Elastoflex® E manufactures lightweight, slim parts for automotive interiors

Lightweight slim system wins SPE environmental category award

Local support is available worldwide

Automakers and processors are constantly looking for cost-effective new solutions to create more perfect parts, which presents material suppliers with many challenges. For example, dashboards with extremely complex structures must meet new trends in autonomous driving while complying with current safety component regulations. Dimensions, design and safety requirements, as well as technical equipment that may be integrated, will increase the complexity of this safety component. Not only that, but the dashboard must be as comfortable and easy as possible for the driver.

BASF has been providing innovative polyurethane technology for many years to manufacture instrument panels with back foam. The production process requires the injection of polyurethane foam between the skin and the skeleton of the instrument panel to bond the skin and the support material. The material of this foam is extremely soft to the touch. This custom system is attractive because it has low emissions and good adhesion to surfaces made from different materials. Even PVC skins can be easily processed.

Bio-based foam reduces weight

The new Elastoflex® E product line offers a significant weight reduction, achieving a foam density of approximately 120 g/L without compromising the physical and mechanical properties of the foam. The foam weight can be reduced by up to 30% depending on the geometry of the part. Thanks to its extremely rugged unit construction, this lightweight and slim system can be used for small parts with a profile of less than 5 mm, resulting in extremely lightweight and slim instrument panels or door components, offering an expanded range of new designs. The newest members of the BASF product range meet stringent standards and offer a range of flexible options to help customers move into the future of the automotive industry.

Marc Martin, automotive interior specialist at BASF's Specialty Materials business unit, said: "The new PU system is designed to integrate sensors or control components 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 a foam system based on renewable raw materials. Elastoflex E 3496/102 uses castor oil as a renewable raw material for the manufacture of lightweight, lightweight and complex components with excellent adhesion to a wide range of materials. The development was awarded the SPE Environmental Category Award at the end of 2017. The project shares the Renewable Innovation Award with the International Auto Parts Group (IAC).

With a new lightweight and slim system, BASF will further expand its global line of PU foam for instrument panels, doors and armrests.