The most important information about foams (PPU, polyurethane foam, foam rubber)

First of all, about the terms.

What is now fashionable to call foam used to have another common name - foam rubber. However, at all times, the name of the material itself will be relevant and unchanged - polyurethane foam (a foamed form of polyurethane - an elastic rubber-like plastic).

Polyurethane is the undisputed hit of our century, which, due to its properties (stability, hypoallergenicity, chemical inertness, elasticity), is used in the vast majority of branches of human activity from the automotive industry to implantology.

Alternative names for polyurethane foam only confuse the consumer - polyurethane foam, latex foam, viscolatex, artificial latex, etc.

Table

Can you list all the names of polyurethane foam so that I can no longer be deceived?

Certainly! Get it!

• Foam rubber
• Foam
• PPU
• Latex foam
• Foam
• Highly elastic foam
• Vegetable foam
• Foamed corn oil
• Artificial latex
• Waterlatex
• Tiger touch
• Wisco shawm
• Sloth
• Memory
• Memorylatex
• Smart foam

Which foam rubber to buy for a sofa: what to look for

Hi all! Some create furniture from scratch, while others simply need to replace elements of old furniture that are worn out and no longer suitable for further use.

A striking example here is foam rubber for a sofa. Even in high-quality furniture, it can wear out and sag over time. This violates the desired level of comfort, and therefore the foam needs to be replaced.

Self-assembly is even easier. To reupholster, you first need to lay something soft under the sheathing material. And here the best solution would be foam rubber.

And so that it does not get pressed, the pillows can serve for a long time and create a high level of comfort, you need to approach the issue of choice wisely. Therefore, today I suggest you find out how to choose a suitable product, how important parameters such as density, thickness and hardness play, and what are the key nuances of purchasing this product.

Want to understand foams better? Please!

There are few main technical properties of the foam - only 3 pieces. This:

• Foam grade (ST, EL, HR, HS, LR, HL) - characterizes the formulation and elasticity properties of the foam;
• Foam density - the amount of material per cubic meter, kg/m3 (kilogram in 1 cubic meter), is responsible for the reliability and price of the material.
• Foam hardness index - measured by pressure per m2 in kPa at 40% compression.

However, the line of polyurethane foams is very diverse; in the world you can find more than 50 different combinations of brand/density/hardness of foam - and each option is unique and has different properties from the others.

Etymology in the service of spelling

Most etiquette formulas in the Russian language originate from verb phrases that have lost their basic lexical meaning. These are “hello” - a wish to be healthy, “thank you”, which comes from the expression “God bless”, or “thank you” - from the phrase “to give good”. This is the etiquette formula of the request. This word comes from the imperative mood of the verb pozhalovat, meaning to give as a gift, to present. To it was added the particle hundred, which was, according to one version, an abbreviation for sir, according to another - the past tense form of the verb to become. Thus, the spelling can be explained by knowing the origin of please from welcome:

• Pozhat is formed from complain by adding the prefix po-. This prefix is ​​always written the same way: with the letter o.
• The imperative form is formed by adding the suffix -й- to the present tense stem. For example: give-give-give. The welcome form is formed in the same way.
• Whatever the origin of the particle -sta, its spelling is the same: with an “a” at the end.

I want to understand better about brands! Can you help?

No problem!

• ST is a standard brand of polyurethane foam, the original classic, the foam that started it all. Neither hard nor soft, fluffy foam with excellent recoverability at good densities;
• EL - a reinforced grade of polyurethane foam, was invented much later, but today has taken a dominant position in many market niches, thanks to its increased rigidity;
• HL - extremely hard foam, used in conditions of increased loads and for maximum durability;
• HS is an ultra-soft foam used in low densities in headrests and armrests of furniture. In tall ones it turns into waterlatex - into jelly superelastic foam;
• HR is a highly elastic, rubber, latex-like brand. Extremely popular in mattresses for its springy elasticity.
• VE (LR) is a viscoelastic brand, memory, which is called by many names, including “smart foam that remembers you personally.”

