products& P E R F O R M A N C E

T E C H N O L O G Y

A Z O T Ethe comple te expandedpolyole f in foam fami ly

P L A S T A Z O T E ®

•E V A Z O T E ®

•S U P A Z O T E ®

•P R O P O Z O T E ®

ZOTEFOAMS plcThe head office and factory are situated in the UK at Croydon wherethe Company has manufactured high quality closed cell materials since1936 using the nitrogen process. Zotefoams Inc., the North American

subsidiary, now manufactures the product range in the USA.

AZOTE is the group brand for a variety of foams manufactured fromdiffering base polymers but using the same unique process route.

PLASTAZOTE®, EVAZOTE®, SUPAZOTE® and PROPOZOTE® are world-wide registered trademarks for the current product range which is

available through a global distributor and converter network.

A Z O T Ehigh per formance polyole f in foams

Z O T E F O A M S

Z O T E F O A M S

ZOTEFOAMS plc675 Mitcham Road, Croydon,Surrey, CR9 3AL EnglandTel: +44 (0) 20 8664 1600Fax: +44 (0) 20 8664 1616e: info@zotefoams.comw: www.zotefoams.com

APPROVED SPECIALIST CONVERTERS

KEWELL CONVERTERS LTD60 Holmethorpe AvenueHolmethorpe Industrial EstateRedhill, Surrey, RH1 2NL EnglandTel: 01737 771 710Fax: 01737 769 732e: sales@kewell-converters.co.ukw: www.kewell-converters.co.uk

The fundamental difference

The superiority of Azote foams,compared with polyethylene foamsmade using other technologies, stemsdirectly from the use of this high pressuregas technology.

The small-scaleimperfections in thechemically blownsamples can seriouslyreduce the mechanicalstrength of the foam.Irregular cell structurecan cause significantvariation in densitythroughout these foamsthat, in turn, may lead tofabrication difficulties.

Unique process

Zotefoams plc produces an unparalleledrange of closed cell, crosslinked,polyolefin foams using a unique,environmentally friendly, high-pressurenitrogen gas solution process.

T O D E V E L O P S U P E R I O R F O A M S

(b) Impregnation andsaturation

The plastic slabs are loaded into acarriage system that feeds into high-pressure autoclaves where they areheated above softening temperature inan atmosphere of pure nitrogen. Processtemperatures of up to 250°C (482°F)and pressures of up to 10,000 psi (670bar) combine to dissolve the nitrogen gasinto the molecular structure of the softenedplastic. Final cooling retains the nitrogenin the plastic.

It produces a pure, low odour, chemicallyinert foam without blowing agentresidues and with a uniform cell structureand regular cell walls.

Most other crosslinked technologies usechemical blowing agents that react attemperature and release a gas into theplastic in order to create the foam. Non-crosslinked foams have been expandedusing ozone depleting CFCs, HCFCs,HFCs and more recently, flammablevolatile organic compounds (VOCs).Residues of the chemicals blowing agentsremain within these materials and canbe seen with a relatively low level ofmagnification. The presence of theseresidues within foams can detract fromtheir physical properties and cansometimes act as reactive impurities orcontaminants. They cause an unwelcomeodour and may even continue to reactupon subsequent heating, furtherexpanding the foam.

Evazote® foam

Cross linked and chemically expanded LDPE foam

Non cross-linked LDPE foam

Magnification x 50 Magnification x 500

Plastazote® foam

The manufacturing process comprisesthree essential stages:

(a) Mixing, extrusion andcrosslinking

The polymer is blended in-line andextruded into solid sheet form. This sheetis then cross-linked, a process thatenhances material strength, durability andtemperature resistance.

Crosslinking is effectively the formationof a lattice like structure at molecularlevel. It gives benefits in many areas suchas thermal moulding. A high temperaturewindow exists where crosslinked foamscan be compressed or stretched and whencool they retain their shape. (Noncrosslinked materials would collapse andmelt at these temperatures.)

The sheet is subsequently cut to size,ready for the gas solution process.

(c) Final expansion

The nitrogen charged slabs are loadedinto a low-pressure autoclave where thematerial is again heated above itssoftening temperature under moderategas pressure. When this pressure isremoved the nitrogen expands, physicallyfoaming the soft plastic in a uniformmanner.

No other manufacturing route canproduce foam with such a consistent cellstructure as that achieved with theZotefoams process.

Magnification x 50 Magnification x 500

These photomicrographsshow the cell structuresof polyolefin foams madeby different methods.Note the uniform andregular cell walls of thePlastazote and Evazotesamples that give thefoams their consistentand isotropic mechanicalproperties.

Pushing the boundaries

The use of this unique manufacturingroute enables foams to be producedfrom polymers such as HDPE and othertechnical polymers that could not befoamed easily using any other method.

The separation of these manufacturingstages allows very accurate control ofthe individual parameters that governthe production of these high qualityfoams and contribute so fundamentallyto their performance properties, cell sizeuniformity and consistency.

t e c h n o l o g y

Cell size consistency is highly importantfor optimum workability, colouruniformity, impact absorption andphysical performance predictability.

Extrusion

Expansion

Impregnation

T H E

T O S T I M U L A T E Y O U R I M A G I N A T I O N

The unique nitrogen expansionprocess results in the AZOTErange of foams produced from awide range of polymers,including:•Low Density Polyethylene (LD)•High Density Polyethylene (HD)•High and Low Density PE Mix (HL)•EVA copolymers (EV & VA)•EMA copolymer (EM)•Polypropylene (PP)

Plastazote® Foam

Closed cell, cross-linked polyethylenefoam.

