BASF Plastics at the VDI conference “Plastics in automotive engineering 2013” – an overview
At the VDI Conference and exhibition "Plastics in Automotive Engineerig 2013", BASF presents and discusses many of its engineering plastics and polyurethane systems that have been optimized specifically for the automotive industry in terms of performance, system cost reduction and new applications.
News from BASF’s Engineering Plastics
Automotive:
Front end carrier without metal reinforcement (see P 128/2013)
A front end carrier without metal reinforcement has gone into production at Volkswagen as an all-plastic injection molded part. The part is installed in the new Golf 7 and consists entirely of Ultramid® B3WG8, a polyamide from BASF. Through use of Ultrasim®, the company’s universal simulation tool, it was possible to develop a very sturdy and lightweight part. This allowed the weight of the entire front end module to be reduced considerably compared to that of the predecessor model.
Metal Replacement in Hot Coolant (see P 207/2012)
Thermostat housings molded from Ultramid® A3WG6 HRX are now in use at VW as well. The new polyamide specialty from BASF which is available worldwide has been developed specifically for applications requiring high hydrolysis resistance in conjunction with high strength. The coolant control module’s cover, which is molded from the new material, must withstand demanding conditions – a pressure of several bars at a peak temperature of up to 130°C – and exhibit minimal deformation, as this would reduce the module’s efficiency. In contrast to the all-aluminium predecessor, the molded plastic component does not need to be finish-machined, and the desired dimensional accuracy, especially of sealing surfaces, is easier to achieve. Supports, holders, valve seats and other functions can be integrated and the high surface quality of the plastic counteracts abrasion by the coolant.
E+E:
Laser-transparent PBT (see P 344/2012)
Another topic to be discussed is the motor developer Precision Motors Deutsche Mineba (PM DM)’s control module made of the highly laser-transparent PBT Ultradur® LUX. The company is employing this easily laser weldable BASF plastic to make the housing cover of an air flap control unit. The small actuator consisting of gears, an electric motor and an electronic unit serves to control the air flaps in motor vehicles, thus contributing to better aerodynamics and lower CO2 emissions. The material accounts for stiffness and dimensional stability, even in damp environments, two properties which are particularly important in the electric and electronic realms. The product’s key characteristic, however, is its high transparency toward near-infrared light in the 800 to 1100nm wavelength, precisely the crucial range for penetration laser welding. The improved transparency to laser light means that this material can be welded faster than other PBT grades available on the market. Moreover, the processing window is considerably wider and the risk of damage to the material is much lower.
Endless fiber composite:
First production part made from Ultramid® with endless fiber reinforcement (see P 187/2012)
The next big step in light weight construction will be with thermoplastic composites: A still impressing example is the Opel Astra OPC, a sport coupe: It has a seat shell made from a thermoplastic laminate with endless fiber reinforcement. This is the world’s first auto seat shell based on this technology manufactured for a production vehicle. The plastics used are special polyamides from BASF’s Ultramid product line: an unreinforced grade serves as impregnating material for the glass fiber fabric, whereas an impact-modified, short glass fiber-reinforced Ultramid serves as the overmolding material used to achieve the necessary ribs and edges of the part by means of conventional injection molding. Thanks to the high strength of the laminate, the wall thicknesses could be reduced considerably, so that the weight of the seat shell was lowered by 45 per cent.
Automotive and Design:
sit down. move. Global competition – The Winners (see P 461/2012 and new publication)
In a joint effort with automobile manufacturers and customers, BASF has already played a role in the development of several serially produced seats and studies on seat designs, a process in which its materials were instrumental in meeting a wide array of requirements. Nowadays, a car seat is a complex material system that has to combine the aspects of design and safety, cost considerations and functionality, weight reduction and resource savings, comfort and ergonomics. End of September 2012, BASF launched its first international competition in the realm of car seat design. This contest was open to anyone interested in automotive seating to develop a design concept for a car seat using BASF materials. At the VDI conference the winning concepts will be shown.
Polyurethanes
Low weight, high performance
For weight saving in automotive interiors, two new extremely light materials are available: Elastoskin® I and Elastoflex® E.
Elastoskin is a new polyurethane spray system for high-grade, soft-touch surfaces for instrument panels, door modules, armrests and centre consoles – in the car and commercial vehicle segments. Elastoflex E is the ideal material for flawless back-foaming. Skins made with the new Elastoskin® spray technology are up to 35 per cent lighter than PVC and 20 per cent lighter than conventional polyurethane skins.
Engine compartment materials resistant to high temperatures and oils
The integral polyurethane (PU) foam Elastofoam® I is particularly applicable in the engine compartment, as it shows outstanding resistance to elevated temperatures. What also makes the material special are its high dimensional stability and excellent sealing characteristics. It can be used for the end caps of filters, for cable sheathing on cable bushings and harnesses exposed to high temperatures, and on engine covers.
Cellasto® solutions for the chassis and power train – lightweight, compact and high-performance
Cellasto applications not only enhance automotive comfort and athleticism, but the special product properties of microcellular polyurethane also help to reduce weight and fuel consumption. The latest developments show that weight reductions up to 30 per cent are possible over conventional components. Thanks to durable bonds between Cellasto and other connecting parts, the range of possible applications is being consistently extended as well.
Comment: The P numbers are referring to existing press releases on:
http://www.plasticsportal.net/wa/plasticsEU~en_GB/portal/show/content/plasticsportal_news/plasticsportal_news
Press photo: Available at www.basf.com/pressphoto-database under the heading "Plastics" or search term "Ultramid”. Text and photo are also available in the Plastics press archive of BASF: www.basf.de/plastics/pressreleases.