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Questions in Regard to COVID-19 Pandemic

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Questions in regard to COVID-19 Pandemic

General Questions

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Q: What do your product codes mean?

A: An example of our full product code is:  XP-40-X-4-CH

XP-40-X-4-CH
The first two letters signify the type of material. The following are our current materials:
XP = Crosslinked Polyethylene (XLPE)
EV = Ethyl Vinyl Acetate (EVA)
SC = Static Control
XI = Irradiated Crosslinked Polyethylene Roll
XE = Chemically Crosslinked Polyethylene Roll
EPP = Expanded Polypropylene
EPE = Expanded Polyethylene

XP-40-X-4-CH
The number in the middle signifies the density of the foam. If this is followed by a R, it indicates that the material is the single stage.
20 = 2lb, 30 = 3lb, 40 = 4lb, etc..

XP-40-X-4-CH
The letter code represents the billing size

Size Code X M W T
Billing Size 48″ x 96″ 39″ X 79″ 60″ x 96″ 42″ x 89″

XP-40-X-4-CH
The number after represents the thickness in inches, if this is followed by a B, it indicates that the material has skins.

XP-40-X-4-CH
The letters at the end signify the color of the foam.

Code CH GY WH MG LV BU
Color Charcoal Grey White Mint Green Lavender Blue
Code YL RD LG NA BK
Color Yellow Red Lime Green Natural Black

XP-40-X-4-CH = Crosslinked Polyethylene, 4lb density, 4 x 48 x 96, Charcoal
For more information on color and size, please check out our XLPE sizing & color chart.

Q: What is a Class "A" surface

A: Class “A” surface is defined as packaging and materials utilized in the production, handling, and delivery of automobile parts (most often) must not in any way, affect the quality of the product. The parts must remain in the same condition as they were when originally produced. Despite the wide variety of materials that packaging engineers consider for class A protection, there is no universal standard that would independently establish this protection.

Q: Are Worldwide Foam's Materials Class A Compatible?

Crosslinked polyethylene (XLPE) has long been considered the gold standard in providing Class A surface protection. XLPE is used to make durable, long-lasting expendable and returnable packaging for those parts designated as Class A. In short, XLPE has low abrasive properties and Worldwide Foam’s XLPE is Class A compatible. 

Q: Do you manufacture your own foam?

A: Worldwide Foam manufacturers our XP/EV product line overseas using our own presses and molds. We also work with a variety of top foam manufacturers across the world to provide a wide range of products and SKUs.

Q: How many locations do you have?

A: 7 locations across North America. Company Locations

Q: Do you fabricate and convert foam outside of skiving?

A: WF does offer a variety of services to offer press-ready goods such as foam looping, PSA application, heat-lamination, and slitting. Contact us today for more information on our capabilities.

Q: What new products are you developing?

A: We are constantly expanding our product line with new materials. Please contact us at sample@worldwidefoam.com if you would like a free sample kit with all of our products.

Buying Questions

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Q: What is your lead time?

A: Standard stock and skived sheets will generally ship out with a 1 day lead time. PSA, Heat-Lamination, and Looping tend to have a 1-2 week lead time for stock items.

Q: Who pays the freight?

A: Shipments are considered FOB our warehouse. We do cover the freight on qualifying full truckload orders over $35,000USD.

Q: How much can you fit on a truckload (T/L)?

A: 53’ trailers can hold around 36,000 bdft depending on the material type.

Q: How to place an order?

A: We process all orders through the corporate headquarters in Elkhart, IN. Send your orders to info@worldwidefoam.com for fastest service. Orders will be shipped from the most geographically correct location.

Q: What are acceptable forms of payment? What is your minimum order?

A: We accept checks, wire transfers, ACH payment, and online credit card payment. We do offer credit for those approved.

Standard stock and skived items will not have a minimum order, but there is a $50 processing fee on orders less than $500. Looped rolls and non-stock items will vary depending on material type. Contact us today for more information.

Q: Do you offer discounts on each order based on quantity?

A: No, we do not. We do have different competitive pricing levels based on total annual volume. We also have annual contracts that provide you with a fixed price for the entire year. For more information, please contact our customer service..

Q: What if you do not have the foam in a density or color I am looking for? Can I put in custom order?

A: If certain quantities are met we can do a custom foam run.

Buns:

-100 bun minimum of 4″ x 48″ x 96″ or equivalent
– At least 8-10 week lead time
– At least 10% price increase

Rolls:

-25 rolls or more for 2lb, 18 rolls or more for 4lb, and 15 rolls or more for 6lb and up (Or equivalent board feet)
-5% price increase on special size. Roll width ranging from 39″ to 60″
-10% price increase on special colors
-At least 8-10 week lead time

Please contact us for more details.

Q: What densities and sizes are available?

A: Please refer to our color and sizing chart, or contact us for more details.

Q: Does your material come with skins?

A: Generally no, although some materials are available with skins upon request.

Q: What are the common fabrication methods?

A: Most tools that can be used to fabricate wood can also be used to cut our foam. These include table saws, band-saws, table routing, water-jet, etc..

