Upholstered Furniture
Polyurethane foam is a widely used material in the upholstery and furniture industry due to its versatility, comfort, durability, and cost-effectiveness. Here’s a comprehensive breakdown of its application and usage:
There are two main types:
Flexible polyurethane foam (FPF) – Soft and used in cushions, mattresses, etc.
Rigid polyurethane foam – Used for insulation and structural applications, not typically for furniture.
Description
Foam Densities in Upholstery
| Density (lbs/ft³) | Application | Characteristics |
| 1.2 – 1.8 | Low-end furniture cushions | Softer, less durable, budget-friendly |
| 1.8 – 2.5 | Mid-range sofas/chairs | Good durability and comfort balance |
| 2.5 – 3.0+ | High-end furniture, mattresses | Firm, long-lasting, premium feel |
Best Practices for Upholstery Use
- Select appropriate foam density based on usage (e.g., frequent seating needs higher density).
- Use a protective barrier (e.g., batting or dacron wrap) between foam and fabric.
- Consider fire-retardant foam if required by safety regulations.
- Allow foam to air out before covering to reduce odor from manufacturing.
Cushioning: PU foam is used in sofas, chairs, mattresses, and automotive seats, offering support and comfort in seat and back cushions. It comes in varying densities and firmness levels to meet different comfort and durability requirements.
Mattresses: PU foam is used in memory foam and hybrid mattresses to provide body contouring, pressure relief, and motion isolation.
Padding: PU foam is applied under fabric or leather upholstery to create a soft surface, reducing wear on outer materials and enhancing comfort.
Structural Filling: In low-density forms, it can fill out curved or contoured shapes in upholstered items.
Comfort: Good cushioning and support.
Durability: Long-lasting and retains shape with proper density.
Lightweight: Easy to handle and work with during manufacturing.
Cost-effective: Economical compared to other types of padding or filling.
Customizable: Available in multiple densities, firmness levels, and sizes.
High Resilience (HR) Foam: Offers better support, elasticity, and durability.
Memory Foam (Viscoelastic PU): Adapts to body shape, used in premium cushions and mattresses.
Rebonded Foam: Made from recycled foam scraps, used for firm cushions or underlayers.
Related Products and Applications
Testing Rooms
Testing RoomsPolyurethane acoustic foam is a key material used in automotive sound testing rooms (also known as NVH test labs or acoustic chambers) to create a controlled, reflection-free environment. These rooms are essential for testing vehicle components, interior cabin noise levels, engine sounds, and more — and PU foam plays a critical role in absorbing sound and eliminating echoes.
Office Chairs
Office ChairsPolyurethane (PU) foam is a core material in ergonomic office chairs, providing the necessary cushioning, support, and durability for extended sitting periods. Its versatility allows manufacturers to design seats and backrests that balance comfort with posture support.
Chair Pads
Chair PadsPolyurethane (PU) foam is a popular material used in chair pads for its combination of comfort, durability, flexibility, and cost-efficiency. Whether for office chairs, dining chairs, wheelchairs, or outdoor seating, PU foam enhances sitting comfort while providing necessary support.
Headrests and Armrests
Headrests and ArmrestsPolyurethane (PU) foam is widely used in automotive interiors, particularly in armrests and headrests, where comfort, durability, and design flexibility are essential. Its ability to be molded into complex shapes and maintain its properties over time makes it ideal for these applications.
