Nearly all household furniture is made primarily out of a very common and versatile product called polyurethane. This is a durable foam with insulating properties that, if bent or pressed, will always return to its original shape. This makes it extremely comfortable as a padding, and ideal for any number of modern utilities.
To create this omnipresent and useful product, a furniture foam manufacturer will use a tried and true process that was developed in the 1930’s. The creators of polyurethane were most likely unaware of just how useful their invention would prove to be; now, it is used in building insulation, construction molding, paint rollers, athletic pads, ship and airplane walls, and household furniture. Its production has become a major industry, and the process for it has not changed much over the years.
At the start, a furniture foam manufacturer has a large steel vat containing a variety of liquids. These liquids are basically a formula of highly reactive alcohols and several additives that maintain the integrity of the alcohols against light and oxygen. A specific amount of the raw material (controlled by a meter at the end of the initial storage vat) is pumped into a tube leading to a heat exchanger. This is where the liquid is heated to the temperature necessary to begin the reaction.
The raw materials continue to move through the heat exchanger, and by the time they reach the end of the tube system, the reaction is done, the polyurethane is formed, and a dispenser is set up to shape the foam. In this specific circumstance, a furniture foam manufacturer will feed the foam onto paper that runs through the processing line. This helps keep the final product rigid, which is necessary for use as furniture padding.
As the polyurethane is blown onto the roll of paper, carbon dioxide is mixed in, causing the product to expand as it moves along the conveyor belt. This expansion process is controlled throughout the production line. A second layer of paper is pressed on top to keep the material in its desired shape, and a series of panels help to control the width and height. A drying process also begins here, which completes the chemical reaction. At the end of the production line, a saw cuts the polyurethane into the length desired by the manufacturer.
Once the production is completed, there is a quality control phase. Quality control actually begins with the raw materials, where chemists make sure the chemical mixture is optimized for the perfect final product. At the end of the production line, characteristics such as thickness, firmness, absorbency, flexibility and elasticity are checked.
If more information is desired, interested parties may call a furniture foam manufacturer for more information. The desired use of the final product also affects the production process.
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