There is a wide range of applications for polyurethanes, none more so than in the automotive sector, where it finds usage in the form of adhesives, sealants, coatings, elastomers and flexible foams. Polyurethane flexible foams in particular can be found in the seats, armrests and headrests of most cars for cushioning, and also in the car body to provide acoustic insulation and support. Thanks to their unique combination of durability and light weight, their use means that the overall weight of cars is reduced, resulting in greater fuel efficiency and improved environmental performance.
According to OICA, global production of vehicles was 93.54 million units in 2023, an increase of 10.3% compared to 2022. Growth in production was strongest in Europe and Asia. Bus and coach production increased 22.5%, while heavy truck output increased by 13.8%. The production of light commercial vehicles saw an increase of 8.8% compared to 2022. Passenger car production saw growth of 10%.
After stabilising in 2022, the global automotive industry rebounded in 2023 with higher sales and production. Improved supply chains and recovering demand after semiconductor shortages drove global new car sales up by 10% to 72 million units. In emerging markets like India, changes in consumer preferences and new models are driving a shift towards individual mobility. 2023 was a year of recovery and growth for the global automotive industry, setting the stage for future advancements and challenges.
Polyurethane is an important material in the automotive industry, particularly in the design and manufacturing of electric vehicles (EVs). This versatile material offers a range of benefits that help improve the performance, safety and efficiency of EVs. Today’s vehicles contain an average of 74 pounds of polyurethane, which makes up 18.5% of their weight.
Worldwide Vehicle Production by Type, 2020-2023 (‘000s)
Vehicle Type | 2020 | 2021 | 2022 | 2023 | % Change 2022-2023 |
Cars | 55,864 | 57,086 | 61,554 | 68,020 | 10.5 |
Light commercial vehicles | 16,990 | 18,430 | 19,706 | 21,441 | 8.8 |
Heavy trucks* | 4,365 | 4,289 | 3,317 | 3,774 | 13.8 |
Heavy buses and coaches* | 219 | 199 | 253 | 310 | 22.5 |
Total | 77,438 | 80,004 | 84,830 | 93,545 | 10.3 |
Source: OICA (*As of 2011 some EU countries no longer report their HCV and heavy bus figures)
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.
Growth in the application of PU in the automotive sector is intrinsically tied to the number of vehicles produced and also to efforts to reduce the weight of vehicles and thereby curb emissions. The trend towards electric vehicles will also boost polyurethane usage in areas such as seating and acoustic insulation.
Due to the rising production of electric and hybrid vehicles, demand for lightweight materials, and sustainability, polyurethane use in automotive applications is expected to grow significantly. New formulations and technologies, like bio-based polyurethanes, may expand the material's use and market growth.
In addition, polyurethane moulded parts are used to manufacture battery enclosures that protect the batteries from damage caused by impact, vibration and temperature changes. Polyurethane battery enclosures are lightweight and have high strength-to-weight ratios, making them an ideal choice for electric vehicle manufacturers.
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