Buyer's mistake - foam rubber

The main misconception of 90% of consumers is the understanding of what is actually inside the chair. What is soft filling? Foam rubber - many will answer. But it's not right. Foam rubber is an outdated name for what is truly called polyurethane foam, or, easier to pronounce, PPU. Why is this so important? Simply for the reason that many manufacturers or ordinary mass marketing distributors of finished products on the “buy and sell” principle pay attention to the advantages of their upholstered furniture, losing sight of the most significant features.

For example, some manufacturers, taking into account the consumer’s ignorance of what foam rubber actually is, compare their polyurethane foam with a sample of another brand. At the same time, the definition of “foam rubber” is no longer acceptable for a person who actually knows everything about his “quality” products. After all, this definition in popular use dates back to Soviet times, when the only production of polyurethane foam was of Scandinavian origin, hence the name - foam rubber. In fact, foam rubber is, in its chemical composition, porous, soft and elastic polyurethane foam.

To compare the incorrectness of reasoning, we can cite as an example a more understandable definition for all mothers. The same misconception applies to baby diapers, which everyone now calls “diapers” after the type of the first company, which for the first time in the post-Soviet space offered its products to children. Pampers is the name of the company, but among the people it has become the definition of diapers as such.

Beware, deception!

Some (even many in Ukraine) unscrupulous manufacturers often call standard brands of polyurethane foam highly elastic. THIS IS OFTEN NOT TRUE.

Highly elastic brands are an elite, expensive and durable material. Highly elastic polyurethane foam cannot be cheap.

Foam density is more important than brand! (in terms of durability)

The most important thing you need to know is the density of the foam. Density is how many kilograms of polyurethane foam are pumped into one cubic meter, m3!

Generally accepted gradation of densities of standard and highly elastic foam brands as interpreted by the GASH mattress workshop (kg/m3):

• 16 (and further kg/m3) - to create the appearance of foam, a completely non-functional brand with a forecast of service for a couple of weeks in any, even the mildest conditions;
• 18 - popular for kitchen sponges, we have seen the use of this density in mattresses, the history of mattresses with natural linen covers is extremely interesting (more on that next time);
• 20 - intended for use as packaging; in Ukraine it is used everywhere in budget mattresses;
• 22 - intended for use as packaging, on backs and seats in furniture (not for constant loads), in Ukraine it is used in budget mattresses everywhere;
• 25 - classic furniture density, intended for backs and seats in furniture. Due to the nuances of physical mechanics, standard foams in this density are practically not produced (ST2535), because a completely different, reinforced brand of the same density EL2540 is in demand.
• 28 is an advanced furniture density, but almost no one uses it in the standard brand, and therefore the plant does not put it into production. Many people work with EL2842.
• 30 is the penultimate level of quality among standard foams; it is known that this density, although it softens over time, is already of such high quality that it does not shrink for 7 years or more. In Ukraine it is used in mid-budget toppers, as insulating flooring in good mattresses. Italians bring here their “budget” mattresses based on this foam.
• 30 in highly elastic brands - an ultra-soft brand, which is not recommended for use in mattresses, is rather weak. Mainly used in cushions, backs and armrests of upholstered furniture. However, many manufacturers still work with it and call it artificial latex.
• 35 is the highest density in the line of standard foams, which is currently produced in Ukraine. GASH, of course, only works with this top-of-the-line standard foam.
• 35 kg/m3 - the classic density of highly elastic latex foam, very popular on the market for its high comfort, good durability and low price. At the moment, GASH does not work with this brand, but is considering the possibility of introducing it as an alternative to Euro-foam. Interesting fact! The global company IKEA calls artificial latex, incl. and 35-density latex grade, which is what happened in the IKEA Morgedal mattress. GASH, in turn, cannot call HR3535 an artificial latex; the tongue is hesitant to equate the average quality foam with a truly high-quality material.
• 40 kg/m3 - only expensive highly elastic grades and extra-hard grade HL4065 are produced in such densities. 40 kg/m3 is a very popular, average business and working density among highly elastic foams. It is most popular in Europe for its optimal price and quality.
• 50 kg/m3 is a serious and businesslike thing, this is already impressively heavy foam with a huge service life. Ukrainian factories do not operate with such a density, but Italian and German mattresses (at wild prices) in such a density are supplied to our market.
• 55 kg/m3 is the most popular density of highly elastic foam throughout the world, with which, incl. Our plant is also working. It is this density that GASH considers worthy of bearing the proud name of “artificial latex.” It is truly tall, powerful, durable and expensive to live up to its name.
• 60 kg/m3 - ultra-high, almost maximum density of highly elastic foam. GASH purchases one of its super-soft modifications - HR6030LL, but more on that in another article. The commercial name for this foam in our frame is waterlatex.
• 65 kg/m3 - ultra-high, almost mythical density. Individual manufacturers may claim that they produce this particular brand, but this is a dubious claim that needs to be checked on a scale.

