Role of Polyurethane in Enhancing Electric Vehicle Performance

Polyurethane has become 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. Studies by the U.S. Environmental Protection Agency (EPA) suggest that just a 10% reduction in vehicle weight creates a 7% reduction in fuel consumption.

Due to the demand for fuel efficiency in conventional vehicles and for light weighting in general, manufacturers are continually improving and making new interior parts out of polyurethane. The seats that support your back, legs, and arms are made up of high-resilience polyurethane foam that conforms to your body while driving or sitting. About 20 to 30 pounds of foam are used in vehicle seating. These foams are on average 50% thinner than they were several years ago. Thinner seats are not only lighter weight, but they allow for more headroom without raising the roof height of the vehicle.

Some of the keyways polyurethane is being used in battery vehicles are:

Crash Safety and Battery Protection

Innovative battery pack designs using polyurethane-based materials, adhesives, and pultrusion technology prioritize crash safety, outperforming benchmark materials in crash simulations, reducing battery deformation and damage.

Example: BASF provides polyurethane-based solutions for battery protection in electric vehicles, enhancing safety during crashes.

Lightweight Construction

Polyurethane, a lightweight alternative to traditional materials, can significantly reduce the weight of electric vehicles (EVs), improving range and efficiency, and potentially reducing fuel consumption.

Example: Covestro supplies lightweight polyurethane materials used by automotive manufacturers like BMW and Daimler to reduce the overall weight of their electric vehicles.

Thermal Management

Polyurethane-based thermal interface materials (TIMs) enhance heat transfer from battery cells to cooling devices, enabling faster charging and isolating overheated cells, reducing fire risk.

Example: Huntsman Corporation offers polyurethane TIMs used in the thermal management systems of electric vehicle batteries to maintain optimal operating temperatures.

Noise Reduction

Polyurethane foams in EV components reduce heat and sound, enhancing the peaceful driving experience by reducing engine and muffler noise.

Example: Recticel provides polyurethane foam solutions for noise reduction in EVs, used by manufacturers like Tesla to enhance cabin comfort.

Battery Resilience

Polyurethane-based foams are used in electric vehicle (EV) battery systems to isolate shock and vibration, enhancing their resilience and longevity. As EV popularity grows, the use of polyurethane in design and manufacturing is expected to expand. 

Example: Dow Chemical offers polyurethane foams designed to protect EV batteries from shock and vibration, extending their lifespan and reliability.

Companies Activities

Companies have created products that use polyurethane to improve automotive seating while using sustainable raw materials derived from by-products of the chemical industry. Some of the products use flexible polyurethane foam for soft, comfortable, and versatile moldings, while others use polyurethane films for headrests and armrests. Key benefits of these products include versatility, stability, durability, and a simple, responsible manufacturing process.

Example: Johnson Controls manufactures automotive seating with polyurethane foam, providing enhanced comfort and sustainability for EVs produced by companies like General Motors and Ford.

Without a doubt, polyurethane is making its mark on the automotive industry. As the popularity of electric cars increases and the demand for more fuel-efficient and sustainable vehicles expands, so will the use of polyurethane. As electric vehicles grow in popularity, it is important for the automotive industry to provide drivers and passengers with convenience as well. Today, polyurethane-based materials are being used in a range of areas to enhance the overall operations of electric vehicles.

Fig. Electric Vehicles

Key Concerns

One of the main areas of concern for electric vehicle owners is how far they can travel before they have to recharge. Taking a cue from the aerospace industry, automotive companies are using polyurethane to reduce the weight of electric cars, making them lighter and more efficient, allowing them to travel longer distances per charge. By replacing common materials such as steel with aluminum or polyurethane, manufacturers can significantly decrease weight, and therefore, the amount of energy expended.

While engine and muffler noise is the challenge in conventional vehicles, electric vehicles can be so quiet that road noise is more noticeable. That’s why polyurethane foam can also be found in bumpers, exterior and interior door parts, and the trunk.

Other ways electric cars are evolving is through the battery system. By isolating shock and vibration with polyurethane-based foam, batteries are more resilient and able to last longer.