back to top
My wish lists
Save your wish list
If you want to add more content to your wish list, simply log in. If you do not have a user account, please register for the Hanser Customer Center.

» Do you already have a user account? Please log in here.
» Don't have a user account yet? Please register here.
Your wish lists
If you want to use your wish list during your next visit, simply log in. If you do not have a user account, please register for the Hanser Customer Center.
» Do you already have a user account? Please log in here.
» Don't have a user account yet? Please register here.

« Back

Your advantages at a glance

  • One login for all Hanser portals
  • Individual home page for faster access to preferred content
  • Exclusive access to selected content
  • Personal wish lists on all portals
  • Central management of your personal information and newsletter subscriptions

Register now
Deutsch
Bookmark Bookmarked
09-18-2015

PU Foam System Can also Be Used Outdoors

Honeycomb on the Car Roof

Lightweight roof made from polyurethane foam (figure: BASF)

Lightweight roof made from polyurethane foam (figure: BASF)

The Elastoflex E polyurethane (PU) foam system from BASF SE, Ludwigshafen, Germany, supports mass-production of an exterior car component featuring a honeycomb sandwich technology with a Class A film. The roof module in the standard model of the new Smart Fortwo from Daimler AG, Stuttgart, Germany, consists of a paper honeycomb and two surrounding glass fiber mats, which in an impregnation process are sprayed with the low-density, heat-activatable Elastoflex E 3532 polyurethane foam system and pressed together with a solid-colored Class A film. A single operation thus produces a roof module that is claimed to be 30 % lighter than the standard roof on the predecessor model – but retains the same strength and flexural rigidity. The lightweight roof was developed by F. S. Fehrer Automotive GmbH, Kitzingen, Germany, which manufactures it at its plant in Großlangheim, Germany.

The honeycomb technology has previously been is used in car interiors, e. g. for loading floors, roof linings and rear shelves. For use in exterior components, the chemical company has adjusted the viscosity and reactivity of the semi-rigid polyurethane system which was developed specially for the honeycomb technology, so that it can be optimally processed in each manufacturing step and exhibits good adhesion properties: it guarantees uniform, thin wetting of the glass fiber mats and does not drip. After the semi-finished product has been impregnated, it is pressed into shape in a heated mold together with the Class A film. This causes the polyurethane system to foam up slightly at the edge of the sandwich and creates a solid material composite between film, reinforcing mats and paper honeycomb core.

The reactivity of the PU foam system has been adjusted so that long spray times of up to 120 s for large-scale parts as well as short demolding times of up to 60 s are possible. The company maintains that decorative materials and films can be directly back-foamed in the mold, as the material adheres well to many materials. The roof module is fitted on the outside with a Class-A film while a textile covering is attached on the inside.

Translated from Kunststoffe 9/15, p. 13

Company profile

BASF SE

Carl-Bosch-Str. 38
DE 67056 Ludwigshafen
Tel.: 0621 60-0
Fax: 0621 60-42525

F.S. Fehrer Automotive GmbH

Heinrich-Fehrer-Str. 3
DE 97318 Kitzingen
Tel.: 09321 302-0
Fax: 09321 302348

These articles might be interesting for you
Patents Stimulate Innovation

Patents encourage innovation: Stay on the ball with the latest innovations in the plastics industry in our patents section.

Patents

Newsletter

Would you like to subscribe to our Newsletters on plastics technology and profit from the latest information?

Subscribe here

Subscribe here

Trade Names

You know the trade name but want to know the material manufacturer, type of polymer and delivery form? Search here!

Trade Names