If you were asked what is polyurethane you may well have a succinct answer. We throw the spotlight on some lesser-known facts about this highly versatile and prolifically used polymer.
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Polyurethane now plays a massive role in everyday life – featuring in everything from cushions to aircraft. It’s also a much-favoured substance for moulding manufacturing and engineering parts and components to enable the ‘wheels of industry to keep turning’. In fact, it’s literally used for wheels, runners and stops!
Yet sometimes Polyurethane is still a bit of a mystery.
To help illuminate this increasingly valuable synthetic substance, here are ten facts about polyurethane that may well surprise you.
Polyurethane is the material of choice for a diverse range of industry sectors seeking to innovate and manage costs. So, it’s easy to think of it – wrongly – as a highly modern material.
Who invented polyurethane, and when?
This extraordinarily versatile material for parts is often attributed to American chemist William Edward Hanford. He worked with Donald Fletcher Holmes in the s on the catalytic process that achieves perfectly bonded polyurethane and patented this incredible invention in .
However, you will also see the invention of polyurethane attributed to German chemist Professor Otto Bayer (-), who also worked on the concept in the s. He is often referred to as the Father of polyurethane chemistry and received many patents and accolades for his work.
During the second world war, rubber was scarce, and this new organic polymer was the perfect alternative. It was used for everything from mustard gas resistant clothing to high-gloss aeroplane finishes.
By the mid-s polyurethane was being mass-produced to use as a coating, adhesive and rigid foam. In the same decade, the option to vary its composition to create a soft foam was discovered. This led to its use in the construction of all sorts of seats and cushioning components, and ultimately to its popularity as a low-cost polyether polyol for use in contemporary upholstery and automotive applications.
It’s possible to manufacture polyurethane in an infinite range of ways, changing its structure and performance according to its blend of components, and the type of additives and catalysts used. However, the two main categories of PU are polyester and polyether.
These are both elastomers, and the biggest difference between polyester vs. polyether is their performance.
Polyester can withstand high temperatures for even longer, holding its shape and flawless surface. However, it’s less resistant to moisture than the other form of polyurethane.
Polyether has an increased ability to withstand cold temperatures and moisture, and it is also resistant to heat caused by friction, Making it an ideal material for fast-moving wheels, or outdoor applications, for example.
Working with a specialist provider of bespoke polyurethane products, you can confidently match any item’s performance with a polyurethane solution. As well as getting a part that is perfect in terms of dimensions and tensile properties.
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What is polyurethane made of? It’s a combination of polymers (which have a long chain of molecules) and urethane (which is a manmade synthetic crystalline). When mixed, they bond in a way that even makes them heat, energy and moisture resistant.
The advantages of polyurethane are clear, including significant reasons to choose it instead of rubber, plastic, metal or wood.
However, the actual process involved in manufacturing polyurethane is highly complex. Not least as there are so many ways to vary its tensile properties; from a version hard as metal to pliant and soft foams, and strong coatings.
The secret is in the incredible chemical reaction that creates polyurethane. It involves mixing a diisocyanate (or a polymeric isocyanate) with a polyol (which is an alcohol containing more than two reactive hydroxyl groups per molecule).
By varying the diisocyanate and additives, you can achieve extremely diverse results. All sharing polyurethane’s strong structural bond and unrivalled durability.
Getting the ideal PU blend for each task is a skilled process. You also need specialist equipment and experience to create customised polyurethane moulding.
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There really is nothing like PU when it comes to versatility and by varying its mix and moulding it can take on a vast range of forms. This includes everything from liquids and foams, to super-strength parts that defy immense pressure and constant friction.
This is probably the least known of all polyurethane facts! The whole topic of why polyurethane is sustainable needs to be publicised more. Especially as many part specifiers are seeking environmentally-sound solutions that still manage unit costs brilliantly.
Many of the uses of polyurethane are linked to creating parts for machinery and to reinforce processes such as rollers for conveyor lines. However, when it is mixed to be a stable material and dried properly, polyurethane is safe enough to use in everyday situations in your home too! Even under environmental pressures, the stable versions release no toxins and or smells! Polyurethane does not alter PH in soil or water either. Though it is recommended that it is not used to mould eating implements, and the liquid form is highly poisonous.
PU foam manufacturing requires carbon dioxide and water – highly sustainable ingredients! Polyurethane is also a great insulator when you need materials that manage energy efficiency.
Read more: How the polyurethane industry helps the economy
This is possibly one of the less obvious ways to use polyurethane. The most obvious applications are solid and substantial forms of PU. This includes the exterior casings or covers of electrical items. However, it can be mixed and moulded to seal and insulate even the most fragile of components, including delicate wiring. So, it could be used as electronic instrument bezels as well as forming a protective exterior.
