TAGS: Automotive Metal Replacement Part Design & Manufacturing
BASF and Grupo Antolin in close cooperation have successfully validated the Polybutylenterephthalate (PBT) Ultradur® High Speed in plastic frames for open panorama headliners. The newly developed panorama roof is integrated into the ceiling trim (called the headliner) of the car which is made from the very light Polyurethane Elastoflex® E 3943/134.
The actual sunroof opening in the headliner is supported by a structural bracket. Traditionally this is made of heavy steel. With Ultradur® High Speed a metal replacement solution is now used. Besides a high dimensional stability, the Engineering Plastic convinces with excellent mechanical properties.
60% Weight Reduction and Excellent Performance
The novel and new design of these parts allow a weight reduction up to 60% compared to other traditional solutions. This special material allows the injection of large parts with unique performance such as excellent dimensional stability, low warpage at short cycle times,
high stiffness, high temperature resistance and an outstanding flowability.
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One of the main advantages of the newly designed plastic parts is the change in the process. We attach the frame to the headliner. During the production process the panorama reinforcement frame is fixed to the interior trim part while at the same time the part is formed in the mold. That leads to the elimination of additional process steps and moreover it improves tolerances during assembly and the quality of the final part is increasing,” explains Enrique Fernandez from Grupo Antolin. “
In addition, the new process does not involve the use of any solvents nor generate hazardous emissions.”
Outstanding Flowability for Interior Trim Parts
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The new rheological modified Ultradur® High Speed has an outstanding flowability that is crucial to obtain large and slim interior trim parts. Moreover, considering its unprecedented processing advantages, we have been able to reduce weight without losing stiffness and dimensional stability at high temperatures,” says Dirk Salzmann, key account manager in the performance materials division at BASF.
Following the predevelopment with a German customer, the first pilot project was launched for a best-seller vehicle with outstanding results. More opportunities with this solution have been identified for several OEMs at global scale.
BASF's Complete PBT Product Range
Source: BASF
