Lightweight polyurethane foam won the Altair Enlighten Award

Marelli has developed a new lightweight polyurethane foam that can be used in all foam-in-place (FIP) applications, especially for main instrument panels. This result was developed together with its materials partner Covestro.

40% weight reduction

Compared to the foam currently in use, the new foam is 40% lighter with new tools (8% weight reduction when using existing tools); 50% reduction in foam thickness to support aesthetic styling; Raw material costs were reduced by 20%. In line with the industry's ongoing focus on sustainable and eco-friendly materials, the new foam also reduces the environmental impact of automotive production by reducing the amount of material used per part, reducing density and reducing volatile organic compounds (VOCs) by 80%.

In addition to bringing environmental benefits, this lightweight foam meets or exceeds customer requirements for high-quality haptics and appearance of interiors. Foam-in-place (FIP) technology is a staple technology in automotive interiors, effectively achieving the soft-touch feel required for major contact surface parts such as main instrument panels, door panels, and center console armrests.

Solvay's Ajedium PEEK slot liner was runner-up

Solvay Specialty Polymers' Ajedium PEEK slot liner was the runner-up in the "Lightweighting of the future" category. Its Ajedium PEEK slot liner reduces battery pack weight by 12 kg (36.4 lbs) and motor weight by 4 kg (8.8 lbs). In addition, since the PEEK tank liner can be inserted through existing equipment, there is no need for high-power dust collectors or climate-controlled storage to prevent moisture absorption, reducing energy consumption.

As EV manufacturers are increasing system voltages from 400 volts to 800 volts or higher, traditional paper laminate groove liners are no longer able to meet the challenges posed by this trend. "In comprehensive simulation tests, Ajedium PEEK films have proven their outstanding properties to improve the thermal, electrical and mechanical properties of the channel lining, while enabling thinner secondary insulation and providing a more sustainable mono-material solution," said Solvay's Head of Automotive Marketing. "

Ajedium PEEK provides excellent electrical insulation and heat dissipation, as well as improved thermal management efficiency, enabling designers to reduce the size of aluminum castings and create more sustainable electric motors with less energy and material consumption. In addition, PEEK film has excellent chemical resistance to automatic transmission fluids (ATF) and good adhesion to varnishes. It also eliminates the need for dust collection equipment and climate-controlled storage, reduces energy costs, and improves workspace conditions.

Thermoplastic Polyurethane (TPU) is a type of polymer resin that is known for its flexibility, durability, and versatility. It is a thermoplastic material, which means it can be melted and reprocessed multiple times without losing its original properties.

TPU is commonly used in various industries, including automotive, electronics, footwear, and sportswear. It is often used to make products such as phone cases, cables, hoses, seals, gaskets, and inflatable structures.