One superb illustration of just how versatile polyurethane comes in the form of human exercise. Gym equipment often incorporates PU moulded guards, stops or wheels. However, you might also be wearing clothes made of spandex, which is a highly elasticated type of polyurethane mix!
The creative manufacturers of polyurethane products are constantly finding new ways to mould its strongest and most dense form into highly energy-efficient construction materials. PU can be used to create seals and insulation products that herald ever-more sustainable buildings, such as rigid foam insulation panels.
As polyurethane is so commonly used for wheels, stops, bushes and other machinery and equipment parts – or as a foam in seating – its more innovative aspects can be overlooked. Including the possibility of using polyurethane as an adhesive agent or coating.
In fact, commissioning clear polyurethane as a topcoat is a great industrial opportunity. It can not only improve the appearance of items but will also protect the base coats. Remember, polyurethane is strong and resistant to moisture, moulds, abrasion, friction and extreme temperatures.
Various types of particles and fibres can be bound together using polyurethane. A great example of this is rebound carpet underlay. In some cases, a form of this incredibly versatile material is used to manufacture foam. Another form binds scrap pieces of that foam together to produce the protective and insulating material that goes under carpets.
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One application of polyurethane may particularly surprise you. It is commonly used to manufacture medical instruments and fittings, including items for hospitals such as catheter tubing, surgical drapes, wound dressings and bedding.
These facts about polyurethane show just how widely it is used, and in so many different forms!
Which leads to the question, can PU create the part you need for your project? Contact Custom Moulded Polyurethane as ‘the fact is’ that this is a universal solution to match any industrial need.
There are many myths and misconceptions about polyurethane. We explore some of the worst ones to show how safe and versatile this material is for a vast range of purposes and products.
Foams, adhesives, wheels, rollers, bushes, thermal insulating materials, soundproofing boards and super-strong supports and stops; the list of items that can be successfully formed from polyurethane is truly astounding. This versatile material features in every industrial sector you could think of, as well as being used for everyday applications such as car and furniture parts.
Yet, there are still some lingering misunderstandings about how polyurethane is made, how safe it is to use, and whether it’s low-cost means compromising on performance.
To set the record straight, we tackle five misconceptions about polyurethane.
With such a global push to reduce dependence on plastics, one of the most widespread myths about polyurethane is that it has the same negative environmental impact. Yet, polyurethane is not the same as plastic!
It’s a type of elastomer, which means it’s a polymer with elastic properties (like rubber) but it has the capacity to be produced with the strength of the metal.
In fact, due to its unique chemical structure, polyurethane is an eco-friendly alternative to plastic. That’s because it can be recycled successfully, breaking down its polymers leaving nothing that harms the environment.
Interestingly, polyurethane is also energy efficient to produce, and in skilled hands can be moulded and finished with adherence to lean manufacturing principles. Plus, when used in construction, it has important thermal properties to reduce energy waste.
Contact us to discuss your requirements of Polyurethane Materials. Our experienced sales team can help you identify the options that best suit your needs.
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This is another important misconception, as it could prevent you from exploring the many advantages of using polyurethane to create medical parts or components for children’s toys, for example.
It’s true that creating polyurethane is a skilled and complex process that requires careful handling of the chemical compounds used.
However, once it’s blended and formed, polyurethane is entirely stable. Which means it does not put toxic fumes into the atmosphere.
Keep in mind that it’s an incredibly durable and resilient substance too, so parts and components made from polyurethane won’t flake, shed or crumb – even under intense pressure and severe friction.
Polyurethane is also resistant to moulds, mildew and rot, making it a truly safe substance to use in house construction, as well as in products used in homes.
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Following on from the myth that polyurethane is toxic comes the incorrect hypothesis that its chemical structure makes it a fire risk. This is another occasion when the opposite is actually true.
If it does come into contact with flames, polyurethane won’t spread them but tends to dampen them down.
Interestingly, the composition of polyurethane makes it a great insulator, offering energy efficiency advantages as it traps heat inside a building. It’s also resistant to abrasion and friction and stands up to high temperatures without an issue.
All of which disproves the view that polyurethane is dangerous!
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One of the most common uses of polyurethane is automotive and engineering parts. As it is so strong and hardworking, it’s easy to see why.
Yet, there’s a lingering misunderstanding this doesn’t include high-performance bushes. The mistaken assumption is that polyurethane is too hard to create a smooth motion or a comfortable driving experience.
This flies in the face of the infinite possibilities of producing polyurethane to different tensile specifications. As well as the potential to create bushes from polyurethane with 100% accuracy. Meaning all steering and suspension targets can be met effortlessly when you produce bushes in polyurethane.
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When you dig down on how polyurethane is made and the expertise invested in creating bespoke parts made from this versatile material, it’s easy to fall into a trap. Surely something this complex to produce as a durable customised part must carry a hefty price tag?
