HE high efficiency energy absorbing polyurethane foam for head impact application

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HE high efficiency energy absorbing polyurethane foam for head impact application

Ng, G. / Schmidt, H.

Polyurethane (PUR) molded, energy absorbing (EA) foam is currently being used as a passive protection device in automobiles to protect occupants from injury during a collision. Safety regulation FMVSS201U is amended specifically to improve passenger safety relating to head impact in the areas of pillars and headliners within an automobile. These interior areas are usually limited in space and do not allow sufficient part thickness for energy-absorbing devices to function effectively. To meet safety requirements under such a space constraint, a highly efficient, energy absorbing material is needed. This paper describes a newly developed, high efficiency (HE), energy absorbing urethane-based chemistry. Through the study of the dynamic response of various types of EA urethane foams at different load-bearing capacity and thickness, a model was developed to depict the minimum Head Injury Criteria (HICd) as function of load, chemistry and thickness. The application of the model enabled us to design the most efficient urethane foam system to satisfy safety impact requirements where space is limited. Energy absorbing efficiency of HE is further optimized by urethane chemistry such that it fulfills head impact safety requirements of FMVSS201U regulation (HIC(d) < 1000) down to 0.8 inch foam thickness. Impact performance is compared among HE, existing commercial EA foams, and other competitive materials. The results show that polyurethane based EA foam continues to be the material of choice in occupant protection and energy management.