Polyurethane Foam
Polyurethane foam is created in a basic chemical reaction of a Polyol and Isocyanate, and the final product is determined by the addition of other chemicals but also by the actual polyol type determines the 2 basic family types.
- Polyether Foam (ether foam) - These tend to be the softest of grades and used in many retail and low cost applications. Densities range from 15 – 30 Kg/m³ as standard but others are available. The foams are prone to “blow holes” due to the foaming process.
- Polyester Foam (ester foam) - Mainly of improved physical properties, and controlled cell structure. Densities in general are from 20 – 60Kg/m³ Used where better performance is required and more technical characteristics.
PU foam is also known as Sponge, because early grades were developed that gave the look of Natural Sea Sponges, and are used for car sponges or bath sponges. Intec Foams has the ability to create shapes from these grades for bespoke applications.
There are also some grades of sponge and foam that have been developed with Hydrophilic properties, used for absorbing water e.g. in the Pottery Industry for removing water from pots before firing.
Technical Grades exist, which are derivatives of the above 2 family types:
Reticulated PU Foams
Special foams where the cell windows have been completely removed by a controlled explosion technique called “Zapped” Reticulation; in polyether and polyester grades. Available in different porosities to filter out different particle sizes.
Polyether |
10ppi to 60ppi for aquatic and pond filtration |
|---|---|
Polyester |
10ppi to 90ppi for air filtration. |
Typical Applications:
- Water Filters
- Pond Pump Filters
- Tertiary Sewage Tank Filters
- Heat & Moisture Exchange Filters
- Cosmetic Foams
- Air Filters
- Ink Reservoirs
- Pre-Cursor’s for Ceramic or Metal Filters
- Many More
Sealtec PU Foam
Produced in polyether and polyester grades for low compression seals to replace heavier/higher density EPDM in Automotive applications where weight saving is important.. Needs to be compressed by 60 - 70% to achieve a seal.
Typical applications
- Automotive lamp cluster seals
- Automotive door seals
- Caravan window and skylight seals
Sealtec Aqua PU Foam (new product)
Sealtec - Aqua has been developed to provide reliable sealing against gases, liquids and particulates at reduced levels of compression, in comparison to traditional PU sealing foams which have inferior qualities. Needs only a 30% compression to achieve a seal.
Key Features v's conventional PU foams for sealing
- Improved Durability
- Improved Hydrolytic Stability (better in water/moisture)
- Lower compression to create a seal
- Fine cell structure
- Soft
- Low density
This special foam has been developed to replace higher density sponge rubbers as an efficient sealing medium with an improvement in the amount of compression required to achieve a seal compared to standard Sealtec foam.
Firetec PU Foam
Available in polyether and polyester versions, with UL94 HF1 and UL94 HF1 and V0 grades of fire retardancy which is an important factor in many electronic and acoustical applications.
Typical Uses:
- Lining of Electrical/ Electronic Cabinets
- Lining of Acoustic Hoods and Generator Housings
- HVAC panels for acoustic applications
- Transfer rollers in high tech business machines
- Prison Cell Mattresses
- Fire-blockers for seating applications in aircraft
Microcellular PU Foams
Flexible, high density foams with excellent resistance to compression set (collapse), high resiliency, good vibration damping and impact absorption. Similar to Poron™ grades.
Typical Uses:
- Gaskets and Seals.
- Shoe Insoles & Orthotic Devices
- Sound absorbers for small communications devices
- Prosthetic Padding
- Shock Absorbers
SAF (Shock Absorption Foams) Visco Elastic PU foams
Similar in nature to memory foam used in mattresses, except ours exhibit improved visco-elastic behaviour similar to Conforfoam™ but at a fraction of the price. Ideal for comfort management and protective padding applications especially shock absorption foam products.
- Soften and conform when exposed to heat.
- Virtually pressure free support
- High energy absorption (up to 97% of an impact)
- Resist Compression set
Typical Uses:
- Wheelchair Cushions
- Medical slings
- Wrist rests
- Shoe Insoles
Felted Foams
These are special grades of PU foams that are thermally compressed until the foam takes a compression set. Effectively, this treatment increases the density, reduces the pore size and makes the foam firmer.
This is especially effective when taking a reticulated foam and felting it. By reducing the cell size, it creates a structure which creates a "Wicking" effect and draws in liquids into the foam structure. Ideal for the creation of an ink reservoir.
The foam can be compressed by several factors, only restricted by the height of the daylight press and the final thickness required.
Typical Uses:
- Ink rollers
- Ink pads
- Acoustic pads
- Filters
- High density padding
Most PU foams can be felted and some others too.
Special grades:
Polyurethane Foams can be developed to give specific properties or adding to existing grades
- Automotive Foam Types
- Anti-Microbial & Biocide additives to Resist Growth of mould/mildew
- Anti-Static
- Edge weldable
- Water Seal (Superseal)
- Low Permeability
- Thermoformable
- Hydrophilic - (Absorbs water)
- High Elongation - Neoprene Replacement
- UV Stabilised foams (Staywhite)
- Many Others
Should you have a specific requirement or enquiry for these products or any other potential application, please give us a call for a friendly impartial discussion, or simply complete our online web form or email us at: info@intecfoams.co.uk and we will respond immediately.