Abstract
Recent technical breakthroughs have enabled the development of soft touch, fine cell, noncrosslinked polyolefin foams. By optimizing the foam formulation and processing/forming conditions, the foam properties and performance attributes have been tailored to match that of crosslinked polyolefin foams in automotive material handling applications. Environmental pressures have created an unmet market need for a 100% recyclable, low-cost replacement product. This article details the physical properties, cushioning characteristics, abrasion performance, and thermoformability of the tough, resilient foams. The durable foams absorb shock, dampen vibration, and protect fragile products with high-quality surfaces from abrasion during handling, storage, and transportation. The foams thermoform over a relatively broad temperature range at low-to-moderate draws to produce well-defined fabricated products that closely match the mold contours while preserving cellular structure. The unique attributes of the noncrosslinked foams facilitate their penetration into several market segments currently dominated by crosslinked foams.
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