After two years of intensive research, BASF 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, extreme light weight and high hardness and strength. Therefore, it is particularly suitable for the manufacture of components with complex shapes inside automobiles, airplanes and trains. These components not only require excellent mechanical properties, but also withstand high temperatures or meet stringent flame retardancy requirements. The foamable PESU particles are pre-expanded to a particle having a density as low as 40 to 120 g/L, and can be processed into a molded part having a complicated three-dimensional geometry by the prior art on the market.

BASF's PESU product Ultrason® E is an amorphous thermoplastic with unique temperature characteristics: a glass transition temperature of up to 225 ° C and dimensional stability at this temperature. At the same time, its excellent mechanical and dielectric properties are extremely temperature dependent. Foam made with Ultrason® E has been approved for use in aircraft. This material has an extremely high limit oxygen-containing light-off index of 38 (according to ASTM D 2863). Because of the inherent flame retardant properties of the material, it can meet commercial aircraft requirements in terms of flammability, low heat release and low smoke density ("fire, smoke, toxicity"), even without the addition of flame retardants.

Particle foam for the production of lightweight components

The new PESU particle foams, despite their low density, can still produce extremely hard and strong parts that have excellent dimensional stability at high temperatures. Foamed molded parts made from a single material have many advantages over conventional honeycomb structures coated with a phenolic resin: foamed molded parts have considerable flexibility in terms of density and shape to meet greater design freedom; Less process and lower system cost; other additional features such as inserts and threads can be integrated into complex geometries. Finally, it is worth mentioning that the use of 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 produce new lightweight components that perform better than traditional thermoplastic components to meet automotive electrification, modern aircraft cabin interiors and public transportation. Trends in increasing flame retardant requirements.

Ultrason® is the trade name for BASF's range of Ultrason® E, Polyson® S and Ultrason® P. This high-performance material can be used to manufacture lightweight components in the electronics, automotive, and aerospace industries, as well as in the manufacture of water purification membranes and related components in contact with hot water and food. The Ultrason® brand excels in its ability to replace thermoset materials, metals and ceramics.