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Polyurethane foam is a low-density material that can be flexible or rigid and has many applications, including in bedding, upholstery, insulation, automobile interiors, construction, and as a spray-on material. It is versatile and customizable, but care must be taken when applying it due to potentially harmful fumes.
Polyurethane foam refers to a number of different types of foam made up of polymers made up of molecular chains linked together by urethane linkages. It can be flexible or rigid, but has a low density. Flexible polyurethane foam is used more often in bedding and upholstery, while the more rigid variety is used for thermal insulation and in automobile dashboards.
The flexible polyurethane is made in blocks and then cut into the desired shape. This is how, for example, furniture cushions are made. Some materials can replace this application of polyurethane foam, such as polyester fiber or steel springs. However, polyester fiber does not recover as well as foam after compression. The steel springs bounce back well, but can get noisy as they wear out. They also require some form of cushioning between them and the user.
In addition to the flexible and rigid types, there is also semi-flexible polyurethane foam, which is widely used in automobile interiors. Seats, armrests and headrests are often made from the semi-flexible variety of this material. In the case of seats, the foam is formed into a mold, then removed and stuffed.
Rigid polyurethane foam has many relevant applications in construction. Many weird and detailed shapes like sculptures and domed ceilings are much easier to make with foam than wood. Some manufacturers sell a special hard foam that is used to replace wood in carved signs and three-dimensional topographical models. It is also used as home insulation, rigid boat hulls, tennis racket grips, and even surfboards.
Polyurethane foam can also be made into a form that sprays on easily and then expands rapidly as it dries. It can be customized to have many different physical properties, depending on the intended use. In this form it can be used as an industrial insulation, but also as a waterproof and durable roofing material. It is often applied to boats, ships and floating docks. In higher density forms, it has also been used to increase the structural strength of aircraft wings.
Spray polyurethane foam is one of the most versatile building materials out there. It is also environmentally friendly as it does not contain or emit chemicals that are harmful to the environment or to air quality in general. Even so, care must be taken when applying the foam, because the fumes it gives off can be dangerous if not properly vented.
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