Polyurethane has been shaping industries since its invention in 1937, playing a key role in everything from textile coatings to construction and automotive design. However, its widespread use has also raised environmental and safety concerns. For example, high carbon impact and use of toxic isocyanates. In turn, this has lead to development of decarbonized and detoxified alternatives, such as Polaris. In this article we explore the lifetime of polyurethane. Below is a timeline that captures the key developments in the history of polyurethane and its evolution towards 100% biobased materials.
Otto Bayer, a German chemist working at IG Farben, invents polyurethane through a polyaddition reaction between diisocyanates and polyols, forming the first PU polymer.
During World War II, polyurethane is used as a replacement for rubber, primarily in military coatings and adhesives. Polyurethane foam is developed for insulation and cushioning in military aircraft.
Flexible PU foam becomes commercially available, used in furniture, mattresses, and automotive seating. PU coatings gain popularity in the textile industry, providing durable finishes. Elastomers enter the market, used in seals, gaskets, and industrial components.
Rigid polyurethane foam is developed, becoming a key material for building insulation and refrigeration. Thermoplastic polyurethane (TPU) is introduced, offering flexibility and reshaping properties, used in footwear and sports equipment.
PU gains widespread adoption in the automotive industry for parts like bumpers, dashboards, and interior trim. PU becomes a popular material for lightweight, cushioned shoe soles.
Spray polyurethane foam (SPF) becomes widely used for building insulation due to its excellent sealing and insulating properties. Polyurethane coatings advance and are extensively used in marine, automotive, and industrial applications for corrosion and abrasion resistance.
A toxic gas leak from a pesticide plant owned by Union Carbide in Bhopal, India, exposed over 500,000 people to methyl isocyanate (MIC), leading to one of the world's worst industrial disasters. The immediate effects caused thousands of deaths and long-term health issues, with estimates of the death toll ranging from 15,000 to 20,000 over time.
The Supreme Court of India approves a settlement between Union Carbide and the Government of India, with Union Carbide agreeing to pay $470 million in compensation to the victims.
Polyurethane elastomers continue to evolve and are used in industrial parts, wheels, and gaskets for their flexibility and toughness. Polyurethane adhesives gain widespread use in construction, packaging, and automotive sectors.
Biobased polyurethane, made from plant-based polyols like soy, castor oil, and corn, emerges as a more sustainable alternative. Polyurethane foam insulation becomes a critical component of green building practices, though environmental concerns persist regarding fossil fuel reliance and hazardous byproducts.
Waterborne polyurethane coatings gain popularity due to their lower VOC emissions compared to solvent-based versions. Development of recyclable polyurethane begins, aiming to address the environmental challenges of non-biodegradable PU. Polyurethane sees performance improvements in sports equipment, medical devices, and electronics.
A fire breaks out at the Flexfoam factory in Valenzuela City, Philippines, which produced polyurethane foam products. The fire was caused by electrical sparks near stored foam materials and spread quickly due to the flammable nature of polyurethane foam . This incident raised concerns about safety in factories handling polyurethane, particularly due to the toxic fumes released when the foam burns.
Advances in circular economy practices aim to create more recyclable or reusable polyurethane in closed-loop systems. Biobased polyurethane development focuses on improving scalability and performance to replace petroleum-derived components. Nanotechnology is integrated into PU, creating stronger and lighter composites for advanced applications like electronics and aerospace. Polyurethane materials are increasingly used in 3D printing for flexible, strong, and customizable components in footwear, medical devices, and prototyping.
From its early days of invention to its widespread applications across multiple industries, polyurethane has continually evolved. The journey from military coatings to sustainable alternatives has taken decades, with continuous advancements in chemistry and technology. While it took ten years from invention to commercialization, further decades were spent perfecting its applications in consumer goods. Today, with the integration of AI through the Matereal platform, we are fast-tracking the innovation process, accelerating the development of new polyurethane formulations for the future.
