Open cell polyurethane foam, also called PU foam, is a versatile material used in numerous industries from aerospace engineering to manufacturing and packaging. With its lightweight structure and ability to conform to nearly any space, open-cell foam is ideal for a wide range of applications.
In this blog, we’ll explore what makes open-cell foam unique, how it benefits various industries, and how custom converting can be used to create foam pieces that meet your exact specifications.
Open-Cell Foam Properties
One of the main attributes of open cell polyurethane foam is that its structure is composed of air bubbles that are not trapped within the material. In other words, air can flow freely between the membranes.
The key benefit of this is that open-cell PU foam is highly resistant to compression set or C-set. This means the foam can spring back to its original shape without becoming compacted or losing its structure.
In addition to having high compression resistance, the benefits of open-cell foam include:
- Lightweight Properties. The open structure between the air bubbles means that you can have a thick foam without added weight.
- Sound Absorption. With its airy structure, foam is ideal for dampening sound and absorbing vibrations.
- Flexibility. Open-cell foam can fit into a variety of spaces and fill air gaps as it expands to its original size.
- Breathability. With an open structure, air flows freely through the cells, making this foam ideal for applications that require air circulation.
- Filtration. Because of its permeable structure, open-cell PU works well for trapping contaminants while still allowing fluids or gasses to pass through the cells.
- Cost-Effectiveness. With its airy structure, less material is required to produce open-cell foam, making it typically more cost-effective than denser options like closed-cell foam.
Limitations of Open-Cell Foam
The lightweight, porous structure of open-cell foam is beneficial for a number of reasons, but this foam isn’t suitable for all applications. Potential drawbacks include:
- Low Tear Resistance: While this foam can withstand compression, it generally tears more easily than closed-cell options. However, this can vary depending on the specific product.
- Not Waterproof: Because of its structure, water passes through open-cell foam easily. This makes it an ideal filter foam, but it’s not a good choice when you need to create a moisture barrier.
- Poor Insulation: With more space between the membranes, open-cell PU is not as effective for thermal regulation compared to other options.
- Easy Compression: While its compressibility is ideal for some applications, open-cell foam doesn’t work well for padding heavy items that may cause the structure to flatten.
With so many factors to consider, finding the right foam for your application can be challenging. At American Flexible Products, we can help you select the ideal material with all the properties you need for any project, regardless of its complexity. Contact us to learn how we can help.
Open-Cell Polyurethane Foam Applications
PU foam can be used in a wide range of industries, from aerospace engineering to agriculture. Common uses include:
Filtration
Open-cell foam is an ideal filter foam because of its porous structure. Foam is commonly used in air filtration systems, such as those found in HVAC systems or vehicles. The structure allows air to pass through while trapping dust, pollen, and other debris.
Foam can also be used to filter contaminants from liquids, especially in industrial applications. Specialty open-cell foam can withstand extreme temperatures and resist chemical corrosion, making these products ideal for demanding industries.
Cushioning
With its structure, open-cell foam is suitable for providing padding for sensitive components. Foam packaging, for example, can protect electronics and medical devices during shipping and transportation.
Specialty products such as Rogers PORON foam are designed to withstand constant pressure without deforming or becoming permanently compressed. This makes it ideal for applications like:
- Orthotics
- Doors and Access Panels
- Medical devices
- Electronics
- Communication devices
As it’s flame retardant and able to withstand extreme temperatures, PORON is also suitable for demanding industries like satellite construction.
Sealing
With the ability to expand and fill an empty space, open-cell foam is suitable for creating seals. Urethane foam gaskets are commonly used to absorb sound and vibration where hard surfaces meet. Gaskets can be converted into any custom shape to meet specific requirements. Depending on the material, open-cell foam can be used for applications such as:
- Medical devices that adhere to the skin.
- Creating a bond between components in manufacturing.
- Preventing contaminants from entering a closed system.
Keep in mind that with its porous structure, open-cell foam can’t keep moisture out. If you need a watertight seal, consider materials such as closed-cell foam.
Explore the Possibilities of Open-Cell Foam
Foam is one of the most versatile materials and can perform under a wide range of demanding conditions. Because no two projects are alike, American Flexible Products can create custom foam components tailored to your exact needs.
With die-cutting, water-cutting, and other precision capabilities, we can convert foam products to fit any design specifications. Contact us today to discover how open-cell foam can enhance your process.
