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NEW COMFORT LEVELS, CAL 117 APPROVAL FOR EZ-Dri® OUTDOOR CUSHIONING FOAM

Flame retardant additives permit compliance with California Bulletin 117 standards

New versions of its EZ-Dri reticulated polyurethane foam outdoor cushioning materials have been introduced by Crest Foam Industries Incorporated, Moonachie, NJ. In addition to new comfort grades  from very-plush to ultra-firm  the foam is now available to meet California Bulletin 117 standards for fire retardancy. CAL 117 approval permits use of these materials for indoor applications that have heretofore been prohibited. The states standards are the most stringent for any in the U.S. with regard to use of outdoor foam materials indoors  even in screened-in areas.

Prior to incorporating new additives to permit compliance with CAL 117 standards, chemicals used to impart various degrees of fire retardancy in foam materials typically contained significant amounts of halogens. Even with high halogen content, however, these foams did not meet CAL 117 standards. Under actual fire conditions these foams release deadly halogenated acids such as hydrochloric and hydrobromic acid.

Some European countries prohibited use of halogenated additives in foam because of their propensity to create noxious gases when burning, thus increasing danger to people nearby. To eliminate this problem new, non-halogenated fire retardants were developed in Europe. Without halogens, toxic halogenated acids cannot be generated by these materials when burning.

All burning polyurethane foams generate dangerous carbon monoxide. However, CAL 117 EZ-Dri does not create additional noxious gases associated with foam materials that have been coated or impregnated with halogenated fire retardant chemicals. As a result this foam is less toxic than comparable foam materials which contain halogenated fire retardants.

There are many reasons why foam cushions for outdoor casual furniture would be brought indoors other than the obvious advantages of their comfort and convenience; these include severe weather, high winds, or even protection of the fabric in hot, sunny conditions to prevent fading when not in use.

The ability to develop outdoor cushioning foam that meets CAL 117 was a long and arduous process, according to a company spokesman. One of the design problems concerned the fact that the material required an open pore size so that water would flow through it to permit cushions to drain quickly for virtually immediate use. At the same time because of its open pore construction (reticulation) there is a significant opportunity for high oxygen content to feed a fire. Conventional fire retardants did not solve the problem; Crest scientists developed a non-halogenated fire retardant that, not only incorporated well, but also substantially retarded foam fire, the spokesman concluded.

EZ-Dri polyether-polyurethane reticulated foam outdoor cushioning materials are constructed with large, open pores for maximum water drainage and air circulation, permitting their use quickly after being saturated or dampened. This material provides long lasting wear and comfort combined with extremely fast drying properties, thus making EZ-Dri cushions ideal for outdoor casual furniture applications in homes, hotels/resorts, and many other commercial facilities. New fire retardant additives incorporated in the foam during its manufacturing process open up a wide variety of new applications possibilities.

EZ-Dri is an open cell polyurethane foam which is subsequently processed in a reticulator  essentially a chamber that, with a controlled explosion using heat and pressure, removes the cell membranes. The remaining foam structure thus takes the form of a twelve-sided geometric shape known as a dodecahedron. Reticulated polyurethane foam materials are produced with this process, and are used for a wide variety of outdoor cushioning applications for casual furniture as well as for recreational vehicles and boats, golf carts, personal watercraft, and similar applications. With CAL 117 approval, the material may now also be used as underlayment in damp environments where it promotes air circulation to prevent mold and mildew under cushions and mattresses.

EZ-Dri offers casual furniture manufacturers a premium quality cushioning option for their customers with comfortable, long-lasting, mold/mildew proof cushions which may be used immediately after washing, rain, morning dew, or any other moisture event. These materials essentially drain water like a sieve (because of their open pore construction), yet are also comfortable and resilient as ordinary foams including closed cell foams. They are available in a wide variety of thicknesses and firmnesses. To further enhance flexibility, the foam may be easily fabricated into virtually any shape. EZ-Dri foam is strong and resistant to most chemicals including most cleaning agents, solvents, alkalis, and acids. A built-in fungistatic additive (Ultra-Fresh®) inhibits growth of stain- and odor-causing bacteria, mold, mildew, and fungus.

Six different grades of EZ-Dri cushioning materials are available from very-plush to ultra-firm. All have pore sizes of 25 pores per inch (PPI) with 1.8 lbs./cu. ft. density. Crest also offers other EZ-Dri grades with lower densities upon request to meet lower cost requirements; some of these grades are also available in biofriendly materials.

For additional information on new EZ-Dri premium reticulated outdoor cushioning foam with CAL 117 approval, technical assistance, or applications advice, contact Crest Foam Industries Incorporated, 300 Carol Place, Moonachie, NJ 07074; telephone: 201-807-0809; email: info@crestfoam.com