Fewer welds dramatically reduced installation time and in turn, labor costs.

Reflection

In these compression/ delivery systems, there is a steel rail framework that the
motor and pump are attached to and a large metal enclosure then sits on the frame
rails to enclose the package. I think the solution lacks implementation however can
be improved.
 Rubber Vibration Isolators for Class 5-8 Trucks

Polymer Technologies met with a large American heavy truck manufacturer to discuss
DuraFlex®, an easily moldable compound which can be used to replace the trucking company's
existing rubber radiator mounts. Before radiator mount designs are put into production, they
must withstand extensive testing that simulates real world conditions. Since road testing parts
500,000 or 1,000,000 miles is impractical, this particular truck manufacturer uses an accelerated
test.

Due to hysteretic damping of typical mounts, testing engineers expect to use up to half of a
dozen sets over the course of the test. Since DuraFlex® builds up no internal heat when flexed, it
does not degrade and is an extremely long-life material for use in vibration mounts. For this
reason, Polymer Technologies' engineers felt this accelerated test would be ideal for
demonstrating the long-life properties of DuraFlex®.

Polymer Technologies' Solution:

Created by Polymer Technologies' material experts in conjunction with Akron Rubber
Development Laboratory, Inc. (ARDL), DuraFlex® is designed to withstand excessive amounts
of shock and vibration without building up internal heat. This is why Polymer Technologies
knew it would outperform any other rubber radiator mount product the truck manufacturer had
previously tested. Polymer Technologies produced a set of radiator mounts identical in design to
the truck manufacturer's existing mounts and provided them for testing.

The power of the DuraFlex® solution lies within the rubber’s ability to not generate internal
heat. Typical rubbers build up heat as they move from a flexed to a relaxed position. This kind of
movement happens constantly for rubber mounts as the engine shakes and vibrates as the truck
travels on bumpy roads.

DuraFlex® rubber is highly resilient, has an ultra-high fatigue life, and is prone to almost no
damping. In fact, it is the lowest temperature rise rubber known to exist. One of the DuraFlex®
rubber formulas scored a 0° temperature rise on the Goodrich Flexometer Test. This test
measures how much internal heat is generated by the flexing and relaxing of the rubber. A
general purpose natural rubber will usually see a rise of 12-14° F, and a long-life rubber blend
will typically see a rise of around 6° F.

The truck manufacturer followed their standard testing process, and after a week-long test, a
single set of DuraFlex® radiator mounts survived the entire shake testing process. As opposed to
our competitor’s products which quickly became no longer fit for use, the DuraFlex® mounts
were not degraded in any way. Not only did they stand up to the test, but they were also in strong
enough condition that they could continue to be used going forward.

Reflection

Because of its durability and ultra-high fatigue life, the rubber radiator mounts made of
DuraFlex® proved to be superior to any that had been previously utilized by the heavy
truck manufacturer.
 Analysis of Proper Flame Retardant Seating for Tactical Vehicles

With tactical military vehicles being exposed to significant threat levels, the safety of interior
materials, including seat construction, is undergoing intense scrutiny as of late. Traditional
materials for interior tactical vehicle applications, as well as seats, traditionally evolve from the
commercial market. Although many of these materials are made with fire retardant components,
the level of fire resistance and ultimate performance under fire is not adequate to the exposure
that tactical vehicles regularly experience.

In most cases, it is important to consider materials designed for use in aerospace and mass transit
vehicles in order to achieve the degree of fire resistance required to offer a significantly higher
level of protection and survivability for military personnel. This paper will touch on some basic
considerations and offer alternative materials to consider.

However, there are many materials to choose from with varying performance characteristics for
each. Adequate choice of flame retardant materials and appropriate construction will depend on
the ultimate performance criteria established for the final seat construction. This is best achieved
through a close collaboration with sales engineers from material suppliers such as Polymer
Technologies, Inc.

Traditional Materials:
Traditional seating materials consist of a multi-layered or homogeneous seat, either molded or
contour, cut from a series of commercial grade polyurethane foams. These foams have high
resiliency and are designed as excellent cushions and used across a broad spectrum of
automotive, truck, and commercial seating. Military seat cushions utilizing this same
construction with polyurethane foam may or may not be manufactured with fire retardant
additives. Even commercial grade cushions that are manufactured with fire retardant materials
are still highly flammable and not readily self-extinguishing.

The challenge in evaluating these traditional materials is that many tests for flammability are not
severe and laboratory performance does not directly relate to actual performance in a fire. Many
traditional cushioning materials that pass tests such as FMVSS-302, UL 94 HBF, or CAL 117
would still burn readily in a seat configuration exposed to an actual fire. In addition to the threat
posed by burning and molten plastic foam, the resulting smoke is black and noxious, and as a
result can quickly compromise breathing in a confined area such as a vehicle cabin.

