Ultra-lightweight PP foam air ducts for future vehicles

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.

Background

In the highly competitive automotive market, car and truck manufacturers are always seeking to improve the safety, comfort and energy efficiency of vehicles. These improvements require material with exceptional properties, which is why our PP foam materials have been used for the production of ultra-lightweight foamed air ducts. This lightweight material improved thermal conductivity and acoustics, and reduced energy consumption and emissions without compromising on power.

Challenge

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.

Benefits of Borealis Daploy™ WB140HMS PP material for air duct applications

• 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


To Know more about Borealis Foam Solutions, products and talk to technical expert or sales manager. Please visit our Foam Website

Any further questions? Then please reach out to:

Denisa George, Application Marketing Manager PO Foam
Email: denisa.george@borealisgroup.com