The production of architectural decoration is a complex and science-intensive process. Historically, architectural decor was made of gypsum, the main advantage of which is the ability to obtain products of any configuration, no matter how complex it may be. The development of science and technology has led to the emergence of other technologies for obtaining such products. The most technologically similar to gypsum production is the production of architectural decor elements from polyurethane foam.
High-density polyurethane foams are absolutely inert and do not interact with the external environment. Due to their properties, they are widely used in various industries, including medicine, as bone implants. The density of all Europlast products is 300 kg/m3. This is the minimum density at which production does not require the use of hydrochlorofluorocarbons. To obtain products of lower density, it is necessary to use hydrochlorofluorocarbon, which not only remains in the products, but during operation is released into the atmosphere of the room for a long time. Concern Evroplast, taking care of the health of its consumers, deliberately goes to increase the cost of production (manufacturing of products with high density), abandoning the technology with the use of dangerous hydrochlorofluorocarbon. In addition, high density provides less shrinkage and greater hardness of products. The process of production of decorative elements from polyurethane foam can be divided into several stages.
MANUFACTURE OF MOLDS FOR CASTING PRODUCTS
This is one of the most important and defining stages of the entire production, because the appearance of products depends on the mold. Unlike gypsum technology, polyurethane foam does not just harden, but greatly increases in volume, filling the entire internal space of the mold. The result is a product that exactly repeats the shape. Since the mold is subjected to a lot of pressure, it is important that it is strong. On the other hand, the rigidity of the form leads to the limitation of products in configuration. After all, the element must subsequently be removed from the rigid form without damaging it. At this stage, many manufacturers are faced with the problem of the impossibility of casting products with a non-standard configuration and with a complex pattern. Europlast makes molds from carbon fiber – a modern material that has greater strength than metal. This technology arose as a result of the conversion of technologies of the military-industrial complex and allows you to create the most durable molds for casting products of almost any configuration. The equipment used without repair withstands at least 50,000 castings and ensures high reproducibility: the cast parts are almost indistinguishable from each other. Not all manufacturers of products made of polyurethane foam own the technology of manufacturing molds from composite materials due to its high cost. The manufacturing technology of carbon molds is an exclusive development of the Europlast company. If the product configuration is simple enough, the mold is made from a piece of metal on special jig boring machines.
MAKE RAW MATERIALS
The production of polyurethane foams is a very complex process, in the understanding of which there are still many blank spots. For example, the same raw material can give different results on different equipment. It is no secret that one batch of raw materials may differ slightly from another. Sometimes this difference is insignificant, but it happens that such differences cause a noticeable change in the properties of the final products. Our own component preparation laboratory eliminates such problems. Specialists of the Europlast laboratory carry out incoming control of all raw materials used in the manufacture of components, according to the results of which the technological department corrects the recipe. Then an experimental process is carried out, during which the recipe is finalized. And only then the raw material goes into production.
MANUFACTURE OF DECOR ELEMENTS
For the production of its products, Evroplast uses the most modern equipment from the world’s leading manufacturers – CANNON, KRAUSMAFFEI, SIEMENS, ABB. It allows, firstly, to automate the process of mixing and dosing of components. Each machine is equipped with a powerful computer, the memory of which contains the filling programs for each product, which eliminates the negative impact of the human factor. Secondly, modern devices are installed on all machines, which allow very accurate dosing of components and maintaining their ratio for a long time. Elements of architectural decor differ significantly in weight, dimensions, configuration. Certain parts require specialized equipment and special settings in the organization of the manufacturing process. For example, for casting large and elongated parts, such as columns, a high-capacity pouring machine is required, and for casting wall decor parts, with low productivity and high dosing accuracy. In order to obtain the excellent quality of all products, the Europlast plant has 4 pouring sections, which provide optimal manufacturing conditions for various parts.
The overall dimensions of the elements after pouring always differ from each other, while all Europlast products fit exactly together. High precision of articulation of parts with each other after pouring is achieved with the help of their additional precision processing. Two identical elements will exactly match in profile, and if a fragment of any size is cut from any part of the product, the two remaining fragments will also exactly match in profile. Europlast technologies take into account the inertness of polyurethane foam. If special measures are not taken, the finished material cannot be glued and painted (glue and paint do not penetrate inside, the glue does not dissolve the surface layer). During mechanical processing, a surface specially prepared for gluing is created on the inside of the products. Before painting products, a special polyurethane primer is applied to them, which has good adhesion to polyurethane foam products and allows the paint to adhere well to their surface.
At all stages of the production of products, 100% independent input and output quality control is carried out.
The Europlast concern is constantly improving the technology for the production of polyurethane foam products, offering its customers products that compare favorably in quality and consumer properties from those presented in the catalogs of other companies.
GLUING PARTS AND ASSEMBLY
Reliable bonding of polyurethane foam parts and their installation on various surfaces is possible only with the use of original adhesive compositions made taking into account the high inertness of polyurethane foams. The Evroplast company offers two original types of glue for its products: “Extra” for gluing parts together and “Standard” for installation work.