When contemplating a cushioning material that is safer and enhances survivability for tactical
vehicles, consideration should be given to seating materials developed and used for both mass
transit and aerospace applications. A cost-effective approach would be to consider graphite or
melamine-loaded polyurethane foams, which exhibit significant fire resistance and would be
considered a flame retardant seating material exhibiting significantly improved performance over
traditional seating products. The density of these modified fire retardant polyurethane foams
range from 3 ½ lbs. per cubic foot to 6 lbs. per cubic foot, which would be 2 to 3 times the
weight of traditional polyurethane cushioning materials. This increased weight is necessary
because these products are highly filled and highly fire retardant.
In both mass transit and aerospace applications, weight is a critical consideration to seat
construction since weight is a premium in these applications. Due to this, POLYDAMP®
Melamine Foam (PMF) is used as a core material. PMF weighs between .4 to .6 lbs. per cubic
foot, and is 15 times lighter than the highly filled and combustion modified polyurethane foams.
Therefore, a composite construction that utilizes PMF as a core with thinner increments of
traditional fire retardant modified urethane foam as top surface are effective in maintaining low
weight with enhanced foam resistance and improved survivability.

The highly filled and combustion modified urethanes noted above are traditionally cut to shape
and assembled into a required seat profile. Alternatively, there are moldable grades of
polyurethane foams, which may also use a core of PMF for weight reduction. Polymer
Technologies' POLYFORM® Molded Foams, and specifically a UL94 V-0 compliant High
Resilient (PLDM-V0) grade, are an ideal choice for concise seat designs while also offering
opportunities to efficiently integrate blast mitigation materials and other components of seat
assembly. The actual construction of the seat can take many forms depending on weight
requirements, thickness profile, and covering materials. The details of specific seat designs may
be supported by contacting your Polymer Technologies' Sales Representative.

Reflection
The challenge in evaluating these traditional materials is that many tests for flammability
are not severe and laboratory performance does not directly relate to actual performance
in a fire. I believe that in proper testing materials used by technological institutes would be
functioning better.
 Noise Control POLYFORM Molded Outboard Motor Application
Developing equipment for marine vessels requires manufacturers to consider the safety and
comfort of both passengers and pedestrians on the shoreline. A renowned manufacturer of
recreational equipment contacted Polymer Technologies to help them reduce the noise produced
from their latest outboard motor.
The manufacturer's two-cycle motor was producing sound levels 11 to 12 decibels higher than
their competitor’s four-cycle motor. The high volume of noise was uncomfortable for passengers
and those living and vacationing beside waterways. The manufacturer requested that Polymer
help them design and develop acoustical barriers so the noise level produced during operation
would be comparable to the competition’s four-cycle outboard motor of equal horsepower.

After extensive testing, we determined that the majority of the noise was emitted from the lower
exhaust section of the outboard motor, which is just above the waterline. The culprit of the sound
source was the motor itself under the upper motor housing, or bonnet.

Often, the motor housing is lined with die-cut foam to absorb excess sound. The manufacturer
was utilizing a 15 piece die-cut foam solution within the engine compartment, but it was not
absorbing noise as required. To improve the manufacturer’s equipment, we realized a bold new
custom solution for noise reduction was needed.

Using our in-house PMP production facilities, we devised a molded foam solution that
encapsulated the upper and lower parts of the outboard motor to reduce noise.
The final design utilized two different types of molded foam to meet the manufacturer’s noise
absorption and environmental requirements. POLYFORM® High-Density Molded Foam with
Integral Skin surrounded the lower unit of the motor below the waterline, providing a higher
level of containment and energy absorption. The integral skin helped to prevent water absorption
while providing noise reduction.

Reflection
This resulting sound reduction was at levels equal to and, in some RPM ranges, below that
of the industry-leading four-cycle competitor. By switching to a molded foam solution, the
manufacturer was able to reduce noise while also eliminating the number of parts and
assembly time needed.
 Motorcycle Exhaust Module Application
A leading motorcycle manufacturer needed to reduce the amount of shock produced from an
electromechanical muffler exhaust actuator without altering the design of their specialized
exhaust system. They contacted Polymer Technologies to help them think inside the box to
develop a custom solution.

The motorcycle original equipment manufacturer (OEM) developed a sophisticated and unique
exhaust system that incorporated an electromechanical actuator. The actuator opened and closed
a baffle plate in the muffler, allowing the bike to operate in two different ways depending on the
rider’s preference. Closing the baffle caused the motorcycle to run very quietly, making it
suitable for operating in residential areas.

Opening the baffle created a straight through muffler for increased performance on the open
road. Understanding the need for an isolator to protect the actuator, the motorcycle OEM had
contacted a leading vibration isolation manufacturer.

This materials manufacturer stipulated the need for over 5‖ of design space within the exhaust
system.

The additional 5‖ would allow for an appropriately sized isolator to reduce the shock energy
from the motorcycle’s current 40+ G's to the desired 15 G's. This stipulation caused the
motorcycle OEM to put on the brakes as they wanted to maintain the original design and
functionality of their exhaust system.

That’s when they turned to Polymer Technologies. Unlike the other manufacturer, Polymer
Technologies was willing to work within the existing design constraints to come up with a noise
reduction solution.

After providing us with their requirements, we were able to work one-on-one with the
motorcycle manufacturer to develop an ideal solution. The experts at our Polymer Molded
Products Division (PMP) determined that a POLYFORM® molded urethane foam would offer
the necessary resilience to isolate the actuator, as well as maintain the durability needed to live
within the intended environment.

Reflection
In my opinion the manufacturer was able to implement the molded foam in their exhaust
system and eliminate warranty claims for premature failure of the actuator. Not only was
the manufacturer able to fix their energy management problem, but they were also able to
keep their original design intact.