Upholstered furniture is a serious purchase. Everyone wants her to please for at least 10, and preferably 20, years. When choosing a sofa, you need to take into account the appearance and its quality characteristics. Before buying, you need to ask yourself which filling for the sofa is better. The comfort, ergonomics and durability of the sofa will depend on this.
Manufacturers of upholstered furniture present many types of sofas:
- for office;
- for the living room;
- for kitchen;
- for the hallway;
- for a children's room;
- classic bay windows.
The last type of sofa is suitable for rooms with a bay window, since ordinary ones will not fit into such an interior. Each type of sofa has its own price range and technological characteristics.
Let's look at what types of fillings there are in order to understand which filling to choose for a sofa.
Sofa stuffing
Spring blocks
Spring blocks have long been used in upholstered furniture. This is one of the oldest fillers. The spring block makes the sofa elastic and comfortable. Manufacturers especially often install spring blocks in double sofas (Eurobook type). Blocks can be dependent or independent.
Dependents
The springs are interconnected. When pressure is applied to one spring, pressure is applied to the adjacent one. Springs can have different diameters. The smaller the diameter, the higher the density and vice versa. The top of such blocks is usually covered with polyurethane foam and coconut board.
We recommend reading the article about wooden sofas.
Independent
Each spring is packed in a fabric case. They compress under a part of the body independently of each other and create comfort for sleeping and sitting. Mattresses are made from such blocks. Therefore, they are usually used in beds rather than sofas.
Springs
Molded foam rubber (FPPU) in the production of soft chairs
Since the technical properties and wear resistance qualities of molded foam rubber differ from other types of polyurethane foam, the technique of its use in the manufacture of chairs also differs. In the following articles we will talk about what a “foam rubber sandwich” is, and at this stage, we should understand the features of using a more advanced material - molded polyurethane foam or FPPU.
The peculiarity of using such material is the absence of constructive technologies that are difficult to implement. All that is required is to select the desired shape of the anatomical FPPU and attach it to the frame base of the seat. No other material is placed on top of the FPPU, but everything is simply covered with dense material, creating visual appeal.
A clear example of the quality of the synthesis of new technologies and innovative developments is presented in the Barsky models:
- Armchair Barsky Eco.
- Butterfly.
- Barsky Style.
These options will not only last 7-10 years, but will also look equally attractive all this time.
Today, molded foam rubber is a new technological development that is popular in the production of car furniture. However, the advantages of elastic material did not go unnoticed by the Ukrainian manufacturer Barsky. Today you can buy a chair with anatomical memory and high wear-resistant properties in Ukraine directly from the manufacturer. You will get tired of the design of the chair faster after several decades than it will have time to wear out.
Polyurethane foam
Probably the most common filler. The second name for polyurethane foam is foam rubber. Thanks to its plasticity, manufacturers can recreate fancy shapes in pillows.
Foam rubber is divided into types:
- standard ST;
- hard EL, HL;
- soft S;
- increased comfort HR;
- viscous elastic LR.
The rigidity of PU foam reflects the degree of compliance of the walls of the bubbles. The lower the rigidity, the easier it is to push through the polyurethane foam, that is, the softer it is. Indicated by the second digit of the PPU brand. Polyurethane foam with high rigidity is used in formative elements, as well as for shelling the frame. Polyurethane foam with reduced rigidity - in the seat and back. At the same time, the rigidity in the backrest will be lower than in the seat, since it bears the main weight of the person, and if there is insufficient rigidity, he will simply fall down to the frame. However, excessive rigidity leads to the fact that sitting will be uncomfortable, like on a stool.
ST (Standard) - popular and often used fillers. They are used in any part of the sofa - from lightly loaded ones (armrest) to seating areas that can withstand a load of more than 90 kg.
EL, HL (Enhanced Loadbearing, High Loadbearing) – rigid foams with high load-bearing capacity. They are used mainly to create a configuration (for example, for shelling a frame).
S (Soft) – soft foam. Used in back cushions and sandwich seats
HR (High Resilience) – highly elastic foams. These are more expensive brands. They are used to provide greater comfort. Unlike standard PU foam, inside HR the air bubbles have different sizes, and the walls between them are of different thicknesses, which gives the PU foam special properties. During initial loads (when a person is just starting to sit on the sofa, but has not yet sat down completely), large bubbles begin to work, since air comes out of them faster, and the person feels soft when sitting down. As the load increases, smaller bubbles begin to work, which resist more strongly, providing a supporting effect. Thus, HR PU foam has two properties: pliability and elasticity at the same time. Such foams are comfortable for both a person with a large mass and a small one.
Balloons
LR – viscous elastic or memory foam. The most expensive foam rubber. It conforms to the body's shape and provides the best comfort. If there is no strong pressure on the pillow, it returns to its original position.
Manufacturers create original pillows in the form of so-called sandwiches. Sandwich is a combination of several brands of polyurethane foam with different properties of the soft element, which gives the pillow design increased comfort.
