Molded Foam and Insole Systems

With a mission to provide polyurethane products that facilitate life in a manner sensitive to people, the environment and nature while prioritizing customer satisfaction and quality standards, Flokser has been in continuous development in the textile and chemistry sectors for 30 years and continues its chemical industry production under the "Flokser Kimya" brand. As of 2016, our company obtained the distinction of being the first Research and Development Center in its sector; polyurethane systems are being developed for the footwear (slippers, soles, insoles, occupational safety), rigid (refrigerators, cold room panels, sandwich panels, spray, pipe insulation, decoration), molded sponge, filter, integral, coating, adhesive and synthetic leather sectors. Flexible sponge systems generally serve the office, automotive and medical sectors. These systems are products formed as a result of an exothermic reaction occurring from the reaction of polyol mixtures and isocyanates. As a result of the reaction of 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. Formulation contents can be adjusted in line with requirements according to application area and demand characteristics. Molded sponge systems are obtained in the desired form by casting into molds with high or low pressure machines. Ultimately, for the final product to have the desired properties, in addition to depending on the content of the raw material system, the mixing quality of the machine used and the type of mold employed also have a decisive effect. For an appropriate production process, the use of high pressure machines equipped with cooling systems and aluminum molds equipped with heating systems is recommended.

Tests applied to our products both at the laboratory work stage and afterwards are as follows:

Free Density: The ratio of the minimum gramage filling a container of known volume to the container's volume.

% Deformation Test: A sponge sample is held under constant load at specified temperature conditions for a specified period, and after this period the load is removed and the change in thickness resulting from compression is measured. Hardness Test: A measure of the sponge's load-bearing property. The forces required to compress the sponge sample to 25% and 65% respectively of its original thickness are measured. Comfort Factor Test: The ratio of the force required to compress to 25% of the sponge's original height to the force required to compress to 65% gives the comfort factor. Tensile and Tear Test: Tensile strength is the value of the maximum force of the material before tearing. Resilience Test: A steel ball is dropped onto the sponge sample from a certain height, and it is calculated what percentage of the initial height the steel ball reaches upon rebound. Flammability Test: A sponge held to a flame source for a specified period is moved away from the flame source, and the distance the flame travels on the sponge per unit time is measured. Molded Density: The ratio of the weight of molded sponge to the volume of the mold.

One of the various application areas of polyurethane is insole systems with an increasingly growing market share. Memory foam insoles, which particularly exhibit shape-memory properties, completely support the feet that bear the entire body weight all day and significantly reduce the pressure that occurs in the feet during walking and running.

Memory foam insoles make the shoe anatomically more suitable, more flexible and ergonomic. Serving the polyurethane sector since 2006, Flokser has pioneered many innovations in this sector and has conducted 27 project studies supported by TÜBİTAK for bringing environmentally friendly technologies to the sector. As a result of these studies, • 2010 TÜBİTAK Success Award, • 2012 R&D Project 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 efforts to increase product variety in the flexible sponge market; launched sponge systems usable in the automotive and office sectors to the market. Products were prepared taking into account different working ranges and mold densities. Also, products with ECE.R.118 Annex 6 and Annex 8 horizontal and vertical flammability reports according to sector needs were launched to the market. As Flokser Kimya, with the aim of serving every sector touched by polyurethane, for the molded sponge sector we have a product range capable of meeting market needs with our different sponge systems possessing low density, required flammability and mechanical values. With a strong R&D team, Flokser Kimya continues its work at full speed with the know-how it possesses, together with demands from the market, and with innovative projects that the market may need. Mehmet Başdal R&D Specialist Flokser Kimya