This article will take an in-depth look at closed cell foam.
The article will bring more understanding on topics such as:
This introductory chapter delves into the definition of closed cell foam and its production process. You will also discover the techniques used for cutting closed cell foam and learn about the key factors to consider when choosing this material.
Closed cell foam is a specific type of foam characterized by tightly packed and enclosed "cells." Unlike open cell foam, like polyurethane which features interconnected open cells, closed cell foam's lack of interconnection results in small, tightly packed cells containing pockets of gas. This structure contributes to its durability, making it ideal for more rigorous applications.
Thanks to its sealed cellular structure, closed-cell foam does not allow the penetration of water or moisture, making it highly resistant to pressure. It possesses higher density and is available in various forms, from rigid polyethylene to softer styles like Flotex. This versatile material ensures enhanced stability and offers a secure seal. Moreover, closed-cell foams come in a range of colors and thicknesses, and their superior robustness generally sets them apart from other foam types in terms of stiffness.
The production of closed-cell foam involves a series of specific processes and materials:
Polyethylene Foam - This type of polyethylene closed cell foam resists water absorption and stains. It's ideal for a broad spectrum of uses, offering excellent sound dampening, buoyancy, and shock absorption qualities, making it suitable for everything from packaging to arts and crafts.
Polyethylene Rolls – Available in rolls, this closed-cell foam suits a variety of sectors, including automotive, healthcare, and sports and recreational applications.
Cross-Linked Polyethylene – Offered in thicknesses between 0.063 and 0.700 inches with densities varying from 2 to 20 lb/cubic foot, this foam is available in rolls or buns that you can cut to any thickness. Its versatility and resistance to mildew, stains, and water make it an excellent option for packaging, flotation devices, construction, and industrial use. The durability and visual appeal of cross-linked polyethylene add to its applicability in diverse settings.
Polystyrene Foam – This material is ideal for projects necessitating closed cell foam blocks and is available in various densities to cater to different project needs. Known for its rigidity, polystyrene foam is extensively used for storage and packaging due to its resilience.
Neoprene Rubber – Available in rolls or sheets, neoprene rubber suits applications prioritizing cleanliness and insulation. It's commonly used for flooring, wall paneling, and athletic equipment. Resistant to mildew, mold, and bacteria, neoprene is appropriate for sports venues, daycares, and medical establishments.
Gym Rubber – Known for its high density and moderate firmness, gym rubber provides significant shock resistance with a slight bounce, making it perfect for daycares, gyms, and building insulation. It is offered in different densities and sizes, providing a viable choice for maintaining cleanliness and safety.
Polypropylene Foam – For heavy-duty applications requiring foam with substantial rigidity, polypropylene foam stands out. Its high density is particularly useful in protective packaging scenarios requiring strong protection.
The creation of foam involves capturing gas within a liquid, followed by applying pressure and heat to solidify it. Depending on its design, foam can provide benefits such as impact cushioning, noise reduction, safety enhancement, and waterproofing. In its solid state, closed-cell foam is non-toxic and is widely utilized in medical applications. However, in its initial gas or liquid forms, it can be harmful.
Widely recognized as one of the most effective insulation methods, closed-cell spray foam insulation offers exceptional energy efficiency. Its high thermal properties make it an ideal solution for both residential and commercial applications, ensuring enhanced thermal conversion.
For slicing through closed-cell materials, the optimal tool is a straight, non-serrated blade, like those found in utility or crafting knives. These blades offer convenience due to their replaceability. For smaller tasks requiring less precision, scissors may suffice, though only for certain types and thicknesses of foam. Employ a straight edge for crisper cuts. Always cut on a stable surface to protect both the foam and the work environment.
Neoprene, Gym Rubber, Cross-Linked Polyethylene, and Polyethylene Roll possess nearly identical physical structures, allowing you to utilize similar cutting approaches across these materials.
When handling materials like neoprene, XLPE, gym rubber, or polyethylene rolls, assess the material's thickness first. For sheets no thicker than 1/8", sharp scissors could work, but their use is primarily confined to lighter, hobbyist projects due to the potential for uneven edges. For tasks like designing bath toy shapes or trimming card backings, scissors offer quick solutions. Polyethylene roll is notably receptive to scissor cuts due to its pliability.
For any project involving materials over 1/8" in thickness, a straight blade is advisable. The material's thickness determines the ideal cutting strategy using a knife.
The single pass-through technique is best for cutting through materials as thick as 1/2". This method entails making one steady cut to separate the material along the chosen line, achieving a neat edge. Foam sheets up to 1/2" thick are ideal for this method, as thicker foams might inhibit seamless blade progress. Use a sharp knife to avoid snagging on deeper cuts. It's crucial to secure the foam to prevent it from shifting to maintain smooth, precise cutting.
For closed-cell foams exceeding 1/2" thickness, a single pass-through cut is typically impractical, possibly resulting in jagged edges. In contrast, the multi-pass technique is more apt for thicker foams, involving several cuts with the blade, guided by an extended straight edge to ensure clean and precise cuts.
After setting the cutting line and positioning the straight edge, initiate cutting similarly to the single-pass approach. Rather than cutting entirely through in a single try, make light cuts into the foam, about 1/8" to 1/4" in depth, covering the material's total length with minimal pressure. Continue with these shallow passes, progressively deepening the cut until ultimately cutting through the entire thickness, resulting in a tidy, efficient edge.
Polyethylene, a popular closed-cell foam with various densities, impacts its rigidity, cell structure, and flexibility. At lesser densities, its cell arrangement becomes more irregular and bubbly, complicating the cutting process—making scissors unsuitable. For sheets beyond 1/2" in thickness, adopt the single-pass cutting process; for thicker sheets, utilize a multi-pass cutting formation for optimal results.
Closed cell foam insulation proves to be an outstanding option when seeking strong structural stability, energy efficiency, and water resistance. Besides these advantages, it offers extra perks—high-density foam provides superior insulation compared to traditional materials like polyester, polyethylene fibers, or foil.
Density of Closed Cell Foam - This type of insulation boasts a densely packed cellular framework.
Water Resistance - Its cellular arrangement makes closed cell foam a formidable response to water-related issues.
Moisture Control - Closed cell foam's ability to repel water helps extend the insulation's lifespan significantly.
Reduction of Air Currents - This foam aids in reducing convective processes within walls and roofing structures.
Air Quality Improvement - The dense composition of closed cell insulation considerably boosts indoor air quality by blocking out contaminants, dust, and preventing mold progression and moisture penetration.
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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