Toray's ToraSoft Cross-Linked Olefin Foams for Automotive Applications

MATERIALS:  Toray Plastics (America) Inc. PEF Div. recently introduced new ToraSoft^TM closed-cell foams for all automotive interior trim applications requiring a soft, luxurious feel, precise edges and exceptional rebound. New ToraSoft^TM foams are up to 70 percent softer than previous generations of Toray cross-linked olefin foams.  Made with Toray’s proprietary polyolefin resin system, the applications include armrests, instrument panels, sun visors, glove box covers, door bolsters, door panels, and other interior trim components. Auto industry OEMs, parts molders and laminators now have available to them a technologically advanced cross-linked composite foam that offers Toray’s renowned thermoforming capabilities along with unprecedented haptics. Never before have Toray’s foams delivered such a plush, soft feel. Also, the lightweight nature of ToraSoft^TM foams helps manufacturers reduce the weight of vehicles, thereby lowering fuel consumption and reducing emissions along with costs, so vehicles will be more environment-friendly.

Trim component processors and Tier 1 suppliers utilizing low-pressure molding, vacuum-forming, (including in-mold grain technology), and compression molding processes will benefit from ToraSoft^TM foams’ high tensile properties, tear strength, thermal stability, and compression set resistance, all of which enable processing flexibility, increased production efficiencies, and overall lower systems costs.

When compared with urethane materials’, powder slush and spray molding processes, Toray’s composite materials minimize processing, which reduces labor, lowers capital investment and consumes less energy. ToraSoft^TM foams, which can be used with existing equipment, can be delivered to market more quickly than alternative products. There is no need to invest in new molding technologies. In addition, ToraSoft^TM foams produce lower skin scrap during production and enable a cleaner manufacturing environment-no release agents are needed for demolding. Overall, ToraSoft’s extremely desirable haptics are matched by significantly improved manufacturing value.

ToraSoft^TM foams resist fracturing at low temperatures and form beautifully with exceptionally tight radii. ToraSoft^TM foams range in thickness from 1.0 mm to 6.0 mm and are available in a variety of colors, densities and widths. Formulations can be customized to meet specific application requirements.

- Edited by Liz Taurasi