The Versatility of Flexible Polyurethane Foam

Furniture
Carpet Cusion
Transportation
Bedding
Packaging
Textiles and Fibers

Flexible polyurethane foam (FPF) affects our lives in many ways and new applications are rolling out on a regular basis. It is used as cushioning for a wide variety of consumer and commercial products including furniture, carpet cushion, transportation, bedding, packaging, and textiles and fibers. FPF accounts for 40% of the entire North American polyurethane market and consists mostly of slabstock, which is used primarily for carpet cushion and furniture. Most of the remainder, a little less than 23% of the total FPF produced, is used by the transportation industry for automotive interiors and other purposes.

Furniture
FPF cushions upholstered furniture, office chairs, stadium seating and auditorium seating. As a cushioning material, FPF has been proven t

  • provide support and comfort;
  • offer durability;
  • provide resiliency;
  • absorb energy; and
  • provide handling strength.

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Carpet Cushion
FPF improves the comfort and lifespan of our carpet. By absorbing much of the energy from traffic, FPF protects the carpet face allowing the carpet to look better longer. Its design and construction provides long-term comfort without excessive thickness, maintaining the desired feel underfoot throughout the life of the installation. FPF is used in both residential and commercial applications, the majority of which is supplied by the bonded version of the cushion. Studies have repeatedly shown that polyurethane provides outstanding durability, improves carpet appearance retention, and provides comfort and support to occupants. The life cycle extension of the carpet alone can often justify the upfront cost. Add to that polyurethane carpet cushion helps absorb sound by as much as 50% - making the workplace quieter and more productive through reduced noise distraction, less fatigue, and improved employee satisfaction – and the compelling basis for including cushion in the carpet floor covering system is undeniable. There are even environmental benefits: in addition to the fact that bonded polyurethane cushion is made from recycled materials and can be recycled in many localities, the potential extension of carpet life should mean less frequent replacements, resulting in less carpet going to landfill. Some of the many benefits of polyurethane carpet cushion include:

  • Extended carpet life -- carpet cushion can improve the life expectancy of carpet by up to 50%
  • Increased savings and reduced downtime due to less frequent replacement
  • Added comfort
  • Reduced ambient noise
  • Enhanced thermal insulation
  • Easier carpet maintenance
  • Recyclable in many localities

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Transportation
FPF is used extensively in the transportation industry for seating, headrests, arm rests, HVAC components, interior panels and skins, car and truck fenders, truck beds and support rings for run-flat tires, headliners and other interior systems. Recent developments in polyurethane technology for automotive design are contributing to increased weight reduction, passenger comfort, energy and sound absorption, resiliency, moisture and heat resistance, and compressive strength in vehicles. Among the five largest markets for polyurethane (in terms of volume), the automotive market shows the fastest growth: up 8.5 percent from 1998 to 2000 in North America alone. Polyurethane is increasingly valuable to original equipment manufacturers, also known as OEMs, because it simultaneously offers:

  • weight reduction
  • sound/vibration absorption
  • fuel efficiency
  • durability

All of these benefits translate to better gas mileage and a more comfortable ride.

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Bedding
FPF is the primary material used today for adding support and comfort to padded bedding products. Over the past two years, the industry has produced thicker and larger bedding products. This is evidenced by the increasing popularity of pillow-top mattresses.

FPF is produced in slab or block form and cut to size. Because of its durable comfort and support, resistance to smoldering ignition, ease of fabrication, adaptability to styling, cleanliness, FPF has become a major component in the bedding industry.

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Packaging
FPF provides protection and cushioning to packaged products. Polyurethane foams are often used to package highly sensitive equipment such as electronics, printed circuit boards, jewelry and delicate foods. FPF’s lightweight, water resistance, shock absorption and resiliency make it an attractive application for packaging.

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Textiles and Fibers
Nearly a half-century after its development, FPF continues to impact nearly every aspect of our lives. It is also used as insulation for fabric products including clothing. In clothing, FPF provides thermal insulation, tear resistance, fire resistance and light weight to a variety of textiles and fibers including leather products, shoe uppers, tents, life rafts, labels, hand bags, insulation liners and more.

View CPI member companies that provide polyurethane equipment used in the flexible foam market.

spotlight

The polyurethane industry, working together through the American Chemistry Council's (ACC) Center for the Polyurethanes Industry (CPI) and the Spray Polyurethane Foam Alliance (SPFA), has launched an enhanced product stewardship program to support further understanding of the benefits of spray polyurethane foam and its continued safe use and handling. A part of this outreach, a new Spray Polyurethane Foam Health and Safety website, www.spraypolyurethane.com, has been launched by CPI and SPFA that contains new materials, literature and posters to increase understanding of spray polyurethane foam (SPF) product stewardship information.

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