Using a new process developed by BASF and STR Automotive, flat components made from short-fibre polyurethane can now be produced even thinner, while still retaining their stability and processability.
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.
BASF
With the help of a process developed by BASF and STR Automotive, flat mounting parts for cars can now be produced even thinner, by using an optimised short-fibre reinforced polyurethane (PU-RRIM). Up until now, front and rear bumpers of small car series have usually been produced from PU-RRIM material with a wall thickness of 3.0 mm. Attempts to lower the weight by reducing the component thickness or using a special filler combination with a lower material density failed due to the resulting insufficient mechanical properties.
Rear bumpers up to 1.5 kg lighter
Now, for the first time, the partners have brought premium vehicle components with a reduced thickness of 2.5 mm into serial production. According to BASF, reducing the material does not have any detrimental effects on processing, quality or the mechanical properties. Elastolit R 8819 Lightweight, the high modulus PU basic raw material used for this process, has high temperature resistance, rigidity and toughness. The material can be combined with various filler options such as the established standard fibres, carbon fibres or hollow glass spheres.
The weight of the first serial components produced with this method has already been reduced by 600 g/m² surface area. According to the company, this approach saves up to 1.5 kg in a rear bumper.