These are enduring misconceptions about polyurethane we are particularly keen to dispel. Thanks to our experience, expertise and investment in the latest equipment, Custom Moulded Polyurethane offers highly cost-effective precision engineering services.
You may well find that your polyurethane prototype – or a bulk order of PE parts – costs less than if you opted for alternative substances.
Polyurethane is a class of synthetic polymers that are commonly used to make a variety of insulation materials. Given its wide range of starting materials, polyurethane can be made into a spray foam of different consistencies and rigid insulation boards.
Notably, polyurethane insulation products exhibit exceptional heat retention properties, with an impressive r-value range of 3.6 - 4.5 m²K/W, making them some of the most effective on the market today. However, its synthetic nature and unsustainable production raise some equally worth exploring concerns.
This ultimate guide by GreenMatch UK aims to do just that. This article will cover everything you need about polyurethane-derived insulation products, their applications, pros, cons and costs.
Looking to insulate your home? Let GreenMatch UK be your one-stop solution for the best bargains. By filling out our 30-second online survey, you can get 3 free home-tailored quotes from our nationwide network of trusted installers. No charges, no obligations. Click the button below to begin!
Get your best dealQuickly compare FREE quotesPolyurethane insulation is simply insulation products that derive from synthetic polyurethane. The fact that polyurethane utilises a wide range of base materials means that it can be formed into several different material consistencies such as spray foam, rigid boards, or sheets.
The most popular pu insulation materials are polyurethane spray foam, and rigid insulation boards (PUR or PIR).
While both derive from polyurethane as the main material, PIR insulation and PUR insulation boards have a slight difference to them. PIR stands for polyisocyanurate, which is a derivative material that has all that PUR offers, but builds upon it further.
Polyisocyanurate (PIR) boards exhibit exceptional heat resistance, flame and smoke resistance, as well as the same low-moisture barrier properties that PUR boards do.
Given that polyurethane can either be applied as a spray foam or rigid insulation board, it makes it a versatile material that can be suitable for almost any home insulation application.
Polyurethane spray foam insulation is most notably used for cavity walls, basement ceilings, underfloors and loft insulation. However, the incredibly rigid nature of PU foam insulation makes it difficult to remove, often becoming a very costly and complex process down the line.
Polyurethane spray foam in small applications also works as a perfect airtight seal for door and window frames, effectively stopping draught in a home. The same goes for roof insulation.
On the other hand, rigid PUR and PIR boards can also fit a range of home insulation jobs, such as external and internal wall insulation, roof rafters, solid concrete floors and more.
Polyurethane-derived insulation materials have plenty of pros and cons to consider. While they may be exceptionally effective, it goes without saying that some concerns with their sustainability and safety should filter into your decision.
Let’s start by exploring some of the main perks of polyurethane-based insulation materials:
With the pros in account, it’s also important to reflect on some of the key downsides that come with polyurethane-based insulation materials. Here are some of the key ones:
Looking at the various pros and cons, it's important to ask yourself what you aim for when looking for suitable insulation. It’s recommended to work with a professional installer who can conduct a house assessment and present to you your alternative options as well.
In general, polyurethane spray foam costs around £21.5 per m2 of application, while PUR and PIR insulation boards can cost £5 – £15 per m2, with PIR boards tending to cost a bit more.
Like any insulation material, your final investment will hinge on several factors, such as your chosen insulation manufacturer, density and thermal efficiency, home type, job complexity and size of insulation needed amongst many more.
While these costs may be high, certain households can qualify for free insulation through a UK grant scheme. The two main schemes currently available are the Great British Insulation Scheme (GBIS) and the Energy Company Obligation (ECO4).
Working with a material like polyurethane, especially as a spray foam, will most definitely require an industry expert to carry out. This is because the material itself can be toxic, but also a poor insulation job can damage your property irreversibly.
That’s why it’s important to work with a professional accredited installer to ensure decades of home comfort, instead of decades of burdensome repair costs. However, not everybody has endless hours to spend researching and vetting installers to find the right fit. That’s where GreenMAtch UK comes in.
Through our services, you can receive up to 3 free home-tailored quotes from our nationwide network of pre-vetted installers, completely free of charge. All you have to do is fill out our simple 30-second online form and let the bargains come to you. Click the button below to begin!
Get your best dealQuickly compare FREE quotesPolyurethane-based insulation materials can indeed be used for insulation. They can be found in the form of spray foam, rigid boards or sheets.
From a thermal efficiency perspective, polyurethane is a great insulator, exhibiting some of the most impressive thermal retention properties available today. From a sustainability and safety standpoint, polyurethane is quite damaging to the environment and personal health.
If you are looking for more details, kindly visit PU Catalyst.