High Efficiency Energy Absorption Olefinic Foam

The passing of the federal regulation for head impact protection for upper interior components (FMVSS 201U) has led to the use of a variety of foam materials in interior trim pillar and headliner reinforcement applications. Polyurethane foams and expanded bead foams are some of the commonly used foams in these applications. However, the low energy absorption efficiency (35% - 55%) of the current foams requires the use of 20 mm - 40 mm of packaging space to integrate the countermeasures that make it possible to meet the regulations.

A newly developed high efficiency olefin based foam is able to meet the performance requirements at a reduced packaging space. A combination of physical structure and superior mechanical properties provides the much needed higher efficiency (80% - 90%) of the olefinic foam. This paper discusses the foam architecture and performance benefits for many interior applications, such as energy absorbing countermeasures in pillar trim, headliners, and door panels. Performance comparisons with current competitive foams for head impact applications are also presented.