Design, Application Development, and Launch of Polyurethane Foam Systems in Vehicle Structures

The use of two-component polyurethane foam materials to improve sealing, stiffness, and crash performance in vehicle structures has increased significantly in the past 10 years. The proven cost and performance advantages associated with polyurethane chemistry, along with recent development efforts by Dow Automotive to minimize industrial hygiene concerns traditionally associated with polyurethane use [1], have resulted in increased activities associated with design, application development, and launch of foam systems in the automotive industry.

This paper describes the key considerations that must be addressed to successfully incorporate polyurethane foams into vehicle structures from design, application development, and launch perspectives.