This article will take an in-depth look at closed cell foam.
The article will bring more understanding on topics such as:
This chapter will cover the definition and manufacturing process of closed cell foam. It will also explore the methods for cutting closed cell foam and provide guidance on factors to consider when selecting this material.
Closed cell foam is a type of foam where the "cells" are tightly pressed together and enclosed. It contrasts open cell foam, such as polyurethane, with interconnected open cells. With closed-cell foam, because none of the cells are connected, each contains a tiny pocket of gas. The cells are tightly packed and smaller, which makes the foam more durable and makes it usable for heavy-duty applications.
Closed-cell foam is characterized by its impermeability to water and moisture, thanks to its sealed cellular structure. This type of foam, known for its resistance to pressure and higher density, comes in various forms, from rigid polyethylene foam to the softer texture of Flotex. It is a versatile material that provides enhanced stability and a tight seal. Available in various colors and thicknesses, closed-cell foams are generally more robust and stiff compared to other types.
The manufacturing process of closed-cell foam includes:
Polyethylene Foam - polyethylene closed cell foam, is made to be safeguarded from water retention and stains. This type of foam solution is highly suitable for a range of uses. This foam offers sound dampening properties and great buoyancy, and shock absorption making it ideal for all purposes from packaging to crafts and arts.
Polyethylene Rolls – This type of closed-cell foam is available in rolls and is suited for various applications, including automotive, healthcare, and sports and recreation uses.
Cross-Linked Polyethylene – This foam comes in thicknesses ranging from 0.063 to 0.700 inches and densities from 2 lb/cubic foot to 20 lb/cubic foot. Available in rolls or buns that can be cut to desired thicknesses, cross-linked polyethylene is versatile and suitable for various applications. It is resistant to mildew, stains, and water, making it ideal for packaging, flotation devices, construction, and industrial uses. Its durability and appearance also add to its appeal in different contexts.
Polystyrene Foam – For applications requiring closed cell foam blocks, polystyrene is a highly suitable material. Available as single units or in packs, this foam comes in various densities to meet specific project requirements. Known for its rigidity, polystyrene foam is commonly used in storage and packaging applications due to its strength and durability.
Neoprene Rubber – Available in rolls or sheet form, neoprene rubber is ideal for applications where cleanliness and insulation are important. It is often used in flooring, walls, athletic packaging, and support systems. Neoprene is resistant to mildew, mold, and bacteria, making it suitable for environments such as sports facilities, daycares, and hospitals.
Gym Rubber – This foam features high density and medium firmness, providing excellent shock absorption with a slight bounce. It is ideal for use in daycares, gyms, and building insulation. Available in various densities and sizes, gym rubber is a practical choice for maintaining a safe and sanitary environment.
Polypropylene Foam – For applications requiring heavy-duty foam with high rigidity, polypropylene foam is an excellent choice. Its high density makes it ideal for packaging, providing superior protection where it is most needed.
Foam is created by trapping gas within a liquid, then applying pressure and heat to solidify it. Depending on the type, foam can offer properties such as shock absorption, cushioning, safety, soundproofing, and waterproofing. Closed-cell foam, in its solid form, is non-toxic and is commonly used in medical applications. However, during its production process, when the foam is in its gas or liquid state, it can be toxic.
Closed-cell spray foam insulation is widely regarded as one of the most energy-efficient and effective insulation options available. Its high thermal value makes it an excellent choice for both residential and commercial properties, providing superior thermal conversion.
When cutting closed-cell materials, it's best to use a straight, non-serrated blade, like those found in crafting or utility knives. These blades are convenient because they are replaceable when they become dull. For smaller or less precise tasks, scissors might be sufficient, though they are limited to specific foam types and thicknesses. To ensure cleaner cuts, use a straight edge as a guide. Always perform cutting on a stable surface to prevent damage to the foam and the workspace.
Neoprene, Gym Rubber, Cross-Linked Polyethylene, and Polyethylene Roll, the physical structures of these materials are almost the same. Similar enough to approach them in the same way when cutting the foam.
When working with materials such as neoprene, XLPE, gym rubber, or polyethylene rolls, it's important to first assess the thickness of the material. For sheets that are 1/8" thick or thinner, sharp scissors might be a viable option. However, scissors are generally recommended only for lighter, recreational projects due to their tendency to leave uneven edges. For tasks like cutting shapes for bath toys or trimming card backing, scissors offer a quick solution. Among these materials, polyethylene roll is the most amenable to cutting with scissors due to its flexibility.
For projects involving materials thicker than 1/8", using a straight blade is recommended. The thickness of the material will influence the cutting technique, as it determines the most effective method to employ with the knife.
For cutting sheets up to 1/2" thick, the single pass-through method is recommended. This technique involves making one continuous cut to slice through the material. Move the blade steadily along the intended line to achieve a clean edge. This method is best for foam up to 1/2" thick, as thicker materials may resist smooth blade movement. Ensure you use a very sharp blade to avoid snagging as you cut deeper. Secure the foam before starting to cut to prevent it from shifting or distorting. Begin cutting from an outer edge and maintain a continuous cutting motion throughout the process.
