Series W -spongy foams

   The spongy foams, with optimal softness and flexibility, have been specifically developed for creating upholstery materials that combine flexibility, softness, dimension stability, stability of the material during erosion and pressure burdens, energy absorption and low spatial weight.

Casting with this PU foam results in excellent acoustic quality, ability of shock absorbance together with maintaining its flexibility and density for a long period of time.

By choosing the appropriate ensemble of raw materials and developing unique formulas, one can get a wide spectrum of features. This enables exact matching of the PU system to the specifically required application. These spongy PU systems canceled the need for large investments in the production process of complicated multi-components. By simple pouring into cost-effective aluminum or composite materials moulds, at the environment temperature, one can get elastic cushions and an abundance of linings/upholstery in a short production time and relatively low work force.

Working method:
Casting of two-component mixture into prepared cavity or moulds, with the help of a machine or by hand-mixing. The casting can also be processed by cutting into the required shape.
2-phased pouring process: This is another development in which in the first step, rigid PU of the D series is poured. In the second step: spongy PU foam of the W series is poured into the same mould, so that during the first step the rigid frame is being created and during the second step the lining is added. This development is applied for example for the manufacturing of complete arm chairs. The regular process of gluing and cutting, during normal production, is herewith not required and hence the production costs are reduced.

A unique development is the visco-elastic sponge – this is a version of the “possesses memory” sponge with regards to fitting itself to the body putting pressure on it. This special foam was originally developed to avoid bedsores in bedridden patients. Its application was extended to additional situations where support of the body is needed over a long period of time and today its use is also accepted for prestigious mattresses, special pillows etc.

Examples for use:
Automotive, aviation and the train industry: Production of seats, back, hand and head rests, with low weights and comfort features, thermal insulation and noise absorbance.
Furniture industry: for the production of upholstery for chairs, beds etc.
Packaging industry: for the manufacturing of flexible padding for the packed product in a box so that the sponge fits exactly to the shape and weight of the product. Possible also as an anti-static material.
Orthopedic branch: for the production of protective padding for knee/ankle/joint. For the production of lined bandages. For the manufacturing of padding for prostheses.
For acoustic applications, to absorb noises.
Manufacturing of mattresses and pillows.

Characteristics of the PU foams

Additional benefits:
There is neither minimum quantity nor the necessity to purchase large quantities.
JIT supply.
An option exists to include machinery for the optimization of the production process.