® = registered trademark of BASF SE

General Technical Information

Neopolen®

Contents

1. Product
1.1 Description
1.2 Forms supplied
1.3 Delivery, Conveying, Storage

2. Processing
2.1 Filling the mold cavity
2.2 Molding
2.3 Cooling
2.4 Demolding
2.5 Conditioning

3. Properties, Applications
3.1 Properties of Neopolen
3.2 Flammability
3.3 Applications

4. Product Safety and Environment

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1. Product

1.1 Description Neopolen is expanded polypropylene (EPP) in the form of beads.

The cells are largely closed.

1.2. Forms supplied Neopolen is supplied as expanded polypropylene (EPP) beads.

1.3 Delivery, Conveying, Neopolen is delivered in bulk by road in large-capacity hopper vehi-
Storage cles. The silo volume available for storage must be about 150 m3.
Neopolen is transferred to the silos pneumatically at a rate
determined mainly by the performance of the blower (dependent on
type, speed of rotation, and drive power) as well as the cross-sections
and lengths of the duct on both the suction and pressure sides. The
loading of Neopolen in the air stream should not exceed 30 %.
Experience has shown that for fast unloading the duct diameter
must be at least ≥ 200 mm on the suction side and ≥ 150 mm on the
pressure side. The radius of bends must be at least five times the
duct diameter.
To avoid abrasion of the product, all surfaces it comes in contact with
must be smooth, and there should be no obstructions (e. g. edges at
joints). This applies as well to the blower, whose rotor in particular
needs to be carefully constructed.
Neopolen needs to be protected both from the weather (rain and
snow, frost, direct sunlight) and excessive mechanical stress. For
storage bins higher than 4 m measures should be taken to minimize
pressure on material at the bottom.

2. Processing Neopolen is molded on machines whose steam chambers are de-

signed for excess pressures of at least 5 bar (cf. fig. 1).
There are five distinct stages in the process.

Fig. 1: Equipment for molding Neopolen

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2.1 Filling the mold cavity
The expanded beads are introduced into the mold cavity via injectors,
which are fed from a pressurized vessel. Since Neopolen contains no
expanding agent, the beads in the cavity must be compressed at the
start.
This can be achieved in one of two ways:
a) Pressure filling:
The beads are forced in by compressed air until back-pressure stops
the flow.
b) Crack-press-filling:
The beads, driven by low excess pressure, enter the larger cavity
formed by opening the mold slightly, and then the mold closes, com-
pressing the beads.
Prepressurizing
Prepressurizing the beads increases the pressure of the air within
the cells, which leads into higher volume expansion capability of
the material. During processing, the range of material density can
be scaled down. It is carried out by immersing the beads in hot
compressed air for several hours before they are molded. The filling
techniques given above are also used with prepressurized beads.

2.2 Molding The beads packed into the molds are heated with steam, which
makes them swell and fuse. For the Neopolen, the inlet pressure of
saturated steam must be at least 7 - 8 bar. The maximum pressure in
the steam chambers should be 2.5 - 4 bar.

2.3 Cooling The moldings are cooled until there is no risk of swelling and splitting
when demolded. The time taken depends largely on the density and
wall-thickness of the moldings.

2.4 Demolding The moldings are removed by means of mechanical ejectors,

compressed air or a combination of both.

2.5 Conditioning The moldings must be conditioned for at least 6 h in warm air
(preferably at 80 °C), to partially restore their volume and remove
any interstitial water. Good air circulation is required around the
moldings, so the oven should not be overfilled.

3. Properties, Applications
3.1 Properties Neopolen is characterised by very good cushioning and recovery
of Neopolen properties, as well as high energy absorption. Its heat resistance is
good, and it is chemically inert.
The low water absorption and easy cleaning of the beads, the
good thermal insulation and environment-friendly properties (free
of gas and other chemical blowing agent) are further advantages
of Neopolen.
The values of physical quantities given in tables 1 - 3 and fig. 2 - 7
should serve as guideline for properly processed Neopolen.
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Fig. 2: Recovery of compressed Neopolen P 9230 K –

molded test piece, density 60 [ kg/m3 ]

Table 1: Physical properties of Neopolen (guideline values)

Property Method Unit Material Density as ISO 845

[ kg /m3 ] (Core density)
20 40 60 80 100
Tensile strength DIN EN ISO 1798 [ kPa] 300 600 880 1150 1410
Elongation at break DIN EN ISO 1798 [%] 40 33 27 23 20
Compressive stress according to [ kPa]
at 10 % Strain ISO 844 70 180 310 480 680
at 25 % Strain 80 220 370 550 750
at 50 % Strain 150 330 550 810 1100
Residual compressive strain DIN EN ISO 1856 [%] 30 28 26 25 25
(50 %, 22 h, 23 °C) (Method C)
24 h after stress release
Compression hardness DIN EN ISO 3386 [ kPa] 50 200 400 – –
Cushion factor (optimum value) ISO 4651 – 2.8 2.7 2.6 – –
Specific Energy ISO 4651 [ kNm • m-3 ] 90 320 700 – –
at h / d = 10
Static area loading DIN 53 421 [ kPa] 12 23 92 – –
5 %, 100 d
Dimensional stability at heat according to [%] <2 <2 <2 <2 <2
Linear size alteration DIN ISO 2796
(after 4 d, 110 °C)
Thermal conductivity 2) DIN 52 612 [ W • m-1 • K-1 ] 0.036 0.038 0.040 0.043 0.046
Water uptake according to
1 day DIN 53 428 [ Vol.-% ] <1 <1 <1 <1 <1
Surface resistance 1) DIN IEC 60 093
(23 °C, r.h., 50 %) [Ohm] ≥1012 ≥1012 ≥1012 ≥1012 ≥1012
1) divergent at Neopolen P 9230 ESD

