The Types, Qualities, and Benefits of Foam Rubber Products

Foam rubbers are durable materials made of varying blends of polymers and elastomers that produce some of the most versatile and unique materials in the world of foam. With their substantial list of applications and characteristics, neoprene sheets and gymnastic rubber are two of the most useful and utilitarian products in Foam Factory, Inc.’s catalog, and can easily be customized to fit any application for which their attributes provide the best solution.

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A medium-weight, resistant material, neoprene is a foam rubber available in multiple variations. The three major types include chloroprene rubber (CR), styrene-butadiene rubber (SBR) and ethylene-propylene-diene-monomer (EPDM). These varying blends create slight variations in the material, with each having their own set of performance characteristics and best applications.

The simplest and “purest” form because of its lack of blending is the CR foam rubber, the oldest of the three. This material is durable, but not to the degree of some of the blended forms which have undergone formulaic additions to enhance performance attributes. Still, this material performs well as seals, bearings and in gasket applications because of its resistance to water and many oils and fluids. SBR is a blending of the monomers styrene and butadiene, developed during World War II to compete with natural rubber and compensate for its supply shortage. The advantages over natural rubber include better water, organism, and abrasion resistance, as well as better flex and tear resistance and tensile strength.

Foam Factory carries the blended EPDM rubber as their neoprene product. This formulation of monomers allows excellent moisture and temperature resistance which makes it useful in gasket and insulation applications. It is very resistant to weather, sunlight, chemicals, oxidation and petroleum derivatives like similar formulations, but it also includes Ozone resistance, a quality not all other materials possess. A very consistent foam rubber, this closed-cell foam is cut into sheets as thin as 1/8″, or as thick as 2″, and is available in regular and high quality. These rubber sheets have even been used to line roofs and aid in the collection of rainwater, as it is a non-toxic material. EPDM also holds an advantage in cost over CR neoprene rubber by using more affordable materials in its blend.

Gymnastic rubber is another widely recognized high density foam rubber product. These durable sections of black foam are frequently seen as matting or padding in school gymnasium flooring or as a fitness flooring in health clubs. Gym rubber products are based similarly to the neoprene types, with a butadiene rubber formula, but including nitriles as well (NBR). The materials Foam Factory stocks are polyvinyl-chloride nitrile-butadiene-rubber, or PVC/NBR. These dense, flexible forms of foam rubber have many applications beyond their athletic flooring uses. Gym rubber is frequently used as kneeling and camping mats because it is able function as a foam cushion for hard surfaces while still providing enough stability and strength to keep users from bottoming out to the ground. Its insulation values keep people warm on the ground as sleeping pads, as well as allowing it to be used for building insulation because of the relatively small space it takes up for the amount of insulating performance it provides. This product is cut most typically in sheet form but can be modified to contain interlocking edges for temporary or traveling mat setups.

Foam rubbers provide a range of services that go from money-saving and practical like insulation, to recreational and interactive like exercise mats. The variances in formula allow many different products to share core traits while tailoring them to special jobs at the same time. The benefits of foam rubbers can be applied to all of their applications, with their specialization making each one stand out as an individually useful material.

Foam and sponge rubber are essential materials in many industries due to their unique properties. This article will help you understand the different types of foam and sponge rubber, their benefits, and how they can be used effectively. Understanding these materials can help in selecting the right foam product for your specific needs.

Foam is a lightweight material formed by trapping gas bubbles within a solid or liquid matrix, such as rubber, plastic, or other polymers. Its structure can range from soft to firm, depending on its density and composition. Foam is widely used for its cushioning, insulation, and shock-absorbing properties, making it ideal for applications in packaging, construction, automotive components, and more.

Sponge rubber is often confused with foam, but the key difference lies in the production process and cellular structure. Sponge rubber is created by adding a chemical blowing agent during the manufacturing process, causing the rubber to expand and form a spongy texture. Sponge rubber can also be open-cell or closed-cell, and it is often used for thermal insulation, weatherproofing, and soundproofing applications.

