Expanded Polypropylene Replacement of ABS in a Seat Bolster System

Dan Jannette; Thomas Gillette

doi:10.4271/2006-01-1471

2006-04-03

Expanded Polypropylene Replacement of ABS in a Seat Bolster System 2006-01-1471

Advancements in Expanded Polypropylene (EPP) foam molding technology have created opportunities for EPP to move into new markets within the automotive industry. One such area is the automotive interior market. This paper will describe how advancements in steam chest molding techniques have allowed for EPP use in the rear seat bolster area of passenger cars.

The use of EPP in the rear seat bolsters of passenger cars allows for part consolidation, mass reduction, cost reductions in both piece price and tooling as compared to existing rear seat bolster technology. A typical bolster system construction will be compared against an EPP bolster system construction.

The baseline bolster system consisted of an injection molded ABS frame, a polyurethane foam pad, and a trim cover with sewn-on plastic J-clips.

The new bolster system consists of an EPP bead foam part with two separate nylon fastener hooks insert molded into the EPP. The polyurethane foam pad was eliminated. The trim cover is attached directly to the EPP.

Functional pull out testing (FMVSS 207) was performed on the system and the results are shown.

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Expanded Polypropylene Replacement of ABS in a Seat Bolster System 2006-01-1471

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