A wide range of polymer combinationsis available to give increased stiffness,improved temperature resistance andimproved mouldability. Application areasinclude packaging, marine, protectivepadding in contact sports, automotive,health care and construction. The inertqualities of Plastazote foam have led toits widespread use in healthcareapplications.

Evazote® Foam

Closed cell, cross-linked ethylenecopolymer foam.

Evazote foams are more resilient thanPlastazote foams and are mainly usedin a wide range of sports, leisure andfootwear applications. Evazote is alsoused widely in the construction industrywhere its enhanced durability, alongwith its sealing properties and chemicalresistance qualities, make it ideal forexpansion joints.

Supazote® Foam

Closed cell, cross-linked ethylenecopolymer foam.

The softest foam in the rangerecommended for ‘soft touch’ applications.Zotefoams' products are used in themanufacture of a variety of sports andleisure equipment such as buoyancy aids.Supazote is also an excellent inertthermal insulating material that canaccomodate any size of space or gap.

Propozote® Foam

Closed cell, 100% polypropylene foam.

Propozote foam has high temperatureresistance and can be recycled. Mainapplication areas are in the automotiveindustry where high temperatureperformance is a requirement andreturnable packaging industries wherethe material is subjected to rigoroussterilisation processes.

ColourMany grades are available in brightattractive colours.See Colour Waves folder for details.

Special Properties

Special grades are available with flameretardant properties (so essential in theaerospace, automotive and constructionindustries) and with conductive and staticdissipative properties for the transitpackaging and storage of electronicsdevices and EMC shielding.

Azote foams are available in a widerange of densities, ranging from 15kg/m3

(1lbs/ft3) up to 120kg/m3 (7.5lbs/ft3)

1

Polymer Nominal density in kg/m3

15 18 24 25 26 29 30 32 33 34 35 45 47 50 60 65 70 79 80 115 120

LD •4 • •4 • •3 •2 •4 •1 •2 • •

HD • • • •

HL • • •

EV • •2 • •2 •2

VA • • • •

EM •

PPA •1 Available as Flame Retardant Grade (FR)2 Available as Conductive Grade (CN)3 Available as Static Dissipative Grade (SD)4 Available as Flame Retardant Grade to meet FMVSS specification (FM)productsT H E

• PURE

• NON CORROSIVE

• CONSISTENT

• LOW WEIGHT

• HIGH STRENGTH AND

DURABILITY

• GOOD AESTHETICS

• WATER AND CHEMICAL

RESISTANT

• CONDUCTIVE

• FLAME RETARDANT

• INSULATIVE

• BUOYANT

• EASY TO PROCESS AND

MANIPULATE

• ENERGY ABSORBING

T O D E V E L O P Y O U R P R O D U C T P O T E N T I A L

CONSISTENTThe high consistency and stress freenature of Azote foams enables extremelycomplex shapes to be produced withgreat accuracy and processing andfabrication is eased. Sheet material canbe cut to 1.0mm thickness.

HIGH STRENGTH AND DURABLEMuch re-useable packaging dependson the durability of Azote foam for itslongevity. From dunnage to protectiveinserts for cases and boxes, Azote foamsare the natural preference.

INSULATIVEAzote foams’ thermal and soundinsulation properties are of benefit tothe building, aircraft and automobileindustries and encourage its use in coldweather camping mats

PUREThe purity of Azote foams makes themideal for a range of hygienic applicationsin the healthcare field. It also makesPlastazote the material of choice forprotecting valuable artworks andmuseum pieces during storage andtransit.

NON CORROSIVEThe use of pure nitrogen for expansionensures Azote foams (unlike chemicallyblown foams) have no corrosive residues,encouraging its use for long termprotection of munitions and weapons

BUOYANTSuitable for many buoyancy applicationsfrom floating oil pipelines and boats topersonal flotation devices.

CONDUCTIVE AND STATICDISSIPATIVEThese special grades are highly suitedto the protection and packaging ofelectronic equipment, assemblies andcomponents as well as for EMC/RFIshielding and gasketing.

GOOD AESTHETICSOutstanding aesthetic properties add afurther dimension to retail packagingprotection. The colour depth anduniformity of Azote foams areunmatched.

WATER & CHEMICAL RESISTANTThese inherent properties make Azotefoams ideal for a range of applicationsfrom automotive gaskets to expansionjoints and eaves fillers for the buildingand construction industry.

EASY TO PROCESSThe consistency and crosslinking of Azotefoams makes them easy to manipulateand fabricate. Azote foams are idealfor conversion using commonthermoforming techniques.

GOOD ENERGY ABSORPTIONSports protection benefits from Azotefoam’s energy absorbing properties asdoes a whole range of returnablepackaging applications.

LOW WEIGHTWeighing as little as 1.5% of the solidpolymer, Azote foams are ideal for manyapplications where weight is a costpenalty, from automotive to marine andaerospace.

FLAME RETARDANTFlame retardant grades are used in manyaerospace applications such as aircraftseating.

Impact absorbing sports wear forpersonal protection

Expansion jointing for civilengineering project (Shae Stadium,Home of Major League Baseball'sNew York Mets)

Complex moulded gaskets and noisecontrol components for theautomotive industry

Display packaging forperfume brand

Safety buoyancy in Man OverboardBoat (MOB)

Returnable transit packaging usedby automotive manufacturers

Lightweight aircraft seatingand interiors

Lightweight, flame retardantinsulation for aircraft

Professional and militarycamping mats

Complex, lightweight packaging forin-flight medical diagnostic unit

Static dissipative packaging forsensitive electronics devices

Customised packaging for theprotection of fine art

Thrust rocket motor cradle

Moulding used to shapeprosthetic legs

Rib formers for FRP marine construction.

performanceT H E