What is polyurethane foam

Polyurethane foam refers to a type of plastic that is a product of the oil refining industry. The raw materials for production can also be oils of vegetable origin (soybean, rapeseed, sunflower). But due to their high cost, they are rarely used.

The porous material is 85-90% filled with inert gas. Depending on the cell fraction and wall thickness, several subtypes of polyurethane foam are distinguished regarding strength indicators:

• solid;
• hard;
• soft and very soft;
• viscous;
• elastic.

Important! In construction, energy-saving and sound-absorbing material with a density of 30-86 kg/cubic meter is more often used. m.

Hard PUF
If the indicator is close to 70 or more units, then such PUF products are distinguished by their ability to retain moisture without absorption, which is important for waterproofing work (but constant contact with water is excluded, since the development of a hydration reaction is possible). The thermal conductivity of polyurethane foam ranges from 0.019-0.035 W/m, so the scope of application includes protecting various structures from cooling.

Okay, there are a lot of numbers, but I don't understand anything about it? Is it possible somehow easier?

Before purchasing a mattress, ALWAYS find out the density of the foam used by the manufacturer. This is a guarantee of durability.

Conventionally, in the context of the mattress topic, all foams can be divided into 3 groups:

• low-density 16-25 kg/m3 (not durable in mattresses, but cheap for a one-time purchase!). Buying a mattress with such a density means that it will collapse in the coming year. As a rule, such densities do not normally last longer than 2-3 years.
• medium dense 28-35 kg/m3 (in mattresses they serve well for medium-sized sleepers). Such densities are used by self-respecting, but not the best, manufacturers. Forecast of good service - 4-7 years.
• heavy quality foams 40-60 kg/m3 (very durable comfortable foams). These are cool mattresses with a service forecast of 10+. It is with these densities that GASH primarily works.

Main characteristics

We found out that PPU filler and foam rubber are the same thing. The material is widely used for sofas.

By the way, I have already talked about polyurethane foam mattresses separately, and also discussed the possibility of making simple mattresses from foam rubber with my own hands.

PU sofas are distinguished by the fact that there are no coil springs or other wire blocks in the design. The entire space is occupied by polyurethane foam.

When choosing PU foam filler for a sofa, pillows and other items, focus on the following characteristics:

• Convenience
  . This is a priority indicator. During operation, it is important that dents do not form under the human body. In cheap PU sofas this is a disease. Therefore, the quality of the filler must be high. Medium and high-level products are manufactured using special technologies. They are stiffer and also more elastic. They last longer. Can return to their original shape;
• Build quality
  . The PU foam filler is not inferior in quality and performance characteristics to furniture models with spring blocks. They can be used in any room. Springs may begin to rust when installed in the kitchen or in rooms with high humidity;
• Duration of service
  . Roughly, PPU lasts for 8 years or more. But at a certain point, the chemical decomposition of polyurethane foam begins. It is irreversible. The released substances become harmful. Therefore, inexpensive models usually do not last more than 10 years. Or you need to completely replace the filler;
• Price
  . One of the main features of PU foam filling for sofas is the price of the furniture. Good models cost from 10 thousand rubles. An analogue with spring blocks will cost more.

Based on these characteristics, you can decide whether PPU filler is suitable for you or not.

Beware of manipulation!

