TDI Based Automotive Seating: Solutions for Enhancing Foam Durability

Improving the comfort and durability properties of automotive seating is an increasingly important issue within the global automotive seating industry. The technology for enhancing the comfort properties of polyurethane foams is one of the major needs of seating foam manufacturers and seat producers, whose focus is both foam density reduction and overall weight reduction of car seats. Shell Chemicals has therefore embarked on a fundamental programme, focusing on the foam formulation - durability relation of TDI-based foam grades. The study consists of a thorough investigation of the influence of independent formulation variables such as raw materials composition, water level, ancillary chemicals levels on foam processing and durability performance. A statistics driven experimental approach (central composite and full factorial designs) helped to increase the predictive power of the outcome, concerning overall mechanical foam properties and comfort performance in particular.