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Welcome to Ifoam Ltd
Specialist foam solutions for multiple applications
iFoam is a UK-based manufacturer of specialist intumescent and PU foam solutions for the transport and insulation industries.
Based in the Midlands, our core business is the production of melamine foam (Crib 5) and graphite foam (Crib 7), predominantly for seating in a range of markets. Our customers range from the large automotive Tier 1 suppliers through to small independent producers. The majority of our customers are from the rail, automotive, aviation, bus & coach, military, furniture and insulation markets but we are also keen to build new partnerships with customers in other sectors.
We can work with the customer’s specification, whether that is producing moulded foam using their tooling or developing products from scratch. Our flexible way of working means we can manage large projects with high volumes through to small and ‘one-off’ orders. Our projects span from the production of single parts for a specialist developer through to the production of large volume (5,000+) seat places for high profile companies.
Our processes enable us to develop moulded products to fit many different (and unusual) requirements. We are building on the work we are doing with moulded foam blocks and sheets cut to customers’ requirements as well as moulded in place inserts of wood, plastic, wires, Velcro and fabric.
Whilst we do not manufacture our own tooling, we enjoy an excellent working relationship with toolmakers which specialise in tooling for our processes. Customers are also welcome to supply their own tooling. Day-to-day maintenance of our customers’ tools is done in-house and tools are stored securely within our unit.
iFoam’s workforce is made up of experienced and skilled craftsmen, most of whom have many years’ experience within the transport seating sector and the production of polyurethane foam in particular. We are supported by BASF, one of the largest chemical producers in the world, for our raw materials.
We enjoy a high level of repeat orders and nearly all our business comes from recommendation or referral.
Applications
ifoam have provided foam solutions for a wide variety of applications. We currently operate in a range of markets including transport, aviation and furniture.
Automotive
iFoam manufacture melamine foam for automotive seating and interior trim. Our customers range from the large automotive Tier 1 suppliers through to smaller independent producers.
We work with the customer’s specification, whether that is producing moulded foam using their tooling or developing products from scratch. Our processes enable us to develop moulded products to fit many different requirements.
Aviation
iFoam is a producer of graphite foam for the aviation industry. Products are manufactured from moulded tools or are fabricated from block foam.
We use graphite foam for our aviation customers who require Crib 7 fire safety levels for their products. It is highly flame retardant in comparison with other solutions and will not catch alight even if exposed to a naked flame. Our foam meets both the FAA vertical burns test and the Kerosene test.
Bus and Coach
iFoam is a manufacturer of melamine foam for the bus and coach market. We produce cushions, backrests and headrests for a variety of styles of seat, many with moulded in armatures.
We can work to the customer’s specification, whether that is producing moulded foam using their tooling or developing products from scratch.
Furniture
iFoam manufacture foam for domestic and contract furniture.
Domestic furniture tends to be in melamine (Crib 5) foam whereas contract furniture such as that used by the prison service is usually graphite (Crib 7) foam.
We can accommodate the moulding of one off components through to large contract quantities with component weights from less than 100 grams to over 6Kg.
Insulation
iFoam fabricate insulation panels from block foam and woven fabric. Foam is cut into sheets on a computer controlled band saw and laminated together to form a panel that can be bonded directly onto the internal face of an external wall, the hull of a boat or perhaps a caravan wall.
The advantages besides the obvious heat retention are flexibility, it can be applied to curved surfaces, energy saving and noise insulation with minimum disruption.
Rail
iFoam is a manufacturer of graphite foam for the rail industry. We mould foam for a variety of international customers and our product is used on rail seating throughout Europe.
Depending on the method of construction and materials used, compliance with Category 2*, Category 1b or even Category 1a may be obtained using our graphite foam.
Our Technology
Graphite (Crib 7) Foam
This high quality foam is usually used for our aircraft and rail customers that require the Crib 7 fire safety levels for their products. It is highly flame retardant in comparison with other solutions and will not catch alight even if exposed to a naked flame. This degree of fire retardance makes it a very attractive product solution for suppliers to industries that have to meet tough fire safety standards such as in the passenger transport markets.
Graphite foam is fairly heavy at 80 to 85Kg/m³. It is grey in colour and the hardness can be formulated from 120 to over 1300 Newtons.
Melamine (Crib 5) Foam
This type of foam is commonly found in domestic transport seating and is a lower cost option to the graphite foam. This foam has a density of 50-55 Kg/m³ but can be formulated down to as low as 40 Kg/m³. It is creamy white in colour and the hardness can be formulated from 120 to over 600 Newtons.
