Noncrushing Foam System for Automotive Seats

Abstract

In general, cold-cured flexible foams have a high content of closed cells during a foaming process because of a high reactivity of foaming components and curing at a low temperature. Cold-cured flexible foams require a mechanical method such as roll crushing or vacuum crushing to open a high content of closed cells for preventing shrinkage and cracking of foam after demolding. But this mechanical crushing process can yield foams with poor properties and reduce productivity on account of increasing costs for utilities, electricity, manpower and repair. A noncrushing foam system developed by Kumho Mitsui Chemicals Inc. (hereafter referred to as “KMCI”) is a new cell opening technology that makes complete cell opening during the foaming process. Thus, this technology results in no shrinkage and cracking after demolding. In addition the noncrushing foam system makes possible manufacturing automotive seat cushions having an open cell structure and excellent cell stability compared to conventional foam by minimizing the degree of cross-linking density and increasing urea linkage. Our new technology has been used to make seat cushion at Hyundai Motor Company in Korea since 1999. We expect that the noncrushing foam system will be applied in various flexible foam applications and will contribute to improvement of productivity and seat cushion quality.