Search Results

Cream foam is a polyurethane technology designed for molding foam articles such as automotive headrests or armrests directly into their decorative coverstocks. This process allows for the single step molding of covered foam articles eliminating the secondary step of attaching the cover needed in conventional operations. The advantage cream foam offers over conventional molded foam is that penetration of the stitched seams and foam backing of the coverstock is avoided or controlled. Cream foam technology has improved with the development of a MDI-based polyurethane system that reduces penetration of the foam and fabric bilaminate coverstocks by 25% and the molded foam density by 15%. These improvements result in a cost reduction in the manufacturing of arm or head rests.

Low density structural RIM is a well established process that is used to make polyurethane foam matrix composites for automotive interior trim substrates. This technology has gained this position because these substrates are high in quality, durable, and most importantly, light weight. A vehicle equipped with low density structural RIM door panel substrates will save about 40% of the substrate weight, over one equipped with substrates made from thermoplastics or other traditional materials. Low density reinforced RIM is a similar process that is used to make polyurethane foam matrix composites for interior trim substrates. These composites will save about 15% of a door panel substrate weight. Since saving weight is a goal for the automotive engineer, low density structural RIM systems have been developed to produce even lighter weight composites.

Glass mat reinforced structural polyurethane foam or low density structural reaction injection molding (LD-SRIM) has found a niche in the manufacture of high quality, light weight, automotive, interior trim substrates. Current trends in the automotive industry indicate the need for cost reductions without sacrificing quality. A high productivity LD-SRIM system has been developed which meets this need. This cost reduction is achieved by the incorporation of an internal mold release agent and a 25 % decrease in demold time compared to current LD-SRIM technology. These technological advancements give the trim component manufacturer an increase in productivity by eliminating the time and labor required to apply external mold release and a shorter demold time. These advancements also provide for a significant reduction in the volatile organic compounds and cost associated with external mold release agents.