When working with closed-cell foam thicker than 1/2", making a single pass-through cut is generally impractical and can result in uneven or snagged edges. Instead, using the multiple-pass cutting technique is more effective for these thicker materials. This approach involves making several passes with the blade, guided by a straight edge that extends along the entire length of the cut. This method ensures more precise and cleaner results, as the straight edge helps maintain consistency and accuracy throughout the cutting process.
Once the cutting line is established and the straight edge is positioned, begin cutting similarly to the single-pass method. Instead of cutting through the entire thickness in one go, make shallow cuts, about 1/8" to 1/4" deep. These initial cuts should be light and should cover the full length of the foam without applying excessive force. Continue making these shallow cuts, progressively deepening each pass. This technique will eventually slice through the entire sheet, ensuring a clean and precise cut.
Polyethylene, a commonly used closed-cell foam, comes in various densities that influence its rigidity, cell structure, and flexibility. At lower densities, polyethylene exhibits a more irregular, bubbly cell arrangement, which can complicate achieving clean cuts. Therefore, scissors are not recommended for cutting polyethylene. For sheets thicker than 1/2", follow the single-pass cutting technique, and for even thicker polyethylene foam, employ the multi-pass cutting method to achieve the best results.
Closed cell foam insulation is an excellent choice for those seeking superior structural stability, energy efficiency, and resistance to water. Beyond these benefits, it offers additional advantages. Its high density provides exceptional insulation compared to traditional materials like polyester, polyethylene fibers, or foil.
Density of Closed Cell Foam - Closed cell foam insulation features a highly compact cellular structure.
Water Resistance - The cellular structure of closed cell foam prevents water from penetrating, making it a strong solution for addressing dampness and moisture issues.
Moisture Control - Due to its water-resistant properties, closed cell foam effectively inhibits moisture, contributing to a longer lifespan of the insulation.
Reduction of Air Currents - This insulation type helps minimize convective currents within walls and roofs.
Air Quality Improvement - With its dense composition, closed cell insulation significantly enhances indoor air quality by blocking out pollutants, dust, and deterring mold and moisture growth.
There are various machines available to produce closed cell foam. These machines are important in today's society because closed cell foam is widely used in various industries such as construction, packaging, and insulation due to its excellent thermal insulation properties, buoyancy, cushioning, and sound dampening abilities. These machines enable efficient and precise production of closed cell foam products to meet the growing demand in these industries. Below, we briefly discuss five notable manufacturers of machines used for producing closed cell foam:
The Cannon Viking Series features equipment designed for producing closed cell foam through both continuous and discontinuous processes. These machines come with advanced capabilities for precise mixing, foaming, and curing.
Hennecke provides high-pressure metering machines that excel in closed cell foam production. These machines are equipped with cutting-edge mixing and metering technology, sophisticated control systems, and the versatility to manage a broad spectrum of foam formulations.
Linden Industries focuses on high-pressure foam machines designed to produce closed cell foam. Their machines offer accurate control over foam density, ensure a consistent cell structure, and allow for customizable foam formulations.
The Gusmer H-20/35 Pro is a high-pressure foam machine well-suited for closed cell foam production. It features precise ratio control, effective temperature regulation, and high-output performance for reliable and efficient foam manufacturing.
Evonik Industries provides high-pressure foam systems tailored for closed cell foam production. These systems are known for their advanced mixing and dispensing functions, precise control over foam formulation and density, and adaptability to various foam formulations, ensuring both flexibility and consistency.
Keep in mind that equipment specifications and models may have changed since this update. For the latest information on the newest models and their features, it is recommended to consult the manufacturers or current industry resources.
Closed cell foam comes in several types, including:
EVA foam is offered in grades ranging from #2 to #8. Known for its flexibility and resilience, EVA foam is commonly used for padding in sports gear, helmets, shin guards, knee pads, hot tub insulation, and boating bumpers due to its ability to mold and return to shape.
This foam type features a medium firmness and a rubbery texture, making it versatile for various industries. It's commonly used for crafting boat cushions, yoga mats, camping pads, and life preservers. Its water-repellent properties make it especially suitable for marine applications.
Closed cell foam is often manufactured into polyethylene rolls. While these rolls remain effective for various applications, thinner rolls may not offer the same level of durability and strength as their thicker counterparts. Polyethylene foam rolls are commonly used in piping, plumbing, medical supplies, automotive applications, and sports equipment. They come in diverse types, shapes, and thicknesses to suit different needs.
In addition to being resistant to air, water, and stains, cross-linked polyethylene is also impervious to mold and mildew. Its attractive appearance sets it apart from other foams, making it an excellent choice for packaging branded products. Typically, this foam is utilized for packaging, construction applications, and flotation devices.
