The prototype has a unique combination of properties: light weight, high hardness and strength, high temperature resistance, inherent flame resistance
Suitable for manufacturing complex-shaped components inside cars, airplanes and trains
Shanghai, China — September 25, 2018 — After two years of intensive research, BASF has launched the world's first polyethersulfone (PESU) -based particle foam prototype. The foam has a unique combination of properties: high temperature resistance, inherent flame retardancy, extremely lightweight and high hardness and strength. Therefore, it is particularly suitable for manufacturing complex shaped parts in automobiles, airplanes and trains. Such components not only need excellent mechanical properties, but also need to withstand high temperature operation or meet strict flame retardancy requirements. The foamable PESU particles are pre-expanded into particles with a density as low as 40 to 120 g / L, which can be processed into shaped parts with complex three-dimensional geometry through the existing technology on the market.
BASF's PESU product Ultrason® E is an amorphous thermoplastic with unique temperature characteristics: its glass transition temperature is as high as 225 ° C and it remains dimensionally stable at this temperature. At the same time, its excellent mechanical and dielectric properties have very low temperature dependence. Foams made of Ultrason® E are approved for use in aircraft. This material has an extremely high limiting oxygen light-off index of 38 (according to ASTM D 2863). Because of the inherent flame retardant properties of the material, even without the addition of flame retardants, it can still meet commercial aircraft requirements in terms of flammability, low heat release, and low smoke density ("fire, smoke, toxicity").
Particle foam is used to produce lightweight components
The new PESU particle foam, despite its low density, can still produce extremely hard and sturdy components that still have excellent dimensional stability at high temperatures. The foam molded parts made of a single material have many advantages over the traditional honeycomb structure with a phenolic resin coating: the foam molded parts have considerable flexibility in terms of density and shape, which can meet greater design freedom; due to processing Fewer processes and lower system costs; other additional functional components such as inserts and threads can be integrated into complex geometries. Finally, it is worth mentioning that using a single polymer makes it easier to recycle parts in the future. Thanks to this lightweight thermoplastic foam for complex geometries, we are able to manufacture new lightweight components that perform better than traditional thermoplastic components, meeting the needs of automotive electrification, modernization of aircraft cabin interiors, and public transportation Increasing flame retardant requirements and other trends.
Ultrason® is the commercial name for the BASF polyethersulfone (Ultrason® E), polysulfone (Ultrason® S), and polyphenylsulfone (Ultrason® P) product lines. This high-performance material can be used to make light parts for the electronics, automotive, and aerospace industries, as well as water purification membranes and related parts that come into contact with hot water and food. The Ultrason® brand offers outstanding performance as a replacement for thermoset materials, metals and ceramics.
BASF: unique technical expertise in foam
BASF's unique technical expertise in foam has been successfully applied in many industries. In 1951, the company patented the first ever particle foam: Styropor®, a classic white foam made from expandable polystyrene (EPS). Since then, the material has set the standard for insulation and packaging applications, and was further developed in 1997 to upgrade to Neopor®, a high-performance insulation material. BASF is also a pioneer of slabstock foam: BASF has been producing Styrodur®, an expandable polystyrene (XPS) insulation material for the construction industry, since 1964. Since then, the company has continuously introduced a variety of high-performance foams to the market: Basotect® is an elastic open-cell foam made from melamine resin as a raw material for applications in acoustic engineering, transportation, and cleaning; Neopolen® It is a polypropylene foam (EPP) with high energy absorption and high resilience. The latest innovation is Infinergy®, the world's first foaming thermoplastic polyurethane (E-TPU) Infinergy®, and ecovio® EA, a certified compostable foamable foam with high performance Bio-based ingredients can be used in transportation packaging and are beneficial to circular economy.