Q: What is your return policy?

A: A 20% restocking fee, FOB your facility. This fee is sometimes waived for contract customers.

Q: Do you have any conductive or anti-static materials?

A: We stock 3lb & 6lb static control XLPE with a surface resistivity measured from 105 to 109 ohm. For more information about the static control materials, please refer to the Static control foam whitepaper.

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Typical Properties Questions

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Q: What is the thermal resistance of the foam (R value)?

A: The foams were tested in accordance with ASTM C518-10. The R value for 2lb XLPE is around 4. Higher density foam has a lower R value. Our 15lb XLPE tested just under 2 in R value. Generally, the higher the R value, the better the insulation.

Q: What is the working temperature of the foam?

A: Maximum continuous operating temperature of our XLPE foam is between -40°F to 225°F (-40°C to 107°C)

Q: What is the shelf life of the foam?

A: XLPE foam does not have a shelf life.

Q: Does the foam float?

A: Yes, it does; Due to the closed cell structure, XLPE is a water-resistant foam.  Click here for foam buoyancy calculation.

Q: Do you have cleanroom foam?

A: A clean room is a controlled space in which airborne contaminants are carefully kept within strict limits. These rooms are often used in manufacturing to prevent contamination. Our foam is biologically inert or dormant and is commonly used in many applications where a clean room is required.

Q: Do you have fire retardant foam?

A: Currently, we carry XP-18UL in charcoal color. It is compliant with UL 94 testing standard. In addition, most of our foam passes the FMVSS-302 motor vehicle specification. This standard measures the horizontal burn rate of materials that will be used in the occupant compartments of motor vehicles. A horizontal burn rate of fewer than four inches per minute qualifies as a pass.

Q: Does your foam work with adhesives?

A: Our foam does work well with adhesives. However, your adhesive supplier would be the best person to speak with regarding any specific questions. We carry 4 types of pressure sensitive adhesive as an add-on service. Contact us for more info. PSA Selection Guide PDF.

Q: What are the differences between EVA and XLPE?

A: EVA stands for ethylene vinyl acetate. WF’s XLPE and EVA foam products are similar materials and are difficult to distinguish. The primary differences are that EVA is softer, more resilient, and has stronger recovery after compression. Whereas polyethylene foams are firmer and more resistant to heat. Both of them provide excellent protection and shock absorption for packaging applications. EVA is a copolymer of ethylene and contains wide range percentage of VA. The VA additive enhances the typical properties such as tensile, tear, elongation, and compression set while providing greater resilience and a smooth soft feel.

Q: What is the thickness tolerance?

A: Less than 0.3125″ +/- 0.03125″ (1/32″)
From 0.32″ – .875″ = +/- 10% of thickness
From .88 to 2″ tolerances = +/- .094″ (3/32″)
Greater than 2″ tolerances = +/- .125″ (1/8″)
2″ single-stage foams, designated by the R = 1.875″ Min, 2.00″ Max
3″ and 4″ single-stage foams, designated by the R = +/- .125″ (1/8″)
(Single stage foam skived sheets fall under our standard tolerances)

Q: What is the difference between open- and closed-cell foams?

A: Cellular foams are composed of millions of small cavities or cells. These cells may be interconnecting (open-cell) or non-connecting (closed-cell). Most of the cells or bubbles in closed-cell foams are not broken; they resemble inflated balloons compressed together in a compact configuration. Open-cell foams are connected to each other with an opening so that water, air, or gas can pass through them, similar to the way water is absorbed by a sponge. The cell walls, or surfaces of the bubbles, are broken and air fills all of the spaces in the material.

Q: What is the difference between one-stage and two-stage foams?

A: One-stage production uses only one set of molds and is considerably faster. Two-stage, as the name implies uses two sets of molds to manufacture the finished product. Within the same density range, two-stage foams typically come out with a smoother surface, less pinholes, and slightly better physical characteristics. One-stage tends to be heavier for a given hardness and have a coarser surface. Click here for One Stage v.s. Two Stage white paper.

Q: Is your foam antimicrobial/ safe for food packaging/UV resistant, and/or how will it react to diesel fuel/transmission fluid/ chlorine etc?

A: XLPE is naturally UV resistant, dormant to bacteria, and non-toxic. We regularly test our foam for characteristics outlined in our typical property sheets. If you need to meet a certain standard or would like to do testing on your own we will gladly supply a sample of the desired foam. If certain volume requirements are met we may be able to test for a certain standard you are looking for. If you wish to have any additives added to the foam, this will count as a special order and special rates and requirements will need to be met.

Q: Is XLPE foam recyclable?

A: Due to the crosslinking cell structure, XLPE foam is difficult to be recycled. However, after years of study and development, there are a few companies that have successfully developed ways to recycle XLPE scraps and reuse the materials for other applications.  This allows producers and converters of XLPE foam to save their scraps from the landfill. It provides thousands of dollars in savings for their supplier partners by eliminating disposal fees. Good for the planet, good for your bottom line. For more XLPE recycle information, please check out our Resources Web Page

Q: What does "Shore" mean?

