Foam Rubber
(also known as cellular, sponge, or expanded rubber) refers to rubber that has
been manufactured with a foaming agent to create an air-filled matrix
structure. Commercial foam rubbers are generally made of either polyurethane or
natural latex.
Latex foam rubber, used in mattresses, is well known for its endurance. Polyurethane is a thermosetting polymer that comes from combination of Methyl di-isocyanate and polyethylene and
Latex foam rubber, used in mattresses, is well known for its endurance. Polyurethane is a thermosetting polymer that comes from combination of Methyl di-isocyanate and polyethylene and
some other chemical additives.
Manufacturing
process
Rates of
polymerization can range from many minutes to just a few seconds. Fast reacting
polymers feature short cycle periods and require the use of machinery to
thoroughly mix the reacting agents. Slow polymers may be mixed by hand, but
require long periods on mixing, as a result industrial application tends to use
machinery to mix products. Product processing can range from a variety of
techniques including, but not limited to spraying, open pouring, and molding.
Material preparation
Liquid and solid material generally arrive on location via rail or truck, once
unloaded liquid materials are stored in heated tanks. When producing slabstock
typically two or more polymers streams are
.used
Mixing Open
pouring, better known as continuous dispensing is used primarily in the
formation of rigid, low density foams. Specific amounts of chemicals are mixed
into a mixing head, much like an industrial blender. The foam is poured onto a
conveyor belt, where it then cures for cutting.
Curing and
Cutting After curing on the conveyor belt the foam is then forced through a
horizontal band saw. This band saw cuts the pieces in a set size for the
application. General contracting uses 4’x12’x2’’.
Further
processing Once cut and cured the slabstock can either be sold or a lamination
process can be applied. This process turns the slabstock into a rigid foam
board known as boardstock. Boardstock is used for metal roof
insulation, oven
insulation, and many other durable goods.
Recycling
Due to the variety in
polyurethane chemistries, it is difficult to recycle foam materials using a
single method. Reusing slab stock foams for carpet backing is how the majority
of recycling is done. This method involves shredding the scrap and bonding the
small flakes together to form sheets. Other methods involve breaking the foam
down into granules and dispersing them into a polyol blend to be molded into
the same part as the original. The recycling process is still ever developing
for foam rubber and the future will hopefully unveil new and easier ways for
recycling
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