Polyurethane Foam in Automotive Seats-Bachelor Year Project
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Transcript of Polyurethane Foam in Automotive Seats-Bachelor Year Project
AUTOMOTIVE APPLICATION OF POLYURETHANE FOAM
BY
M. Osama Adil PP-30
Rabia Raza Khan PP-19
Noureen Naz PP-37
Group-8 Department of Polymer & Petrochemical Engineering
In Collaboration With:
BASF-The Chemical Company
Internal Advisor: M. Raza Khan External Advisor: M. Abbas Ameer Meerani
• Overview
03/12/2012 Automotive application of polyurethane foam 2
Introduction
Polyurethane Foam and their Chemistry
Application’s Selection
Aims and Objectives
Mold and Tools Designing
Experiments
Testing Results and Comparison
Profit Estimation
Conclusion and Future Work
• Introduction
Foam
Classification of f oam
o Open cell foam
o Closed cell foam
03/12/2012 Automotive application of polyurethane foam 3
• PU Foam and their Chemistry
03/12/2012 Automotive application of polyurethane foam 4
Polyurethane Foam
o versatile comparing with all polymer foams
o can be manufactured between two extremes of softness and
hardness
o resist bacterial growth
o availability of raw materials at cheap rate
o can be classified as
a) rigid polyurethane foam
b) flexible polyurethane foam
03/12/2012 Automotive application of polyurethane foam 5
Applications of Flexible Polyurethane Foams
• PU Foam and their Chemistry
03/12/2012 Automotive application of polyurethane foam 6
Polyurethane Chemistry
o Reactants are:
1) Polyol
1) Isocyanates
• PU Foam and their Chemistry
03/12/2012 Automotive application of polyurethane foam 7
Reactions
o Blow reaction
• PU Foam and their Chemistry
03/12/2012 Automotive application of polyurethane foam 8
Reactions
o Gel reaction
• PU Foam and their Chemistry
• Application’s Selection
03/12/2012 Automotive application of polyurethane foam 9
Major automotive applications of PU Foam we discussed
1. Tyres 2. Headliners 3. Seats
SEATS Final Selection
Car Seats Bike Seats
03/12/2012 Automotive application of polyurethane foam 10
• Application’s Selection
Motorbike Seat Car Seat
1. Product divisions 1 Part: Seat 4 Parts: Seat base,
Backrest, Headrest
and Armrest
1. Additional Parts Nothing Supports
1. Cost 800-2000 PKR More than 3000 PKR
Comparison between bike seat and car seat
So after doing general feasibility analysis, bike seat was
selected to proceed our project
03/12/2012 Automotive application of polyurethane foam 11
• Aims & Objectives
Depending on selection of automotive application of PU foam,
aims of this proposal are:
o To significantly reduce the density of PU foam without
disturbing its mechanical properties
o To reduce the production cost of PU foam for bike seats
03/12/2012 Automotive application of polyurethane foam 12
• Tools & Stirrer Designing
Mold Designing
o Sample seat of OEM’s product – Master Foam CD-100 Seat
o Reverse engineering
o CAD Models
o Fabrication
03/12/2012 Automotive application of polyurethane foam 13
CAD Model
o Front View
• Tools & Stirrer Designing
03/12/2012 Automotive application of polyurethane foam 2
CAD Model
o Top view
• Tools & Stirrer Designing
03/12/2012 Automotive application of polyurethane foam 14
03/12/2012 Automotive application of polyurethane foam 15
Fabrication of study mold
• Tools & Stirrer Designing
03/12/2012 Automotive application of polyurethane foam 16
• Tools & Stirrer Designing
Stirrer Designing
o CAD Model
03/12/2012 Automotive application of polyurethane foam 17
• Tools & Stirrer Designing
Stirrer Designing
o CAD Model
03/12/2012 Automotive application of polyurethane foam 18
Stirrer
o Before fabrication, workshop concluded that discussed model of stirrer would
be failure due to wings instability during mixing which can break it.
