Polyurethane foam

They cannot be melted and reshaped after initially formed, because the chemical bonds between the molecules in the material are very strong and are not broken down by heating.

Depending on the properties of the end application, the two most often used at large scale production are moulding and slabstock (block) foaming.

[6] The flexible polyurethane foam (FPUF) is produced from the reaction of polyols and isocyanates, a process pioneered in 1937.

Because of this property, lightweightness, and efficient production process, it is often used in furniture, bedding, automotive seating, athletic equipment, packaging, footwear, and carpets.

[7] Flexible polyurethane foams with a high volume of open pores have been greatly regarded as an effective noise absorption material and are widely used as acoustic insulation in various sectors, from construction to transportation.

Since the invention of polyurethane chemistry there have been constant innovations in the industry, driven by the need to decrease the toxicity of chemical substances used in production processes.

[13] In the last decades, the main focus of the FPUF industry has been improving the environmental impact of its products and processes.

Today, it is possible to make flexible PU foams from alternative, non-fossil sources, thus significantly improving its environmental footprint.

[25] Like many applications, there has been a trend to make rigid PU foam from renewable raw materials in place of the usual polyols.

However, it requires a perfect application, as any air pocket, dirt or an uncovered tiny spot can knock it off due to extreme conditions of liftoff.

According to the Columbia accident report, NASA officials found foam loss in over 80% of the 79 missions for which they have pictures.

[31] By 2009 researchers created a superior polyimide foam to insulate the reusable cryogenic propellant tanks of Space Shuttles.