14/5/2021 Polyurethane Applications

American Chemistry Council

Polyurethanes
Introduction to Polyurethanes:

Polyurethane
Applications
Heating and cooling costs amount to about 56 percent of the energy used in the average
American home, according to the U.S. Department of Energy. The nature of the chemistry allows
polyurethanes to be adapted to solve challenging problems, to be molded into unusual shapes
and to enhance industrial and consumer products.

Polyurethanes are formed by reacting a polyol (an alcohol with more than two reactive hydroxyl
groups per molecule) with a diisocyanate or a polymeric isocyanate in the presence of suitable
catalysts and additives. Because a variety of diisocyanates and a wide range of polyols can be
used to produce polyurethane, a broad spectrum of materials can be produced to meet the
needs of specific applications.

Types of Polyurethane:

Flexible Polyurethane Foam

Flexible polyurethane foam is used as cushioning for a variety of consumer and
commercial products, including bedding, furniture, automotive interiors, carpet underlay
and packaging. Flexible foam can be created in almost any variety of shapes and
firmness. It is light, durable, supportive and comfortable.

Flexible polyurethane foam accounts for about 30 percent of the entire North American
polyurethane market, and is used largely for bedding, furniture and in the automotive
industry.

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Rigid Polyurethane Foam

Rigid polyurethane and polyisocyanurate (polyiso) foams create one of the world's most
popular, energy-efficient and versatile insulations. These foams can significantly cut
energy costs while making commercial and residential properties more efficient and
comfortable.

According to the U.S. Department of Energy, heating and cooling account for about 56
percent of the energy use in a typical U.S. home, making it the largest energy expense for
most homes. To maintain uniform temperature and lower noise levels in homes and
commercial properties, builders turn to rigid polyurethane and polyisocyanurate foam.
These foams are effective insulation materials that can be used in roof and wall
insulation, insulated windows, doors and air barrier sealants.

Coatings, Adhesives, Sealants and Elastomers (CASE)

The uses of polyurethanes in the coatings, adhesives, sealants and elastomers (CASE)
market offer a broad and growing spectrum of applications and benefits. Polyurethane
coatings can enhance a product’s appearance and lengthen its lifespan. Polyurethane
adhesives can provide strong bonding advantages, while polyurethane sealants provide
tighter seals. Polyurethane elastomers can be molded into almost any shape, are lighter
than metal, offer superior stress recovery and can be resistant to many environmental
factors.

Thermoplastic polyurethane (TPU)

Thermoplastic polyurethane (TPU) offers a myriad of physical property combinations and
processing applications. It is highly elastic, flexible and resistant to abrasion, impact and
weather. TPUs can be colored or fabricated in a wide variety of methods and their use can
increase a product's overall durability.

TPU is an elastomer that is fully thermoplastic. Like all thermoplastic elastomers, TPU is
elastic and melt-processable. In addition, it can be processed on extrusion, injection,
blow and compression molding equipment. It can be vacuum-formed or solution-coated
and is well suited for a wide variety of fabrication methodologies. TPU can provide a
considerable number of physical property combinations, making it an extremely flexible
material adaptable to dozens of uses such as construction, automotive and footwear.

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Reaction Injection Molding (RIM)

Car bumpers, electrical housing panels and computer and telecommunication equipment
enclosures are some of the parts produced with polyurethanes using reaction injection
molding (RIM). Adding design flexibility, the polyurethane RIM process produces parts
that are usually not achievable using typical injection molding processes, such as thick-
and thin-walled parts, encapsulated inners and foamed cores. In addition to high
strength and low weight, polyurethane RIM parts can exhibit heat resistance, thermal
insulation, dimensional stability and a high level of dynamic properties. Automotive,
construction, appliance, furniture and recreation and sporting goods are a few of the
markets and applications using RIM technology.

Binders
Polyurethane binders are used to adhere numerous types of particles and fibers to each
other. Their primary areas of use are in the manufacturing of wood panels, rubber or
elastomeric flooring surfaces and sand casting for the foundry industry. The highest
volume application for polyurethane binders is in the manufacture of Oriented Strand
Board (OSB). These wood panels are used in structural sheathing and flooring,
manufactured housing, joists and beams and shop panels. Rebond carpet underlay uses
polyurethane binders to adhere scrap pieces of foam, which are often flexible
polyurethane foam, together in its production.

Waterborne Polyurethane Dispersions (PUDs)

Waterborne polyurethane dispersions (PUDs) are coatings and adhesives that use water
as the primary solvent. With increasing federal regulation on the amount of volatile
organic compounds (VOCs) and hazardous air pollutants (HAPs) that can be emitted into
the atmosphere, PUDs are being used in more industrial and commercial applications.

Applications for Polyurethane:

Apparel
When scientists discovered that polyurethanes could be made into fine threads, they were
combined with nylon to make more lightweight, stretchable garments. Over the years,
polyurethanes have been improved and developed into spandex fibers, polyurethane
coatings and thermoplastic elastomers.

Because of today’s advances in polyurethane techniques, manufacturers can make a

broad range of polyurethane apparel from man-made skins and leathers used for
garments sports clothes and a variety of accessories
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garments, sports clothes and a variety of accessories.

