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Types of Synthetic Sponge and Foam

We have been specialist converters of synthetic sponges and foams for more than 40 years and offer a supreme range of sponge products for various industries.

These industries include ceramics, baby-bathtime, packaging, automotive, agricultural plus other general industrial and commercial sectors.

We offer these specially-sourced sponges and foams not only in standard shapes and sizes, but we also offer a bespoke manufacturing service to produce sponge products in accordance with customer’s individual ideas.

The most popular types of synthetic sponge and foam that we offer are as follows :-

Reticulated Hydro Sponge

Reticulated Hydro Sponge
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Reticulated Hydro Sponge
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Reticulated Hydro Sponge
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These hydrophilic foams are relatively dense sponges with a high tensile strength and elongation at break.

These characteristics make them ideal for cleaning, smoothing and fettling ceramics during the casting process, as they are tear-resistant. This means that the sponge does not disintegrate during use, which is very important.

Cheaper and lower density sponges can disintegrate during casting, which causes small pieces of sponge to stick to the ware before it is glazed. If this happens, then the sponge burns off during the firing process and causes pin-holes in the surface of the ware, which renders the finished product to be un-saleable.

Therefore it is better to spend more money on high quality sponges, rather than to purchase low quality sponges and risk losing money on potential product losses.

The most popular types of these sponges that we offer are the following qualities, photographs of which are shown in our gallery :-

HF2 

A small-pored sponge type used in the tableware industry

HM1

Medium pored sponge which is probably the best sponge for general use on all types of ceramics

HR3

This sponge quality has medium/large pores, which offer an abrasive quality that is popular in the sanitaryware industry

HN4

This sponge quality also has medium/large pores and similar characteristics to the HR sponge above

The standard characteristics and specifications of the Hydro sponges are shown in the below table :-

Standard Tolerances

Foam Type   HM HF HR HN
Density (kg/cbm) Min 32 27 28 28
  Max 38 31 32 32
Compression Load Deflection (kPa) Min 4.0  2.5 2.5 2.5
  Max 6.0 4.5 4.5 4.5
Tensile Strength (kPa) Min 140 120 120 120
  Max 140 150 150 150
Elongation at Break (%) Min 140 210 150 150
  Max 140 230 200 180

 

IMPORTANT :- Please note that these specifications are correct as of November 2013, but can be altered at the manufacturer’s discretion subject to revised test results

Prepolymer Polyester Sponge

Prepolymer Polyester Sponge
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Prepolymer Polyester Sponge
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Prepolymer Polyester Sponge
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Prepolymer sponges are produced from polyester foams that are manufactured by a special process and have excellent mechanical stability.

Very good abrasion and tear resistance give these special foams an extraordinary tenacity.

The two most popular types that we offer are V2M2 (Yellow) and V5W2 (White) which are both used in the sanitaryware industry. Photographs of both of these sponges are shown in our gallery and the standard specifications are shown in the below table :- 

Standard Specifications

Foam Type V2M2 V5W
Density (kg/cbm) 36 40
Compression Load Deflection (kPa) 5.5 7.0
Tensile Strength (kPa)    120 230
Elongation at Break (%) 85 145

Reticulated Polyester Filter Foams

Reticulated Polyester Filter Foams
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Reticulated Polyester Filter Foams
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Reticulated Polyester Filter Foams
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Our filter foams are pore-controlled polyester foam with a defined and uniform pore size. The number of pores is defined as PPI (Pores Per linear Inch).

The cell membranes are completely removed by an additional reticulation process, which gives an open pore structure which lends these foams to have excellent flow characteristics.

The porosity of our standard range of Filter Foams ranges from 10 – 80 PPI and photographs the most popular types are shown in our gallery.

We offer the following filter foams for the ceramics industry :-

R1 (10PPI);  R2 (20PPI)1 :- for the sanitaryware industry

R3 (30PPI);  R42 (45PPI) :- for earthen ware and stoneware

R63 (60PPI);  R84 (80PPI) :- for fine tableware, china and porcelain

Please note that we can source both coarser and finer filter foams if required

The standard specifications of the most popular types of Filter Foams are shown in the below table :-

Standard Specifications

Foam Type R2 R4 R6 R8
Density (kg/cbm) 34 33 33 33
Compression Load Deflection (kPa) 3.3 3.5 3.5 3.2
Tensile Strength (kPa)    140 160 190 280
Elongation at Break (%) 150 240 300 320

 

IMPORTANT :- Please note that these specifications are correct as of November 2013, but can be altered at the manufacturer’s discretion subject to revised test results.