Flexible Polyurethane Foam Applications

Specialty Applications

Flexible polyurethane foam (FPF) is used in hundreds of household and consumer products. In other Application pages, we have looked in depth at its use in upholstered furniture, bedding, transportation and carpet cushion.   Some of the same properties exhibited in those products—resilience, cushioning, moisture absorbing, sound deadening, and mold resistance—have driven FPF’s acceptance into a variety of other consumer and industrial uses.

Top: Flexible polyurethane is used in scores of consumer goods. A common use is the insoles of athletic shoes. Viscoelastic, or “memory” foam is frequently used to absorb impact. It also contours to the shape of the user’s foot for a better, more comfortable fit. Left: Flexible polyurethane foam is often used for household sponges because of its absorption properties and because foam doesn’t support the growth of mold or bacteria. Foam is also very cost effective.

Flexible polyurethane foam is used in thousands of common speciality consumer products, thanks to its versatility and value.

Because FPF is cost effective and can be shaped in various ways, it has applications based on properties including:

  • Absorption
  • Cushioning
  • Style
  • Sound Deadening
  • Protection
  • Filtration
  • Resilency

Foam is used for clothing, footwear, cleaning supplies, ink cartridges, cosmetics, filtration, protective gear, first aid supplies, toys, novelty products, and more.

Benefits of FPF In Specialty Applications

Support

FPF can be chemically engineered to be firm or soft. The density of the foam can be varied. This lets makers of products like footwear use foam for soft, cushioning insoles that can also enhance arch support.

Comfort: Softness And Firmness

Foam’s ability to contour its shape means that foam is comfortable when used in applications like ear plugs.

Hygienic

Flexible polyurethane foam does not support the growth of bacteria or mold. Antimicrobial additives can be added to provide extra protection.

Absorption

Foam can absorb water and other liquids, making it ideal for mops and cleaning sponges, cosmetic sponges, paintbrushes, and many other household goods.

Versatility

Because foam can be fabricated or molded into virtually any shape, it is used for a spectrum of products, including toys and novelty items.

Filtration

A “maze” of cells in the foam structure can trap solids, particles and impurities, while allowing air and water to pass freely through.

Protection

Flexible foam and polyurethane elastomers are often used to protect delicate electronics, in packaging, storage cases, and in shock absorbing products like cell phone cases.

Durability

FPF is resilient and tough. It can withstand many shocks and impacts and still continue to perform.

Value

Flexible polyurethane foam is readily available and affordable. It’s lightweight and transportable, and can easily be shaped for myriad uses.

Sound Deadening

Flexible foam is used in studios to deaden sound and to prevent echos. It can also help manage sound in other uses, like headphones, where it blocks unwanted noise.

Recyclability

Foam can be recycled, and a number of programs are in place to recycle foam in home furnishings applications.  FPF carpet cushion is one of the biggest success stories in recycling. Virtually all commercial foam scrap, along with thousands of pounds of post-consumer scrap (and continually increasing) are recycled into high quality bonded carpet cushion. 

Types Of FPF Used in Specialty Applications

Slabstock

Foam is manufactured in large buns then cut and fabricated into specific shapes.

Molded

Foam is made in a custom mold to a specific shape. 

Viscoelastic

Often called “memory” foam, viscoelastic foam was developed for NASA. It relieves pressure and conforms to the body.

Reticulated

This foam has large openings between cells that can trap fluids and minimize spills. The foam can be formulated to be hydrophilic, which means it attracts moisture.

Related Resources

Related

Flexible Polyurethane Foam: A Primer

How FPF is made, specified and used in different applications.

Technical: Foam Density

Details on the most important foam property, and how it affects other properties, such as softness and durability.

Technical: Fabrication

Processes for cutting and shaping foam.

Technical: Viscoelastic Foam

Properties viscoelastic or “memory” foam.

Technical: Molded Foam

How molded flexible polyurethane foam is produced and its uses.

Technical: Foam Sustainability, Part 1

Information on foam recycling and other foam sustainability programs, Part 1.

Technical: Foam Sustainability, Part 2

Information on foam recycling and other foam sustainability programs, Part 2.

Video: Foam Applications

A video on foam uses from our “Introduction To The Flexible Polyurethane Foam Industry.