Flexible moulded polyurethane foam is a versatile polymeric material created through the reaction of polyols and isocyanates, typically in a mould, to form a customized shape. It is widely used in automotive seating, office chairs, and other applications requiring precise forms, comfort, and durability.

Slabstock foam is produced in large continuous blocks and then cut to size, whereas moulded foam is produced directly in a mould to create specific shapes. Moulded foam is often used in applications where precise geometries and consistent dimensions are required, such as car seats and ergonomic office chairs.

Flexible moulded polyurethane foam is made by mixing polyols, isocyanates, catalysts, and other additives. The mixture is then poured into a mould where it undergoes a chemical reaction, expanding and curing into the final foam shape. The process allows for the creation of intricate shapes tailored to specific applications.

Flexible moulded polyurethane foam is used in a variety of applications, including:

• Automotive seating: Providing comfort, support, and durability in car interiors.
• Office furniture: Offering ergonomic cushioning in chairs and seating.
• Medical devices: Used in supports and cushions for orthopedic and rehabilitation purposes.
• Bedding components: Moulded foam may be used in pillows and mattress toppers.

Polyurethane foam is an article. This view was supported in ECHA’s Guidance on requirements for substances in articles from 2011, which in its page 50 states that: “in the conversion unit, the structure and design of the polymer compoulds is changed. In the resulting material, the design and structure is kept during further processing. For the polymer sector, this means that processes including for example, but not limited to, pipe extrusion, film blowing, blow moulding, sheet forming, rotomoulding, foaming, compression moulding, fibre spinning or tape slitting calendaring, coating or injection moulding mark the ‘red line’ between mixture and article”.

Moulded polyurethane foam is ideal for automotive seating due to its ability to be shaped precisely, providing enhanced comfort, support, and durability. The material also offers lightweight benefits, which helps improve fuel efficiency, and can be formulated to meet fire safety and durability standards required in automotive environments.

If polyurethane foam is chemically recycled, due to the process of degradation the final products are its constituent raw materials, which can be then used in new foam formulations.

The environmental impact of producing moulded foam is similar to other polyurethane foam types, involving energy use and chemical reactions that emit some greenhouse gases. However, technological advancements have helped reduce emissions, and manufacturers are increasingly exploring the use of renewable or bio-based materials to improve sustainability. Recycling options, including mechanical and chemical recycling, are also available for moulded foam.

Yes, flexible moulded polyurethane foam can be recycled through mechanical recycling (where the foam is shredded and repurposed for applications like carpet underlay) or chemical recycling – also known as depolymerisation or waste-to-monomer (breaking down the foam into its raw components for reuse). infrastructure and regulations.

Additives are substances that can be added to the mixture of polyols and diisocyanates at the time of foam production to be present in the foam and/or to provide it with specific properties. They for example help controlling cell structures, cell opening, odor formation or flame resistance. They can also be added for aesthetic reasons, with pigments for example allowing for foam of any colour to be produced.

Natural Oil Polyol (NOP) polyurethane foams are produced by using in part polyols from renewable sources such as soybean, castor, sunflower, rapeseed oil or a mix thereof. Apart from that, they are manufactured in the same way as traditional foams.

Spontaneous ignition of polyurethane foam is not possible under normal operating temperatures. However, being produced from crude oil derivatives, polyurethane foam does have high energy content and can burn when submitted to high heat or a direct flame. Depending on the specifications of customers or national regulations, flame retardants may thus need to be added as additives, for example for upholstered seating in public places such as theatres or cinemas which need to comply with strict fire regulations.

Fogging is mentioned in automotive applications. It refers to the deposition of volatile compounds coming from interior trim materials on the windscreen and rear window of the car. This notably happens under the influence of high temperatures in the passenger compartment. Low fogging foams are designed to reduce this phenomenon.

Flame lamination is used to produce laminates of foam and fabrics by passing the polyurethane foam over an open flame. The heat melts the upper surface of the foam. This melted layer acts as glue bonding the foam and the fabric.

Flame laminated foams are typically used in the automotive industry for seat covers, headliners and door panels, as well as in the shoe and clothing industry.

Fresh polyurethane foam comes with an odour that can be compared to the smell of fresh paint. This odour disappears within days and usually well before end-products are being placed on the market. Controlling odour is a matter of discipline in raw materials sourcing, production and quality control by the foam manufacturer.