Molded Foam Systems

Placing customer satisfaction and standard quality at the forefront, Flokser has been in continuous development in the textile and chemical sectors for 30 years with a mission to provide polyurethane products that facilitate life sensitive to people, the environment and nature. The company continues its chemical sector production under the "Flokser Kimya" brand. As of 2016, our company obtained the distinction of being the first R&D Center in its sector; polyurethane systems are being developed for the footwear (slippers, soles, insoles, occupational safety), rigid (refrigerator, cold room panels, sandwich panels, spray, pipe insulation, decoration), molded foam, filter, integral (office furniture armrests, various auto parts, cables), adhesive and synthetic leather sectors. Molded foam systems generally serve the office, automotive and medical sectors. These systems are products created as a result of an exothermic reaction occurring from the reaction of polyol mixtures with isocyanates. As a result of the reaction between raw materials used in the polyol mixture and the isocyanate prepared for this mixture, an open-cell polyurethane structure is formed. Thanks to this open-cell structure, flexibility is provided in the product. Based on usage area and demand characteristics, formulation contents can be adjusted in line with requirements. Molded foam systems can be given the desired shape by casting in molds using high or low pressure machines. Ultimately, while the desired properties of the final product depend on the content of the raw material system, the mixing quality of the machine used in product manufacturing and the type of mold used also have an absolute effect. For an appropriate production process, the use of high pressure machines with cooling systems and aluminum molds with heating systems is recommended.

Image 1: Foam application to aluminum mold with high pressure machine

Serving the polyurethane sector since 2006, Flokser has pioneered many innovations in this sector and has carried out 27 project studies supported by TÜBİTAK to introduce environmentally friendly technologies to the sector. As a result of these studies: • TÜBİTAK Success Award in 2010, • 2012 R&D Project Market Summit, R&D Award, • 2016 TÜBİTAK, TÜSİAD 12th Technology Awards finalist. As of 2016, registered as an R&D Center by the Ministry of Industry, Flokser accelerated its work due to gaps in the product range in the molded foam market and introduced CREAPOL SUN 8010/52 and CREAPOL SUN 8010/45 systems to the market. Working conditions for the products and physical and mechanical test properties are given in the table below.

Table 1. CREAPOL SUN 8010/45 Test Results

Table 2. CREAPOL SUN 8010/52 Test Results

In the tables above, two different products are systems prepared with different mold densities and different working ranges. In addition to the tables above, ECE.R.118 Annex 6 and Annex 8 horizontal and vertical flammability reports were obtained for our CREAPOL SUN 8010/45 system. As Flokser Kimya, with the aim of serving every sector touched by polyurethane, with our different foam systems for the molded foam sector having low density, required flammability and mechanical values, we have reached a product range capable of meeting market needs. With a strong R&D team, Flokser Kimya, with its know-how, continues its work at full speed on demands that may come from the market and innovative projects that the market may need. Mehmet Başdal Flexible R&D Specialist Flokser Tekstil San. ve Tic. A.Ş.