We run low pressure machinery for graphite foam and high pressure for melamine. Our machines service 6 metre carousels which can accommodate up to 16 tools.
Our fully equipped laboratory is able to measure hardness and density of components and carry out macroscopic examination of cell structure. We are also able to carry out durability testing of products to guarantee their conformance to our customers’ specifications.
Testing and Certification
Our foam has been extensively tested for suitability in all our markets. Testing is generally carried out by our customers on their assembled components but we carry out indicative tests on our materials to assist our customers to achieve their required specifications.
Our foam products have passed the following tests:
- BS476 Part 7 – Surface Spread of flame
- BS5852 Ignition source crib 7
- BS6853 Annex B.2 – Toxic fume
- BS853 D8.5 – Smoke density (3 metre cube test)
- ISO 5660 Cone Calorimeter
- CS-25.853 App F Part 1a 1(ii) – Vertical burns test for aircraft.
- BS EN ISO 3385 – Constant load pounding test – 240,000 cycles (extremely severe)
- EN 45545 HL3 – Fire Risk Evaluation
FAQs
Why choose iFoam?
It’s nothing to do with the Apple corporation! The “i” stands for the intumescent quality of our original product – suspended graphite foam.
Intumescent means it swells when exposed to heat; in this case, the swelling will be 2 -300 times its original volume once the temperature reaches approximately 230 degrees Celsius. This swelling results in a char of burnt material which hinders further combustion giving excellent FST (Fire, Smoke & Toxicity) properties.
Today, we don’t just produce graphite foam which is classed as Crib 7 foam, we also produce Crib 5 (melamine) for the transport, automotive and furniture industries.
Is it the same as the blocks of foam I can buy?
It is similar, but not exactly the same. Block foam, as the name suggests, is made in large blocks perhaps 2 metres x 1.5 metres x 30 metres or even larger. These are then cut into smaller blocks that are then sold to “convertors” to make into the shapes their customers want.
Our foam is moulded foam. A simple analogy is baking a sponge cake. You pour a mix of ingredients into a shaped tin and, after baking, the cake comes out – hopefully light and fluffy and in the same shape as the tin. This is very similar to how we make our moulded foams.
The primary differences between block and moulded foam is that the density of the moulded foam may be higher than that of block foam. This is especially so with graphite foam; complex shapes can be moulded, these moulded parts have a “skin” of thicker material on the surface (not to be confused with skinned PU components!) and there is no waste from the moulding process.
Why is graphite (Crib 7) foam more expensive than melamine (Crib 5) foam?
This is partly because you are getting more foam for your money. A piece of moulded foam measuring 500mm X 500mm X 100mm will weigh approximately 2.25 Kg whereas our Crib 5 foam will weigh approximately 1.375 Kg.
Also, the graphite foam is much more difficult to process, has a chemical formulation peculiar just to it and has a much lower demand.
What is Crib 5 and Crib 7?
BS 5852 details various fire tests for furniture starting with a lit cigarette and going up to a Crib 7 test which is the most severe. The Cribs are actually small wooden, open sided, boxes that house material that has been soaked in flammable liquids. The higher the crib number, the more severe the test.
One of these cribs is placed on a complete seat and set fire to. It must behave in a certain way to meet the requirements of the standard BS5852. In effect, it must self extinguish within a certain time period and must stop generating smoke within a certain time.
Is the foam hard or soft?
We can produce the foam to meet the hardness of the customer’s specification. We can vary the hardness of foam simply by adjusting the chemistry or amount of foam we put in the tool. Generally with block foam you will get what you are offered unless you are ordering very large volumes.
As a guide, specifying a 200 Newton foam will give a very soft and squidgy foam whereas a 1000 Newton foam will have very little give in it when, say , sitting on it.
The thickness of the foam has a significant bearing on the perceived hardness of the product. Please speak to us about the degree of hardness required for your application, it will cost you nothing the have the conversation and may save you a lot of trouble later on!
If your question is not answered here, please give us a call or send us an email as we have technical staff on site who will be able to give you objective advice and guidance on your own product specification.
Please contact us for advice on your next project
01536 260480
info@ifoamltd.com
iFoam Ltd
Unit A Tyson Courtyard
Weldon South Industrial Estate
Corby
Northamptonshire
NN18 8AZ