The push for lightweighting is likely to continue far beyond 2025. Consumers and governments alike will continue to demand increased energy efficiency in transportation and we in the polyurethane industry are already looking for more ways we can help reduce the weight and, by proxy, the footprint of automobiles on our environment.

BASF’s Performance Materials division encompasses the entire materials’ know-how of BASF regarding innovative, customized plastics under one roof. Globally active in four major industry sectors – transportation, construction, industrial applications and consumer goods – the division has a strong portfolio of products and services combined with deep understanding of application-oriented system solutions. Key drivers of profitability and growth are our close collaboration with customers and a clear focus on solutions. Strong capabilities in R&D provide the basis to develop innovative products and applications. In 2019, the Performance Materials division achieved global sales of €6.06 bn. More information online: www.plastics.basf.com.

The Corporate Average Fuel Economy (CAFE) standards, set by the National Highway Traffic Safety Administration and the Environmental Protection Agency (EPA), established a goal that model year 2025 vehicles will attain an average of around 50 miles per gallon (mpg). This is an approximate 40% increase in fuel efficiency over current levels. Auto manufacturers are keenly focused on creating lighter vehicles to meet this standard. In response to this need for lighter yet durable parts, the polyurethane industry is responding with new ways to incorporate polyurethane into different vehicle components.

The inherent flexibility of polyurethane chemistry allows automotive designers to make their dream models a reality. Sleeker, more aerodynamic designs also have an impact on fuel needs.

In seating, polyurethane is moving into the seat frames with the use of reaction injected molded (RIM) polyurethane parts. Similarly, one of the newer applications is the use of polyurethane in the actual frame of the car. While bumpers have long incorporated polyurethane, the frame remains mainly steel. Some manufacturers have begun using polyurethane foam in the B pillars. These are the vertical support between a car's front door window and rear side window and the area that is vulnerable in a side impact. Hollow steel tubes can be filled with polyurethane foam that hardens into an incredibly rigid barrier for impact.

Polyurethane has long been a staple for seating foam. Polyurethane foam offers high performance over a wide range of firmness while adding only nominal weight to the car overall. The foam holds its shape over long periods of time and heavy use. In addition to the seats, foam is also widely used in headrests, arm rests, headliners, and even instrument panels.

Lee Salamone is the Senior Director of the American Chemistry Council Center for the Polyurethanes Industry (CPI), a value chain organization that represents companies that manufacture the raw materials and machinery used to make all kinds of polyurethanes materials including those used in automotive applications. CPI promotes the use of polyurethanes in many end use markets and provides information on safe use of these materials. For more information: www.polyurethanes.org and www.incrediblepolyurethane.com.

The Corporate Average Fuel Economy (CAFE) standards, set by the National Highway Traffic Safety Administration and the Environmental Protection Agency (EPA), established a goal that model year 2025 vehicles will attain an average of around 50 miles per gallon (mpg). This is an approximate 40% increase in fuel efficiency over current levels. Auto manufacturers are keenly focused on creating lighter vehicles to meet this standard.

Norifumi Miyashiba, Daiwa’s General Manager of Manufacturing Division, says: “Daiwa School Ware is winning increasing popularity among Japanese elementary and junior schools due to its excellent features and cost efficiency. In particular, BASF’s Ultrason® P 2010 nat offers us a balanced cost option for product designs where aesthetics and functionality are equally important.”

Shanghai, China – May 14, 2020 – With BASF’s new polyphenylsulfone (PPSU) Ultrason® P 2010 nat, the Japanese plastics manufacturer Daiwa developed a series of dishes and bowls, which are now increasingly being used in Japanese elementary and junior schools. BASF’s PPSU extends the Daiwa School Ware series with food containers that are light, easy to clean, chemically and heat resistant, hard-to-break and good-looking – all features that are needed for containers used in catering services.

Ultrason® P 2010 nat is characterized by improved flow behavior in injection molding and by good mechanical properties: excellent notched impact strength and stability, high chemical resistance, good hot steam sterilization at 134°C and inherent fire resistance. Furthermore, the transparent high-performance thermoplastic is approved for food contact in the EU and the US.

At BASF, we create chemistry for a sustainable future. We combine economic success with environmental protection and social responsibility. More than 117,000 employees in the BASF Group work on contributing to the success of our customers in nearly all sectors and almost every country in the world. Our portfolio is organized into six segments: Chemicals, Materials, Industrial Solutions, Surface Technologies, Nutrition & Care and Agricultural Solutions. BASF generated sales of €59 billion in 2019. BASF shares are traded on the stock exchange in Frankfurt (BAS) and as American Depositary Receipts (BASFY) in the U.S. Further information at www.basf.com.

For interior design, molded polyurethane panels can be treated to have the appearance of hand wrapped leather. Polyurethane also adds "warmth" to soft touch surfaces such as steering wheels and gear shifts.

The dishes are made of a special resin combined with Ultrason® P 2010 nat as one key ingredient, thanks to Daiwa’s advanced molding technology. Compared with porcelain tableware, the containers are characterized by their low weight and their high break resistance. They are also safer to use and easier to clean as they contain no harmful ingredients. The catering items can be repeatedly cleaned in dishwashers under standard industrial conditions without loss of properties. They can be sterilized in repeated steam sterilization. The heat resistance together with the resistance to food ingredients and washing agents allows the Daiwa School Ware to be recirculated for a long service life.

Ultrason is the trade name for BASF’s product range of polyethersulfone (Ultrason E), polysulfone (Ultrason S) and polyphenylsulfone (Ultrason P). The high-performance material is used to manufacture lightweight components in the electronics, automotive and aerospace industries, as well as in water-filtration membranes and in parts that come into contact with hot water and food. Because of their extraordinary properties, the Ultrason brands can substitute thermosets, metals and ceramics.

At one time, sound proofing in automobiles just focused on keeping road noise out. Today, with in-car wireless technology and global positioning systems (also known as GPS) in cars across all price points, the acoustic needs of cars have become even more important. Many components impact the sound quality within a car. Headliners, for instance are an important part of how automakers can keep the interior of the car quieter. Some manufacturers use open-cell acoustic polyurethane foam made with some soy-based polyols. This product also features permeable thermoplastic adhesives and permeable felt fabrics in the headliner construction. The result is delivery of excellent noise / vibration / harshness (NVH) performance and lower weight.

Both auto manufacturers and polyurethane producers are looking beyond the seats and soft surfaces to other applications of polyurethane-enabled lightweight materials in the automotive industry.