Composite Sponge Project for Automotive Interior Headliners (Dongguan Auto Parts Factory)

In June 2025, a Dongguan-based automotive interior manufacturer required polyurethane sponges featuring high resilience, compression resistance and strong composite bonding performance for the lamination of automotive headliners and door panel linings. The customer's requirements are specified as follows: the sponge shall have a resilience rate of ≥60% and no deformation after long-term compression; no degumming or bubbling shall occur after being laminated with fabric; the sponge shall be free of peculiar smell with low VOC content to meet in-vehicle environmental protection standards; the products shall be supplied in roll form to match the automatic lamination line, with a monthly demand of 100,000 meters.

Targeted at the automotive interior application scenario, Jinyili optimized the high-resilience formulation to deliver stable resilience and durable compression resistance. By adopting the PUR hot-melt adhesive lamination process, the bonding strength between the sponge and fabric is significantly improved, which enables excellent high temperature resistance and zero degumming risk. With strictly screened raw materials, the finished sponge features low VOC content and no pungent odor, fully complying with the environmental protection requirements for automotive interiors. In terms of production, Jinyili owns an integrated foaming + lamination production line, which can produce rolls with a width of 1.5 meters at a daily output of 40,000 meters to ensure sufficient production capacity. Full-process quality control is implemented, with spot checks on thickness, density, resilience and odor for each batch to guarantee consistent product performance.

The first batch of 100,000-meter rolls was delivered on schedule. The customer achieved smooth on-machine lamination without any bubbling or degumming issues, and the products successfully passed the in-vehicle environmental protection test. A long-term supply agreement was signed subsequently to ensure stable monthly supply, making Jinyili a core supplier in the automotive interior sector. This project demonstrates Jinyili's outstanding strengths in high-resilience material development, lamination process optimization, eco-friendly quality control and large-scale production capacity.