Polyurethane Foam (Foam Fabricating)

Overview of Polyurethane Foam

Polyurethane foam is a porous, cellular-structured, synthetic material made
from the reaction of polyols and diisocyanates. Its structure is a composite of a
solid phase and a gas phase. The solid phase is made from polyurethane
elastomer, while the gas phase is air brought about by blowing agents.

The huge gas phase of polyurethane foams has good thermal and acoustic
insulation, high force absorption, low density, and flexibility. Polyurethane
foams are sometimes referred to as foam rubber, a broader type of material
that include foams made from latex, neoprene, and silicone.
Polyurethane foams are used in the manufacturing mattresses, furniture, car
seats, thermal insulations, and packaging materials. They comprise around 67%
of global polyurethane production, with an estimated market of around $37.8
billion in 2020.
Flexible and Rigid Polyurethane Foams
The two main types of polyurethane foams are flexible and rigid polyurethane
foams. Flexible polyurethane foams can be made slabstock or molding
processes from either polyether or polyester polyols. They have lower bulk
densities, higher sag factors, and permeable structures. Flexible polyurethane
foams are mostly used in furniture, seat cushions, mattresses, and acoustic
dampers.
Rigid polyurethane foams are denser and have a high percentage of closed
cells. Foams with closed cells do not easily allow air to escape from the foam.
This gives the foam higher load-bearing capacities, good water resistance, and
lower thermal conductivity. This makes rigid polyurethane foams suitable as
construction and insulation material. Rigid polyurethane foams can also be
manufactured through slabstock and molding processes, with the addition of
lamination and spraying.
Production of Polyurethane Foam
The production process of polyurethane foam can be divided into the polymer
system preparation and the foam production process. The polymer system
preparation involves blending and mixing the components through a mixing
head or in a master batching system.
The main reactive components are polyols, diisocyanates, and chemical
blowing agents. Polyols and diisocyanates are the components for the
polymerization process, while diisocyanates and chemical blowing agents
(water) are for the gas generation process. Different types of polymer system
preparation differ in the method of combining these components.

Polyurethane Foam Production Processes

Enumerated below are the different foaming methods for both flexible and
rigid polyurethane foams.
Slabstock Foam: A slabstock foam is a continuous loaf of foam made by
pouring the foaming polymer system onto a moving conveyor. The slabstock
process typically uses a single shot polymer system with water as the blowing
agent. The polymer system foams or rises as it spreads across the conveyor.
Molded Foam: Unlike slabstock foam, molded foams are usually produced in a
discontinuous process. Foam molding is used to create products with intricate
shapes such as seat cushions, paddings, head restraints, dampers, and
construction materials.