PU Products

1.Wide range of hardness
The classification of hardness for polyurethane relies on the prepolymer's molecular structure and can be manufactured from 20 SHORE A to 85 SHORE D
2.High load bearing capacity
Polyurethane has a high load capacity in both tension and compression. Polyurethane may undergo a change in shape under a heavy load, but will return to its original shape once the load is removed with little compression set in the material when designed properly for a given application.
3.Flexibility
Polyurethanes perform very well when used in high flex fatigue applications. Flexural properties can be isolated allowing for very good elongation and recovery properties.
4.Abrasion & impact resistance
For applications where severe wear prove challenging, polyurethanes are an ideal solution even at low temperatures.
5.Tear resistance
Polyurethanes possess high tear resistance along with high tensile properties.
6.Resistance to water, oil & grease
Polyurethane's material properties will remain stable (with minimal swelling) in water, oil and grease. Polyether compounds have the potential to last many years in subsea applications.
7.Electrical properties
Polyurethanes exhibit good electrical insulating properties.
8.Wide resiliency range
Resilience is generally a function of hardness. For shock-absorbing elastomer applications, low rebound compounds are usually used (i.e. resilience range of 10-40%). For high frequency vibrations or where quick recovery is required, compounds in the 40-65% resilience are used. In general, toughness is enhanced by high resilience.
9.Strong bonding properties
Polyurethane bonds to a wide range of materials during the manufacturing process. These materials include other plastics, metals and wood. This property makes polyurethane an ideal material for wheels, rollers and inserts.
10.Performance in harsh environments
Polyurethane is very resistant to extreme temperature, meaning harsh environmental conditions and many chemicals rarely cause material degradation.
11.Mold, mildew & fungus resistance
Most polyether based polyurethanes do not support fungal, mold and mildew growth and are therefore highly suitable for tropical environments. Special additives can also be added to reduce this in polyester materials as well.
12.Color ranges
Varying color pigments can be added to polyurethane in the manufacturing process. Ultraviolet shielding can be incorporated into the pigment to provide better color stability in outdoor applications.
13.Economical manufacturing process
Polyurethane is often used to manufacture one-off parts, prototypes or high volume, repeat production runs. Size ranges vary from a couple grams to 2000lb parts.
14.Short production lead times
Compared to conventional thermoplastic materials polyurethane has a relatively short lead time with significantly more economical tooling costs.

While polyurethane polymers are used for a vast array of applications, their production method can be broken into three distinct phases. First, the bulk polymer product is made. Next, the polymer is exposed to various processing steps. Finally, the polymer is transformed into its final product and shipped. This production process can be illustrated by looking at the continuous production of polyurethane foams.

● At the start of polyurethane foam production, the reacting raw materials are held as liquids in large, stainless steel tanks. These tanks are equipped with agitators to keep the materials fluid. A metering device is attached to the tanks so that the appropriate amount of reactive material can be pumped out. A typical ratio of polyol to diisocyanate is 1:2. Since the ratio of the component materials produces polymers with varying characteristics, it is strictly controlled. 

● The reacting materials are passed through a heat exchanger as they are pumped into pipes. The exchanger adjusts the temperature to the reactive level. Inside the pipes, the polymerization reaction occurs. By the time the polymerizing liquid gets to the end of the pipe, the polyurethane is already formed. On one end of the pipe is a dispensing head for the polymer.
Processing

● The dispensing head is hooked up to the processing line. For the production of rigid polyurethane foam insulation, a roll of baking paper is spooled at the start of the processing line. This paper is moved along a conveyor and brought under the dispensing head.

● As the paper passes under, polyurethane is blown onto it. As the polymer is dispensed, it is mixed with carbon dioxide which causes it to expand. It continues to rise as it moves along the conveyor. (The sheet of polyurethane is known as a bun because it "rises" like dough.)

● After the expansion reaction begins, a second top layer of paper is rolled on. Additionally, side papers may also be rolled into the process. Each layer of paper contains the polyurethane foam giving it shape. The rigid foam is passed through a series of panels that control the width and height of the foam bun. As they travel through this section of the production line, they are typically dried.

● At the end of the production line, the foam insulation is cut with an automatic saw to the desired length. The foam bun is then conveyored to the final processing steps that include packaging, stacking, and shipping.

Regular cleaning: Clean PU products regularly to remove dirt, dust, and stains. Use a mild soap or detergent mixed with water and a soft cloth or sponge. Gently wipe the surface in a circular motion, avoiding excessive scrubbing or rubbing.

Avoid harsh chemicals: Avoid using harsh chemicals, solvents, or abrasive cleaners on PU products as they can damage the material. Stick to mild cleaning solutions and test them on a small, inconspicuous area before applying them to the entire surface.

Protect from sunlight: PU products can be sensitive to prolonged exposure to direct sunlight, which can cause fading or discoloration. Keep PU items away from direct sunlight or use protective covers or curtains to shield them.

Prevent sharp objects: Avoid placing sharp objects or tools on PU surfaces as they can cause scratches or punctures. Be cautious when handling or using items near PU products to prevent accidental damage.

Avoid excessive moisture: PU is not completely waterproof, so it's important to avoid excessive moisture or prolonged exposure to water. Wipe off any spills or moisture immediately with a dry cloth to prevent absorption into the material.

Use protective coatings: Consider using a PU protectant or conditioner specifically designed for PU products. These products can help maintain the material's appearance, flexibility, and durability.

Store properly: When not in use, store PU products in a cool, dry place away from direct sunlight and extreme temperatures. Avoid folding or compressing PU items for extended periods, as this can cause creases or permanent damage.

Polyurethanes were invented back in the 1930s by Professor Dr. Otto Bayer (1902-1982). There are various types of polyurethanes, which look and feel very different from each other. They are used in a diversity of products, from coatings and adhesives to shoe soles, mattresses and foam insulation. However, the basic chemistry of each type is essentially the same.

Widespread use of polyurethanes was first seen during World War II, when they were utilised as a replacement for rubber, which at the time was expensive and hard to obtain. During the war, other applications were developed, largely involving coatings of different kinds, from aeroplane finishes to resistant clothing.

By the 1950s, polyurethanes were being used in adhesives, elastomers and rigid foams and, in the latter part of the same decade, flexible cushioning foams similar to those used today.

Subsequent decades saw many further developments and today we are surrounded by polyurethane applications in every aspect of our everyday lives. While polyurethane is a product that most people are not overly familiar with, as it is generally ‘hidden’ behind covers or surfaces made of other materials, it would be hard to imagine life without polyurethanes.

Polyurethane (PU) is a composite material made of: (1) one or more layers of polymer resins joined by urethane links; and (2) a woven or non-woven textile backing such as polyester, cotton, nylon, or ground leather. The PU coating is applied to a single side of the base fabric and then treated to look more like animal hide. This makes the fabric water resistant, light weight and flexible. This fabric provides the most realistic imitation of leather when it comes to its soft supple hand. When stitched, gathered, or tufted it actually “breaks” or wrinkles like real leather.

PU resins are made of a soft polymer and unlike vinyl don’t need added plasticizers. Because no plasticizers are used in PU upholstery there is no cracking or peeling, and it remains soft and supple for the duration of time it remains on the furniture. PU fabrics are also easier to decorate. PU is considered greener than vinyl because it does not create dioxins. PU costs less than real leather, but it can be more expensive to produce than vinyl.