Polyurethane Foam Sheets & Inserts

Open Cell Polyurethane Foams

Our extensive range of Polyurethane open cell foams complement our closed cell product range. These being the least expensive of the foams in our range of products, they offer suitable integrity for the packaging of fragile items. Various densities, colours and hardness of foams are available combined with the additional processing capability of supplying convoluted (egg box) sheets, pads or die cuts.

Think of open cell foam as soft and spongy to touch due to its lighter, less dense and compact properties. Similar to a sponge which has cell walls filled with air, hence its name open cell. Less popularly used too, however their structure allows the foam to expand once it has been applied to a surface. This is hugely beneficial when you need the foam to reach hard to reach places during application.

It's important to note, that open cell foam does not possess properties to make it water resistant due to its tiny pockets of holes (cells). It has a lower heat resistance than closed cell foam, so in extreme temperatures, its durability and insulation ability is reduced significantly. They have a very poor UV resistance and should not be used in outdoor applications without being encapsulated to inhibit sunlight. However its affordability and low costs compared to closed cell foam, makes it the more favourable choice when budgetary factors are important.

Open cell foam inserts are popularly used for reliable cushioned support of fragile or small mechanical items within packaging applications; pink anti-static grades are available for sensitive electronic equipment, either within storage boxes or for their transportation. Jewellery box inserts with or without a flock coating are typical of the type of high value objects that are stored, displayed and transported using open cell foam. Its lightweight attributes benefit low shipment costs whilst protecting and supporting the items.

Open cell foam is extensively used in furniture, beds, padding for lightweight cushions and much more. Its uses are varied and diverse. Other uses of open cell polyurethane foam sheets are for outdoor seating on boats and yachts, again contributing to the lightness of the boat. Typically combustion modified foams, which contains fillers and additives during their manufacturing process, complying with the very latest Fire & Safety Regulations are mandatory grades in this field of applications. Other Flame Retardant grades are available; however it is worth noting that they are not non- flammable, as all polyurethane foams are combustible above 250C or in the presence of other combustible sources.

Reticulated Foams

Within the family of open cell polyurethane foam comes reticulated foam or as it is more commonly known filter foam. The foam is predominantly used for filtration purposes whether it is of airborne particles or in water/liquid environments. They range in cell size, more commonly known as PPI, from coarse, large cells of 10PPI to finer cell grades of 90PPI. All grades are none flame retardant and non- toxic.

Typical applications range from domestic use age in filters in overhead cooker fans, vacuum filters through to fish and aquarium filters. Finer/tighter cell variants are found typically in noise applications such as microphone shields.

Reconstituted Foam

Open cell polyurethane waste is recycled by chopping and gluing under pressure to make reconstituted foam or ‘Chip foam’. They are available in a very limited range, ranging in density from 64kgs/m3 to 192kgs/m3 and standard colours. Typical applications are very limited mainly seating and packaging.