In the automotive industry, where energy efficiency is a priority, lightweight vehicle design is gaining increasing importance. The use of composite parts in next-generation vehicles helps reduce overall weight, resulting in lower fuel consumption and reduced emissions. With its lightweight properties, polyurethane contributes to energy efficiency and supports sustainability goals by reducing vehicle weight.
In recent years, graphene, often referred to as a “miracle material,” has taken the advantages of polyurethane foam even further.
Our R&D Flex Team has developed two systems using graphene obtained from recycled automotive tire waste:
KIMflex® Sound Insulation System – Used for acoustic insulation in the automotive industry.
KIMflex® HR Foam Systems – Used in the production of automotive and office seating.
Graphene-Based HR Foam Systems
HR foam systems developed with graphene derived from automotive tire waste offer significant improvements in mechanical properties. These systems provide the following advantages:
• Optimization of material consumption
• Reduction of carbon dioxide emissions during the production process
• Elimination of the need for additional materials
Proven through testing, these systems meet high performance expectations while supporting a sustainable approach. Test results are presented in Table 2.
Table 2: Comparison of test results of graphene-based HR foam systems and standard HR foam systems | Test | Standard HR foam systems | Graphene-based HR foam systems | Improvement rate |
| SAG factor | 4,36 | 4,62 | %22,47 |
| Tear resistance (Fbreak N/cm²) | 1,05 | 1,12 | %10 |
| Compression set (%) | 13,48 | 10,45 | %13,82 |
* Tests were performed at an operating ratio of 100/65 and a molded density of 50 kg/m³.
Graphene-Based Sound Insulation System
Graphene-based polyurethane foams offer superior sound insulation performance without increasing the overall weight of the vehicle, thanks to their lightweight structure. Test results have shown that these systems provide up to a 65% improvement in sound absorption compared to standard systems.
Table 1: Comparison of test results of graphene-based sound insulation systems and standard sound insulation systems | Test | Standard sound insulation systems | Graphene-based insulation systems | Improvement rate |
| SAG factor | 3,57 | 4,42 | %23,80 |
| Tear resistance (Fbreak N/cm²) | 6,21 | 7,2 | %15,94 |
| Tensile strength (εR) | 180 | 193,67 | %7,59 |
| Compression set (%) | 20 | 16 | %20 |
| % Sound absorption coefficient – 1/3 octave band frequency (Hz) |
| 500 | 0,08 | 0,09 | %12,5 |
| 630 | 0,10 | 0,12 | %20 |
| 800 | 0,12 | 0,16 | %33,3 |
| 1000 | 0,17 | 0,21 | %23,5 |
| 1250 | 0,26 | 0,28 | %7,7 |
| 1600 | 0,30 | 0,39 | %30 |
| 2000 | 0,32 | 0,53 | %65,6 |
| 2500 | 0,43 | 0,71 | %65,1 |
| 3150 | 0,60 | 0,87 | %45 |
| 4000 | 0,75 | 0,93 | %24 |
| 5000 | 0,82 | 0,87 | %6,1 |
| 6300 | 0,80 | 0,80 | – |
* Tests were performed at an operating ratio of 100/64 and a molded density of 39 kg/m³.