Elastoflex® E manufactures lightweight, thin parts for automotive interiors
Lightweight slim system wins SPE environmental category award
Local support available worldwide
Ludwigshafen, Germany—August 24, 2018—Automakers and processors are constantly looking for new, cost-effective solutions to make more perfect parts, which poses many challenges for material suppliers. For example: extremely complex instrument clusters must meet new safety trends while complying with current safety component regulations. The size, design and safety requirements, as well as the technical equipment that may be integrated, will increase the complexity of this safety component. Not only that, the dashboard must be as comfortable and easy to use as possible for the driver.
BASF has been providing innovative polyurethane technology for many years for the manufacture of instrument panels with back foam. Its production process requires polyurethane foam to be injected between the skin and the skeleton of the instrument panel, so that the skin and the supporting material are combined. This foam material is extremely soft to the touch. This custom system has low emissions and good adhesion to surfaces made of different materials, making it attractive. Even PVC skins can be easily processed.
Bio-based foam reduces weight
The new Elastoflex®E product series significantly reduces weight and achieves a foam density of about 120 g / L without losing the physical and mechanical properties of the foam. Depending on the part geometry, foam weight can be reduced by up to 30%. Thanks to its extremely rugged and delicate unit structure, this lightweight and slim system can be used for small parts with a profile of less than 5 mm, creating extremely lightweight and slim instrument panel or door components, expanding the range of new design options. The latest members of the BASF product family meet stringent standards while offering a range of flexible options to help customers move into the future of the automotive industry.
Marc Martin, an automotive interiors expert at BASF's Performance Materials business unit, said: "The new PU system is designed to integrate sensors or control elements to reduce weight. In addition, we have further reduced emissions and may simplify the use of airbag laser weakening processes. "
As part of a new generation of systems, BASF has also developed foam systems based on renewable raw materials. ElastoflexE 3496/102 uses castor oil as a renewable raw material, which can be used to make light and thin complex components, and has excellent adhesion to a variety of materials. The development achievement won the SPE environmental category award at the end of 2017. The project shares the Renewable Innovation Award with the International Automotive Components Group (IAC).
With the new lightweight and slim system, BASF will further expand its global PU foam product range for dashboards, doors and seat armrests.