Traditional urethane systems employ a methodology in which the two main raw materials (the polyglycol and the diisocyanate) are metered and mixed concurrently with the foaming process with the minimal addition of water. In contrast and unique to the industry, Filtrona Porous Technologies utilizes a process employing a functionally reactive urethane prepolymer and a separate aqueous phase as the only two principle components in the foam. The liquid prepolymer imparts structural integrity and stability to the foam; the use of large amounts of water (up to 300% stoichiometric equivalents) permits a wide range of foam product possibilities and the ability to control and customize product properties. A high speed mix-head intimately mixes the two components at specific temperatures, pressures, and weight ratios and dispenses the pre-foam on a moving conveyer to produce continuous slab stock hydrophilic foam.
Our prepolymer,
PrePol™, is independently synthesized by the combination of a dialcohol and TOLUENE DIISOCYANATE (TDI). Polymerization variables include reactant stoichiometries, additives, temperature exotherms, and mode of addition; all are intimately related and lead to the specific and unique properties of PrePol™. The viscous liquid is stored in nitrogen blanketed barrels for subsequent use or sale.
The isocyanate end groups of PrePol™ are capable of reacting with any active hydrogen-containing compound, specifically water, to generate a cross-linked foam. Because such atypical amounts of water are incorporated during the foaming process, any water-compatible or soluable component can be intimately dispersed into the foam. Careful control of surfactants and fillers allows for a plethora of foam properties; from soft, resilient, and smooth textured cosmetic foams to open celled, semi-rigid foams.
As the prepolymer and water mix, the chemical reaction cross links the polymer chains and expels CO2 gas. The latter acts as the foaming or rising agent and is vital to the soft feel and overall density of the foam. The timing of such dynamic events is important and the final properties of the system are not realized for up to 24 hours after initial reaction. The slab stock hydrophilic foam can be cut into various shapes and sizes to meet the ever growing and diverse product demands at Filtrona Porous Technologies.
Foam Applications∙ Acoustical
∙ Agricultural
∙ Anti-Static
∙ Automotive
∙ Consumer Products
∙ Cosmetic
∙ Cushioning
∙ Filtering
∙ Fire Protection
∙ Flotation
∙ Industrial
∙ Insulations
∙ Medical
∙ Sports/Leisure
∙ Thermal
∙ Toys
∙ Wicking
∙ Wiping
Our Converting CapabilitiesFoam Converting∙ Buffing
∙ Coating
∙ Die Cutting - Rotary and Flatbed
∙ Embossing
∙ Flocking
∙ Heat Sealed Edges
∙ Horizontal and Vertical Slitting
∙ Laminating to any substrate
∙ Molding
∙ Olmanizing
∙ Spooling
∙ Spraying
Foam Specifications∙ Roll Goods, Bun Stock or Sheeted
∙ Poured to Thickness: 1mm - 50mm
∙ Widths: 1" to 30"
∙ Lengths: Up to 47" Diameter Roll
Bulk Packaging∙ Bagged and Boxed - Parts or Rolls
∙ Container Lots for Export
∙ Plastic Lined Cartons
∙ Palletized with Stretch Wrap
Finished Goods Packaging∙ Auto Bagged - Regular or Zip Style
∙ Blister Packs
∙ Shrink Wraps
Filtrona Porous Technologies utilizes a truly unique polyurethane production process for the manufacture of a diverse range of hydrophilic foam products.
