Polyurethane foam is a porous substance made from synthetic polymers. People often use the name “foam rubber”. PPU is used as a filler for sofas and other furniture. High-quality material is characterized by high elasticity and density. If you are interested in specific brands, the following are usually used:
- ST 2236 - designed for a load of up to 60 kg, short service life;
- ST 2536 - provides a hard surface and can withstand up to 100 kg of load;
- ST 3540 is a brand of high-quality polyurethane foam, durable and designed for heavy weight.
Advantages of PPU:
- High-quality, dense polyurethane foam serves faithfully for more than 15 years.
- Products made from it have the highest level of hygiene: they do not retain moisture, dry quickly and do not rot; are not a breeding ground for pathogenic bacteria and mold fungi; do not accumulate dust and dust mites. There are practically no insects in them.
- The material does not cause allergic reactions even in the most sensitive people and infants. Does not emit toxic substances when heated and exposed to ultraviolet radiation. It is completely safe for the health of people and pets.
- Quickly returns to its original shape even after extreme compression. Does not deform over time.
- The polyurethane foam surface easily adapts to the contours of the body, perfectly relieving muscle tension and stress from the spine and joints. This sofa provides complete rest and a comfortable night's sleep, no worse than on specialized orthopedic mattresses.
- Thanks to the porous structure, the entire internal contents of the sofa cushions are perfectly ventilated. Air and moisture do not stagnate, which increases the service life of the products.
- It serves as an excellent insulator, so a PPU mattress is always warm and cozy.
What is the difference between spring and polyurethane foam sofas?
According to the type of filling, upholstered furniture, in particular sofas, are divided into two main types:
- spring;
- polyurethane foam.
Each of these types has its own pros and cons. It is worth noting that there is no universal option without a single drawback. Therefore, to figure out which sofa is better - a spring one or one with polyurethane foam filling, you should consider both fillings in terms of ease of use, durability, cost and design.
Are spring sofas outdated or time-tested?
The design of modern and old sofas based on a spring block has remained virtually unchanged. This technology has been widely used since Soviet times. The difference lies in the higher quality of manufacturing of new furniture.
Nowadays, special flooring materials are used between the metal springs and the upholstery to seal the frame. At the same time, they perform the function of a protective layer - the springs do not penetrate the upholstery and are not felt when the furniture is used for its intended purpose.
Required design elements of a spring sofa:
- upholstery;
- laying sealing layer in the form of padding polyester, felt fabric or a thin ball of foam rubber;
- springs;
- Chipboard or plywood that serves as a solid base for the block.
The device of a spring sofa.
Depending on the design features, there are two types of spring blocks:
- Bonnell spring block;
- independent block (“Pocket Spring”);
Sofas with Bonnell spring block.
Bonnel spring sofas are traditional and widespread. They have been used by upholstered furniture manufacturers for decades. The design of such a spring block is based on bicone-type steel springs. They are connected to each other using wire and knots or a special frame.
Bonnell spring block.
In this case, each spring narrows in the middle and expands closer to the edges. The main block consists of upper and lower frames. Due to this, the strength of the entire structure is achieved. It is also possible to avoid unwinding of the springs, each of which is attached to the block by the first turn and the last. There are special locks on the turns.
The main difference between such a block and an independent one is the tight fastening of all elements to each other. They are connected, but there is no squeaking sound because the springs are not touching. When pressure is applied to the surface, the entire structure is activated in a chain reaction, i.e., not only those springs on which the pressure is applied bend, but also all neighboring ones.
Sofa with Bonnell spring block.
Each manufacturer independently determines what the spring density should be. On average, their number is 100-150 pieces per square meter. Springs can consist of four or five turns, depending on the type of weaving. Five-turn blocks are slightly taller and slightly more expensive. To ensure increased elasticity, the material is additionally processed using a thermal method. Bonnell has a certain number of advantages and disadvantages.
Advantages of sofas with Bonnel spring block
- Long service life.
- Strength, elasticity, ability to withstand heavy loads.
- Low cost.
- Good level of ventilation.
Disadvantages of sofas with Bonnel spring block
- Low orthopedic properties associated with possible compression of several adjacent springs attached to the frame. The surface becomes wavy and uncomfortable.
- A “hammock effect” occurs. Uneven load distribution.
