The prototype has a unique combination of properties: lightweight, high hardness and high strength, high temperature resistance, inherent flame retardancy
Suitable for manufacturing complex components in cars, airplanes and trains
September 25, 2018 - After two years of intensive research, BASF introduced 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 Lightweight and high in hardness and strength. Therefore, it is particularly suitable for the manufacture of complex shapes in cars, airplanes and trains. These components not only require excellent mechanical properties, but also have to withstand high temperatures or meet stringent resistance. Flammability requirements. The foamable PESU particles are pre-expanded into particles with a density as low as 40 to 120 g/L. They can be processed into molded parts with complex three-dimensional geometry by existing techniques on the market.
BASF's PESU product Ultrason® E is an amorphous thermoplastic with unique temperature characteristics: its glass transition temperature is as high as 225 ° C, and its dimensional stability is maintained at this temperature. At the same time, its excellent mechanical properties and dielectric properties The dependence on temperature is extremely low. Foam made with Ultrason® E has been approved for use in aircraft. This material has a very high limit oxygen-containing light-off index of 38 (according to ASTM D 2863). Because of the inherent flame retardancy of the material Characteristics, even without the addition of flame retardants, it can meet the requirements of commercial aircraft in terms of flammability, low heat release and low smoke density ('fire, smoke, toxicity').
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 parts made from a single material are more phenolic-coated Traditional honeycomb structures have many advantages: Foamed molded parts offer considerable flexibility in terms of density and shape for greater design freedom; lower system costs due to fewer processing steps; additional functional features such as inserts and threads It can be integrated into complex geometries. Finally, it is worth mentioning that using a single polymer makes it easier to recycle parts in the future. Thanks to this lightweight thermoplastic foam for complex geometries, we It can produce new lightweight components with better performance than traditional thermoplastic components, thus meeting the trend of automotive electrification, modernization of aircraft cabin interiors and increasing flame retardant requirements in public transportation.
Ultrason® is the trade name for BASF's Ultrason® E, Ultrason® S and Polyson® P series. This high performance material can be used in the electronics, automotive and aerospace industries. Lightweight parts can also be used to make water purification membranes and related parts that come into contact with hot water and food. The Ultrason® brand excels in thermosetting materials, metals and ceramics.
BASF: Unique technical expertise in foam
BASF's unique technical expertise in foam has been successfully applied in many industries. In 1951, the company patented the first ever particle foam: a classic white foam made of expandable polystyrene (EPS) - Styropor® Since then, the material has set the standard for insulation and packaging applications and was further developed in 1997 to become a high-performance insulation material Neopor®. BASF is also a pioneer in block foam: BASF has been in 1964 since 1964 Producing Styrodur®, a foamable polystyrene (XPS) insulation for the construction industry. Since then, the company has been bringing a variety of high performance foams to market: Basotect® is made from melamine resin. Flexible open-cell foam for acoustic engineering, transportation and cleaning; Neopolen® is a polypropylene foam (EPP) with high energy absorption and high resilience. The latest innovation is Infinergy®. The sneakers perform the world's first blasting E-TPU Infinergy®, as well as ecovio® EA, a certified compostable foamed particle foam with high growth Group component may be packaged for transport, and recycling economy benefit.