{"id":9710,"date":"2021-04-14T21:37:05","date_gmt":"2021-04-15T00:37:05","guid":{"rendered":"https:\/\/www.amino.com.br\/?p=9710"},"modified":"2025-04-11T10:48:43","modified_gmt":"2025-04-11T13:48:43","slug":"how-to-manufacture-agglomerated-foam-blocks","status":"publish","type":"post","link":"https:\/\/www.amino.com.br\/en\/blog\/how-to-manufacture-agglomerated-foam-blocks\/","title":{"rendered":"How to Manufacture Bonded Foam Blocks"},"content":{"rendered":"\n<h2 class=\"wp-block-heading\"><strong>Bonded Foams: What Are They?<\/strong><\/h2>\n\n\n\n<p>First, let\u2019s revisit the concept of bonded foams. After the production of foam blocks through continuous or discontinuous processes, these blocks are sent for lamination, which inevitably generates a significant amount of leftover material\u2014commonly referred to as \u201cscraps.\u201d<\/p>\n\n\n\n<p>These foam scraps can be mixed with a polyurethane bonding material (a prepolymer that binds the foam flakes) to form new bonded foam blocks.<\/p>\n\n\n\n<p>Bonded foam blocks provide great firmness and high support capacity, making them suitable for various applications, such as mats and mattresses. Additionally, they play an environmentally friendly role by helping to reduce waste generated during the production of flexible foams.<\/p>\n\n\n\n<hr class=\"wp-block-separator has-alpha-channel-opacity\"\/>\n\n\n\n<h3 class=\"wp-block-heading\"><strong>Prepolymer Binder (Bonded Foam Adhesive)<\/strong><\/h3>\n\n\n\n<p>The foam binder used in the block production process is typically a single-component adhesive with fast drying properties. It is partially volatile or non-volatile and odorless (a product without smell).<\/p>\n\n\n\n<p>Speaking of odor, this is a critical factor when discussing foam binders. It is essential that the bonded foam adhesive is made from low-toxicity and odorless raw materials. This ensures better quality for the operator by preventing application issues and reduces costs for the company by minimizing hazards and health risks. Additionally, it is non-flammable, non-toxic, and free of harmful volatile compounds, making it safer for both the operator and the environment.<\/p>\n\n\n\n<h3 class=\"wp-block-heading\"><strong>Key Features and Differentiators of &#8220;Bonded Foam Adhesive&#8221;<\/strong><\/h3>\n\n\n\n<ul class=\"wp-block-list\">\n<li><strong>Increases block firmness<\/strong><\/li>\n\n\n\n<li><strong>Enhances tear resistance<\/strong><\/li>\n\n\n\n<li><strong>Versatility<\/strong>: Adheres to various substrates, such as fabrics, foams, rubbers, EVA, and more.<\/li>\n\n\n\n<li><strong>Fast curing speed<\/strong><\/li>\n\n\n\n<li><strong>Low viscosity<\/strong>: Facilitates easier spreading on substrates.<\/li>\n\n\n\n<li><strong>High yield<\/strong><\/li>\n\n\n\n<li><strong>Odorless<\/strong> (no smell)<\/li>\n\n\n\n<li><strong>MDI-based<\/strong><\/li>\n\n\n\n<li><strong>Sustainable<\/strong>: Promotes the reuse of foam scraps.<\/li>\n\n\n\n<li><strong>Compliant with IMETRO standards<\/strong><\/li>\n<\/ul>\n\n\n\n<p>The secret to an excellent bonded foam adhesive lies in achieving the lowest viscosity possible (thin liquid) while maintaining undiluted (100% solid) properties. This allows the adhesive to penetrate all the foam&#8217;s pores, enabling better adhesion in bonded foam applications.<\/p>\n\n\n\n<p>The rapid curing speed of the adhesive enhances productivity, allowing multiple mold releases in a single day.