Surgical removal of polyurethane foam from nasal cavity.

Hidden Dangers: When Nasal Congestion Turns Into a Medical Mystery

Beau Callahan in Health & Wellness November 2025 • 4 min read.

"Unveiling the rare case of polyurethane foam inhalation and its surprising impact on nasal health"

Nasal foreign bodies are a common issue, particularly among children and individuals with mental disabilities. These objects can range from plastic toys and pebbles to seeds and buttons. While many are easily removed, some adhere to the nasal mucosa, potentially causing complications like necrosis or neurovascular injury.

A recent medical case in Korea highlights a rare and previously unreported occurrence: polyurethane foam inhalation leading to nasal cavity obstruction and a subsequent inflammatory response. This article delves into the details of this unique case, exploring the challenges and treatments involved.

Polyurethane, unlike typical foreign objects, can adhere strongly to the skin or mucous membranes. If hardened, it becomes difficult to remove and may cause parts of the surface to detach, leading to further complications. The potential toxicity of polyurethane as a chemical compound must also be considered.

The Case Unfolds: A Polyurethane Puzzle

Surgical removal of polyurethane foam from nasal cavity.

A 38-year-old man presented with complaints of foreign body sensation, nasal obstruction, and decreased sense of smell in both nasal passages. These symptoms began two days prior when he inhaled polyurethane during a work-related activity. His medical, social, and family history were unremarkable.

Upon examination with a nasal endoscope, soft, whitish, sponge-like masses were observed surrounding the middle and inferior turbinates on the right side, extending to the nasopharynx on the left. Initial attempts to remove the material with forceps were unsuccessful due to its strong adherence to the surrounding mucosa. The patient experienced significant discomfort during the attempted removal, accompanied by nasal discharge. The presence of a bony spur in the left nasal cavity further complicated access to the foreign material.

The challenges in the case included:

Strong adhesion of the polyurethane foam to the nasal mucosa.
Patient discomfort and nasal discharge during removal attempts.
Limited access due to a bony spur in the nasal cavity.
Potential toxicity of the inhaled material.

A paranasal sinus computed tomography (CT) scan revealed the presence of a foreign material with air bubbles throughout both nasal cavities, surrounding the turbinates, and extending into the nasopharynx. While the sinuses themselves were clear, some foreign material was observed near the openings of the maxillary sinuses. Given the difficulty of removal and the uncertainty of the material's behavior over time, surgical intervention was planned.

Lessons Learned and Future Considerations

This rare case underscores the importance of considering unusual foreign bodies in the nasal cavity, especially in occupational settings. Clinicians should be aware of the potential for polyurethane foam inhalation and its associated complications. Careful endoscopic examination and CT imaging are crucial for accurate diagnosis and treatment planning. This case highlights the need for a multidisciplinary approach to managing complex nasal foreign bodies and preventing potential long-term complications.

About this Article -

This article was crafted using a human-AI hybrid and collaborative approach. AI assisted our team with initial drafting, research insights, identifying key questions, and image generation. Our human editors guided topic selection, defined the angle, structured the content, ensured factual accuracy and relevance, refined the tone, and conducted thorough editing to deliver helpful, high-quality information.See our About page for more information.

This article is based on research published under:

DOI-LINK: 10.18787/jr.2016.23.1.65, Alternate LINK

Title: A Case Of Nasal Cavity Foreign Bodies By Inhalation Of Polyurethane Foam

Subject: General Medicine

Journal: Journal of Rhinology

Publisher: Korean Rhinologic Society

Authors: Jae Hyuk Lee, Jin Su Park, Kyung Chul Lee, Seok Jin Hong

Published: 2016-01-01

Everything You Need To Know

What are the primary dangers and complications associated with polyurethane foam entering the nasal cavity?

Polyurethane foam in the nasal cavity can strongly adhere to the nasal mucosa, making removal difficult. If the polyurethane hardens, attempts to remove it can cause parts of the surface to detach, leading to further complications. Additionally, the potential toxicity of polyurethane as a chemical compound is a significant concern.

What are the typical symptoms experienced by someone who has inhaled polyurethane foam into their nasal passages?

Symptoms of polyurethane foam inhalation in the nasal cavity include a foreign body sensation, nasal obstruction, and a decreased sense of smell. Nasal discharge and discomfort can occur during attempts to remove the material. A CT scan can reveal the presence of a foreign material with air bubbles throughout the nasal cavities, surrounding the turbinates and extending into the nasopharynx.

Why is a CT scan considered a crucial diagnostic tool in cases of suspected polyurethane foam inhalation in the nasal cavity?

A paranasal sinus computed tomography (CT) scan is crucial for diagnosing polyurethane foam inhalation, as it helps visualize the extent and location of the foreign material within the nasal cavities and sinuses. Endoscopic examination is also essential for direct visualization, but CT imaging provides a more comprehensive view, guiding treatment planning and helping to rule out other potential complications.

In the case of polyurethane foam inhalation, what factors can complicate its removal from the nasal cavity?

The presence of a bony spur in the nasal cavity complicates the removal of polyurethane foam by physically obstructing access to the foreign material. The strong adhesion of polyurethane to the nasal mucosa, combined with patient discomfort and nasal discharge during removal attempts, further adds to the complexity. These factors often necessitate surgical intervention for complete removal.

What key lessons can medical professionals learn from rare cases of nasal obstruction caused by inhaled materials like polyurethane foam?

This case underscores the importance of considering unusual foreign bodies like polyurethane foam in the nasal cavity, especially in occupational settings where exposure is possible. Clinicians should be aware of the potential for polyurethane foam inhalation and its associated complications and highlights the need for a multidisciplinary approach to managing complex nasal foreign bodies and preventing potential long-term complications. Endoscopic examination and CT imaging are essential for accurate diagnosis and treatment planning.