In a joint project, BASF and STR Automotive have brought components for premium vehicles into serial production for the first time using a new lightweight material – ‘Elastolit R 8819 Lightweight’.
In comparison to conventional processing with PU-RRIM materials, the new process creates significant weight reduction. The usual component thickness of 3.0 mm can be reduced to less than 2.5 mm, without detrimental effects on processing, quality or mechanical properties, the company says.
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In comparison to conventional processing with PU-RRIM materials, the new process convinces due to significant weight reduction. The usual component thickness of 3mm can be reduced to less than 2.5mm, without detrimental effects on processing, quality or mechanical properties.
Weight reduction with Elastolit
Front and rear bumpers of small car series are usually produced from PU systems with short-fibre reinforcement (PU-RRIM). Attempts to lower weight by reducing the component thickness, or using a special filler combination and an associated lower material density, failed due to insufficient mechanical properties. In an intensive exchange between BASF and STR Automotive, a technological solution has been found based on a high modulus PU basic material with high temperature resistance, stiffness and very good impact strength.
Jürgen Schneider of BASF Polyurethanes GmbH said: “The improved performance of the matrix material allows the designer to create a noticeably thinner component, without having to accept limitations in quality.”
Elastolit R 8819 Lightweight can be combined with different filler materials: a mineral standard fibre for rear bumpers, a mineral/carbon fibre combination for vertical components with low thermal expansion coefficient, or a combination of carbon fibres and light hollow glass spheres for components for which a particularly high weight reduction is a priority.
Giuseppe Monaco, Key Account Manager in the Performance Materials department at BASF Italia S.p.A, said: “A decisive factor for the successful market launch of this new development was the close co-operation with STR Automotive. With this innovative specialist, we have a partner who supports material development at an early stage in existing components and has brought expertise from component construction and manufacturing.”
In the first serial components made using Elastolit R 8819 Lightweight, the weight has been reduced by 600g/m². For rear panels, this means a weight reduction of up to 1.5kg.
STR Automotive CEO Dr Massimo Cecchini added: “With the new material and the compatible filler options, we have a good set of tools enabling us to satisfy different requirements. For our customers it is important that they get high-quality components. Weight reduction must not be at the expense of quality and there must be balanced price-performance ratio.”
The Italian specialist in trim parts for automotive exteriors and interiors also sees potential for applications arising from the higher temperature stability of the material. This creates additional areas of application for the material, for example in the engine compartment.
