Polyurethane cold foam materials are produced by a chemical reaction between polyols and isocyanates. The liquid, homogenised mixture reacts slightly exothermically without energy supply. For these systems the term “cold foam” has come into use, because the tools in which the components are foamed are operated with relatively low temperatures. In contrast, so-called “hot-cured foam” is made in tools that are briefly heated in very hot ovens in order to set the foam.

The reaction components foam in tempered moulds. The tool is filled under pressure while at the same time all air is removed from the tool. After completion of the reaction the final cold foam part is removed from the mould and can be provided for its intended use.

Advantages of Moulding Components from Flexible Foam    
Deserving to be mentioned first are the flexible, adaptable material properties that have excellent sound absorption and the almost unlimited creative structural possibilities. Moreover, carriers and fasteners can easily be foamed or other functions can be integrated. High elasticity, low compression set, and low permanent compression fatigue guarantee a durable and reliable quality.
The use of the materials can be optimised by the fact that the density of the part is adapted to the respective requirements. They thereby also determine the cost effectiveness of production.

Areas of Application     
For example, in the automotive industry and specifically where high quality durability and comfort are required: in motor vehicle seats, centre armrests and headrests. Also included is the entire area of sound insulation, as for example engine encapsulation and carpet back foaming.

The seating and upholstered furniture industry uses soft mould materials for back, seat and side elements. Due to the relatively large volume, these parts are foamed with a low density. For chair furniture soft foam is used, for seats, backs and scatter cushions: thin pads with a relatively high specific gravity, which are then upholstered. In this area the creative structural possibilities of soft foam mould parts are particularly valuable.