- In rare cases, under heavy loads, the spring may straighten, causing a visual defect and inconvenience in use.
- Long-term use can lead to loosening of the fastening system and the appearance of creaking sounds. The solution to this drawback is the use of durable layers of foam rubber, which serve as additional reinforcement of the frame.
Sofas with independent spring block
Sofas with an independent spring block (Pocket Spring) are considered less common. Unlike Bonnell, this design has a significantly increased spring density. In addition, they are not connected to each other in any way; each is equipped with a separate case.
The spring compresses only when pressure is directly applied to it and does not affect its neighbors. Thus, at all points of contact of the body with the structure of the sofa, the load on it is distributed evenly. The furniture does not sag and retains its original appearance throughout long-term use.
Sofa with independent spring block.
Compared to the dependent block, in this case the springs are slightly smaller. Accordingly, their density becomes higher, up to 1000 pieces. The optimal option is considered to be a density of 350 springs per square meter. It is believed that if there are too many springs, they will begin to deform over time, affecting more and more neighboring elements. At the same time, the anatomical properties of the structure, which affect ease of use, are reduced.
An independent block is a more preferable option than Bonnell, as it provides a comfortable stay. However, design features also affect the cost of such a sofa.
Polyurethane foam: comfort and flight of design imagination
Polyurethane foam (PPU) filling of upholstered furniture is known under a simpler name - foam rubber. The material has been used for quite a long time and gradually it was possible to achieve the most useful properties of polyurethane foam, due to which foam rubber is considered environmentally friendly and has high performance qualities. Foam can have different degrees of rigidity, but the most elastic varieties are used in the manufacture of furniture.
Polyurethane foam is light and airy due to its specific structure. The filler is a polymer foam whose structure resembles a honeycomb. Each cell in it is a bubble filled with air. Due to the fact that most of the total mass is air, a sofa with such filling quickly restores its previous shape.
Advantages of PPU filler:
- light weight;
- elasticity (restoration of shape);
- high breathability.
Next, we will consider the types of polyurethane foam filler depending on the structure.
Cast (molded) polyurethane foam.
If the sofa has a non-standard shape, cast filler is most often used. To produce it, you need a special blank into which raw materials are poured. The result is a finished block of the required shape. It has higher elasticity and density.
Sofa made of polyurethane foam.
Sheet polyurethane foam.
In order to improve quality and performance properties, manufacturers often combine different types of foam rubber in one product. The polyurethane foam block is cut into separate sheets, which are glued together. If layers of different degrees of hardness are used, they are painted in different colors.
Sofa made of sheet polyurethane foam.
Highly elastic polyurethane foam (artificial latex).
The most comfortable use is furniture made using highly elastic polyurethane foam. This type of filler is characterized by a combination of density and softness, which provides high orthopedic properties.
However, sofas made of polyurethane foam also have their pitfalls - it is important to fully study the design features. In high-quality sofas, polyurethane foam is attached to a movable base. As such a base, special tightly tensioned belts with elastic properties or a block of lamellas can be used.
Sofa with belt base.
Sofa with slats base.
Some sofa manufacturers are trying to save money and use chipboard or plywood instead of slats. This kind of saving leads to the fact that the foam sags if significant pressure is applied to the surface. After some time, you can notice irregularities on the surface, which are also felt physically.
Sofa with plywood base.
How to determine the presence of a lamella frame? It is located under the seat block and has the shape of a frame with curved wooden slats. The presence of this base indicates the quality of the product.
Features of the material
Polyurethane foam has found its greatest application in the furniture industry. Today it is difficult to imagine mattresses, upholstered furniture, garden furniture, car upholstery materials or even foam toys without the use of polyurethane foam. Polyurethane foams are produced in different shapes, densities, hardness, and colors. The functionality of upholstery foams and their diversity have made it possible to use this material wherever you need comfort while sleeping and sitting, silence or the lightness of solids. Polyurethane foam and upholstery sponge surround us every day in public and private spaces.
The furniture industry is one of the fastest growing in the Russian market. The high development potential of this sector and the market maturity of manufacturers have a significant impact on the domestic production of polyurethane foam. It is a frequently used material for upholstered furniture and mattresses.
