Kuheli Sen, Research Analyst, Chemicals and Advanced Materials, MicroMarketMonitor (MMM), provides an overview of the importance of thermoplastic polyurethane (TPU) in the automotive segment, particularly in India. Excerpts from the interview:

What exactly is TPU?

Thermoplastic polyurethane (TPU) provides a potential platform for various manufacturers, particularly in the automotive space, to meet the constantly changing needs of customers across the globe. It is a thermoplastic elastomer, which has physical properties such as melt processability and elasticity. TPU is extremely flexible and adaptable to a broad spectrum of applications. It has been in production since 1937.

Can you elaborate on it?

TPU is manufactured from a chain extender, a polyol, and a diisocyanate. An isocyanate and a polyol enable TPU to have elastomeric characteristics such as flexibility. Furthermore, the isocyanate and chain extender enable physical properties such as toughness. Moreover, it could be processed on injection as well as extrusion, compression moulding, and blow equipment. TPU is suitable for various fabrication methodologies, as it could be used in different forms such as solution-coated or vacuum-formed, and so on. There are various ways to synthesize TPU, which enables TPU manufacturers to customize the TPU structure depending on the end-user specifications. It can also be reprocessed, which helps in reducing industrial waste.

Its unique structural design gives it versatile properties such as impact resistance, high resilience; and resistance to weather, abrasions, hydrocarbons, and so on. Without using plasticizers, TPU offers flexibility, which reduces the dependency on plasticizers. TPU also offers high elasticity and structural hardness, due to which it could be efficiently used as a soft engineering thermoplastic and hard rubber. Furthermore, it also has anti-static properties, flexibility at low temperature, optical clarity, hydrolytic stability, and bio-compatibility. TPU offers flexibility without the use of plasticizers as well as a broad range of hardness’ and high elasticity. In fact, TPU bridges the material gap between rubbers and plastics. Its range of physical properties enables TPU to be used as both a hard rubber and a soft engineering thermoplastic. TPU’s can be sterilised, welded, easily processed, coloured, painted, printed, die-cut and slit.

How does TPU find use in the automotive segment?

TPUs are used in various applications such as building and construction, aerospace, railways, energy, automotive, leisure and sports, furniture, and others. Rising applications of TPU in manufacturing automotive components such as sensors, panels, instruments, levers, and so on is expected to lead to rise in the demand for TPU in the automotive industry. These are increasingly being used in the aviation industry in the manufacturing of cable jacketing, aircraft wire arm-rest surfaces, masks, seat cushions, interior panels, and other products. About 40 per cent of all Thermoplastic Elastomers (TPEs) products consumed worldwide are used in vehicle manufacturing. Therefore, the development of the automotive and transport industries, as well as their suppliers, is an important indicator for forecasts of future TPE demand. As there are numerous types of TPE, each with highly diverse properties, TPE applications in the automotive industry are widespread and cover various segments ranging from fabric coating to sealing components and bumpers.

What are your findings for the Asia-Pacific market for the use of TPUs?

Growing applications in industries such as the automotive industry is expected to drive the TPU market. TPU properties, including resilience, impact strength, resistance to oil, flexibility at low temperature, etc. are considered to be most suitable for manufacturing the interiors of an automobile. Furthermore, TPU has been preferred over PVC due to its enhanced output, such as reduced thickness of the surface, better mechanical performance, and UV resistance. In recent years, TPU is increasingly being used for exterior moulding, door handles, and so on due to its high hydrolytic stability. It is also used for manufacturing transparent tubes and films as it enhances the aesthetics as well. India is the sixth-largest vehicle producer worldwide, and one of the largest plastic consumers in Asia-Pacific. The automotive industry in the region is expected to witness high growth in the coming years due to favourable government policies such as free imports, 100 per cent FDI and WTO-compliant policies. The TPU market in Asia-Pacific is expected to grow at a CAGR of 8.4 per cent from 2014 to 2019.

What are the market trends and new opportunities that you see?

TPU manufacturers are constantly focusing on new additive development for improving product specification. Companies such as Merquinsa, Arkema, PolyOne, and Dupont are focusing on developing bio-based raw materials for manufacturing TPU. Thus, the market has been witnessing increased TPU product innovation and rising adoption of TPU products over other conventional materials. Various types of biopolymers such as polylactic acid (PLA), polyhydroxybutyrate (PHB), and so on, could be used to manufacture TPU. Recently, about 95 per cent of the bio-based products are used to manufacture TPU. Major producers of the TPU market such as Bayer Material Science AG (Germany), Wanhua Chemical Group Co. Ltd (China), BASF SE (Germany), Lubrizol Corporation (US), and Huntsman Corporation (US) constitute nearly 80 per cent share of the total market, leading to intense competition in the TPU market.