Appliances
Polyurethanes are an important component in major appliances that consumers use
every day. The most common use for polyurethanes in major appliances is rigid foams for
refrigerator and freezer thermal insulation systems. Rigid polyurethane foam is an
essential and cost-effective material that can be used for meeting required energy
ratings in consumer refrigerators and freezers. The good thermal insulating properties
of rigid polyurethane foams result from the combination of a fine, closed-cell foam
structure and cell gases that resist heat transfer.

Automotive
Polyurethanes are used throughout cars. In addition to the foam that makes car seats
comfortable, bumpers, interior “headline” ceiling sections, the car body, spoilers, doors
and windows all use polyurethanes. Polyurethane also enables manufacturers to provide
drivers and passengers significantly more automobile “mileage” by reducing weight and
increasing fuel economy, comfort, corrosion resistance, insulation and sound absorption.

Building and Construction
Today's homes demand high-performance materials that are strong, yet lightweight;
perform well, yet are easily installed; and are durable, but also versatile. Polyurethane
helps conserve natural resources and helps preserve the environment by reducing
energy usage. With its excellent strength-to-weight ratio, insulation properties, durability
and versatility, polyurethane is frequently used in building and construction applications.
Both the affordability of these versatile materials and the comfort they provide
homeowners have made polyurethane components part of homes everywhere.

Polyurethane is used all over the house. In floors, flexible foam padding cushions your
carpet. In the roof, reflective plastic coverings over polyurethane foam can bounce
sunlight and heat away, helping the house stay cool while helping reduce energy
consumption. Polyurethane building materials add design flexibility to new homes and
remodeling projects. Foam-core panels offer a wide variety of colors and profiles for
walls and roofs, while foam-cored entry doors and garage doors are available in different
finishes and styles.

Composite Wood
Polyurethanes play a major role in modern materials, such as composite wood.
Polyurethane-based binders are used in composite wood products to permanently glue
organic materials into oriented strand board, medium-density fiberboard, long-strand
lumber laminated-veneer lumber and even strawboard and particleboard
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lumber, laminated veneer lumber and even strawboard and particleboard.

Electronics
Often referred to as “potting compounds,” non-foam polyurethanes are frequently used in
the electrical and electronics industries to encapsulate, seal and insulate fragile,
pressure-sensitive, microelectronic components, underwater cables and printed circuit
boards.

Polyurethane potting compounds are specially formulated by developers to meet a

diverse range of physical, thermal and electrical properties. They can protect electronics
by providing excellent dielectric and adhesive properties, as well as exceptional solvent,
water and extreme temperature resistance.

Flooring
Either as a foam underlay or on top as a coating, polyurethanes can make the floors we
walk on every day more durable, easier to maintain and more aesthetically pleasing.
Using flexible polyurethane foam as a carpet underlay in residential or commercial
applications can significantly increase the lifespan of the carpet, protect its appearance,
provide added comfort and support and can reduce ambient noise.

Polyurethanes are also used to coat floors, from wood and parquet to cement. This
protective finish is resistant to abrasion and solvents, and is easy to clean and maintain.
With a polyurethane finish, a new wood, parquet or cement floor wears better and longer,
while an old floor can be refinished to look new again.

Furnishings
Polyurethane, mostly in the form of flexible foam, is one of the most popular materials
used in home furnishings such as furniture, bedding and carpet underlay. As a
cushioning material for upholstered furniture, flexible polyurethane foam works to make
furniture more durable, comfortable and supportive.

Marine
Millions of Americans enjoy boating each year. Part of boating’s ongoing popularity is
thanks to improvements in boating technology, to which polyurethane materials make an
important contribution.

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Polyurethane epoxy resins seal boat hulls from water, weather, corrosion and elements
that increase drag, affect hydrodynamics and reduce durability. Boaters today can have
the comforts of home on the water, thanks in part to flexible polyurethane foam. In
addition, rigid polyurethane foam insulates boats from noise and temperature extremes,
provides abrasion and tear resistance, and increases load-bearing capacity all while
adding minimal weight. Thermoplastic polyurethane is also great for use in the maritime
industry. It is elastic, durable and an easily processed substance, well suited for wire and
cable coatings, engine tubing, drive belts, hydraulic hoses and seals and even ship
molding.

Medical
Polyurethanes are commonly used in a number of medical applications, including
catheter and general purpose tubing, hospital bedding, surgical drapes, wound
dressings and a variety of injection-molded devices. Their most common use is in short-
term implants. Polyurethane use in medical applications can be more cost-effective and
provide for more longevity and toughness.

Packaging
Polyurethane packaging foam (PPF) can provide more cost-effective, form-fitting
cushioning that uniquely and securely protecting items that need to stay safely in place
during transit. PPF is widely used to safely protect and transport many items, such as
electronic and medical diagnostic equipment, delicate glassware and large industrial
parts.  A versatile on-site solution for many packaging challenges, PPF can save time and
be more cost-effective by providing a custom-fit container with each shipment.

Related Resources

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