Soft polyurethane foam is used in the production of furniture and sleeping mattresses. Almost 75% of European production of this material is intended for furniture manufacturers. The demand for this material in the markets is estimated at more than one million tons per year. A good situation in the furniture market means a satisfactory state of PU foam production in Russia. The demand for them is growing every year. It is not surprising, because they are now the main factor influencing the comfort, durability, and safety of furniture.
Flexible polyurethane foam gives furniture elasticity, has a positive effect on comfort of use, and increases durability. For exclusive furniture, highly plastic polyurethane foam is used, which quickly restores its original shape after removing the load. The foam adapts to the shape of the load, especially our body, which greatly increases the comfort factor.
Polyurethane foam is hygroscopic, soft, light and breathable, therefore it is also successfully used by manufacturers of medical and rehabilitation furniture.
Classic polyurethane foams are used for the manufacture of seats, backs, and mattress inserts. They are typically used in conjunction with springs and in popular furniture. Foams with a high plastic content are, in turn, used in the production of mattress inserts instead of innerspring inserts because they can provide the same or even greater comfort. You can buy an orthopedic sofa in our online store in Moscow.
High density foam is used to shape upholstered furniture. It is recommended to use lower density foam for the armrests and backrests. PUF is also used in headboards, decorative headboards, furniture sides, seats, poufs, mattress toppers, surface mattresses and orthopedic mattresses.
The best springless natural fillers
Any filler that is used in the production of upholstered furniture or mattresses has its own properties.
Latex mattress - high quality, comfortable and safe
Horsehair for the production of upholstered furniture and mattresses
Coconut filling for children's mattress
Useful and healing filler for upholstered furniture - sea grass
Bamboo fiber is ideal for mattress covers, blankets and pillows
Camel wool is an excellent warm filling material for blankets, pillows, blankets, mattress covers and winter mattress options.
Natural felt for furniture and other industries
The best springless synthetic fillers
Furniture polyurethane foam - an affordable and convenient material for frameless furniture
Synthetic down - the artificial material of the future
Synthetic winterizer is a material suitable for people suffering from allergies.
PerioTek filler is an elastic, voluminous and durable material
Padded padding for the manufacture of upholstered furniture
Disadvantages of the material
Among the disadvantages of the material it is worth noting:
- Low quality polyurethane foam often cracks - quickly loses its original shape, and furniture quickly sags.
- The material does not tolerate direct sunlight and begins to deform. For production, upholstery is made from materials that protect from light.
- Price. Although it is a durable and soft material, it will be more expensive than most other options. Polyurethane foam may cost more than some of the cheaper alternatives on the market.
- Excessive softness of the material can lead to back problems and spinal curvature in children. Therefore, it is better to sleep on a hard surface.
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.
How to use
Polyurethane foam itself is quite an expensive material. And finding a mattress filled only with it is quite problematic. It is important to know when buying a polyurethane foam mattress: such products, as a rule, contain a filling consisting of several layers: in addition to the main material, coke fiber is often used. Or polyurethane foam is used as a covering for the springs. Even such a small amount of material used to make a mattress can improve its properties.
For greater effect, manufacturers additionally strengthen the walls and corners of the mattress. Thanks to this, when you lie down on the bed, the mattress does not change shape so dramatically (after all, this can usually cause inconvenience). This also extends the life of the mattress, which receives additional protection from damage.
But sometimes you can find mattresses that are a solid block of polyurethane foam. Their price is higher, but this is not without reason. They do not have springs and have a higher density. Therefore, they can be placed even on uneven surfaces, while maintaining the feeling that you are sleeping in your own bed. True, these mattresses take longer to make, which also makes them difficult to buy.
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:
Based on these characteristics, you can decide whether PPU filler is suitable for you or not.
Varieties
In the production of sofas, different types of polyurethane foam can be used as filler.
There are the following varieties, as well as types of polyurethane foam:
PU foam differs in class and physical and chemical properties.
Also in furniture production, block and cast polyurethane foam can be used in the manufacture of sofas.
Block material is supplied in large blocks. At a furniture factory, polyurethane foam is cut into the required sizes and thickness, and then the sofa padding is formed.
Molded PU foam sheets are solid products that are made in special molds for a specific furniture configuration. The advantage of this method is that there is no waste. Not suitable for non-standard shaped sofas.
