Polyurethane Foam for the Automotive Industry
It's no secret that foam is widely used in the automotive industry. From car seating to carpet underlay, it plays an important role in both the safety and comfort of passengers – but its use extends well beyond the obvious.
Where foam is used in cars
In the automotive sector, polyurethane foam appears in trimming, seats, headrests, acoustic insulation and air-conditioning filters. A range of foam types is used, largely because foam is so universal, offering vibration blocking, sound absorption and insulation. The most popular foams in modern cars include open and closed-cell foam that eFoam can cut to size, foam adhesives and melamine foam, with closed-cell foam the most frequently used. Our guide to car seat foam covers seating in more detail.
In modern cars, specialised polyurethane foam gives vehicles more mileage than once possible, because polyurethane foams are durable yet very lightweight, reducing a car's overall weight for greater fuel efficiency and a smaller environmental impact. Manufacturers have predicted that around 11.5 kilograms of the material would be used in a modern car to replace components carrying excess weight.
Choosing foam for each component
So how do manufacturers decide on the right foam for each component? For seating, factories tend to choose polyurethane foam as it's easily assembled and recyclable at the end of a car's lifecycle. It also strongly retains its shape and firmness, making it ideal for heavy everyday use – the same goes for any part used on each journey, such as an arm or head rest. Overall, polyurethane is the most-used foam in the modern car, providing the highest performance without the added weight.
Foam and vehicle performance
So how does foam affect a car's performance? A specialist foam known as Reaction Injection-Moulded polyurethane (RIM) is used to improve the shock absorption of parts including bumpers and fenders. RIM is now commonly used to create exterior components – replacing conventional metal alloys – as it's more versatile and resistant to dents, scrapes and chips, and it's also found inside cars in steering wheels, floor mats and air vents.
Coatings, adhesives, sealants and elastomers
Finally, foam is used in the form of polyurethane coatings, adhesives, sealants and elastomers (CASE). As a protective material, it becomes a coating that gives a car its glossy shine and its scratch and rust resistance, and in sealant or adhesive form it regularly features in the manufacture of headlights and bumpers. In the CASE context, polyurethane is praised for its bond strength, heat resistance, waterproof nature, versatility and UV resistance, confirming it as one of the leading materials in car manufacture.
For more on how eFoam supports the automotive industry, please contact us.
Frequently asked questions
Where is foam used in cars?
Polyurethane foam appears in seating, trimming, headrests, carpet underlay, acoustic insulation and air-conditioning filters. A range of foams is used, including open and closed-cell foam, foam adhesives and melamine foam, with closed-cell foam the most frequently used.
Why is polyurethane foam used in cars?
It's durable and lightweight, reducing a car's overall weight for better fuel efficiency and lower environmental impact. It strongly retains its shape and firmness for heavy everyday use, is easily assembled, and can be recycled at the end of a car's life.
What is RIM foam?
Reaction Injection-Moulded polyurethane (RIM) improves shock absorption in parts such as bumpers and fenders. It's used to create exterior components in place of metal alloys, being more versatile and resistant to dents, scrapes and chips, and also features in steering wheels, floor mats and air vents.
