For the average consumer, the terms foam rubber and sponge rubber may seem like they’re used interchangeably. Manufacturing industry insiders know better, though. In reality, these two materials have different compositions, methods of formation, and intended applications.
Material Composition
Foam rubber is composed of melted polymer matrices injected with large volumes of passive gas. The gas-filled bubbles give foam rubber its unique, light texture. The sponge rubber products available at California Industrial Rubber Co. have a different composition. The material is both denser and finer and is available in both closed-cell and open-cell variations.
Manufacturing Processes
The differences in material composition between foam rubber and sponge rubber can be explained not just by the fact that the former consists of a melted polymer matrix while the latter is made up of elastic and rubber-like materials. The manufacturing processes to create these two unique products are also different.
How Foam Rubber Is Made
Foam rubber manufacturers use substances called blowing agents to create thousands of bubbles in a specialized liquid polymer mixture. The mixture can also contain colorants and water. When mixed with water, liquid polymers begin to generate heat. In different combinations, they can be used to make foam rubber of varying compositions and rigidities.
The type and amount of blowing agents used also have a direct impact on how flexible foam rubber is. Carbon dioxide gas is used for flexible foam rubber products while using hydrofluorocarbons and hydrochlorofluorocarbons produces a more rigid product.
How Sponge Rubber Is Made
Unlike foam rubber, sponge rubber comes in both open-cell and closed-cell varieties. Open-cell sponge rubber, such as the materials found at https://www.cir.net/, features interconnected cells that make it permeable to air, water, and chemicals. The interconnected cells are formed using sodium bicarbonate as an agitator injected into the other ingredients while under heat to create gaps.
Closed-cell sponge rubber is manufactured differently, which is why it’s denser. There are still gaps, but they are sealed. The bubbles created in sponge rubber are filled with nitrogen gas, which forms as a product of chemical decomposition under pressure.
Common Applications
Sponge rubbers are highly versatile, boasting a range of firmness options, excellent compression, shock absorption capacity, and high sealing ability. Open-cell sponge rubber is typically used in protective padding, gaskets, and seals, while closed-cell varieties are more useful for things like soundproofing, cushioning, and thermal insulation.
Foam rubber comes in three primary forms, each of which has a distinct set of applications.
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Polyurethane foams are used for shock absorption and vibration control.
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Polystyrene foams are intended for home and appliance insulation and lightweight product packaging.
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Reticulated foams are designed for use in seats, mattresses, and pillows.
Where to Learn More
Anyone who wants to learn more about the different types of specialized rubbers used in manufacturing can turn to the experts at CIR for help. Visit https://www.cir.net/contact-us/ or browse the company’s website to find product descriptions, educational resources, and more. As an industry leader selling to major manufacturers, CIR understands the importance of finding the right materials for every job and will be happy to help current or future customers understand their options.
Media Contact
Company Name: California Industrial Rubber Co.
Contact Person: Media Relations
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Phone: 559-268-7321
Country: United States
Website: https://www.californiaindustrialrubber.net/