DATA: PU in automotive applications

IAL Consultants reports that 2022 was a good year for light commercial vehicle makers, but passenger vehicles have yet to recover to pre-pandemic levels

Polyurethane plays a crucial role in the automotive sector, with applications in adhesives, sealants, coatings, elastomers and flexible foams. Notably, PU flexible foams are widely used in car seats, armrests, headrests and car bodies, providing cushioning, acoustic insulation and support. Their unique combination of durability and light weight contribute to reducing overall car weight, leading to greater fuel efficiency and improved environmental performance. The largest category by some margin is flexible foam. It can take many different forms for automotive applications, majorly as seating foam and NVH foam.

The global production of vehicles reached 85m units in 2022, marking a 6% increase compared with 2021. While bus and coach production surged by 27%, heavy truck output decreased by 23%. Light commercial vehicles experienced a growth of 6.5% compared to the previous year, and passenger car production saw an increase of nearly 8%, though it still did not reach pre-pandemic levels.
The automotive industry faced challenges in both 2021 and 2022. Shortages of semiconductor chips due to supply chain issues resulted in historically low vehicle inventories, driving record pricing and profitability despite strong customer demand. In 2022, supply chain disruptions continued, hindering vehicle production to meet the growing demand. Additionally, high interest rates, inflation and recessionary fears further complicated the situation, potentially affecting demand in 2023 even as production recovers.

The growth of PU usage in the automotive sector is closely tied to the number of vehicles produced and efforts to reduce vehicle weight to curb emissions. The shift towards electric vehicles will also increase PU application in seating and acoustic insulation. Moreover, PU moulded parts are employed to manufacture battery enclosures, providing protection against impact, vibration and temperature changes in electric vehicles. Polyurethane battery enclosures are lightweight yet strong, making them an ideal choice for electric vehicle manufacturers.