reinventing automotive seating with expanded poly ... polypropylene in the automotive industry ......
TRANSCRIPT
ABSTRACT
Automotive seating supports, protects and
provides a comfortable seating posture to its
occupants. Good seat design is very important for
occupant’s comfort and safety and must be
applied by considering ergonomics and safety
norms. This is influenced by static and dynamic
characteristics of seat systems. Today, vehicles are
manufactured in a wide range of designs, and
seating design consideration and parameters
need to be tailored accordingly.
Seating comfort is a major concern for drivers as
extensive driving coupled with irregular hours can
lead to severe health issues. Automobile
engineers, manufacturers and designers are
becoming aware of seating ergonomics to provide
determined value-add for customers. With the
average time spent in commute increasing,
comfort and style are sought-after and necessary
attributes.
Seating plastics and foams plays a very vital role in
delivering the extra comfort factor to consumers.
This white paper discusses the variety of plastics
and foam considerations in seat design and their
role in improving the ergonomics of automobile
design.
INTRODUCTION
Automobile seating is an important aspect of
consumer comfort. It includes both an individual
seat and part of a bench seat intended to seat one
person. The design must consider all occupants in
the automobile; the driver, front seat passenger
and rear seat passenger(s).
Uncomfortable seating can often be the cause of
bad posture, and together lead to long term
health concerns. The extended period of sitting
can increase the risk of back problem, induce
numbness and discomfort in the buttocks due to
surface pressure and stiffness in the legs and feet
from pressure under the thighs. This issues can be
addressed by choice of suspension system and
cushion material used.
Following Flow Chart shows the different types of automotive seats
Automobile seat
LMV
Rear seatMiddle seatFront seat
Bench type seat Split type seat
Driver
seat
Passenger
seat
Parallel
Seat
Bench
type seat
Split
seat
Bench
type seat
Single seat
XUVMUV
CHALLENGES
In response to customer demand for improved driving comfort and safety, automotive
manufacturers are developing new-age innovative seating systems that places a premium on
comfort.
These innovations take into account the driver comfort, ergonomics, anthropometry and
aesthetics. For example, according to the Occupational Outlook Handbook by United States
Department of Labor, the truck drivers work for 50 or more hours a week which is about 2350
hours of driving in a year. As public transport becomes scarcer, commuters are faced with more
time within their personal vehicles. Hence, in addition to commuting discomfort, rear seat
occupants are at a greater risk of injury in case of an accident. The chances of surviving any
serious car crash vary widely, depending on the nature of the collision and speed and type of
vehicles involved. Automobile manufacturers have paid more attention to driver seating
structures and a host of safety features like airbags to reduce instances of injury. Studies point
out that the front seat occupants comprise roughly 88 percent of the total automobile
occupants. Consequently, the Industry's focus has been on protecting the occupants in the
front.
ADDRESSING THE CHALLENGES
To address the above challenges, automotive engineers specializing in automotive seat design
are introducing a new product EPP to fulfill the demands of comfort and safety.
Expanded poly propylene and its benefits
Expanded Poly propylene or EPP bring in a host of benefits that can deliver immense value add
for the commuters in terms of safety and comfort. Some of its characteristics include:
• Withstands hard impacts
• Flexible and Robust
• Offers high degree stability
EPP is a material with “expanded properties” that translates to excellent lightness-to-strength
ratio - allowing optimization of volumes and weights. It has excellent resistance to multiple
impacts and high energy-absorbing property, making it an ideal material for the protection
components in the automotive industry. The components made of EPP help in reducing fuel
consumption and emissions too.
The multiple benefits make EPP an integral part of high performance components, used in
various applications. It is in the automotive industry however, that EPP demonstrates the best
results, with optimized protection components and ultra-light materials - increasing the product
efficiency substantially.
WHAT MAKES
EPP IDEAL FOR
AUTOMOBILES
EPP is a plastic material with a wide
range of high engineering
applications. Its specific properties
can be used to substantially improve
technical performances and the
absolute value
of the product.
EPP has a very high strength-to-weight
ratio, exceptional load bearing quality
helping to reduce weight and volume.
Its high energy-absorbing property
makes it the ideal material to build a
wide range of materials including
protection components in the logistics
and automobile industries.
RESISTANT AND NON-DEFORMABLE
EPP is an ultra-light material with a high-
degree of resistance to wear and tear. It
not only allows a significant weight
reduction of the end product but also
increases its efficiency and robustness
substantially.
LIGHTNESS
Porous EPP
guarantees acoustic
insulation, a premium
value-add in the
automotive industry
today.
ACOUSTIC INSULATION
EPP provides excellent thermal
insulation and can used in storage
and transportation of food,
medical supplies and temperature
sensitive products. EPP thermal
insulation makes it the ideal
material to be used in thermo-
hydraulics as well.
THERMAL INSULATION
RECYCLABLE
EPP is 100%
recyclable making it
an environmentally
friendly material with
a low carbon foot
print.
EPP FOR AUTOMOTIVE ENGINEERING
During the last few years, there has been an increase in the number of applications for
expanded polypropylene in the automotive industry - to improving car safety and performances,
reducing fuel consumption and emissions among others.
Safety tests have shown its elevated impact resistance, compared to traditional materials. Its
thermal and acoustic insulation properties, temperature resistance and evident malleability,
owing to advanced molding processes, make EPP particularly suitable for planning and
producing a great variety of car components.
CUTTING EDGE SOLUTIONS USING EPP
Anti-submarine ramp zone for EPP
In the below image shows the preferred and the acceptable zone for the EPP ramp design. The
ramp of the EPP should lie within these limits inorder to satisfy the comfort zone. The anti-
submarine zone ensures the human safety in frontal impact test as it restricts the movement of
the occupant towards the front. EPP has an ability to withstand repeated impact without
significant deformation and to return to its original shape following dynamic stress.
The below image also shows the crash hook which locks the movement of the seat in X direction
by holding the EPP wires which are integrated in the EPP. This reduces the impact on the
occupant sitting on the rear seat during the front crash.
Conclusion
The objective of this paper is to describe the
general idea of development of vehicle seat design.
A large majority of vehicle seat studies have
concentrated on seat comfort and safety. The type
of foam and trims used are the major factors
deciding the passenger safety parameters. It is also
imperative that it meets existing safety norms.
Ideally, a good seat design is one which is
lightweight, provides better comfort and safety,
structurally robust, vibration and noise absorbent
and should protect the occupant during crash. EPP
with its structural capabilities can be the go-to
component for an ergonomically designed
automobile seating.
AUTHOR PROFILES
Akash Kalburgi, is an associate at ITC Infotech,
with sound experience in product design and
development. His interest areas include
automotive interiors systems like Seating, Door
trims and OHS. He specializes in Tool Design and
manufacturing. He is an expert in strategy
development for innovation. A true solutionist, he
has successfully undertaken key customer facing
roles when developing solutions with customers
like GM, Daimler.
References
1. Asian Journal of Engineering and Technology Innovation http://www.innovativejournal.in/ajcem/index.php/ajcem/article/download/35/26
2. MPE polypropylene division http://www.mpe.it/epp/eng/moulded-epp-parts.html
3. Occupational Outlook Handbook by United State Department of Labor.
4. http://www.acmemills.com/wp-content/uploads/2014/10/Dymetrol-Automotive-Seating-System-White-Paper-v5.pdf
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