<\/p>\n\n\n\n<hr class=\"wp-block-separator has-alpha-channel-opacity\"\/>\n\n\n\n<h4 class=\"wp-block-heading\"><strong>Optimizing Production<\/strong><\/h4>\n\n\n\n<p>To efficiently produce a bonded foam block, it is important to follow these recommendations:<\/p>\n\n\n\n<h4 class=\"wp-block-heading\"><strong>Dosage<\/strong><\/h4>\n\n\n\n<p>Use <strong>10% to 20% of AMIPRE\u00ae<\/strong> (Amino&#8217;s bonded foam adhesive) relative to the total weight (kg) of the substrates.<\/p>\n\n\n\n<p>This dosage varies depending on the amount of non-foam substrates used, such as fabrics, EVA, rubber, paper, polyethylene films, etc.<\/p>\n\n\n\n<hr class=\"wp-block-separator has-alpha-channel-opacity\"\/>\n\n\n\n<h4 class=\"wp-block-heading\"><strong>Catalyst Used<\/strong><\/h4>\n\n\n\n<p><strong>Tin Octoate:<\/strong> It is recommended to use <strong>0.5% to 1.1%<\/strong> based on the total weight (kg) of AMIPRE\u00ae. It\u2019s important to note that the amount of catalyst is determined by the relationship between:<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li><strong>Production Speed<\/strong><\/li>\n\n\n\n<li><strong>Ambient Temperature<\/strong><\/li>\n<\/ul>\n\n\n\n<hr class=\"wp-block-separator has-alpha-channel-opacity\"\/>\n\n\n\n<h4 class=\"wp-block-heading\"><strong>Demolding<\/strong><\/h4>\n\n\n\n<p>When adhering to the correct usage conditions and procedures, bonded foam blocks can be removed from the mold within <strong>40 to 60 minutes<\/strong>.<\/p>\n\n\n\n<hr class=\"wp-block-separator has-alpha-channel-opacity\"\/>\n\n\n\n<h3 class=\"wp-block-heading\"><strong>Most Common Types of Mixtures<\/strong><\/h3>\n\n\n\n<figure class=\"wp-block-image size-full\"><img loading=\"lazy\" decoding=\"async\" width=\"494\" height=\"313\" src=\"https:\/\/www.amino.com.br\/wp-content\/uploads\/2024\/12\/image-32.png\" alt=\"\" class=\"wp-image-9711\" srcset=\"https:\/\/www.amino.com.br\/wp-content\/uploads\/2024\/12\/image-32.png 494w, https:\/\/www.amino.com.br\/wp-content\/uploads\/2024\/12\/image-32-300x190.png 300w\" sizes=\"auto, (max-width: 494px) 100vw, 494px\" \/><\/figure>\n\n\n\n<div class=\"wp-block-group is-vertical is-layout-flex wp-container-core-group-is-layout-8cf370e7 wp-block-group-is-layout-flex\">\n<div class=\"wp-block-columns is-layout-flex wp-container-core-columns-is-layout-9d6595d7 wp-block-columns-is-layout-flex\">\n<div class=\"wp-block-column is-layout-flow wp-block-column-is-layout-flow\" style=\"flex-basis:100%\">\n<ul class=\"wp-block-list\">\n<li>Integral Skin Foam<\/li>\n\n\n\n<li>100% L\u00e1tex<\/li>\n\n\n\n<li>Latex + Conventional Foam<\/li>\n\n\n\n<li>Fabric + Foam<\/li>\n\n\n\n<li>Foam 100% <\/li>\n\n\n\n<li>Foam + Bra Cup Padding<\/li>\n\n\n\n<li>Foam + EVA + Rubber<\/li>\n<\/ul>\n\n\n\n<figure class=\"wp-block-image size-full\"><img loading=\"lazy\" decoding=\"async\" width=\"514\" height=\"319\" src=\"https:\/\/www.amino.com.br\/wp-content\/uploads\/2024\/12\/image-33.png\" alt=\"\" class=\"wp-image-9714\" srcset=\"https:\/\/www.amino.com.br\/wp-content\/uploads\/2024\/12\/image-33.png 514w, https:\/\/www.amino.com.br\/wp-content\/uploads\/2024\/12\/image-33-300x186.png 300w\" sizes=\"auto, (max-width: 514px) 100vw, 514px\" \/><\/figure>\n<\/div>\n<\/div>\n<\/div>\n\n\n\n<p>The more substrate mixtures used, the more adhesive will be required for proper adhesion of the flakes.