specialized foam rubber supplier

What is Foam Rubber and How is it Made? The Ultimate Guide to Modern Foam Technology

Feb 24, 2025

 

What is Foam Rubber? The Fundamental Science

Foam rubber is a versatile material prized for its lightweight structure, energy absorption, and thermal insulation properties. This guide explores its production process while highlighting two high-performance variants: NBR/PVC blends and EPDM-based foam rubber – materials engineered to meet modern industrial demands. Also called cellular rubber, this type of rubber is created by introducing gas bubbles into a polymer matrix, forming a porous structure. This process yields materials with:

 

  • Low density (0.02-0.3 g/cm³)
  • High compressibility, elasticity and flexibility
  • Energy dissipation capabilities
  • Thermal/acoustic insulation

Research shows these properties make it ideal for applications ranging from personal protective equipment to automotive seals.

 

Manufacturing Process

Core Components

Base Components:

  • Polymeric diol (molecular weight 3000)
  • Toluene diisocyanate
  • Specialized catalysts
  • Water (primary blowing agent)
  • Silicone oil for cell control

 

Production Steps

Component Preparation

  • Precise mixing under controlled conditions
  • Temperature monitoring (up to 130°C)
  • Catalyst addition for reaction control

Cell Structure Formation

  • Gas bubble introduction
  • Structure stabilization
  • Density control through processing parameters

Key Insight: The choice of base polymer and processing parameters (temperature, blowing agent type) directly determines the foam's cell structure and performance. 

 

 

Advanced Foam Technologies

NBR/PVC Blend Foam

This innovative combination offers:

  • Superior oil and chemical resistance
  • Enhanced ozone/weather resistance
  • Temperature resistance up to 120°C
  • Excellent dimensional stability

 

Optimized Formula:

Hairui's R&D studies reveal a 60:40 ~ 70:30 NBR/PVC ratio achieves optimal balance between elasticity (NBR) and structural integrity (PVC). 

 

Performance Highlights:

Property Improvement vs Pure NBR
Tear Strength +25-40%
Ozone Resistance 3X longer lifespan
Compression Set 15-20% reduction

 

Technical Breakthrough: Advanced dynamic vulcanization techniques create a "sea-island" microstructure where crosslinked NBR particles disperse in PVC, enhancing mechanical stability. 

 

 

EPDM-Based Foam

Engineered for demanding applications with:

  • Temperature Range: -50°C to +150°C operational stability
  • Weathering Resistance: 10+ years UV exposure without cracking
  • Low Conductivity: 0.035 W/m·K (ideal for HVAC insulation)

 

Manufacturing Innovations:

1. Salt-Leaching: Creates uniform pores by dissolving NaCl particles post-curing.

2. Chemical Blowing: Azodicarbonamide decomposes to form nitrogen bubbles.

3. Phase-Change Integration: Paraffin wax additives enable thermal energy storage (TES) capacity. 

 

Case Study: Automotive door seals using EPDM foam show 47% better noise reduction vs traditional rubber. 

 

 

Manufacturing Advantages

Modern foam rubber production offers:

  1. Processing Benefits:
    • Reduced equipment requirements
    • Lower energy consumption
    • Increased production efficiency
  2. Performance Advantages:
    • Enhanced fabric adhesion
    • Superior reinforcement capabilities
    • Improved insulation characteristics

 

 

Hairui Rubber's foam rubber pipe

 

 

Quality Control Considerations

Key parameters monitored during production:

Physical Properties:

  • Density uniformity
  • Cell structure consistency
  • Dimensional stability
  • Surface quality

Performance Metrics:

  • Compression characteristics
  • Thermal conductivity
  • Weather resistance
  • Chemical stability

 

 

Industrial Applications

Primary use sectors include

HVACR Systems:

  • Thermal insulation
  • Condensation prevention
  • Vibration dampening
  • Sound attenuation
 

Construction Industry:

  • Building envelope insulation
  • Mechanical system protection
  • Acoustic barriers
  • Moisture control

 

 

close cell foam rubber close-up

 

 

Future Developments

The industry continues advancing through:

Manufacturing Innovation:

  • Enhanced automation systems
  • Improved quality control
  • Environmental sustainability
  • Advanced processing methods

 

Material Development:

  • Enhanced performance characteristics
  • Improved durability
  • Better environmental compliance
  • Specialized application formulations

 

 

Expert Insights

For optimal application selection:

Consider specific requirements:

  • Operating temperature range
  • Chemical exposure conditions
  • Mechanical stress factors
  • Environmental conditions

Match material properties:

  • NBR/PVC for oil/chemical exposure
  • EPDM for weather/temperature extremes
  • Custom blends for specialized needs

 

 

Conclusion

Foam rubber technology continues evolving, offering improved performance and efficiency for modern industrial applications. Understanding both manufacturing processes and material properties ensures optimal product selection and application success.

 

Hairui Rubber Commitment

As a leading Chinese rubber supplier, Hairui Rubber is dedicated to delivering foam rubber and elastomer solutions that meet the most demanding industrial requirements. Our expertise transforms technical challenges into innovative opportunities.

 

rubber production line

Need Technical Support?

 

Contact our materials engineering team for specialized foam formulation guidance based on your specific application requirements.

Need Help? Chat with us

GET IN TOUCH
Ready to experience the Hairui difference? We're excited to learn about your project and show you how our innovative solutions can drive your success. Fill out the form on this page, and we’ll get in touch with you shortly.
Submit

Home

Products

whatsApp

contact