Ultra-lightweight PP foam air ducts for future vehicles

Foam manufacturers compete in an environment with increasingly tough standards and regulations. Manufacturing is becoming ever-more challenging as CO2 requirements are made more stringent, and the shift to eco-friendly vehicles continues.

Solution
Borealis supplied PP foam material for the creation of ultra-lightweight foamed air ducts that distribute low-pressure air inside a car. A zero-waste material that allows for in-process recycling, PP foam material has enabled weight savings of up to 80%, improved insulation, led to significant reductions in CO2, and delivered considerable cost savings due an innovative induction process. Compared to market standards, the improved insulation and possibility of reduced dew condensation can improve the energy efficiency of the AC unit. And combined with extreme light weighting, this enables increased fuel efficiency and cruising range extension. The results are even greater in electric vehicles with a heater compared to traditional fuel engines.

• Reduction of carbon emissions
• Low fuel consumption
• Superior foamability
• Reducing the overall cost of the system
• Improved sound and thermal insulation
• Easy processing
• Great recyclability