A number of unscrupulous manufacturers often operate with densities calculated per SQUARE METER – 45 kg/m2. 73 kg/m2, 80 kg/m2. You need to be very careful and look at the markings. This is the so-called REDUCED density, which is related to the real density through a reduction factor of 0.42. Thus, if the declared “density” is 73 kg/m2 (and that sounds cool), then the actual density of the foam in the mattress is 30 kg/m3 (and that’s already amazing).

We really hope that this section of the encyclopedia will help you choose a quality mattress! If we have not taken into account something in this article, you can always contact us for clarification! We are happy to advise everyone!

Advantages and disadvantages

The advantages of polyurethane foam materials include resistance to deformation, that is, after compression, the material quickly restores its original shape. Regarding products for washing and cleaning, painting and priming the surface, the ability of foam rubber to absorb liquid, which can occupy up to 40% of the volume of contained air, is relevant. Application is possible in a wide temperature range: from -40 to +100 degrees Celsius.

The service life of elastic polyurethane foam declared by manufacturers is in the range of 5-15 years, and rigid polymer materials can maintain quality indicators for 30-80 years.

Among the disadvantages, there is flammability with the release of toxic substances and toxic smoke harmful to humans.

Behavior of polyurethane foam in open flame

Modern additives allow manufacturers to produce polymer products that do not support open fire. And under the influence of direct ultraviolet radiation, materials begin to deteriorate.

Important! If foam rubber is characterized by a relatively low price, then polyurethane foam as insulation is more expensive compared to other analogues.

Polyurethane-based polymer materials have a porous structure, due to which they have noise-absorbing properties. Depending on its density, polypropylene either absorbs moisture or acts as a water barrier. Hard types are actively used for insulating structures, and soft types are used for filling furniture, toys and sports equipment.

PPU release form

The market offers a wide variety of forms, types, brands of polyurethane foam:

1. Leaf.

Manufacturers supply rectangular foam rubber with a thickness of 5 to 1000 mm in standard cuts, or according to individual customer requirements.

2. Rolled.

Reels of various widths are convenient to use, material thickness up to 30 mm. In addition to the usual, manufacturers offer rolled foam rubber made on a backing made of fabric or synthetic materials.

3. Block.

This type of foam rubber is distinguished by a hard, non-porous surface (before processing). In addition to cubic ones, this type of foam rubber is poured into molds of various configurations. After cooling, the crust is removed, the material acquires a homogeneous structure.

4. Acoustic.

They are supplied in the form of separate panels of two types: with relief and without relief. The panels have different shapes, colors, and sizes. In addition to its own properties, a significant increase in the sound absorption coefficient is ensured by the shape of the surface. For more information about acoustic foam rubber, read the article - Acoustic foam rubber: types, installation, sound insulation, price

Sintepon

Creates additional softness and elasticity

Sintepon

It is an intermediate material. The top of the filler is covered with padding polyester. It is also used to fill sofa cushions.

Available in various densities. Required density indicators for different furniture elements:

• back, armrests – 300 g/sq.m
• seat – not less than 400 g/sq.m
• pillows – more than 300 g/sq.m

These indicators must be strictly observed. Then the sofa will be soft and visually attractive. It will delight you with its coziness and comfort.

This material is popular for its properties.

Advantages:

• it is light, voluminous, moderately tight
• cheap
• has good thermal insulation
• does not harm health
• hypoallergenic
• resists moisture and dirt well
• resistant to aging

Flaws:

• Doesn't last long. If the product is actively used, the surface will become deformed.
• high risk of purchasing low-quality material. There is no uniform manufacturing technology

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Cutting polyurethane foam

A soft, elastic material with small cells, foam rubber causes certain difficulties when it is necessary to give it a given shape. In industry, until recently, cutting presses were used. The creation of a shaped matrix, necessary for this type of processing, influenced the increase in the cost of the final product.

Currently, CNC laser machines are widely used. New devices significantly expand the use of polyurethane foam due to the ability to cut products of complex configurations without a significant increase in labor intensity. Laser cutting is performed silently, quickly, and no solid waste is generated during the cutting process.