Low density all-MDI polyurethane foams for automotive seating

ICI Polyurethanes has made significant progress in further density reductions for automotive seating while maintaining or improving the physical properties of the polyurethane foams. The new generation of all-MDI polyurethane systems is processed on conventional equipment routinely used in the industry-allowing low density flexible foams to be produced in large and complex moulds, while showing very robust processing. The new technology is suitable for producing the complete range of automotive foam parts, i.e. seat cushions, seat backs, headrests and armrests, employing conventional or foam-in-fabric methods. A further advantage of these latest developments is that the systems can not only be processed in traditional cold cure moulds, but also in hot cure moulds with a high degree of venting. The fast inherent reactivity of all-MDI polyurethane systems allows for rapid cure and short cycle times. In addition, these foams can be produced with reduced levels of catalysts and additives, and consequently show superior fogging performance. Significant advances have also been made in enhancing foam durability and in providing excellent static and dynamic comfort properties over a wide range of climatic variations in temperature and humidity.