Comprehensive Guide to Polyurethane Applications

Although you may not know it, at some point you will have encountered a polyurethane product. We’re also 100% certain you will own or have used an item containing polyurethane.

Why? Polyurethane is a synthetic resin that is available in many forms. It is mainly made up of urethane and polymer chemical compounds that are linked together via a chemical process. Such formations are then manipulated to form liquid products such as varnish, flexible products such as sealants, and rigid long-lasting car parts.

The polymer compound is responsible for the stability and durability of millions of products people use every day. Their durability is demonstrated when placed under strong heat, as they don’t melt. This makes polyurethane the perfect compound for elements such as ovens that emit a lot of heat and energy.

Chapter 1: Everyday Uses of Polyurethane

There are many applications for polyurethane in products we use in our day-to-day lives. The vast majority of the world’s consumption of polyurethane comes in the form of foams, both flexible and rigid, for a diverse range of applications. It usually plays a role in the production of other materials, like upholstery fabrics, the construction of the interior walls of fridges, and thermal insulation in the building industry.

Household and Commercial Applications

Polyurethane is also becoming an increasingly-present material in clothing, and is often used in mouldings for things like door frames, window headers and columns. In short, polyurethane is a versatile material, and you may be surprised to learn just how many of your everyday household items and machinery use it.

Elastomers

An elastomer is a natural or synthetic polymer with elastic properties, composed of long chain-like molecules that can return to their original shape even after stretching. They are commonly used as seals, moulded flexible parts and adhesives for avenues such as vehicle manufacturing, food production, scientific applications and chemical processes.

Some products that are made from elastomers include tyres, able to maintain a firm grip while still flexible when need be, inner tubing, and rubber flooring, which is manufactured for gyms, kitchens and basements. You will also find elastomers on items of clothing like belts and rubber gloves. Elastomers with a low density are also used for footwear.

Cleaning utensils

Polyurethane foam is the main material for a wide range of kitchen and bathroom sponges. It is tough and durable but highly flexible and absorbent. This makes it perfect for cleaning with water – it will absorb the soap and liquid to scrub whatever needs cleaning, moulding to whatever shape you need it to be then returning to its original shape when you’re finished.

Straps

There are many uses for polyurethane straps. Given the material’s general elasticity and durability, it is an excellent material for watch straps, providing flexibility and comfort for the wearer. Bungee cords are the ultimate evidence of the potential strength of polyurethane – a very thin, long cord is capable of supporting very heavy loads.

Thermal Insulation

Rigid polyurethane with a low density has several uses, and one of the best is its potential for thermal insulation. 

Thermal insulation refers to the reduction of heat transfer between objects as well as the prevention of excessive heat loss. This process is most commonly displayed in the home where thermal insulators provide a strong barrier from the cold.

The energy efficiency of a building can be greatly increased by insulating the walls with polyurethane, helping to regulate temperatures and minimise the need for heating/cooling. Its lifespan is well over 5 decades, and it requires no maintenance, so it is a choice material for insulating new buildings.

You will find the bulk of thermal insulation is used for buildings and keeping them insulated, particularly lofts – a great necessity considering that 25% of house heat is lost through the roof – cavity walls and external walls – 33% of heat loss is due to the walls – as well as flooring – which sees 15% of house heat loss. It can also be a solid insulator against travelling sound.

Keep reading: Polyurethane in building and construction

Furniture for Comfort and Strength

Polyurethane can be moulded into a foam that is perfect for making us comfortable. The foam is so versatile, that polyurethane products are increasingly found in domestic furniture.

It differs in terms of firmness, density and overall quality, with higher densities and qualities typically carrying a higher value. The comfort uses range from baby mattresses to luxurious bay-window cushions – standard car seat cushions tend to use polyurethane.

Despite its incredible resilience, polyurethane is also a lightweight option to create furniture components. So even when it is not a soft foam for seating and bedding, PU can give household furniture incredible support, without making it heavy.

It also makes a remarkable bonding agent when you need a complete and reliable seal.

Polyurethane Desk chairs

One of the many advantages of both prototyping and mass-producing components made from polyurethane is that you can vary its properties to an infinite degree. From liquids and foams to parts that are as rigid and load-bearing as metal.