<\/p>\n\n\n\n<figure class=\"wp-block-image size-full\"><img loading=\"lazy\" decoding=\"async\" width=\"433\" height=\"96\" src=\"https:\/\/www.amino.com.br\/wp-content\/uploads\/2024\/12\/image-34.png\" alt=\"\" class=\"wp-image-9717\" srcset=\"https:\/\/www.amino.com.br\/wp-content\/uploads\/2024\/12\/image-34.png 433w, https:\/\/www.amino.com.br\/wp-content\/uploads\/2024\/12\/image-34-300x67.png 300w\" sizes=\"auto, (max-width: 433px) 100vw, 433px\" \/><\/figure>\n\n\n\n<h3 class=\"wp-block-heading\">Manufacturing Process<\/h3>\n\n\n\n<h4 class=\"wp-block-heading\"><strong>Mixing<\/strong><\/h4>\n\n\n\n<ol class=\"wp-block-list\">\n<li><strong>Weighing the Flakes:<\/strong> By weight or volume.<\/li>\n\n\n\n<li><strong>Weighing AMIPRE:<\/strong> 10% to 20%.<\/li>\n\n\n\n<li><strong>Weighing Tin Octoate:<\/strong> 0.5% to 1.1%.<\/li>\n\n\n\n<li><strong>Adding Tin Octoate to AMIPRE.<\/strong><\/li>\n\n\n\n<li><strong>Manual or mechanical mixing<\/strong> for 1 minute.<\/li>\n<\/ol>\n\n\n\n<hr class=\"wp-block-separator has-alpha-channel-opacity\"\/>\n\n\n\n<h4 class=\"wp-block-heading\"><strong>Process<\/strong><\/h4>\n\n\n\n<ol class=\"wp-block-list\">\n<li>After mixing AMIPRE\/Tin Octoate, pour it evenly over the flakes.<\/li>\n\n\n\n<li>The ideal mixing time for Flakes\/AMIPRE is 4 to 5 minutes.<\/li>\n\n\n\n<li>After mixing, place the flakes into the mold.<\/li>\n\n\n\n<li>Press the flakes according to the desired density.<\/li>\n\n\n\n<li>The ideal time between mixing and pressing is 15 to 18 minutes.<\/li>\n<\/ol>\n\n\n\n<hr class=\"wp-block-separator has-alpha-channel-opacity\"\/>\n\n\n\n<h4 class=\"wp-block-heading\"><strong>Demolding<\/strong><\/h4>\n\n\n\n<ul class=\"wp-block-list\">\n<li>Wait 40 to 60 minutes before demolding.<\/li>\n\n\n\n<li>Bonded foam lamination should be performed after 24 hours.<\/li>\n<\/ul>\n\n\n\n<hr class=\"wp-block-separator has-css-opacity is-style-wide\"\/>\n\n\n\n<p>Check Out the Article on Cylindrical Block Viscoelastic Production <a href=\"https:\/\/www.amino.com.br\/sistema-amino-producao-de-espuma-viscoelastica-em-cilindro\/\">[Click Here]<\/a><\/p>\n\n\n\n<h2 class=\"wp-block-heading\"><strong>Standards for Bonded Foam<\/strong><\/h2>\n\n\n\n<p>Bonded foams must comply with <strong>ABNT NBR 13579-1<\/strong>, adhering to the following requirements:<\/p>\n\n\n\n<figure class=\"wp-block-table\"><table><tbody><tr><td>Propriedades<\/td><td>D \u2265 30<\/td><\/tr><tr><td>Resili\u00eancia, % (min)<\/td><td>25<\/td><\/tr><tr><td>D.P.C. a 50%, % (m\u00e1x)<\/td><td>25<\/td><\/tr><tr><td>F.I.\u00b9 a 40%, N (m\u00edn)<\/td><td>250<\/td><\/tr><tr><td>Perda de F.I. a 40%, (50% deflex\u00e3o), % (m\u00e1x)<\/td><td>35<\/td><\/tr><tr><td>Perda de espessura, % (m\u00e1x)<\/td><td>10<\/td><\/tr><tr><td>\u00b9For\u00e7a de identa\u00e7\u00e3o a 40% sem pr\u00e9-deflex\u00e3o, conforme ABNT NBR 9176<\/td><td><\/td><\/tr><\/tbody><\/table><\/figure>\n\n\n\n<h2 class=\"wp-block-heading\"><strong>Necessary Machinery<\/strong><\/h2>\n\n\n\n<ul class=\"wp-block-list\">\n<li><strong>A flake agglomerator<\/strong><\/li>\n\n\n\n<li><strong>Two adjustable crates<\/strong> (typically 1.6 x 2.00 x 70 cm in height, depending on the process and the piece being produced)<\/li>\n\n\n\n<li><strong>Foam and fabric flocking machine<\/strong><\/li>\n\n\n\n<li><strong>Approximately 100 kg of flakes for one block<\/strong><\/li>\n\n\n\n<li><strong>Approximately 10% of Amipre 132\/1 adhesive<\/strong><\/li>\n<\/ul>\n\n\n\n<hr class=\"wp-block-separator has-alpha-channel-opacity\"\/>\n\n\n\n<h2 class=\"wp-block-heading\"><strong>Important to Remember<\/strong>&#8230;<\/h2>\n\n\n\n<ul class=\"wp-block-list\">\n<li>The more substrate mixtures used, the more adhesive will be required for proper adhesion.