Polyester Foam

Polyester foam is a flexible, open-cell type of polyurethane foam that has a near-infinite amount of applications due to the following characteristics:

Types of Polyester Foam Available

Types of Polyester Filter Foam Available

Polyester Foam

In addition to fabricating polyester foam products to custom designed specifications, New England Foam stocks polyester foam in bun, roll and sheet forms, in densities ranging from 2 to 4 pounds per cubic foot (PCF) and those colors most requested: charcoal (black) and blue. Additional densities and colors are available upon request. Anti-microbial, anti-static, conductive and/or electrostatic dissipative (ESD) types of polyester foam are also available upon request.

Polyester foam’s most brilliant attribute is its evenly spaced cell structure with a high proportion of closed cells or “windows” that reflect light. This large amount of windows makes polyester foam ideal for sealing as it naturally prohibits the flow of air. The uniform cell structure inherent in polyester foam is perfectly suited for the reticulation process (the manufacture of filter foam). New England Foam stocks polyester filter foam in densities ranging from 10 PPI (PPI = pores per inch) to 100 PPI. Polyester filter foam can be easily compressed, forming sheets with a fixed, desirable thickness termed felt. Felted polyester filter foam has a highly restrictive cell structure and is largely used for air and liquid filtration.

Polyester-Polyurethane Foam vs. Polyether-Polyurethane Foam

Traditionally, polyester foam has a higher “tensile” strength than its polyurethane foam counterpart, polyether foam.  Polyester foam is also more resistant to hydrocarbons and alcohols than polyether foam. In applications where the polyurethane foam will come into contact with gases, such as oxygen, nitrogen and/or carbon dioxide, the polyurethane foam should be manufactured with polyester-based polyols. In applications where the polyurethane foam will come into contact with a liquid-based solution, the polyurethane foam should be manufactured with polyether-based polyols.

Manufacturing Polyester Foam

More costly and difficult to manufacture than polyether foam, polyester foam is manufactured in an variety of premium product grades, each with the characteristics to satisfy the demands of every project where presentation is crucial. Due to a higher viscosity rate, polyester foam exhibits physical properties not obtainable with other types of polyurethane foam; including superior solvency, abrasion and cut-resistance.

It is during manufacture that flame retardant additives can be introduced to meet various fire code standards, as well as anti-microbial, anti-static, conductive and/or electrostatic dissipative (ESD) additives.