Raw materials and manufacturing process used in form making

Chemicals which form part of the foam are polyol 50 %, polyisocyanates 40 %, water 10 % and some other chemicals. The first two chemicals are liquid polymers.  When these chemicals combined with water they produce polyuretherane by heat generating reaction.  Wide range of additives is also used. Tin and amines are the catalyst that speed up the reaction of large volume production runs.  Blowing agents are also used to make the foam. These blowing agents form gas bubbles in the polymerizing mixture. Flexible foams have carbon dioxide while rigid foams have hydro fluorocarbons, hydrochloroflurocarbons and pentanes as blowing agents. Cross linking agents, fillers, flame retardants, chain extending agents and coloring material are the other additives used in the foam forming.

Manufacturing process –

The liquid chemicals are put into large tanks. Then they are pumped into smaller heated tanks that are kept separate. More than two monomer streams are used to make the slabstock foam.  For making flexible and rigid foams two continuous dispensing is used. For blending of chemicals, specific amount of chemical is fed into mixing head from mixing tanks. The reactive substances are put on the moving surface or conveyor belt. This is the place where the foam rises and cures to foam the slab stock.

As foam moves Foam Machine Manufacturer in Delhi NCR on the conveyor belt, it is cut into smaller pieces by a horizontal blade. These foam sections are then cured at the room temperature for 12 hours. They are not stacked as they are not firm to withstand any weight. Once the curing process is complete, the foam can be cut into desired shapes. To get the rigid foam insulation panels a continuous process of lamination is used. Liquid chemical is applied between outer and inner walls of the appliance cabinet, for foaming process. This process is for appliance insulation.

For flexible foam molding, Re-bonding Machine Manufacturer in India the ratio of chemicals and components are controls by the dispensing machines. This gives molded foam with double hardness. The molded articles of foam having solid surface of skin are made with liquid chemical in a single step. Here, the carbon dioxide is the single blowing agent. By molding flexible foam behind a pre shaped fabric cover, the automotive cushions are made. The number of steps in the manufacturing of car seats can be reduced by this process. The final product is then tested for various mechanical and physical properties.