<\/li>\n<\/ul>\n\n\n\n<hr class=\"wp-block-separator has-alpha-channel-opacity\"\/>\n\n\n\n<h3 class=\"wp-block-heading\"><strong>Yield<\/strong><\/h3>\n\n\n\n<ul class=\"wp-block-list\">\n<li><strong>1 block every 40 minutes.<\/strong><\/li>\n<\/ul>\n\n\n\n<hr class=\"wp-block-separator has-alpha-channel-opacity\"\/>\n\n\n\n<h3 class=\"wp-block-heading\"><strong>See Also:<\/strong><\/h3>\n\n\n\n<p>[Video] Success Factors in Bonded Foams.<\/p>\n\n\n\n<figure class=\"wp-block-embed is-type-video is-provider-youtube wp-block-embed-youtube wp-embed-aspect-4-3 wp-has-aspect-ratio\"><div class=\"wp-block-embed__wrapper\">\n<iframe loading=\"lazy\" title=\"[Aglomerado de Espumas] Fatores de Sucesso - Qualidade, Produtividade e Lucro\" width=\"640\" height=\"480\" src=\"https:\/\/www.youtube.com\/embed\/sPTMUoQdBa4?feature=oembed\" frameborder=\"0\" allow=\"accelerometer; autoplay; clipboard-write; encrypted-media; gyroscope; picture-in-picture; web-share\" referrerpolicy=\"strict-origin-when-cross-origin\" allowfullscreen><\/iframe>\n<\/div><\/figure>\n\n\n\n<p><\/p>\n\n\n\n<h2 class=\"wp-block-heading\"><strong>Technology for Flexible Foams<\/strong><\/h2>\n\n\n\n<p>Amino provides the most comprehensive range of solutions for Flexible Polyurethane Foams.<\/p>\n\n\n\n<p>Our portfolio includes <strong>silicones, amines, pigments, additives, binders<\/strong>, and <strong>ready-to-use systems<\/strong>, ensuring consistency and quality when it comes to polyurethane. Additionally, our technical team consists of top polyurethane experts to assist and guide our clients toward the best solutions, combining high-quality raw materials with maximum efficiency in production processes.<\/p>\n\n\n\n<hr class=\"wp-block-separator has-alpha-channel-opacity\"\/>\n\n\n\n<h3 class=\"wp-block-heading\">Explore Amino\u2019s Solutions for Flexible Foams<\/h3>\n\n\n\n<h4 class=\"wp-block-heading\"><strong>Performance Additives<\/strong><\/h4>\n\n\n\n<ul class=\"wp-block-list\">\n<li><strong>Surfactant Silicones<\/strong><\/li>\n\n\n\n<li><strong>Amine Catalysts for Expansion and Gelling<\/strong><\/li>\n\n\n\n<li><strong>Delayed Catalysts<\/strong><\/li>\n\n\n\n<li><strong>Low VOC Catalysts<\/strong><\/li>\n\n\n\n<li><strong>Tin Octoate<\/strong><\/li>\n\n\n\n<li><strong>Liquid and Paste Pigments<\/strong><\/li>\n\n\n\n<li><strong>Adhesion Promoter Additives (Flame Bonding)<\/strong><\/li>\n\n\n\n<li><strong>Cell Opener Additives<\/strong><\/li>\n\n\n\n<li><strong>Additives for Elongation and Tear Resistance<\/strong><\/li>\n\n\n\n<li><strong>Hardness Additives<\/strong><\/li>\n\n\n\n<li><strong>Anti-Scorching Additives<\/strong><\/li>\n\n\n\n<li><strong>Halogenated and Non-Halogenated Flame Retardants<\/strong><\/li>\n<\/ul>\n\n\n\n<hr class=\"wp-block-separator has-alpha-channel-opacity\"\/>\n\n\n\n<h4 class=\"wp-block-heading\"><strong>Ready-to-Use Flexible Systems<\/strong><\/h4>\n\n\n\n<ul class=\"wp-block-list\">\n<li><strong>Viscoelastic for All-MDI Block Process<\/strong><\/li>\n\n\n\n<li><strong>Viscoelastic for TDI-Based Block Process<\/strong><\/li>\n\n\n\n<li><strong>Viscoelastic for MDI-Based