Hard Foam: How To Make It Dense At Home? High Hardness Foam For Floats And Modeling, Grade

2024 Author: Beatrice Philips | [email protected]. Last modified: 2023-12-16 05:33

Polyfoam is widely used by many modern companies . Most often - as an additional measure of protection for packaging of various products. Its physical properties make it possible to cushion shocks. However, dense foam has a wider range of properties. It is similar to the usual one and for a long time practically nobody was interested in. However, in recent decades, it has been actively used. The article will discuss the characteristics and areas of application of solid foam, as well as how it differs from its conventional counterpart.

general description

Hard foam is also called styrofoam … Represents plastic filled with gas . The structure itself is composed of cells. The more air has been “pumped” into the plastic during the manufacturing stage, the less durable the final product will be. The material is produced by pressing. The higher the density of the foam, the more rigid it is. Simply put, the more plastic and less air, the harder it is.

Rigid foam is more durable and has a longer service life (as opposed to conventional foam) . Due to its increased density, such a product retains heat better, and is also suitable as an effective noise-insulating material. In the production process, a fire retardant is often included in the composition. Thanks to him, the foam does not burn well. Combustion of expanded polystyrene will not lead to a large-scale fire.

Now, as a rule, sheet polystyrene is produced. This form is convenient for insulation, for which foam of this kind is most often used.

A product with a thickness of 20 mm has a resistance similar to that of a brick. At the same time, it remains quite light, and also easily, quickly and evenly cut. Due to its low weight, transportation becomes easier and cheaper than for other similar materials. On dense foam, it is easy, if necessary, to make stamping (by heating), it is easy to glue it.

The material does not lose its shape when it comes into contact with water and, in general, practically does not absorb it . It can withstand temperatures up to +80 degrees Celsius and does not deteriorate from acids and alkalis. And also the material is safe to use. It does not release toxic compounds into the air. Average service life is 80 years. Mold and other microorganisms do not live on the material.

Not resistant to acetone, gasoline . Upon contact with them, it begins to dissolve and, after drying, turns into a hard, smooth film of a dirty color.

One of the key characteristics of foam is density. Depending on this value, the material is assigned a grade (degree of density) according to GOST.

How to determine hardness?

The hardness or relative density of the foam is its main characteristic .… This value can be used to assess the quality of the material. The higher its density, the more resistant it is to mechanical damage. And also the higher the density value, the longer the service life of the foam as insulation will last. A more compacted material has a higher cost than a less compacted counterpart. This is why the density value of the foam is important.

To determine the density of the material, it is sufficient to have a balance. It is not necessary to use ultra-precise or other similar ones, an ordinary kitchen scale will be enough .… Typically, Styrofoam comes in sheet form, and therefore you need to take one such sheet and weigh it. As you know, density is measured in kg per cubic meter. Further, the weight of the sheet is converted from grams to kilograms. After that, this value is divided by the value, which is the values of the width, height and thickness of the foam sheet multiplied by each other (it must be converted to cubic meter). The resulting value will be the density of this foam. Despite the apparent complexity, the value is very easy to calculate.

There are 4 types of grades that are assigned to foam based on density values. If the obtained value is less than 15 units, then this is 15 marks, if less than 25, then 25, if less than 35, then this is 35 marks and up to 50 is 50 marks.

If there are no scales nearby, but you still need to determine the density, then there is another way . Of course, it will not be possible to determine the exact value, since the method is purely visual. If the balls of the foam are large, and there is a space between them, then the density of the foam is not too high. Usually it is 15 marks. The finer the foam, the denser and therefore harder it is. And you can also look at the foam sheet at a certain angle to the light.

If its entire surface “glows” (there is the effect of having a large amount of sparkles on the surface), then the density is also low and, possibly, such a product has poor quality.

It is believed that the most acceptable foam for insulation will be a material with a density of 25 brands and above. That is, its density should be at least 20 kg per cubic meter.

Applications

It is often used for decoration - both internal and external . Most often, stone houses are insulated. Warming of the foundation is allowed. It can often be used as formwork. They do this to save money during the tying of the reinforcement. And also it is used to prevent heat loss in pipelines. The result is a reduction in heat loss by almost a quarter. Thus, the cost of heating the water is reduced. When installed on walls outside, the room does not overheat in the summer. Floors are well insulated with such a cheap and safe material.

Despite the versatility and a number of advantages of the material, dense foam cannot be used to insulate a bath. Styrene is released from the foam if it is heated too much. It is toxic.

It is actively used in interior design - as tiles, baseboards and other elements. Dense foam is especially convenient because it is easy to cut. And this, in turn, is important when fitting parts. Hard foam is used by artists for modeling. It is also used to make various models or bases for handicrafts and bouquets.

Fishermen often make floats from foam. And also the foam is suitable for fishing as bait. Scented styrofoam is often available for attachments. Craftsmen use solid foam to make various homemade products. For example, you can make fishing rod handles from a hard material. True, this requires material with a density of almost 80 kg / m3. It is almost impossible to get such dense foam. It looks like a tree, but very light. Cutting it with a knife is also practically impossible.

How to make the foam dense?

It is usually necessary to make the foam dense at home for the subsequent manufacture of interior details from the resulting material … Sealing or making solid foam with your own hands is a little troublesome, but nevertheless possible.

First of all, you need to purchase a suitable material - expanded polystyrene. It is usually sold in the form of granules and can be purchased at a budget price from suppliers. The pellets are placed in a mold and exposed to steam. It can be processed both with a steam mop and with washing installations with the corresponding function. The mold is made independently (from wood and other materials) or purchased (various metal molds).

The first stage includes the primary steaming of the pellets. To do this, the metal bucket is filled with one fifth of them. Processing should be done in a circular motion. After a while, the granules will enlarge and fill the bucket. It is in this form that they need to be transferred to molds. Further, the steam treatment should continue. After a while, the granules will stick together. The smaller the granules, the denser the foam will be.

Even before cooling, you need to press down the shape with something heavy. Ideally, pressure can be created with an iron mold with screw-in bolts.

If you already have foam, but you want to make it denser, then you need to disassemble it into granules and place it in a mold. Next, the mold is placed in hot water. It is best to use the aforementioned iron mold. It should stand in hot water for about 15 minutes. After that, it will take about 24 hours to cool. All this time, the foam must be under pressure.

You can also coat the foam with a primer to increase the hardness. This will not increase the density as such, but will make it harder and less susceptible to mechanical stress. Such primer formulations are sold in fishing or hunting shops and may be called, for example, varnishes, coatings. And also to give the foam external strength and hardness, you can impregnate it with paint. Usually fishermen do this so that the outside of the floats are less damaged, and the colors on them look brighter. Some of these coatings can corrode plastic. Quality coatings can be expensive and may not even be available on the market.

User reviews suggest that making foam solid at home is problematic, and the best option in this sense is to buy the material of the right brand.