Polyurethane Foam

New England Foam supplies, converts and fabricates the following types of polyurethane foam (PE):

1. Polyether (Ether
   • 0.9 pcf +/- 0.1 w/ 24-34# IFD (1034) Data
     • Largest sheet size = 54″ x 82″
   • 1.1 pcf +/- 0.05 w/ 22-32# IFD (1234 A/S) Data
     • Largest sheet size = 54″ x 82″
   • 1.2 pcf +/- 0.05 w/ 32-39# IFD (1235 CM) Data
     • Largest sheet size = 54″ x 82″
   • 1.45 pcf +/- 0.05 w/ 40-48# IFD (1544 CM) Data
     • Largest sheet size = 82″ x 108″
   • 1.45 pcf +/- 0.05 w/ 75-90# IFD (Flex) Data
     • Largest sheet size = 54″ x 82″
   • 1.5 pcf +/- 0.05 w/ 75-85# IFD (Flex A/S) Data
     • Largest sheet size = 54″ x 82″
   • 1.9 pcf +/- 0.05 w/ 85-105# IFD (GX2000) Data
     • Largest sheet size = 82″ x 108″
   • 4.0 pcf +/- 10% w/ 77-91# IFD (4.0 SEN) Data
     • Largest sheet size = 54″ x 72″
     • UL94/HF-1 Compliant
       
       
2. Polyester (Ester)
   • 1.9 pcf +/- 0.10 (S82N) Data
     • Largest sheet size = 54″ x 108″
     • UL94/HF-1 Compliant
   • 2.0 pcf +/- 0.10 (LS-2) Data
     • Largest sheet size = 54″ x 72″
     • UL94/HF-1 Compliant, Anti-Static (A/S) & Clickable
   • 4.0 pcf +/- 0.10 (4.0 N) Data
     • Largest sheet size = 54″ x 72″
     • UL94/HF-1Compliant
3. Filter (Reticulated)
   • Largest sheet size = 48” x 118”
     • UL94/HF-1 available
       • Polyester-based
         • 10 PPI Data
         • 20 PPI Data
         • 80 PPI Data
         • 90 PPI Data
       • Polyether-based
         • 20 PPI Data
         • 30 PPI Data
         • 40 PPI Data
         • 50 PPI Data
4. Furniture (Upholstery)
   • 1.2 pcf
     • Largest sheet size = 54” x 82”
       • 35# IFD Data
   • 1.5 pcf
     • Largest sheet size = 82” x 108”
       • 44# IFD Data
   • 1.8 pcf
     • Largest sheet size = 82” x 108”
       • 35# IFD Data
   • 2.6 pcf
     • Largest sheet size = 82” x 108”
       • 35# IFD Data
       • 45# IFD Data
       • 65# IFD Data

Characteristics of PU Foam

Polyurethane foam, also known as Urethane Foam, Foam Rubber, PU, PUF, PUR and FPF, is a flexible, open-cell type of foam that has a near-infinite amount of applications due to the following characteristics:

• Compress-ability
• Cushioning
• Energy absorption
• Fabrication-ability
• Flexibility
• Insulating
• Light-weight
• Low thermal conductivity
• Low water vapor transmission
• Resiliency
• Sound absorption
• Vibration dampening

PU Foam

Polyurethane foam is more than just a simple cushioning material. Aesthetically pleasing, yet still providing adequate protection and enough support to counteract the weight of an object or person, PU foam can be manufactured to provide varying degrees of comfort, support and durability.

In addition to fabricating polyurethane foam products to custom designed specifications, New England Foam stocks PU foam in buns, in densities ranging from 1 to 6 pounds per cubic foot (PCF) and those colors most requested: pink, blue and charcoal.

Additional densities and custom colors, anti-static, conductive and/or electrostatic dissipation (ESD) types of PU foam are also available upon request.

Primary Applications for PU Foam

Polyurethane foam should be durable enough to maintain its form without losing its original, cushioning properties, even after repeated impacts.

The ability to manipulate the physical properties of polyurethane foam during manufacture makes it the ideal material for the bedding and furniture.

The packaging industry uses polyurethane foam’s capacity for its ability to absorb shocks repeatedly while retaining its original cushioning properties.

Polyester Foam vs. Polyether Foam

Traditionally, polyester foam has a higher “tensile” strength than its polyurethane foam counterpart, polyether foam.  Polyester foam is also more resistant to hydrocarbons and alcohols than polyether foam.

In applications where the polyurethane foam will come into contact with gases, such as oxygen, nitrogen and/or carbon dioxide, the polyurethane foam should be manufactured with polyester-based polyols.

In applications where the polyurethane foam will come into contact with a liquid-based solution, the polyurethane foam should be manufactured with polyether-based polyols.

Manufacturing PU Foam

The Polyurethane Foam Association (PFA.org) identifies polyurethane foam as “the reaction of two key chemicals, a polyol and an isocyanate with water.”

These two compounds are combined with the other key ingredients and mixed together with the assistance of a blowing agent.

The foaming begins instantly with the expanding formation of a bubbly froth.

The froth hardens; resulting is a slabstock bun of polyurethane foam ready for fabrication.

This all happens in a matter of minutes and is similar to bread rising.

It is during this manufacturing process that flame retardant additives can be introduced to meet various fire code standards, as well as anti-microbial, anti-static, conductive and electrostatic dissipation (ESD) additives.