Foam was originally made from natural latex taken from the sap of rubber trees. Its usage dates back to the Mayans and Aztecs as far back as 500 BC. In the 1900s, man-made, or synthetic foam began to be created. In 1929, Dunlop Rubber researcher chemists E. A. Murphy and Eric Owen produced foam rubber using whipped latex.
In 1937, isocyanate-based materials were first used for the formation of foam rubbers. Otto Bayer found a commercial use for foam rubber and began working on polyester-based urethane polymers to compete with nylon.
The beginning of World War II and the resulting shortage of essential materials prompted the development of urethane materials for fibers, coatings, and foams.
After World War II, extensive research began in the United States, Germany, and Britain as the German foam technology became commonly known. At first, the research was based on diisocyanates and polyester polyols. However, the difficulty in processing, along with the relatively high costs, and certain poor physical properties of the foam lead to the polyurethane industry looking for alternative hydroxy compounds.
In the 1950s, Charles C. Price discovered and patented polyether polyurethane rubber. Currently, polyurethane-based foams make up over 90%, by weight, of the entire market for polyurethanes. Polyethylene foam is another popular type that is higher density.
1957 saw the discovery of a wide range of polyether polyols. They had a cost advantage, but the foams made had better physical properties than those based on the polyester type of polyols. Along with the arrival of the one-shot process and the introduction of silicone surfactants, this development has motivated tremendous growth in the polyurethane industry.
Polyurethane Foam Tray
Most foams are made of polyurethane, a type of polymer. Polyurethane can be solid or can have an open-cell structure, which is when it’s called foam. Manufacturers create it by reacting polyols and diisocyanates, both products derived from crude oil. A series of additives are necessary to produce high-quality polyurethane foam products, depending on the foam's application.
This type of foam is an all-purpose open-cell foam, meaning it’s light and absorbent. Its applications cover areas such as sponges, general cushioning, protective packaging, and paint rollers. Polyether foam is especially useful for cosmetics and toys.
Polyester foam is a good choice for display packaging and comes in fire-retardant grades. Like polyether foam, it is open-cell, relatively light, and available in several densities. It can also be used for acoustic purposes (like blocking sound), gaskets, and cushioning.
This closed-cell polyethylene foam has a density higher than polyester and polyether foams, typically with a weight of 2.2 pounds per cubic ft, and has excellent shock-absorption properties. It is used for packaging electronic equipment, floatation applications, and material handling. Ethafoam is often extruded or laminated.
EVA Open Cell Packing
The open-cell structure is characterized as being composed of many air pockets held within a polyurethane matrix. As with many insulations such as fiberglass, it is this trapped air that lessens the heat transfer through foams. It does not block vapor but instead allows it to pass through the foam matrix.
A popular material for mouse-pads, this foam has a high density and is highly resilient. A good choice for applications where the rubber is exposed to repetitive wear and tear, such as shoe soles, it possesses anti-fatigue and non-skid properties.
A neoprene and vinyl combination, this type comes in four different densities and is well suited to outdoor use, such as outside electrical outlets, weather-stripping, thermal insulation, and industrial padding. The material comes in sheets and rolls.
Polyethylene foam is also a closed-cell foam. Polyethylene foam offers durable, lightweight, closed-cell characteristics. It has vibration dampening and insulation properties, and high resistance to chemicals and moisture and is often used for packaging.
For more information about the different types of foam, welcome to contact us today or request a quote. 
