High-performance Polyurethane(PU) Tooling Boards"SANMODUR"

 Tooling board is widely used for prototype models of automobile engines and parts because it is easier to cut than wood and has superior dimensional stability and strength. Among these, polyurethane tooling board, which is easy to process and offers a high degree of design freedom, has become the mainstream for models and prototype molds. 

  Polyurethane is produced by the reaction of polyols and isocyanates. When a small amount of water is added, the reaction between the water and isocyanate produces carbon dioxide gas, and by adjusting the amount of bubbles produced by this carbon dioxide gas, a polyurethane foam of the desired density is produced. The "water foaming method" is known as a common method for manufacturing rigid polyurethane foam. 

Reaction1: Urethanation reaction




Reaction2: Carbon dioxide generation in the presence of water

Our "SANMODUR" is a high-performance polyurethane(PU) tooling board that employs a foaming method called the mechanical floss method. In this method, when liquid polyol and isocyanate components are mixed, inert gas such as nitrogen is blown in and stirred vigorously to forcibly create fine, uniform cells in the mixed liquid. The mixed liquid hardens through a urethane reaction and becomes a polyurethane resin with microbubbles ranging from several μm to several tens of μm. The density can be finely controlled by the amount of gas injected, which is the reason why the physical properties of "SANMODUR" differ greatly from those of other tooling boards. 

 Although polyols, isocyanates, and fillers have different characteristics, density is the most important factor that determines the physical properties of synthetic wood. "SANMODUR" has uniform and fine cells and is available in densities from a minimum of 0.35 g/cm3 to a maximum of 1.13 g/cm3.

The mold is poured into a general tooling board mold and each piece is molded in a single batch. One of the concerns with this method is that the density and other physical properties tend to be non-uniform depending on the location in the mold and the batch. 

 In contrast, "SANMODUR" employs the continuous casting method as a unique manufacturing method to achieve a homogeneous structure. In this method, the mixed components mixed by the mechanical floss method are poured, cured, and cut in a continuous process, which enables a large number of sheets to be produced per batch and stable quality. 

Conceptual diagram of the "SANMODUR" continuous casting method 

The high-performance tooling boards "SANMODUR" are designed with polyurethane compositions and our proprietary manufacturing methods (mechanical floss method and continuous casting method) to provide a lineup of easy-to-use functions as tooling materials for various applications. Below is a list of representative functions. 

*1 Measured with a non-contact 3D surface roughness meter manufactured by Keyence Corporation on the cut surface of a tooling board sample cut with an NC machine tool manufactured by Iwama Kogyosho Corporation. 
(The absolute value of the unevenness of the sample surface is averaged.) 

*2 Four-component dynamometer was used to measure resistance during tooling board cutting on an NC machine tool (16 mm diameter carbide throw-away insert, 5,000 rpm, feed rate 2,000 mm/min) at a depth of cut of 3 mm. Resistance was measured while tooling board at a depth of cut of 3 mm. 

*3 After 10 m of continuous cutting of tooling board at a depth of cut of 3 mm on a NC machine tool (10 mm diameter HSS straight edge, 10,000 rpm rotation speed, 100 mm/min feed rate, 1 mm travel) .
After continuous cutting of tooling board with a depth of cut of 3 mm, the wear of the cutting edge was measured under a stereo microscope (×50). 

SANMODUR MH-E, LC-M
 Cyanon D-60 manufactured by Koatsu Gas Industry Co.,Ltd. 
 Pegaloc NC-700 manufactured by Koatsu Gas Industry Co.,Ltd.

SANMODUR MS-E、MDX-M、NO7K-E、TW-E、VM
 SANMODUR AD-221 Manufactured by Sanyo Chemical Industries, Ltd. 
 Cyanon D-60 manufactured by Koatsu Gas Industry Co. 
 Pegaloc NC-501 by Koatsu Gas Industry Co.,Ltd.

SANMODUR NZ-M, HD-M, NV
 Cyanon D-60 manufactured by Koatsu Gas Industry Co.,Ltd. 
 Pegarock NC-501 manufactured by Koatsu Gas Industry Co.,Ltd.

The table below shows the size and packing for each grade of "SANMODUR".