Convoluted foam is a synthetic polyethylene fabric used for protective packaging and lining. It is produced in flat sheets, contorted with a die-cutter to create an egg crate motif, and treated with copolymers to produce stiffness. It is used for noise reduction, bedding, and packing.
Convoluted foam is a synthetic polyethylene fabric used as a protective packaging and lining material for a variety of products. It is initially produced in flat sheets one to eight inches thick (2.54 cm to 20.32 cm), which are then saturated with a thermosetting resin, such as trimethylol melamine or benzoguanamine. The sheets are then passed through a machine which contorts one side with special die-cutters, creating the distinctive egg crate motif. The sheets are then cut in half to obtain two sheets which are compressed with this pattern on one side only so that they can be nested in pairs. The nested pairs are then treated with ethylene-acrylic acid or butene-maleic anhydride, crosslinking copolymers that react with the thermosetting resin to produce enough stiffness that the foam can stand on its own.
This molded foam is known by many other names as it has so many applications. For example, it is commonly referred to as acoustic convoluted foam because it is used to absorb sound. When attached to walls and other surfaces, the unique hills and valleys in the machined pattern trap sound waves in the low-mid frequency range up to four times more effectively than ordinary flat foam. This makes convoluted foam very useful when noise reduction or privacy is desired. In fact, this foam can often be seen inside music studios, machine shops, offices, and computer labs.
Another common use of this material is in the production of bed pillows and mattress toppers. For one thing, the unique pattern offers more cushion than flat foam as the conical peaks absorb physical stress and provide better weight distribution. The material also allows for more air circulation, and many hospitals use medical grade convoluted foam as their bedding material to reduce the risk of pressure ulcers or pressure sores.
Convoluted foam is also a superior packing material. Thanks to its cone-shaped design and ability to nest, products can be fully encapsulated when wrapped for shipping to help resist movement during transit. Some manufacturers of convoluted polyethylene foam produce an antistatic variety as a packing material for computers and other electronic components. The foam can also be cut to fit any product and comes in a variety of densities and colors.
Protect your devices with Threat Protection by NordVPN