Office furniture manufacturers have realised that polyurethane products can be created to form ergonomically correct desk chairs.

Of course, using PU for parts includes basic wheels or casters for moveable chairs and tables. Components that can stand up to incredible amounts of wear and tear. However, by varying the blend of ingredients in polyurethane, you can produce both comfortable foam seats and ideally shaped backs and arms for the latest desk chairs.

Related article: Polyurethane: A Plastic or a Miracle?

Flooring Materials

An example of a household product made from polyurethane could be beneath you.

As an overlay, polyurethane can improve the appearance of floors, making them beautiful, resistant and easy to maintain. Flexible polyurethane foam (FPF) is now being used on a regular basis too. It is used as a form of cushioning for a variety of commercial and domestic products such as carpet, furniture, transportation, packaging and textiles.

Carpet underlay manufactured to last is often formed from a softer, low-density polyurethane mix. However, there are also other flooring solutions being developed incorporating Polyurethane.

One of the reasons polyurethane is preferred for this sort of application is that it offers high levels of insulation – both thermal and sound management. Making it a great choice for a growing range of construction materials. Using polyurethane-based flooring materials gives homeowners the reassurance of low maintenance products that won’t need to be replaced for a very long time!

Related article: Polyurethane in building and construction

Apparel

Over the years, polyurethanes have been developed into spandex fibres and thermoplastic elastomers.

Thermoplastic polyurethane elastomers can be shaped into different parts, and when they are spun, these elastomers produce spandex, which is a flexible material used to make brassieres, swimsuits, and other athletic clothing items. Apparel is light, soft and breathable while offering excellent durability and abrasion-resistance.

Related article: Where to buy polyurethane products in the UK?

Footwear

You may be wearing a polyurethane product right now.

Companies that design and produce work boots and shoes have grasped both the durability of polyurethane and its ability to be moulded into any shape or tensile range. 

This makes polyurethane a great solution for reinforced soles, to withstand work environments. As well as keeping its integrity under duress, polyurethane is great for shaping to provide better foot support.

You can find PU in athletic footwear too. The special properties of polyurethane are particularly useful for running shoes. Sportswear manufacturers are capitalising on the benefits of polyurethane because the material provides a supportive and comfortable base. 

It can bend and stretch through the natural movements of the foot. It also stands the test of time, returning to its original shape even after rigorous daily use, and it doesn’t melt in the washing machine. It can even help resist foot odour.

Polyurethane packaging

Polyurethane packaging earns its popularity on account of it being lightweight, flexible, resilient and suitable for transporting fragile and delicate products. Even the most intrinsic items are guaranteed safe delivery, such as electronic and medical diagnostic equipment, as well as delicate glassware and large industrial parts. In the event of an accident, the polyurethane can absorb some of the shock from sudden impacts, thereby protecting the product and giving the owners some peace of mind.

Chapter 2: Industrial and Specialised Uses

The way polyurethane ‘shapes our world’ is widely understood when it comes to cogs, wheels, stops, and rollers used across manufacturing. So, to illustrate their versatility, we want to explore ways the polymer is used across industries.

Automotive Applications

Widely used in automotive manufacturing, polyurethane foams can be found in armrests, headrests and seats. Their cushioning properties can also reduce the stress and fatigue commonly associated with driving.

Their light weight and durability not only make them suitable for cushioning, but also within the body of the car itself. They’re insulating, providing drivers with protection from the engine’s noise and heat.

Related article: 5 Products that could be made out of Polyurethane but currently are not

Polyurethane Wheels

On account of its strong grip but necessary flexibility, polyurethane is a natural product for wheels, especially car tyres. These wheels are also utilised in warehouse environments, for machinery such as forklift trucks. There is also a special brand of wheel made from polyurethane that offers the elasticity of rubber and the durability of metal wheels.

These tyres are often abrasion resistant, oil and solvent resistant and come with strong load-bearing capacity. You can find wheels like these on the bottom of your suitcase. Overall, these wheels come with a much longer lifespan, resistant to many changing conditions such as weather and accidents.

You’d be surprised by the many uses of polyurethane and there are so many more to name, like electronics, textiles and furniture. But these are the most prominent use of polyurethane and have helped it attain a reputation as one of the go-to materials for all aspects of life.

