Exploring the Science of Polyurethane Foam
Polyurethane (PU) surrounds us, appearing in beds, pillows, chairs, cars, and even in our electronic devices! It exists in different forms such as flexible foam and rigid foam, adapting to the unique demands of each industry. This material is key to enhancing comfort, durability, and functionality in various aspects of our lives. Since its development in 1937, the industry of polyurethane has rapidly evolved with innovative products and production methods continuing to enter the market. Exploring the chemistry behind PU is the key to truly grasping how crucial its role is in shaping our daily lives.
What is Polyurethane?
Polyurethane, a class of polymers, is a composition of organic units joined by urethane links. The production of PU foam involves a reaction between diisocyanates and polyols in the presence of a catalyst. This results in a complex, three-dimensional network of polymer chains, giving rise to the honeycomb-like foam structure we all recognise.
What sets polyurethane apart from other classes of polymers is the extraordinary ability to adapt to unique applications. Additional chemicals or catalysts can be added to the formulation to control the foam’s characteristics - from density, hardness, porosity, resilience, or even infusing it with unique traits such as flame resistance and temperature regulation. The adaptability of PU foam extends beyond its formulation; it can also be cut into distinct shapes and patterns, enhancing its functionality. This proves especially beneficial in acoustic applications, as the unique patterns increase the surface area, boosting its ability to absorb and diffuse sound.
The Ingredients
Polyurethane consists of two essential elements: polyols and diisocyanates. Polyols are organic compounds containing multiple hydroxyl (OH) groups, categorised into various types like polyether, polyester, polycarbonate, and acrylic polyols. The specific type of polyol that is used contributes to the final properties of the foam.
Diisocyanates are also organic compounds containing two isocyanate groups that are highly reactive. The diisocyanates used in foam production are MDI (Methylene Diphenyl Diisocyanate), typically used for rigid foam, and TDI (Tolulene Diisocyanate), typically used for flexible foam. These diisocyanates play a crucial role in the polymerisation process by providing the cross-linked structure, contributing to its durablility and other distinct properties. Other ingredients which may be used include surfactants, catalysts, blowing agents, and other additives.
By leveraging the flexibility in foam formulations, Joyce Foam has developed over 75 unique foam grades tailored for a range of industries.
Production with VPF Technology
Joyce foam is the sole Australian foam manufacturer that has adopted continuous Variable Pressure Foam (VPF) technology. This technology is unique as it is the only method of foam production that requires no hazardous Auxiliary Blowing Agents, such as liquid carbon dioxide or methylene chloride, but instead utilises a vacuum. VPF technology produces foam in an airtight enclosure, and adjusts the air pressure in order to produce the desired foam properties. Not only is this the environmentally preferred method, but manufacturing at low atmospheric pressures allows us to create products exclusive to VPF technology.
Joyce Foam Products
5-9 Bridges Road, Moorebank, NSW, 2170
1800 021 304
Sales@Joyce.com.au
