Abstract: A hinged flexible polyurethane foam protective packaging element is formed from a flexible polyurethane foam laminated to a polyethylene, polypropylene or urethane film. The flexible polyurethane foam has a density in the range of 0.7 lbs/ft3 to 2.8 lbs/ft3 and IFD25 in the range of 25 lbs to 270 lbs. The film has a thickness from 2 mil to 125 mil. The foam is cut through all or substantially all of its thickness without cutting through a portion of the film. The uncut portion of the film creates a repeatably bendable hinge.

Abstract: A hinged flexible polyurethane foam protective packaging element is formed from a flexible polyurethane foam laminated to a polyethylene, polypropylene or urethane film. The flexible polyurethane foam has a density in the range of 0.7 lbs/ft3 to 2.8 lbs/ft3 and IFD25 in the range of 25 lbs to 270 lbs. The film has a thickness from 2 mil to 125 mil. The foam is cut through all or substantially all of its thickness without cutting through a portion of the film. The uncut portion of the film creates a repeatably bendable hinge.

Abstract: Polyurethane foams formed under vacuum (below atmospheric pressure) conditions using a specific mixture of polyisocyanate and with a major portion of methylene diisocyanate (MDI) and a specific mixture of polyether and graft polyols exhibit superb static shock cushioning characteristics (energy absorption) as illustrated by drop curves of deceleration versus static load. The foam-forming ingredients are mixed together and foamed under controlled pressures in the range 0.5 to 0.90 bar (absolute), preferably 0.5 to 0.8 bar (absolute). A major portion of the MDI is 4, 4′ methylene diisocyanate.