Stable form for 80 years

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In 1937, at the age of 35, Otto Bayer makes the discovery he is famous for today: Together with his team, he discovers the polyaddition of isocyanates and polyols to polyurethane. The possibility of forming a hard foam by mixing small quantities of chemical substances does not seem to be feasible. Otto Bayer has to face several difficulties after achieving a usable result. Even after the chemist and his team are able to produce polyurethane foam, it takes several years for the material to be custom-produced.

In the following years, this invention, too, is not spared from the current political development in Germany. Like many other German inventions of that time, it is discovered for its usability for war purposes. Consequently, PUR foam is soon also tested for military use. In particular, parts with a resin-impregnated paper skin are tried out for the construction of, for example, aircraft. Here, too, its lightweight properties and form stability seem to offer advantages for aviation and transport.

In specialist circles, people call such cases dual-use: Civilian inventions are frequently recognised as useful by the military (or the other way round), and are subsequently exploited or further explored. Other prominent examples of this practice are thiodiglycol, better known as mustard gas, which also finds application in the cosmetics industry and microscropy, or the Internet.

The rise of PUR begins after the Second World War

In the 1950s, after the end of the Second World War, the material finds application in areas where it is used even today. Manufacturers start to use soft polyurethane foams for cushioning and mattresses. Harder foams find applications for insulation purposes. The automotive industry also discovers the material and starts using it for impact protection.

Nowadays, PUR foam is everywhere. There is no sign of its triumphal march ending. Still, efforts are being taken today to reduce the use of isocyanates for the synthesisation of polyurethanes. They are said to not so raise severe toxicity issues. Isocyanates are suspected of causing cancer and can trigger allergies. Polyurethanes do not contain harmful substances when fully reacted, but efforts have been taken to reduce harmful ingredients.

Bayer, not alone thanks to Otto Bayer, is still one of the key players on the polyurethane market in Europe today. Other important companies are BASF (Baden Aniline and Soda Factory), and the Swedish company, Chematur Engineering. According to a report by Markets & Markets, the polyurethane market will be worth $ 90 bn by 2021.

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