cars love quiet - welcome to basf polyurethanes asia … · 2012-07-06 · cars love quiet....
TRANSCRIPT
cars love quiet
Innovation and our customers’ success is the driv-
ing force behind our work. Together with our cus-
tomers, we are constantly searching for solutions
to improve comfort and convenience in daily life
while simultaneously conserving resources.
The ceaseless drive to discover something new
has a long tradition at BASF. And it is in the nature
of our engineering material polyurethane that it
has lost none of its fascination even 75 years after
it was invented. Our chemists and engineers are in
constant cooperation with our customers to de-
velop new applications and areas of use, and to
optimize and further perfect them. So naturally it
was only a matter of time before the advantages of
Cellasto® were discovered for the multiple, com-
plex requirements of the automotive industry.
Vehicles are expected to offer ever increasing
levels of safety and comfort, while technical re-
quirements are becoming more and more com-
plex. One of many challenges faced by today’s
chassis engineers. And one of many challenges
the versatile engineering material polyurethane
(PU) is helping us to meet.
Under the brand name Cellasto®, BASF devel-
ops, produces and markets components made
from special microcellular polyurethane (MPU)
elastomers. They are used in the automotive in-
dustry as spring aids, coil spring isolators and top
mounts and contribute significantly to enhancing
driving comfort and safety.
The premier product quality is based on our ex-
pert knowledge and has helped us achieve the
status of world market leader in this application
segment. This is why nine out of ten car manufac-
turers worldwide already use Cellasto® spring
aids. Because they know they have a solution to
reduce noise, vibration and harshness (NVH). NVH
is the study and modification of the noise and vi-
bration characteristics of vehicles and machines.
While noise and vibration can be readily measured,
harshness is a subjective quality, that is measured
either via “jury” evaluations, or with analytical tools
that provide results reflecting human subjective
impressions. These latter tools belong to the field
known as “psychoacoustics.”
Our premium brand Cellasto® convinces users
with its outstanding physical properties. The ma-
terial is highly resilient and has outstandingly high
volume compressibility and low compression set.
In contrast to similar components made of rubber,
for example, the polyurethane foam expands only
slightly under compression. Cellasto® offers better
damping performance, considerably minimizes
driving noise and enhances safety and driving
comfort.
Discover the many uses of Cellasto® and get to
know our global organization. We operate local
production facilities worldwide and offer solutions
custom-tailored to our customers and contact
partners around the world to meet their require-
ments. Discover more applications of this fasci-
nating material and challenge us to accompany
you along new paths.
PAGE 4 5 Globally networked, locally integrated
6 7 Unbeatably resilient – Cellasto® spring aids
8 9 Superiorly quiet – Cellasto® top mounts
10 11 Great loads borne lightly – Cellasto® spring isolators
12 13 The versatility of Cellasto®
14 15 Custom-tailored and high quality – the manufacture of Cellasto®
A FASCINATING RANGE OF POSSIBILITIES FOR OUR CUSTOMERS
Nine out of ten car manu-
facturers worldwide already
use Cellasto® spring aids.
Because they know they
have a solution to reduce
noise, vibration and harshness
(NVH): Cellasto®– the NVH
solution.
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VIB
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ISE
I speak English
Je parle français
Eu falo português
Cellasto® stands for high quality, long-
lasting components. Because Cellas-
to® components have this in common,
we adapt them to meet each custom-
er’s requirements and the associated
production platforms.
Our local development and project
engineers are competent contact part-
ners closely integrated into BASF’s
global infrastructure. Thanks to our
global key account management, we
can respond rapidly and flexibly in all
regions of the world and offer compe-
titive solutions from a single source.
Our customers benefit from this ar-
rangement as they not only save on
development costs but also have a
single reliable local supplier who
speaks their language. BASF produces
Cellasto® at six sites worldwide, cur-
rently: Lemförde (Germany), Nansha
and Shanghai (China), São Paulo (Bra-
zil), Shinshiro (Japan) and Wyandotte
(USA).
Sharing know-how
Major elements of project work such as
tests, creation of drawings and quality
assurance are done by our develop-
ment centers linked with each other in a
worldwide network. Each of our devel-
opers can access a continuously avail-
able central database with all the im-
portant drawings, test orders, and other
development knowledge. The database
permanently offers guaranteed cutting
edge research and development infor-
mation.
It also serves as a calculation plat-
form for the preliminary design of differ-
ent products. These availabilities are
key factors ensuring fast and effective
work on global automotive platforms.