Molded Process<\/strong><\/li>\n\n\n\n<li><strong>Hyper-Soft System for TDI-Based Block Process<\/strong><\/li>\n\n\n\n<li><strong>Hyper-Soft System for MDI-Based Molded Process<\/strong><\/li>\n\n\n\n<li><strong>HR Flexible System for MDI-Based Block Process<\/strong><\/li>\n\n\n\n<li><strong>HR Flexible System for TDI-Based Block Process<\/strong><\/li>\n\n\n\n<li><strong>HR Flexible System Molded, MDI- and TDI-Based<\/strong><\/li>\n<\/ul>\n\n\n\n<hr class=\"wp-block-separator has-alpha-channel-opacity\"\/>\n\n\n\n<h4 class=\"wp-block-heading\"><strong>Complementary Products for Flexible Foams<\/strong><\/h4>\n\n\n\n<ul class=\"wp-block-list\">\n<li><strong>Bonded Foam Adhesive<\/strong><\/li>\n\n\n\n<li><strong>Adhesive for Foam-to-Fiber Bonding (Sponge)<\/strong><\/li>\n\n\n\n<li><strong>Gel Layers<\/strong><\/li>\n<\/ul>\n\n\n\n<hr class=\"wp-block-separator has-alpha-channel-opacity\"\/>\n\n\n\n<h3 class=\"wp-block-heading\">Contact Us<\/h3>\n\n\n\n<p>To learn more about <strong>Amino Technology<\/strong>, call us at <strong>+55 11 4077-3777<\/strong> or email us at <strong><a>vendas@amino.com.br<\/a><\/strong>.<\/p>\n\n\n\n<hr class=\"wp-block-separator has-alpha-channel-opacity\"\/>\n\n\n\n<h2 class=\"wp-block-heading\">About Amino<\/h2>\n\n\n\n<figure class=\"wp-block-embed is-type-video is-provider-youtube wp-block-embed-youtube wp-embed-aspect-16-9 wp-has-aspect-ratio\"><div class=\"wp-block-embed__wrapper\">\n<iframe loading=\"lazy\" title=\"AMINO\" width=\"640\" height=\"360\" src=\"https:\/\/www.youtube.com\/embed\/QISg1h4DKsA?feature=oembed\" frameborder=\"0\" allow=\"accelerometer; autoplay; clipboard-write; encrypted-media; gyroscope; picture-in-picture; web-share\" referrerpolicy=\"strict-origin-when-cross-origin\" allowfullscreen><\/iframe>\n<\/div><\/figure>\n\n\n\n<p>Flexible PU foams play a fundamental role in various industries, and choosing the right system and additives is crucial to achieving the desired performance. If you want to learn more about how to optimize your production processes and explore Amino\u2019s complete line of additives and solutions, contact us. We are ready to help you find the best solutions for your production needs!<\/p>\n","protected":false},"excerpt":{"rendered":"<p>Learn how Amino turns foam scraps into high-performance rebonded blocks using sustainable adhesive and an optimized production process<\/p>\n","protected":false},"author":4,"featured_media":8747,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":false,"footnotes":""},"categories":[1],"tags":[],"class_list":["post-9710","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-nao-categorizado"],"acf":[],"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v27.3 - https:\/\/yoast.com\/product\/yoast-seo-wordpress\/ -->\n<title>How to Manufacture Bonded Foam Blocks - Amino<\/title>\n<meta name=\"description\" content=\"Learn how Amino turns foam scraps into high-performance rebonded blocks using sustainable adhesive and an optimized production process\" \/>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<link rel=\"canonical\" href=\"https:\/\/www.amino.com.br\/en\/blog\/how-to-manufacture-agglomerated-foam-blocks\/\" \/>\n<meta property=\"og:locale\" content=\"en_US\" \/>\n<meta property=\"og:type\" content=\"article\" \/>\n<meta property=\"og:title\" content=\"How to Manufacture Bonded Foam Blocks - 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