FIBIOSEAT

FIre resistant BIObased polyurethane foam for aircraft SEATing cushions

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 Obiettivo del progetto (Objective)

'Flexible polyurethane (PU) foams are widely used in many industrial applications including automotive and aeronautics as fillers for seats, headrests etc. They are made from a reaction of two primary ingredients: an isocyanate and a polyol. Originally, these raw materials were derived from petrochemical feedstocks. The use of bio-polyols, i.e. derived from vegetable oils, as an alternative to standard polyols started around 2004 due to the rising costs of petroleum feedstocks and a growing concern for the environment. But, these bio-polyols can only replace a portion of the polyol part in the formulation and they need to be blended with petroleum-based polyols to maintain the foam physical and mechanical properties. Face to a growing demand for products based on renewable resources, foam manufacturers need to increase that ratio in the formulations while delivering the same foam quality. On top of that, foams used in the aircraft industry, for seat cushions for instance, need to pass highly stringent fire performance tests. It is well-known that the chemical nature of the polyurethane, its low density and the open cell structure cause this material to be highly flammable. In order to achieve high flame resistance requirements, polyurethane foams must be formulated with flame retardants. A multiplicity of flame retardants is known and commercially available for this purpose, like halogenated flame retardants. However, considerable toxicological reservations frequently stand in the way of their use and alternatives are expected. In the FIBIOSEAT project, AXYAL, an innovative SME specialized in the industrial transformation of plastics and composites which owns a leading edge expertise in PU foaming and fireproofing materials, proposes to develop a sustainable alternative for current flexible foams which will comply with aircraft’ fire resistance requirements while meeting the comfort and durability expectations of end users.'

Introduzione (Teaser)

An EU-funded project is developing an alternative to currently-used flexible foams for seat cushions that is meeting the strict fire resistance standards present in the aeronautics industry.

Descrizione progetto (Article)

Flexible polyurethane (PU) foams are widely used in the automotive and aeronautics industries for applications such as fillers in seats or head restraints. However, the low density and open-cell foam makes this material highly flammable. Although conventional halogenated flame retardants can reduce PU flammability, they are harmful to health and the environment.

Scientists initiated the EU-funded project 'Fire resistant biobased polyurethane foam for aircraft seating cushions' (FIBIOSEAT) to develop seat cushions using petroleum-based and natural oil polyols and non-halogenated flame retardants that provide comfort and durability.

Project work included the design of the green PU seat cover solution with computer-aided optimisation software. Scientists also studied the PU foaming machine and selected melamine for use as a fire retardant. Several foaming moulds for seat cushions were designed.

Successful production of foams from petroleum and renewable resources and treating them with increased concentrations of non-toxic fire retardants should provide Europe with a competitive edge.