Foam fabric may provide significant improvements to product quality

Foam fabric may provide significant improvements to product quality, production costs and customer responses. As one solution that offers distinct advantages over synthetic fabrics.

Foam cushions often feature Dacron wrap for additional plumpness and to prevent stretching of their foam core. Dacron fiber also prevents stretching.

Comfort

Foam provides immediate comfort. Durable and flexible, its durability lies in polyfoam production from petrochemicals which allows it to compress easily - often layering it with denser foams for initial softness before firmer support is added later. Latex can be manufactured either naturally from rubber trees or synthetically using compounds derived from petroleum and is widely used for comfort layers, transitional layers, and cores. Wool, cotton, silk, hemp and coconut coir fibers are natural fibers prized for their durability and breathability, being eco-friendly materials as well as sustainable. When coupled with foams and fabrics for cushioning purposes they may benefit from Ultra-Fresh's antimicrobial agent to control dust mites and odor.

Durability

As a textile business owner, you have many decisions that will affect the quality of your products, production costs, customer response and responses from new and existing customers. Selecting foam fabric as part of your fabric selection strategy is an integral decision; offering durability while having less environmental impact.

Fabric designed with this technology retains its shape for longer, helping extend the lifespan of your products. Furthermore, this odorless fabric is treated with Ultra-Fresh antimicrobial agents to stop bacteria growth - and this means a 4" piece of medium density foam will feel firmer than two 2" pieces due to having more foam inside it.

Breathability

Breathability refers to a fabric's ability to allow moisture vapor through its structure. Air permeable fabrics have micropores too small for liquid water molecules to pass through; but water vapor molecules pass easily through these pores, keeping your body at an ideal temperature without overheating or chilling your system.

Polymers such as thermoset and thermoplastic polyurethanes, acrylics and polyvinyl chlorides were previously employed to coat waterproof garments; however, these coatings do not allow sufficient evaporation of perspiration from users, leading to discomfort and chilling effects.

The present invention addresses this challenge through a multilayered coating process, starting with a mechanically formed cellular foam adhesive layer mechanically formed from fully reacted and water based prepolymers, then followed by coating of microporous membrane followed by continuous film coating over it, to create a waterproof fabric with desirable breathability and feel.

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