Cross-linked foam features a more refined and consistent cellular structure compared to non-cross-linked varieties. In cross-linked foam, the polymer chains are interconnected, enhancing its stability. It is easier to handle, recyclable, and less abrasive. Both cross-linked and non-cross-linked foams are waterproof, belong to the closed-cell foam category, and offer similar advantages.
The distinctions between open cell foam and closed cell foam are as follows:
Cell Structure - Open cell foam consists of cells that are not fully enclosed, resulting in a softer and more flexible material. The cells are interconnected, allowing air and moisture to pass through. Conversely, closed cell foam is composed of completely enclosed cells, which are pressed tightly together to prevent moisture and air from penetrating the foam. This structure makes closed cell foam more rigid and stable compared to open cell foam.
Density - Closed cell foam generally has a higher density than open cell foam. Open cell foam typically has a density of around 0.5 pounds per cubic foot, while closed cell foam can have a density of up to 1.75 pounds per cubic foot or more.
Expansion - Closed cell foam expands to about 1 inch in thickness when sprayed. Multiple layers can be applied to achieve higher R-values, with each inch providing an R-value of approximately 7. Open cell foam expands to about 3 inches in thickness, usually requiring only a single application for most standard walls.
Resistance to Air, Moisture, and Liquids - Open cell foam absorbs water due to its interconnected cell structure, while closed cell foam resists water absorption and keeps moisture out. The open cells in open cell foam create pathways for liquids and air to pass through, whereas closed cell foam features isolated cells that prevent the penetration of liquids and air.
Material Cost - Open cell foam usually involves the use of material that costs less. A well-known open cell foam material is reticulated polyurethane foam and polyurethane foam. Partly due to their low cost, they are mostly utilized in carpet underlayment, seat cushion furniture upholstery, and foam filters. Whilst closed cell foam usually provides better performance on insulation and durability, it also leads to a higher material cost.
Sound and Thermal Insulation - Closed cell foam generally provides better thermal insulation due to its lower thermal conductivity, making it suitable for applications such as flooring and roofing. Open cell foam excels in sound absorption because of its numerous tiny open cells, making it effective at dampening external noise.
Applications - Open cell foams are soft and compressible, making them ideal for applications requiring air entrapment, such as sponges and sound dampening materials. They are also used in shock absorbers and cushioning due to their affordability. Closed cell foams, on the other hand, offer greater structural rigidity and are used in applications where water resistance is crucial, such as flotation devices, insulation, and gaskets. Their higher density and more complex manufacturing process make them more expensive compared to open cell foams.
Open-cell foam, with its network of suspended bubbles, tends to be more susceptible to moisture vapor compared to closed-cell foam due to its more porous structure.
In contrast, closed-cell spray foam is made with a similar base material but incorporates an insulating gas within its cells, resulting in a denser and more moisture-resistant product.
Both open-cell and closed-cell foam insulation contribute to improved energy efficiency in properties. However, the main distinction lies in cost: open-cell foam is generally less expensive to install, while closed-cell foam offers superior insulation due to its higher density.
Despite its ease of application, spray foam insulation should ideally be installed by professional technicians to ensure optimal results.
When selecting the appropriate foam material for a given application, it's crucial to take the following factors into account:
This chapter will explore the various applications and advantages of closed cell foam.
Closed cell spray foam insulation is both durable and sustainable, making it an excellent choice for commercial properties. Its superior strength compared to open-cell insulation makes it particularly well-suited for:
To clean closed cell foam, consider using a foam cleaner designed for automotive interiors or for spot treatments on carpets. Closed cell foam is resistant to strong acids and detergents, which means you can clean it effectively without needing to replace it or use abrasive tools like Scotch pads.
Closed cell foam is made by applying a gas, like nitrogen, to a plastic or rubber compound that is under high pressure. The foam can be made by exposing it to the gas directly, or by adding gas-forming agents into the material. Closed cell foam has air trapped in its cells, making it resilient, strong, impact resistant, and buoyant. The uses and applications:
The merits of using closed cell foam outweigh the demerits. There are different techniques used to cut the form which are: the single-pass cutting method and the multi-pass cutting method. They are different types of closed cell foam namely volara, EVA, and polyethylene foams to mention only a few. It can be found in different colors and thicknesses. They can be used indoors and outdoors and are also suitable for domestic and industrial purposes. They are relatively cheap.
It is possible to recycle polyethylene foam. It is possible to melt down the polythene foam and reform it the same way used on other plastic materials. Standard polyethylene foam is not resistant to fire, it can burn if in direct contact with flames. However, it will burn if it’s subjected to very high temperatures or if it is put in flames.
Closed-cell spray foam insulation consists of cells that are enclosed and securely packed together, as different in open-cell spray foam. Of all insulating materials found on the market, closed-cell spray foam insulation exhibits one of the highest R-values because of its extraordinarily high density. This makes it fall among the most energy-efficient choices available.
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