FAQ
Q．What does polyurethane foam (PUF) mean?
A. Polyurethane foam is so-called sponge-like plastic material which is made of polyol and isocyanate as main components, and can be foamed
and cured by chemical reaction with stirring and mixing of foaming agent, a foam control agent, catalyst, coloring agent, etc.
"Flexible polyurethane foam" is compounded and designed to be soft, and "rigid polyurethane foam" is compounded and designed to be hard.
Q．Where are polyurethane foams used?
A. The main usage of flexible polyurethane foam are as follows;
| Classification | Example of usage |
|---|---|
| Four-wheeler | Seat Cushion, Cover fabric laminate backing, Door trim, Shock absorber such as center pillar garnish etc. |
| Motorcycle | Saddle, Air filter, Oil filter, Liner in helmet, Rider cushion |
| Machine | Various materials for sound absorbing, Air conditioning filters, Sealing materials for watertight and airtight, Floor material for soundproofing |
| Furniture | Chair, Seat-chair, Sofa |
| Bedding | Mattress, Pillow, Bed pad |
| Interior | Cushion, Carpet backing |
| Packaging | Packaging materials for precision instruments, food and fruit, Fresh fish trays |
| Convenience goods | Dishwashing sponge, bath sponge, car wash sponge, Gap tape, Cosmetic puff |
| Clothing | Pads for shoulder, bra, etc., Winter Clothes |
| Others | Medium for raising seeding and hydroponics, Microorganism fixed carrier for water treatment, Athletic landing mat |
Q．How is flexible polyurethane foam manufactured?
A. Flexible polyurethane foam is mainly manufactured in the form of "slab" or "mold" products.
“Slab” products are manufactured by flowing reaction solutions that is raw materials of polyurethane on a sheet (process paper etc.) linked to a
conveyor and by foaming and curing. Usually, slabs have a square shape with a width of 1 to 2m and a height of 0.3 to 1m, and are continuously foamed and cut into short blocks of about 2m in length or long blocks of about 60m. Short blocks are cut into various shapes and used for
various purposes. Long blocks are sliced to a thickness of 1 to 15mm with circular cutter machine and laminated with skin materials, and are
mainly used as cover materials for automotive seat cushions.
“Mold” products are manufactured by flowing reaction solutions into plastic or metal mold in each product shapes, by foaming and curing, and by taking out of the mold. This “Mold” method is mainly used for manufacturing automotive seat cushions, as it can make polyurethane foam of
complicated shape.
Q．What kind of features of flexible polyurethane foam?
A. It is possible to give various physical properties and performance according to the demand.
Polyurethane foam can have performance suitable for various usages by selecting the combination of raw materials, such as polyols and
isocyanates, foaming agents, foam stabilizers, catalysts, colorants, if necessary, other compounding agents, and manufacturing conditions, etc.
That is, PUF can exhibit features such as lightweight, cushioning properties, durability, shock absorption, heat insulation, heat resistance,
flame-retardant property, sound absorption, freedom of wide coloration, etc.
PUF can be cut and molded various shapes.
Flexible polyurethane foams can be easily processed into straighten, curved, uneven, and hollow, and can be freely processed into a prescribed
shape from thin sheet to regular products, as well as heat compression molding. In addition, “Molded products” are used in automobile parts with a free design and dimensional accuracy.
Various bonding and integral processing methods can be selected according to the usages.
Flexible polyurethane foams can be easily integrated with each other, but also with metal, cloth, leather, etc. by sewing or bonding process.
And “Frame lamination" is a processing method with good texture and efficient production that exposes the surface of foams instantaneously to
the flame of a dedicated burner, and that melts and bonds to fabrics.
Q．Can flexible polyurethane foam be recycled?
A. It can be recycled. The main recycling method for flexible polyurethane foam is Chipping foam (Rebonded foam), which is made by spraying adhesive onto finely-ground foams, and which is used in various fields including automotive parts and furniture. However, used urethane foams
have not reached material recycling due to dirt and hygiene issues, only urethane foams of waste materials generated in the manufacturing and processing stages have been recycled. As other recycling methods, “fine powder additive”, and “thermal recycling” which burns for energy, are
considering for the practical application in process.
Q．How used flexible polyurethane foam products should be disposed of?
A. Although flexible polyurethane foams are petrochemical products, they are treated as general combustibles generated at home. Generally,
only polyurethane foams are removed from the product, and it is shredded and discarded. However, if disposal methods are defined in each
municipality bylaw, it is necessary to discard according to them.
Please read the handouts on how to put out the waste issued by each municipality and if any instructions about polyurethane foam products,
please follow them. In addition, it is necessary to notify in advance when discarding in large quantities, therefore please dispose in accordance
with the disposal rules of each municipality.