2) divergent at Neopolen P 9335 MG and Neopolen P reFLAM

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Table 2: Effects of various substances on Neopolen

(according to DIN 53428)

Substance Effect
1 Hydrochloric acid, 10 % +
2 Hydrochloric acid, conc. +–
3 Sulfuric acid, 3 % +
4 Sulfuric acid, 30 % +
5 Nitric acid, 10 % +–
6 Distilled water +
7 Seawater +
8 Hydrogen peroxide, 10 % +
9 Alkaline flux +
10 Acid flux +
11 Hydrofluoric acid, 5 % +
12 Sodium hydroxide soln +
13 Sodium chloride soln +
14 Diethyl ether –
15 Acetic acid, 3 % +
16 Acetic acid, conc. +–
17 Ethanol +
18 Mineral solvent 100 - 400 +–
19 Diesel fuel +–
20 Gasoline +–
21 Turpentine +
22 Olive oil +–
23 Mineral solvent + benzene +–
24 Benzene +–
25 Tetrahydronaphthalene –
26 Decahydronaphthalene +–
27 Acetone +
28 Tetrahydrofuran –
29 Ethyl acetate +
30 Trichlorethylene +–
31 Formaldehyde soln +–

+ Unaffected
+ – Prolonged contact may cause shrinking or swelling
– Unstable
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3.2 Flammability

Table 3: Fire Behavior of Neopolen Standard-Grades (divergent at Neopolen P reFLAM)

Material Density according ISO 845 [ kg/m3 ] (Core Density)

Method Thickness 20 30 40 60 80 100
DIN EN ISO 11925-2 1) 10 mm – – – – 2) E E
20 mm – – 2) E E E E
30 mm E E E E E E
DIN 4102 -1 10 mm B3 B3 B3 B3 /B2 3) B2 B2
20 mm B3 B3 /B2 3) B2 B2 B2 B2
30 mm B3 /B2 3) B2 B2 B2 B2 B2
FMVSS 302 13 mm – fulfilled fulfilled fulfilled fulfilled fulfilled
UL 94 8.4 mm – – – – HBF HBF
13 mm – – – HBF HBF HBF
1)
Edge exposure, classification according to EN 13501-1

2)
Edge exposure failed, surface exposure passed with E
3)
B3 (easily flammable), the classification B2 (flammable) applies if the edges of the plate are covered

3.3 Applications Neopolen is ideal for lightweight articles providing excellent

shock-absorption and good thermal insulation.
Its applications include:
• automotive components, e. g.
– shock-absorbing elements in bumpers and side-impact systems,
– head supports, sun visors, tool boxes, etc.;
• packaging, e. g.
– protective packaging for shock-sensitive goods such as
measuring instruments and computers,
– returnable packaging;
• transport containers, e. g.
– crates and pallets;
• components of apparatus and appliances, e. g.
– multifunctional components protecting against vibration and
shock, reducing weight, simplifying assembly, or insulating;
• safety equipment, e. g.
– children’s safety seats, helmets.
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Fig. 3: Stress-strain-diagram

Fig. 4: 100-d Compressive creep of Neopolen

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Fig. 5: Cushioning curves for Neopolen – density 20 [kg/m3]

Fig. 6: Cushioning curves for Neopolen – density 30 [kg/m3]

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4. Product Safety Neopolen is produced without the use of halogenated hydrocarbons or

and Environment compounds containing heavy metals. It contains no materials that
require declaration under the GADSL (Global Automotive Declarable
Substance List, Version 3,0, www.gadsl.org). 1)
At the time of delivery, the product contains no blowing agent and is not
classified under dangerous goods regulations.
Neopolen presents no danger to water (VwVws Germany 17.05.1999,
App. 1) 1)
Neopolen is recyclable.
When using this product, the information and advice given in our
Safety Data Sheet should be observed. Necessary attention should
also be given to the precautions necessary for handling chemicals.

Fig. 7: EPP life-cycle

Note The data contained in this publication are based on our current
knowledge and experience. In view of the many factors that may affect
processing and application of our product, these data do not relieve
processors from carrying out their own investigations and tests; neither
do these data imply any guarantee of certain properties, nor the suita-
bility of the product for a specific purpose. Any descriptions, drawings,
photographs, data, proportions, weights etc. given herein may change
without prior information and do not constitute the agreed contractual
quality of the product. It is the responsibility of the recipient of our
products to ensure that any proprietary rights and existing laws and
legislation are observed.

1)
except Neopolen P reFLAM
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BASF SE
GBM Specialty Plastics
67056 Ludwigshafen
Germany
www.neopolen.com