Polyurethane foam is a linear polymer made of organic units connected by carbamate linkages. The chemical formula is C27H36N2O10. There are also thermoplastic polyurethanes. However, most polyurethanes do not melt when heated, making them thermosetting polymers. Di- or tri-isocyanate and one polyol are typically and regularly used to generate these polymers. Read More…
Leading Manufacturers
American Excelsior Company
Arlington, TX | 800-777-7645The applications for foam fabricating are only limited by one’s imagination; that is our slogan at American Excelsior. We are a foam supplier who offers many different foam cushions & foam padding for over a dozen industries.
American Foam Products
Painesville, OH | 440-352-3434For innovative and cost-effective fabricated foam packaging, American Foam Products should be your preferred vendor! We utilize a wide range of foams and other materials, including polyethylene, polyurethane, crosslink polyethylene, expanded polystyrene and plastic corrugated, as well as a broad range of manufacturing services and capabilities.
Heubach Corporation
Garland, TX | 800-530-0091Our highly advanced foam solution are ideal for a wide range of applications. We take your satisfaction very seriously which is why we offer custom services to accurately manufacture all of your products.
Flextech
St. Louis Park, MN | 952-345-0012As a leader in the foam fabricating industry, FLEXTECH uses a variety of methods to produce your product including compression and encapsulation molding, vacuum forming, laminating, skiving, and die cutting. To guarantee customer satisfaction, every step of production is closely monitored and examined to ensure it meets FLEXTECH’s exacting standards for quality and customer satisfaction. Your requirements are an essential element in the completion of every product and are meticulously followed.
Luxaire Cushion Company
Newton Falls, OH | 330-872-0995At Luxaire, we realize the importance of customer care. No matter how challenging the project, we fabricate our foam with the utmost precision to get it right the first time. Available foams include rigid, semi-rigid, open-cell, and outdoor foam. We are capable of performing detailed fabrication with our cutting-edge CAD production equipment.
Wisconsin Foam Products, Inc.
Madison, WI | 800-989-3626Wisconsin Foam is a foam supplier that serves a multitude of applications & industries with highly targeted, cost-effective precision flexible foam solutions— no matter the size or complexity.
Thrust Industries
Evansville, IN | 800-467-6730Here at Thrust Industries we provide die cut foam that comes in a variety of shapes and configurations. We die cut foam from a number of materials including: urethane, PVC, polyester, neoprene, ether, cellular, volara, and much more.
Packaging Strategies, Inc.
Baltimore, MD | 410-547-7877Packaging Strategies is a leading foam fabricator with over 30 years experience in the design and manufacturing of flexible foam packaging solutions and products. With state of the art in house engineering and computer controlled fabrication machinery PSI has become one of the leading suppliers in the industry. Foams products include flexible polyethylene’s, polyurethanes, cross linked. Specializing in case and container inserts and cushion and vibration analysis PSI is an excellent choice for your next project.
Design Converting, Inc.
Grand Rapids, MI | 616-942-7780Our long-term customers know they can trust us to find them the best deals on foam products. We believe that savings should be passed on. We are not in business simply to make profits, but to benefit our customers with high quality products and services.
Additional ingredients are added to enable the modification of the polymer's processing or qualities. Polyurethane foams are categorized as alternating copolymers because they are made up of two types of monomers that polymerize one at a time. On average, each molecule of the polyols and isocyanates used to create polyurethanes contains two or more functional groups.
Polyurethane is also another varnish of the synthetic resin variety, and it is made with various methods for different needs. The carbonyl carbon in urethane is attached to both a -OR group and a -NR2 group. It is a functional group that contains carbonyls. A polyester or polyether with a hydroxyl terminal reacts with an isocyanate to produce polyurethane.
Manufacturing Process of Polyurethane Foam
The typical method for making polyurethane involves combining two different liquid streams. More than two liquid streams may occasionally mix. Surfactants and catalysts are typically present in the first stream, also called the polyol stream. Blowing agents are also reported to be present in this stream. Other significant additives are in the other streams, influencing the final product's polyurethane. The resin mix additive stream uses cross-linking, chain-extending, pigment, filler, and flame-retardant materials.
Applications of Polyurethane Foam
Three-quarters of all global usage of polyurethane is in the form of polyurethane foam, which has a variety of purposes. There are markets with both flexible and stiff foam types. The flexible foams are positioned behind the upholstery fabrics in residential and commercial furniture, while the rigid ones are positioned behind other materials. Diisocyanates, polyols, supplementary blowing agents, catalysts, and other additives are combined to generate flexible foams, which are then allowed to expand naturally. In addition to furniture, they create mattress padding, carpet cushions, and automobile seat cushions.
On the other hand, rigid foams are positioned between metals, freezers, refrigerators, and plastic sheets. Polyurethanes are being used more frequently in the clothing industry as well. It is utilized, for instance, to line brasserie cups. Manufacturing different kitchen and bathroom sponges is another application for polyurethane foam. Other uses for polyurethane foam include: highly flexible and robust foam seating, rigid foam for insulating panels, gaskets and seals made of microcellular foam, elastomeric wheels and lasting tires, rubber bushings for automobile suspension, and carpet padding.
For one specific and common example, polyurethane is used to make car seats. In this process, the seat maker has a mold for each kind of seat. The seat cushion is quickly cast using the mold, a closable "clamshell"-style construction. After the seat cushion is removed from the mold, it is upholstered.
Advantages of Polyurethane Foam
Medium-To-Firm Density: Although polyurethane is sometimes thought of as light and flimsy, the foam is medium to robust. This indicates that it won't sag under weight like a memory foam mattress, but it also suggests that it won't be as soft as a latex mattress.
When used for mattresses, polyurethane foam's firmness can be modified to a certain extent. There are two ways to accomplish this. One is to increase or decrease foam. The alternative is to select a mattress with various firmness levels in various bed regions.
Low-Cost Option: Polyurethane foam is less expensive than memory foam and other types. For instance, both latex and polyurethane are less expensive than memory foam.
Alleviates Back Pain: Foam made of polyurethane effectively reduces back pain. It offers strong support and can enhance posture, which assists lessen pressure points that cause lower back pain. Additionally, polyurethane foam lessens the pressure on the spine and helps ease stiffness, edema, and irritation in this region.
Simple to Clean and Maintain: Polyurethane foam is simple to clean and maintain. A polyurethane foam mattress cover can be washed and frequently vacuumed or cleaned with a moist cloth.
Resistant, Long-Lasting, and Durable: Polyurethane foam has all three qualities. Also, mattresses of these material are more space-efficient than the majority of other mattresses; they can fit in smaller places because they are more compact than a memory foam mattress.
