BASF is developing more foam to help automakers improve occupant safety and make vehicles quieter and more comfortable.
Because foam can absorb energy, German chemical manufacturers are working on using polyurethane foam in automotive bumpers. These lightweight materials are capable of absorbing 20% to 30% of the impact force caused by the impact. Energy is reduced as the foam is crushed, rather than transferring all the power directly to the occupants.
Jeffrey Hagar, the company's high-performance materials division's automotive interiors marketing manager, said BASF is exploring ways foams can better protect passengers' heads and body collisions in the event of a collision.
Hagar said: "Wrapping a vehicle bumper with energy-absorbing polyurethane foam is equivalent to adding a barrier between the occupant and the vehicle's metal to minimize damage.
BASF also uses polyurethane foam for the manufacture of bodywork. The company's Elasto-flex series of foam can be injected into the vehicle before the vehicle is painted, which quickly expands the cavity filling the pillars and thresholds to reduce noise and vibration.
Car manufacturers can even fine-tune the amount of foam injection during vehicle development, even when fine-tuning the amount of polyurethane when adapting to different models. One of the products, Elastoflex W, is a soft foam that can be customized in different densities in the same vehicle according to its use, such as for seats, armrests or backrests.
Foam also has potential uses to provide insulation for electric vehicles to help collect waste energy and reuse it for air conditioning or to improve battery efficiency.