POLYURETHANE TRANSPORTATION APPLICATIONS
Passenger cars are the fastest growing sector and it is very important that the benefits of polyurethanes are used to their full extent in this sector. Today‘s key objective for the automotive industry is to develop cars which are clean, safe, energy efficient and affordable. PU combines lightweight and flexibility with great strength and durability. Its versatility is instrumental in achieving the precise mechanical properties required for specific applications.
A typical medium sized car of 1,000 kg total weight contains 100 kg of plastics, of which about 15 kg are PU. Car manufacturers recognise that, by choosing PU, they can significantly improve the quality, safety and cost-effectiveness of modern cars, and increase their technical, environmental and economic performance at the same time.
- Seat foam
- Cushion overlay (fabric backing)
- Carpet backing
- Door panels
- Sound absorption and vibration dampening
- Dashboards
- Steering wheels
- Bumpers
- Energy absorbers
- Headliners
- Airbag covers
- Window encapsulation
Polyurethanes in Public Transportation
PU plays an increasing role in buses, trains and trams and in rail tracks and systems. In public transportation PU-based seating is used as well as moulded parts in safety applications, just as in passenger cars. For trains and trams, pre-coated PU encapsulated rails provide high electrical insulation, vibration resistance, noise reduction, anti-skid and anti-corrosion properties. In addition, PU in this application substantially reduces installation time and civil engineering long-term risk and increases service life.
The uses of PU coatings for large vehicles (buses, trucks, rail carriages and aircraft) are similar to those for automotive coatings and save energy during application because they cure at low temperatures and provide excellent protection which ensures a long life in these demanding applications with minimum maintenance reducing overall reliance on virgin materials.
Polyurethanes in Freight Transportation
The PU industry’s products and systems for the commercial transportation market help decrease both weight and cost by enabling thinner vehicle wall construction, reduced steel support structures and fewer mechanical fasteners. PU is used in the commercial transportation industry for body panel, front & rear systems, surrounds, wheel covers, grilles, moulding and trim to improve impact resistance, corrosion resistance, energy management and vehicle aesthetics.
3 A major application of PU rigid foam is in the production of systems for the transportation of food in refrigerated ships and by road and rail in refrigerated containers (reefers) and trucks.
VEHICLE ENERGY EFFICIENCY WITH POLYURETHANE COMPONENTS
This section of the factsheet describes how the various polyurethane applications lower environmental impact by reducing vehicle weight. This improves fuel efficiency and lowers emission levels.
Vehicle Seats
In the last five years the density of polyurethane for major applications has been reduced by 30 to 40 per cent while still maintaining the same mechanical properties. Seating foam, for instance, has one of the lowest densities of any plastic material used in a car: 0.03 to 0.05 g/cm3. Polyurethane foam in headliners is another good example with a density of 0.02 to 0.04 g/cm3.
Truck Bed Liners Truck bed liner
made from compact PU-system, with 50% by weight glass content, displays
• High stiffness at only three mm thickness
• No corrosion, no buckling
• Freedom in design Introducing this material allowed significant weight reduction compared with steel.
Polyurethane Composites
PU enables light weight composites based on paper honeycombs. These parts are very rigid, offer high heat resistance and dimensional stability, allow in-place moulding of inserts and give high freedom of design and tailored property profiles.
Composite Door Panels
In automotive engineering, natural fibre mats combined with PU systems have opened up new possibilities for the production of door trim. They have the particular advantages of being extremely thin and light. A composite containing up to 65% of flax or sisal fibres and 4 and PU as the binder has exceptionally high mechanical strength. Wall thicknesses of only 1.5 to 2.0 mm can be achieved. The weights of the end products are also extremely low at 1,250 to 1,600 g/m2 . Weight reductions of up to 2.5 kg per vehicle can be achieved in comparison with traditional materials. The use of large proportions of renewable raw materials further reduces the CO2 in-balance.
Structural Bonding
The bonding of glass windscreens to the metal body using PU seals and adhesives is very widely used. Glass bonding reduces weight, improves dynamic stiffness and strength, ensures cavity sealing and lowers cost. Newly developed structural bonding applications can save up to 5 kg metal /1 kg of PU structural foam used. A large number of car manufacturers have published information on structural bonding weight saving aspects.
Source: http://polyurethanes.org
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