Scope of application
Excellent performance characteristics make this material optimal for the production of upholstered furniture. Molded polyurethane foam can be used in models with or without embedded elements. Armchairs, sofas, seats with such filling have a higher level of comfort than traditional ones. This opens up broad prospects for the production of luxury furniture.
Strength, reliability, durability - the optimal parameters for arranging public places. Therefore, FPPU is used in the manufacture of seats for public transport, stadiums, arenas, and halls.
MFM offers its clients not only the production of finished products from molded polyurethane foam. If necessary, we will produce custom molds of the required configuration. It is also possible to manufacture soft structural elements for various purposes: buffer, decorative, etc.
You can get more detailed information and free personal consultation from our specialists. Contact us by phone or email listed on the website - and we will advise you on the best option for you!
Molded PPU (FPPU)
Pillows are obtained as a result of the interaction of chemicals that are poured into specially made molds. The part is produced under the influence of pressure and temperature. The advantages of the method are the high quality of the workpiece and smooth shapes. FPPU is the most durable of all categories of polyurethane foams.
If something fails (for example, removable pillows), replacement is done at home with your own hands. You just need to contact the manufacturer, who will make a new soft element, and then insert it into the case.
Purpose of molded foam rubber
The need to satisfy the new technological needs of furniture production gave rise to the invention of a new type of foam rubber - molded. In most cases, it is used to make car seats. This is necessary in order to ensure comfort during a long stay in the chair, and to ensure comfort during any side-to-side movements. In this case, any pressure at one point or completely on the surface of the product does not leave any traces:
- the shape of the seat remains the same even after a long stay in the chair;
- after many hours of work, the soft filler does not lose its shape, it remains just as soft and elastic;
- regardless of the consumer’s body constitution, the load on the surface is distributed evenly;
- It is more likely that the upholstery fabric will wear out than the molded filling itself.
To be honest, the use of such an expensive, but highest quality material in the furniture industry is nonsense. However, such pleasant exceptions still exist. It’s worth mentioning right away that foam rubber of persistent density and elasticity is in itself an expensive material. If we take into account the molded type of such material, then its cost increases several times. But this is not what should worry buyers who want to purchase a high-quality chair for their home or office.
Molded PU foam is made with a relatively higher percentage of latex than primary or secondary PU foam. This form is slippery to the touch, but pleasant.
Molded foam rubber has improved physical properties compared to other types of polyurethane foam. During the manufacturing process, its surface is covered with a special polyester crust, which guarantees the airtightness of the material, but improves its physical qualities. Of course, a number of characteristics are determined by the peculiarities and production techniques.
On the Ukrainian furniture production market it is difficult to find a manufacturer who would use such expensive materials.
Soft fillers
Among the soft fillers, the following stand out.
Britfil (holofiber, synthetic fluff)
Everyone knows artificial filler with different names. The fibers of the material create a strong, springy structure. Britfil compresses well and “breathes”, and is anti-allergic.
Despite all the advantages of this material, to work with it you need certain technological support for production:
- before using Britfil it is necessary to comb and beat it, to make its structure homogeneous and airy, which is only possible in a special machine under air currents, otherwise the filler will look like separate lumps;
- the filling of soft elements must be uniform, which is also ensured by a special machine;
- To ensure long-term service of the soft element and maintain its shape, manufacturers use the cellular structure of the pillow, stuffed with Britfil.
Inside view
Sintepon
This is a synthetic material in the form of a non-woven fabric. Basically, in the furniture industry, synthetic winterizer is used to wrap parts in order to hide any technological transitions (additional layer).
Production Features
Molded foam rubber is the most advantageous wear-resistant material, the main weight component of which is polyester. The percentage of such a component determines the “airiness” and density of the finished product. Polyester is:
- Complex . Due to its qualities, the material is used, as a rule, for the production of filters and fire-resistant duplication (fabric and eco-leather are used). In the production of chairs, such foam rubber is not used for the reason that the moisture present in the room will gradually destroy the soft filling.
- Simple. This option is used and widely used for high-strength soft products for home and office, in particular for extra-class chairs.
Manufacturing technique
The production technique also differs in the method:
- Periodic . It is also called “box”. This method is the most commonly used and has a half-century history. The essence of production: foam is poured into separate boxes with partitions; After the foam has risen (like dough), the partitions are removed. The only peculiarity can be considered the difference between the foam rubber compartments.
- Continuous . Provides for the need for a conveyor along which the formed foam flows. This method makes it possible to obtain blocks of various lengths up to 60 m. This option is more effective because it produces less waste: approximately 1.5 m of the first batch is spoiled (foaming and the start of machine operation). The remaining batches are of ideal shape and identical consistency.
In Soviet times, there was only one elastic polyurethane foam on sale from Sweden, which was called “Porolon”. That’s why we call any flexible polyurethane foam used in the furniture industry – foam rubber.