Polyurethane foam is a highly versatile material known for its light weight and durability. Its flexible structure makes it suitable for a wide range of applications, including furniture upholstery, automotive seating, thermal insulation, and soundproofing. The density of polyurethane foam can vary, with most standard types ranging between 20-50 kg/m³, allowing for tailored solutions in cushioning and energy absorption.

AS Rubber offers a range of polyurethane foams, such as reticulated foam for filtration, reconstituted foam for impact cushioning, and polyether foam for lightweight applications. These foams are available in a variety of formats to meet the needs of industries including automotive, construction, and furniture, providing customised solutions for specific requirements.

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Polyethylene foam is a closed-cell foam characterised by its strength, lightweight nature, and excellent shock absorption properties. It is resistant to moisture, chemicals, and UV radiation, making it ideal for protective packaging, sports equipment, building insulation, and flotation devices. Polyethylene foam has a density that typically ranges between 24-115 kg/m³, which makes it well-suited for both heavy-duty and lightweight applications.

AS Rubber offers polyethylene foams in various forms, including chemically cross-linked PE foam for enhanced thermal insulation, non-cross-linked PE foam for general-purpose protective packaging, and physically cross-linked PE foam for high-performance cushioning. Available in multiple colours and formats, these foams are tailored to meet the specific needs of various applications.

PVC foams are flexible, closed-cell foams that offer excellent sealing capabilities, making them suitable for automotive, construction, and marine environments. These foams are flame retardant and resistant to chemicals, which makes them particularly useful for applications requiring enhanced safety and durability.

PVC foams provide a unique combination of flexibility and strength, making them ideal for gaskets, thermal insulation, and cushioning. They also have excellent resistance to water, air, and dust infiltration. This makes them highly effective for sealing applications.

Within our PVC Foam range we offer Fast Recovery PVC Foam, which features quick rebound properties, making it ideal for applications that require repeated compression and recovery, such as display packaging and protective padding.

Solid rubber is a dense and durable form of rubber that provides excellent resistance to wear, weather, and chemicals, making it particularly beneficial in heavy machinery applications where components are exposed to harsh conditions and require long-lasting performance. Unlike foam, solid rubber does not contain air pockets, making it highly durable and suitable for applications requiring significant resilience, such as seals, gaskets, and bumpers. Solid rubber is typically used in heavy-duty applications, such as industrial machinery mounts and heavy-duty vibration dampening pads, where high resistance to compression and environmental factors is required.

AS Rubber offers solid rubber in various formats, including sheets, rolls, and custom-cut parts, providing you with the flexibility to choose materials or have specific products created to meet your requirements.

Cellular sponges are made from rubber compounds that are expanded to create a network of air pockets, resulting in a flexible and compressible material. Their soft and pliable nature makes them ideal for applications requiring cushioning, insulation, sealing, flexibility, and shock absorption. Our cellular sponges can be used in automotive weather stripping, industrial gaskets, and other sealing applications where flexibility and durability are essential.

Closed cell foam features isolated air pockets that make it more rigid and resistant to water, making it suitable for outdoor applications such as playground flooring, as well as environments with high moisture levels. It provides excellent insulation properties and is widely used for flotation devices, moisture barriers, and packaging. Closed cell foam is also known for its superior resistance to chemicals and UV radiation, making it an ideal choice for outdoor uses and industrial applications.

Our semi-closed cell EPDM sponge is a versatile option that offers excellent weather resistance, making it suitable for sealing and gasketing in outdoor environments where exposure to the elements is a concern.

Choosing the right type of foam or sponge rubber depends on your specific application requirements, including properties such as flexibility, density, and environmental resistance. Whether you need foam for cushioning, insulation, or sealing, there is a type of foam that meets your needs. With 28 years of experience, AS Rubber can cater to customers in the UK and abroad, providing assistance and high-quality products. For more information and assistance in selecting the best foam product for your application, contact AS Rubber today.

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