o Workshop proposed another 3D stirrer(beater) having following properties
Speed Switch 3-Speed
Revolution: 700-1050 rpm
Switches: 700rpm, 875rpm and
1050rpm
Weight: 0.45 Kg
Dimensions (H×W×D): 12.2×8.0×18.4 cm
• Tools & Stirrer Designing
03/12/2012 Automotive application of polyurethane foam 19
• Experiments
Composition of reactants
Composition of Polyol Composition of Isocyanate
Components Parts by weight
Polyol 70.000
Co-polymer polyol 30.000
Silicon Surfactant 1.000
Water, Blowing agent 4.2000
Dimethanol Amine,
Pure, Chain Extender 1.700
Amine Catalyst 0.1
Tin Catalyst 0.5
Component Parts by weight
ELASTOFLEX
Diphenylmethane-
4,4'-diisocyanate
(MDI)
90
Polymeric MDI (P-
MDI)
10
03/12/2012 Automotive application of polyurethane foam 20
Formulations
• Experiments
Sample No Polyol
(A) (gm)
Isocyanate (B)
(gm)
Mixing
time (sec)
Curing time
(min)
Mixing
Speed (rpm)
Foam
Weight
(gm)
Density
(lb/ft3)
A/B Ratio Remarks
A1 30 15 5 4 700 27.00 3.8095 2 Polyol remains in
bottom
A2 30 16 5 4 700 26.21 3.7813 1.87 Still Polyol remains
in bottom
A3 30 17 5 4 700 25.73 3.6319 1.76 Polyol odor in foam
A4 30 18 5 4 700 25.10 3.5471 1.66
A5 30 19 5 4 700 24.81 3.4988 1.57
A6 30 20 5 4 700 24.55 3.4539 1.5
A7 30 21 5 4 700 24.06 3.3947 1.42
A8 30 22 5 4 700 23.56 3.3242 1.36
A9 30 23 5 4 700 23.71 3.3453
1.30
A10 30 24 5 4 700 24.7 3.4850
1.25
A11 30 25 5 4 700 26.13 3.6868
1.20
A12 30 26 5 5 700 27.45 3.8730
1.15
A13 30 27 5 5 700 27.82 3.9252
1.11 Unstable
A14 30 28 5 7.8 700 28.1 3.9647 1.07 Unstable, yellowish,
isocyanate is visible
A15 30 29 5 9 700 28.26 3.9873 1.03 Fail, Settling time is
very high, unstable
A16 30 30 5 Infinity 700 28.49 4.0198 1 Fail, Iso everywhere
un-reacted
03/12/2012 Automotive application of polyurethane foam 21
Formulations
• Experiments
Sample No Polyol (A)
(gm)
Isocyanate (B)
(gm)
Mixing time
(sec)
Curing time
(min)
Mixing Speed
(rpm)
Foam Weight
(gm)
Density
(lb/ft3)
A/B Ratio Remarks
B1 30 15 3 4 875 25.97 3.6642 2 Polyol remains in
bottom,
B2 30 16 3 4 875 25.49 3.5965 1.87 Still Polyol
remains in bottom
B3 30 17 3 4 875 24.85 3.5062 1.76 Polyol odor in
foam
B4 30 18 3 4 875 24.67 3.4808 1.66
B5 30 19 3 4 875 24.41 3.4441 1.57
B6 30 20 3 4 875 24.25 3.4215 1.5
B7 30 21 3 4 875 24.02 3.3891 1.42
B8 30 22 3 4 875 23.91 3.3736 1.36
B9 30 23 3 4 875 24.55 3.4639 1.30
B10 30 24 3 4 875 25.46 3.5922 1.25
B11 30 25 3 4 875 26.93 3.7997 1.2
B12 30 26 3 4 875 27.38 3.8632 1.15
B13 30 27 3 6 875 28.08 3.9619 1.11 Unstable
B14 30 28 3 8.5 875 28.23 3.9831 1.07 Unstable,
yellowish,
isocyanate is
visible
B15 30 29 3 Infinity 875 28.57 4.0311 1.03 Fail, Settling time
is very high,
unstable
B16 30 30 3 Infinity 875 28.74 4.0550 1 Fail, Iso-
unreacted
03/12/2012 Automotive application of polyurethane foam 22
Formulations
• Experiments
Sample No Polyol (A)
(gm)
Isocyanate (B)
(gm) Mixing time
(sec)
Curing time
(min)
Mixing
Speed (rpm)
Foam
Weight (gm)
Density
(lb/ft3)
A/B Ratio Remarks
C1 30 15 3 4 1050 26.47 3.7348 2 Polyol remains
in bottom,
C2 30 16 3 4 1050 25.81 3.6416 1.87 Still Polyol
remains in
bottom
C3 30 17 3 4 1050 25.36 3.5781 1.76 Polyol odor in
foam
C4 30 18 3 4 1050 24.72 3.4878 1.66
C5 30 19 3 4 1050 24.51 3.4582 1.57
C6 30 20 3 4 1050 24.27 3.4243 1.5
C7 30 21 3 4 1050 24.02 3.3891 1.42
C8 30 22 3 4 1050 23.87 3.3679 1.36
C9 30 23 3 4 1050 23.92 3.3750 1.30
C10 30 24 3 4 1050 24.01 3.3877 1.25
C11 30 25 3 4 1050 25.67 3.6219 1.2
C12 30 26 3 4 1050 26.74 3.7729 1.15
C13 30 27 3 6 1050 27.32 3.8547 1.11 Unstable
