Polyurethane Foam
Polyurethane Foam is one of the most versatile plastic materials on the market. It can be adapted to solve challenging problems, molded into unusual shapes and used to enhance industrial and consumer products by adding comfort, warmth and convenience.
It is produced by reacting a polyol (an alcohol with more than two reactive hydroxyl groups per molecule) with a diisocyanate or a polymeric isocyanate in the presence of catalysts and additives. There are two major types of foams: rigid and flexible.
Automotive
Polyurethane foam is widely used in the automotive industry, offering real benefits in terms of comfort, protection and energy conservation. Polyurethane is commonly found in the seating of most vehicles, where its cushioning properties reduce fatigue and stress. It is also used within the body of a car, where it offers insulation properties that protect against heat and noise.
In addition to seats, a range of other car parts are made using polyurethane foams. These include head rests, armrests and roof liners. These components are often fabricated in foam moulds, and then trimmed to fit the car’s interior.
As a result, the overall weight of a vehicle is reduced, resulting in greater fuel efficiency and less environmental impact. This has become especially important as automakers strive to meet the Corporate Average Fuel Economy (CAFE) standards, which aim for a vehicle to achieve an average of 50 miles per gallon by model year 2025.
With this in mind, the auto industry is keen to use specialised polyurethane foams that are both lightweight and durable. These customised materials have been proven to offer significant improvements over standard components in terms of fuel efficiency and sustainability.
The most common type of PU is flexible, but a range of other types are also available. For example, rigid polyurethane is a more resilient alternative to flexible foams, which makes it ideal for seat cushions and other car body panels.
Moreover, PU foam is often used in light commercial vehicles (LCVs), such as delivery vans and pickup trucks. These compact vehicles are built ruggedly, have lower operating costs and powerful fuel-efficient engines.
In fact, the market for LCVs is expected to grow throughout the forecast period. This is due to the increased demand for these vehicles in emerging markets across the world, including China.
Aside from seats, a variety of other car parts are made using polyurethane, such as sealants and adhesives that protect internal electrical components against damage from the elements. These products can be water-based, which is more environmentally friendly than solvent-based versions. In addition, a transparent glaze made of polyurethane can be applied to windshields, windows and headlamps to prevent them from chipping or fogging. These products are often resistant to ultraviolet light, making them long-lasting and needing little maintenance.
Home Furnishings
Whether it’s for the home, office, hotel or other commercial space, nearly all furniture produced today contains polyurethane foam. It is a versatile material that can be molded and fabricated into various shapes for seating, backs, armrests and other furniture components. Foam is also used in upholstery construction to enhance surface softness and support while retaining durability for years of use.
In upholstered furniture, the most Polyurethane Foam common uses for flexible polyurethane foam are seat cushions, arms and other padded components that give support and comfort to a person sitting on a chair or sofa. Foam is commonly paired with cotton or polyester batting to maximize surface softness and provide support for the person’s back and legs.
Foam is made by reacting a blend of polyols, polyisocyanates and other additives with a blowing agent. The combination of these substances can produce foam with a variety of properties, depending on the specific formulation process and raw materials selected.
Typically, the blend includes catalysts, surfactants and other additives to improve foam strength, stiffness, and elasticity. Other additives influence the final product’s flammability and other characteristics.
Although polyurethane foam is a durable material that’s used in many types of products, it may cause significant environmental problems in some applications. Specifically, the manufacturing processes that turn polyols and diisocyanates into a form of foam that we know as PU foam emit toxic chemicals in the air. These chemicals include toluene diisocyanate (TDI) and methylene diphenyl diisocyanate (MDI).
The emissions from these gases can harm a person’s health. TDI is identified as a carcinogen, and MDI irritates the respiratory system and eye and nasal passages.
Some people have been diagnosed with cancer after breathing in fumes from TDI or from working with polyurethane foam products. These pollutants can be emitted from polyfoam factories or from the homes of those who manufacture PU foam products.
Fortunately, the CertiPUR-US program guarantees that foam used in your upholstered furniture is free of ozone depleters, flame retardants, heavy metals, formaldehyde, phthalates and other harmful substances. The foam must pass rigorous tests to earn the seal.
Boating
Polyurethane Foam is a popular material used in many different applications, including boating. It is commonly seen in lifejackets, cushions and engine insulating wires. It also helps keep your hulls safe from the elements by adding insulation and sound dampening.
Using foam in a variety of ways, manufacturers are constantly improving their boats to make them safer, easier to use and more comfortable for people. For example, some manufacturers place a layer of foam in dead space on the hull to increase its buoyancy in case the hull begins to take on water.
Some people even repurpose foam from other Polyurethane Foam projects to give their vessels more flotation and sound-dampening. They’ve done it with hollow and solid-core swimming noodles, Styrofoam and polyurethane spray-on foam insulation.
The foam can be found in a wide variety of densities, with 2LB being the most common. These pourable, two-part liquid foams are resistant to water absorption and are ideal for structural purposes and as a large cavity filler.
These types of foams can be mixed in temperatures of 75 degrees F or higher to ensure proper expansion. They should be mixed in a well-ventilated workspace, and be poured into a container or space that can expand at least 25-30 times its original size.
When mixing foams, it’s important to follow the instructions on the label closely. This will help ensure that the mixture is consistent and provides the desired results. It’s also best to mix foam at a temperature of around 75-80 degrees F, as this will allow for the product to expand more quickly and accurately.
There are several types of polyurethane foam that are widely used for boating applications. This includes rigid, flexible and thermoplastic polyurethanes.
Rigid polyurethanes are usually used for insulating, sound dampening, and floatation. They can also be molded into a shape to fit specific requirements.
Flexible polyurethane foam is a popular material for seating in automobiles and aircraft, replacing cotton and other materials in seating. This is because the material can offer better comfort, support and design options, while also reducing weight and cost.
Thermoplastic
Polyurethane foams are used in a variety of applications across a wide range of industries. They are known for their durability and toughness, ensuring that products made from them can withstand some of the most demanding environments on Earth.
PU foams are used in automobiles to form seats, headrests, armrests and roof liners, as well as in the dashboard and instrument panels. They are also used in the home to make beds, furniture, and carpet underlay.
These materials are able to perform in a wide range of temperatures and humidity conditions, making them suitable for many different types of uses. They are also resistant to harsh chemicals, which helps them resist deterioration from water, mold and mildew.
Another type of material that is made from PU is called “potting compounds.” These potting compounds are used in the electrical and electronics industry to encapsulate, seal and insulate delicate, pressure-sensitive, microelectronic components. They provide a number of electrical, dielectric and adhesive properties, and are incredibly durable at extreme temperatures.
Recently, it has been reported that lightweight conductive porous graphene foams with excellent compression properties can be fabricated by using the thermal induced phase separation (TISP) technique. By adding a small amount of graphene to a polyurethane foam, the thickness of the cell wall was increased and the formation of small holes in the TPU foam cells was hindered, which significantly improved its compressibility property. In addition, the porous graphene foam showed special positive piezoresistive behaviors and peculiar response patterns with a deflection point during cyclic compression tests.
Thermoplastic polyurethanes (TPUs) are widely used to fabricate flexible and semi-flexible foams, which can be used in a wide range of automotive and home applications. They are also used in the electrical and electronics industry to withstand high voltages and corrosive environments.