Medical and Scientific Equipment

Polyurethane is used in a range of medical applications, including general-purpose tubing, surgical drapes, temporary implants and wound dressings. It is used because it often outperforms many other materials in terms of flexibility, abrasion resistance, tear resistance, biocompatibility, flexural endurance and strength.

Custom Moulded Polyurethane is the leading UK supplier of quality custom polyurethane products and all our products are made in the UK. To find out more about manufacturing bespoke polyurethane moulds and products, contact us today.

Polyurethane coatings in Building and Construction

Polyurethane coatings produce an ultra-thin, protective layer for a wide range of materials. The result is an increased lifespan and enhanced look. Polyurethane coatings on wooden flooring enable the wood to retain its look whilst protecting it against the elements. 

On cars, the coating provides a protective varnish that defends against dents, scratches and damage from the weather. They are responsible for giving the exterior of vehicles a high gloss finish while providing improved corrosion and scratch resistance. 

Polyurethane coatings are also used during construction to make steel trusses, building floors and concrete supports more durable by spray-coating them. A single polyurethane coating lasts an incredibly long time.

As you can see, there are a great many applications for polyurethane in products that we use every single day. It has a number of fantastic properties that are applicable to a wide range of uses, making it a versatile and incredibly useful material. The products outlined in this article are just a few of the many that use polyurethane – there are many more, and you’d really feel the difference without this wonderful plastic.

Miscellaneous uses for Polyurethane

The polymer is so flexible, it can be used in even more different ways.

Electronic Components

Even softer versions of this highly versatile material are known for their ability to withstand pressure, extreme temperatures and electrical currents, without altering in any way. Making polyurethane parts the perfect solution for coating or sheathing electrical wires. This includes moulded polyurethane delicately formed to fit around computer wiring.

Related article: Polyurethane For The Car Industry

Moulding

This area sees polyurethane liquefied and then dispensed into heated moulds, after which it is then trimmed or machined into shape depending on the desired finished product. If necessary, other materials can be incorporated into the mix, such as metal. You will find these in products such as scrapers, castors, washers, blocks, bumpers, capper rings and gaskets.

It has also been used as an alternative material for tools such as hammers and can be seen as a suitable substitute for wood, considering polyurethane doesn’t come with the typical disadvantages associated with wood, such as rotting, splintering and cracking. Other products made from moulding include screening mats, star wheels and suction cups.

Related article: Polyurethane Rollers vs Plastic or Rubber Rollers

Glue

Polyurethane can make an excellent adhesive, particularly for woodworking glue. Its water resistance is a particular advantage, and it is used to make very strong, multi-purpose adhesives that we all use regularly. It is also widely used in the bookbinding industry, because its lack of moisture is ideal for binding paper.

Read also: How Polyurethane Saves Lives

Chapter 3: Polyurethane in Advanced Manufacturing

New types of polyurethane products are being put into use all the time, as companies increasingly take advantage of this substance’s many intrinsic values.

That often starts with prototypes. Both small and large parts optimise the incredible strength of polyurethane. As well as its ability to be precision-tooled into intricate designs.

Reaction Injection Moulding (RIM)

Reaction Injection Moulding is a technique that uses pressure to mix two fluid elements. The elements are introduced into a preformed mould before a reaction takes place – polyurethane then takes the shape of the mould. This technique is used to make car bumpers, telecommunication enclosures, and computer equipment.

Conclusion

If we drew up a list of things made from polyurethane, we would be here all day. Basically, polyurethane products pop up anywhere that tensile reliability and high performance are important. Often, invisibly supporting everyday products and processes.

Some of PU’s applications are less complex of course. It is often used for relatively simple structures that do vital jobs. Due to its unparalleled durability and its resistance to moulds, oil, moisture, extreme temperatures and friction.

Its prevalence is down to the fact that it has a number of advantages over other synthetic materials. Its flexibility makes it ideal for products designed for your comfort, while its durability means it is equally applicable to things like tyres for heavy machines.

It is also a relatively ‘green’ material, due to the fact that it can help reduce energy consumption due to its properties as an insulating material. 

With all that in mind, if you need a licensed polyurethane supplier in the UK – Custom Moulded Polyurethane is here to help! Give us a call and we’ll sort you out ASAP.