C14 30 28 3 8.5 1050 27.65 3.9012 1.07 Unstable,
yellowish
isocyanate is
visible
C15 30 29 3 Infinity 1050 27.92 3.9393 1.03 Fail, Settling
time is very
high, unstable
C16 30 30 3 Infinity 1050 28.13 3.9690 1 Fail, Iso- un-
reacted
03/12/2012 Automotive application of polyurethane foam 23
Observations
• Experiments
3
3.5
4
4.5
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
De
nsi
ty (l
b/f
t3 )
Isocyanate (gm)
Graph of A Series Samples -Iso (gm) vs. Density (lb/ft3)
at 700 rpm
3
3.2
3.4
3.6
3.8
4
4.2
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
De
nsi
ty (l
b/f
t3 )
Isocyanate (gm)
Graph of B Series Samples -Iso (gm) vs. Density (lb/ft3)
at 875 rpm
3
3.2
3.4
3.6
3.8
4
4.2
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
Den
sity
(lb
/ft3 )
Isocyanate (gm)
Graph of C Series Samples -Iso (gm) vs. Density (lb/ft3) at 1050 rpm
03/12/2012 Automotive application of polyurethane foam 24
• Testing Results & Comparison
Foam testing is quite different than plastic testing
There were 4 tests conducted to analyze mechanical properties
o Density
o Indentation force deflection
o Compression force deflection
o Tear resistance
03/12/2012 Automotive application of polyurethane foam 25
Density
• Testing Results & Comparison
3 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9
4
Sample 1
Sample 2
Sample 3
Average
OEM foam
Altered foam
03/12/2012 Automotive application of polyurethane foam 26
Indentation force deflection (IFD) test
IFD Comfort Factor
• Testing Results & Comparison
0 100 200 300 400 500 600 700 800 900
1000
IFD@25% IFD@65%
lbf/
50
in2
OEM's Foam
ALTERED FOAM
0
0.1
0.2
0.3
0.4
0.5
Comfort Factor
OEM's Foam
Altered Foam
03/12/2012 Automotive application of polyurethane foam 27
Compression force deflection (CFD) test
• Testing Results & Comparison
0
20
40
60
80
100
120
140
160
180
200
CFD
(K
g f)
OEM's Foam
Altered Foam
Comparison of CFD Values
03/12/2012 Automotive application of polyurethane foam 28
Compression force deflection (CFD) test
• Testing Results & Comparison
0
1
2
3
4
5
6
Rec
ove
ry t
hic
knes
s d
iffe
ren
ce
(mm
)
OEM's Foam
Altered Foam
Comparison of recovery thickness after CFD test
03/12/2012 Automotive application of polyurethane foam 29
Tear resistance
• Testing Results & Comparison
0.25
0.26
0.27
0.28
0.29
0.3
0.31
Tear
Str
engt
h (
N/m
m)
OEM's Foam
Altered Foam
Comparison of tear resistance
03/12/2012 Automotive application of polyurethane foam 30
• Profit Estimation
Comparison of OEM FOAM vs. ALTERED FOAM on basis of
density
OEM’s FOAM ALTERED FOAM
1. Density 3.85 lb/ft3 3.34 lb/ft3
1. Seat Weight 1.76 lbs 1.53 lbs
1. Seat Volume 0.458 ft3 0.458 ft3
1. Polyol/Iso Ratio 1/0.85 1/0.73
03/12/2012 Automotive application of polyurethane foam 31
• Profit Estimation
Profit estimated with respect to material’s cost price
Weight difference 0.23 lbs
Weight difference (%) 13.07 %
Material Saved 13.07%
Cost Price of material for OEM/Product X
Price of Material Saved 0.13X
Material’s Cost Price per seat reduced X-0.13X
Profit in producing higher density PU foam Y
Production Profit using Altered Foam Y+0.13X
03/12/2012 Automotive application of polyurethane foam 32
• Conclusion
Successfully reduced foam density
Better mechanical properties of reduced density foam are
achieved
03/12/2012 Automotive application of polyurethane foam 33
• Future Work
Our Limitations and recommendations for future work
o RIM
o Molecular level research
o Blended reactants
03/12/2012 Automotive application of polyurethane foam 35