Reinventing Automotive Seating with Expanded Poly Propylene (EPP)

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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