RETICULATUS™ Reticulation Machine

Highest Standard For

Who we are

The ATL schubs GmbH was founded

in 1996 by Jörn Struckmann and Axel

Schulz. This joint venture arose from

the collaboration of the two companies

ATL Anlagentechnik Luhden GmbH and

SCHUBS GmbH.

Both specialists developed and still

manufacture the RETICULATUSTM foam

reticulation unit. Ever since the founding,

almost 20 reticulation machines have

been delivered worldwide and are still in

operation.

Reticulation of foam

▪ What is reticulation?

Reticulation is a process whereby the

fine membranes in PU foam are des-

troyed by a controlled explosion. This

procedure creates the required open

cell structure of the foam. With Reti-

culatus™, the cell size can be exactly

adjusted by the process parameters.

▪ How does the RETICULATUSTM work?

1. The first step is to slide the foam

block or roll into the pressure

chamber. The chamber is made of

up to 100 mm thick highly extra-high

strength steel and is built by ATL

schubs itself. Depending on the size,

the chamber can take foam blocks

and rolls between three and six cubic

meters and is prepared according to

customer specifications. As required,

foam between 10 and 100 ppi can

be individually worked on.

2. A vacuum pump creates a vacuum

in the pressure chamber. Sensors

ensure constant conditions and test

continuously during the process.

3. Next, a detonating gas mixture is

fed into the chamber, also computer

controlled and in an exact dose. This

exact, and in view of the results, re-

fined procedure is the main feature

of Reticulatus™ and makes the

system completely different to any

previous solutions.

4. After the detonating gas mixture is

fed into the chamber and all neces-

sary parameters are reached, the

system announces that it is “ready

to ignite”. The operator can then

release the controlled explosion by

pressing the button.

5. The controlled explosion ensures that

a uniform flame front sweeps through

the foam, breaking up the cell struc-

tures and produces the required open

cell structure.

6. Subsequently, the foam cools off for

a short period and is briefly damped

with nitrogen to put out any potenti-

ally remaining fire pockets.

7. Afterwards, the chamber opens and

the foam can be removed for further

processing. The entire procedure

lasts approximately 8 to 10 minutes

and can be carried out by almost any

semiskilled worker.

What is the use of reticulated foam?

The application areas of reticulated foam

blocks and rolls made of polyurethane

are as flexible as the material itself. The

open-pored lattice texture of the foam

assures a low flow resistance to gases

and liquids.

A machine in USA, for example, reticula-

tes foam which is further processed into

polishing pads for automobiles. Reticula-

ted foam is generally used in the entire

automotive industry, e. g. in air filters,

tanks or as cushioning for car seats and

interior trims. For the last ones, reticula-

ted foam rolls and fabric can be directly

bonded via flame lamination.

The Reticulatus™ is also especially

suitable for production of quick-drying

outdoor cushions. Due to the open-pored

cell structure, the foam has an imple-

mented drainage function, so that the

water can flow off easily. Thus, mould

formation and unpleasant smells are

avoided. The same effect is achieved

for viscoelastic mattresses. This foam is

also known as quick dry, easy dry, and

dry fast foam.

But even in other areas, reticulated foam

has become integral part. By dipping in

ceramic suspension and subsequent

firing, ceramic filters for the foundry

industry arise out of the open porous

PUR-foam. Metal foam is produced with

a similar method. This metal foam, for

example, is used as crash protective ele-

ment or catalyst support in the automo-

tive industry. The newest development in

the metal sector is foam, which is based

on a nickel chromium alloy. Due to the

high electrical conductivity, the porous

metal is ideally suited for use in lithium

ion batteries and accumulators with

other charging voltages.

Safety first

Every morning, the system carries out a

tightness test on all components during

the automatic programme start to ensu-

re its operational safety. Furthermore,

automatic reminders of due servicing

dates are generated. The option of

remote servicing via modem is espe-

cially advantageous and allows a remote

programming and replacement of the

receptors via email or data transfer.

The system meets the latest explosion

protection regulations like ATEX 94/9/

EG and can also be certified according to

ASME and UL. Therefore, it complies with

all international regulations. In addition,

every explosion chamber is MOT/TÜV

inspected.

Even manufacturers and converter of

synthetic foams are customers of ATL

schubs, not only because of the safety

concept that specialists offer. Up to now,

the company has not come across a

single competitor that has a comparable

solution to the Reticulatus™.

NST - Nitrogen Sweeping Technolog

Another important benefit of

Reticulatus™ is the so-called

“Sweeping”, or NST (Nitrogen Sweeping

Technology). It is a separate procedure

during the reticulation process.

To avoid external combustion of the

foam, nitrogen is injected into the cham-

ber after the detonating gas mixture is

fed into the machine. Due to this, highest

quality can be ensured, especially for

sensitive foams.

Inspiring technology Square chamber for block and roll sizes

Inside dimensions (W x H x L)

Max. size for

foam block

Max. size for

foam rolls

Size 1 Size 2

1350 x 1050 x 2350 mm 1530 x 1250 x 2040 mm (3.33 m³) (3.90 m³)

1300 x 1000 x 2300 mm 1480 x 1200 x 1990 mm

Ø 950 x 2300 mm Ø 1150 x 1990 mm

Size 3 Size 4

1650 x 1150 x 2140 mm 1450 x 1050 x 4,00 mm (4.06 m³) (6.24 m³)

1600 x 1100 x 2090 mm 1400 x 1000 x 4050 mm

Ø 1050 x 2090 mm Ø 1050 x 4050 mm

Cylindrical chamber for roll sizes

Inside dimensions (W x H x L)

Max. size for foam rolls

Operating media

Medium 1

Medium 2

Medium 3

Size 1 Size 2

Ø 980 x 1900 mm Ø 1250 x 2250 mm (1.43 m³) (2.76 m³)

Ø 980 x 1880 mm Ø 1250 x 2230 mm

hydrogen hydrogen

oxygen oxygen

nitrogen nitrogen

hydrogen hydrogen

oxygen oxygen

nitrogen nitrogen

Electric power supply

400 VAC / 63 A / 50 Hz 400 VAC / 63 A / 50 Hz 400 VAC / 63 A / 50 Hz 400 VAC / 63 A / 50 Hz

ATL schubs GmbH Werftstraße 26 D-31789 Hameln Tel.: +49 5151 9570-0 Fax: +49 5151 9570-71 E-Mail: info@reticulation.de Web: www.reticulation.de Executive board Jörn Struckmann, Axel Schulz Editor Ina-Sophie Kramer, Sales and Marketing Text reference ATL schubs GmbH Picture credits ATL schubs GmbH,

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