Durometer is one of several measures of the hardness of a foam or material. The durometer scale was defined by Albert F. Shore, who developed the measurement device called a durometer. The common test standard is ASTM D2240 (00) for a total of 12 scales, depending on the intended use; types A, B, C, D, DO, E, M, O, OO, OOO, OOO-S, and R. Each scale results in a value between 0 and 100, with higher values indicating a harder material. With foams, the most common type of shore scale used is OO.

Q: What is Compression Deflection (CFD)?

The amount of force required to compress a rubber cellular specimen by a given % over the entire top area of the specimen. (i.e. the force required to compress a ½” thick specimen 25% of its original thickness. It can be expressed in lb/in2 (pounds per square inch) or kPa (kilopascal).

Q: SCE – 41; Types 1 and 2; Classes A, B, C, and D; Grades 0, 1, 2, 3, 4, 5 – what does all this actually mean?

The test standard ASTM D1056 covers flexible cellular products, both open and closed cell. Designated numbers have changed over the years, but the basics remain the same…

SCE is now ‘2C’
SCE-41 is now 2C1
SCE-42 is now 2C2

The first number defines cell structure: 1 (Type 1) = open cell 2 (Type 2) = closed cell

The letter defines oil resistance:
A = no oil resistance required;
B = oil resistance with low mass change;
C = oil resistance with medium mass change;
D = requires extreme temperature resistance (-75 to 175°C or -103 to 347°F) but not oil resistance.

The last number defines compression deflection which ranges from 0 to 5.
Grade 0: For Types 1 and 2 cellular rubber, a compression-deflection range from 0 to 16 kPa 0 to 2 psi.
Grade 1: For Types 1 and 2 cellular rubber, a compression-deflection range from 15 to 35 kPa 2 to 5 psi.
Grade 2: For Types 1 and 2 cellular rubber, a compression-deflection range from 35 to 65 kPa 5 to 9 psi.
Grade 3: For Types 1 and 2 cellular rubber, a compression-deflection range from 65 to 90 kPa 9 to 13 psi.
Grade 4: For Types 1 and 2 cellular rubber, a compression-deflection range from 90 to 120 kPa 13 to 17 psi.
Grade 5: For Types 1 and 2 cellular rubber, a compression-deflection range from 120 to 170 kPa 17 to 25 psi)

Q: What is Cell Count?

The number of cells per linear inch or centimeter, expressed as pore per inch or pores per centimeter.

Q: Define Cell Size?

The average diameter of the cells in the final foam product, often measured in micron units.

Q: What does Compression Set Mean?

A permanent partial loss of initial height of a foam sample due to a bending or collapse of the cell structure. Large percentages of compression set will cause a foam to quickly lose its original appearance, leaving its surface depressed or “hollowed out”.

Q: Define Foam Density?

A measurement of the mass per unit volume. It is measured and expressed in pounds per cubic foot (pcf) or kilograms per cubic meter (kg/m3).

Q: What is Indentation Force Deflection (IFD)?

A measure of the lead bearing capacity of foam. IFD is generally measured as the force (in pounds) required to compress a 50 square inch circular foot into a 4 inch thick sample, typically 15 inches square or larger, to a stated percentage of the sample’s initial height. Common IFD values are generated at 25 and 65 percent of initial height. (Note: previously called “ILD – Indentation Load Deflection).

Q: Define Clickable & Non-Clickable Foam?

Non-Clickable will maintain a pinched edge when die cut, Clickable will pop back-up without pinching. These characteristics apply to Polyester Urethane foams.

Q: Do all foams have a skin layer?

The outer layers of the master buns and rolls typically have a skin like surface. Depending on the thickness you require, some layers may be without skin or will be skin one-side only once the skiving process begins to peel down the master material. J&T can offer skin one-side of a foam but the remaining material from the master must also be accounted for. The fail-safe way to have skin on both sides of a foam is to purchase a product extruded to thickness. Speak to J&T for details as most foams cannot meet this requirement.

Q: What colors can foam come in?

The most common foam colours are white, grey and black. Some foams can be produced to a specific colour match, but the minimum order volumes for this type of request are significantly higher for most foams. J&T can laminate other materials such as a textile and film to the top of your foam if a colour is needed.

Q: What does the term 'Wet-Out' mean when referring to an adhesive?

Wet-out means the level of physical contact between an adhesive and substrate. A visual wet-out can be controlled when the adhesive is applied by machine or hand and is application controlled. A microscopic wet-out is related to temperature and length of time and is predicated on the chemistry of the adhesive and substrate.

Q: What does 'surface energy' mean?

The tendency of a surface to repel, rather than attract, an adhesive. A low surface energy is a hard-to-stick-to surface, which reduces the force of attraction between two substrates. A high surface energy provides an easier-to-stick-to surface, increasing the force of attraction between substrates. A high surface energy substrate allows the adhesive to wet-out, which helps obtain a stronger bond. A low surface energy substrate requires a specially designed adhesive or a primer / promoter to alter the substrates surface energy.

What percentage of Vinyl Acetate (VA) is in your Ethylene-Vinyl Acetate (EVA)?

20%