Location advantage
We find the suitable partners for our
customers’ projects and routinely offer
several options. Being familiar with the
local conditions, we know how to utilize
the economic advantages of regional
locations. We obtain outsourced parts
from all around the world, while the ma-
jor components are purchased from
local suppliers. This is another way we
guarantee cost benefits and security of
supply for our customers.
Vehicle platforms are produced all around the world. With our Cellasto® sites
in North and South America, Europe and Asia, we’re where our customers
are. Whether for Chang´an, Citroën, Ford, GM, Hyundai, SAIC, Suzuki, Tata,
Toyota, or Volkswagen – we know the regional differences and our customers’
local needs.
GLOBALLY NETWORKED, LOCALLY INTEGRATED
4 Global Cooperation Cellasto®– the NVH Solution
Jag talar svenska
Ich spreche Deutsch
Io parlo italiano
90 %OF ALL CAR MANUFACTURERS USE CELLASTO® COMPONENTS WE PRODUCE WORLDWIDE
Why Cellasto® ?
Whether as spring aid, top mount or spring pad –
thanks to their outstanding physical properties,
Cellasto® components are the jackpot for the auto-
motive industry. Because Cellasto® offers:
• verygoodstaticanddynamic long-run behavior,
• highvolumecompressibilitywithminimal lateral expansion (ideal for restricted spaces),
• lowdynamichardeningand amplitude-selective damping,
• lowcompressionset,
• highabrasionresistance,
• resistancetocold,heatandmoisture,
• resistancetooils,greases,ozone and many other important media.
This special combination of characteristics distin-
guishes Cellasto® as an outstanding engineering
material that also decisively reduces noise, vibra-
tion, and harshness in vehicles. Hardly surprising,
therefore, that more than 90 % of all car manufac-
turers are already using Cellasto® components we
produce worldwide.
Cellasto®– the NVH Solution Global Cooperation 5
The chassis is exposed to special stresses. It has to respond to different driving conditions and road surfaces such
as potholes and constantly exercise a compensatory function. With rapid deformations and large spring travel, it
absorbs enormous amounts of energy within the shortest time. If the energy peaks are not absorbed, the dampers
and chassis may be damaged and vehicle occupants subjected to unpleasant jarring and vibrations.
UNBEATABLY RESILIENT – CELLASTO® SPRING AIDS
Energy peaks disappear
Cellasto® spring aids enable relaxed
and comfortable driving as they effec-
tively eliminate energy peaks. The vol-
ume compressibility of Cellasto® per-
mits large spring travel within a confined
space.
It is also abrasion and fa tigue resistant
under high compressive loading. It fea-
tures excellent compression set, a natu-
rally progressive characteristic curve,
and superb absorption behavior. No
other material offers this combination of
properties.
Made to meet
the highest demands
We are constantly working to meet in-
creasing demands placed on spring
aids. For example, using the finite ele-
ment analysis, we can:
Our FEA simulations of the Cellasto® compo-nents provide insights denied in rig testing. For example, optimizing the geometry is easier.
Driving over a pothole is when spring aids come into their own. The wheel speeds with enormous force towards the body. The spring aid has to stop its movement and minimize energy peaks.
Volume compressible material offers invaluable advantages in the restricted spaces of the strut assembly.
This comparison demonstrates the volume compressibility of Cellasto® in enclosed spaces. Rubber expands laterally and shatters the glass.
Cellasto® with its low transverse elongation can be compressed by up to 40 % of its original height.
• identifystressconcentrations
in the material at an early stage,
• visualizeandeliminate
critical deformation states,
• implementshorter
development times,
• anddevelophighmaturity
prototypes in early phases.
6 Spring aids Cellasto®– the NVH Solution
Customized
Cellasto® spring aids
Whether distribution to our worldwide
production sites for high volume pro-
duction with many variants or a limited
number of spring aids for a small
series – we offer customized solutions.
With globally identical standards and
the complete portfolio of formulations,
we can fulfill virtually all our customers’
needs.
We use different formulations, bulk den-
sities and contours, but also mounted /
attached parts that can be either direct-
ly foamed in or fitted. For example, with
a consistently low initial rate, a larger
block height can be implemented.
Efficient and fast
New car models and facelifts are cap-
turing the market at an increasing rate
and with ever shorter development cy-
cles. With efficient processes, we sup-
port our customers, operate with high
efficiency and supply premium quality.
But however efficient we are, our top
priorities are and will remain service and
personal contact.
We supply top mounts, spring aids and dust tube together in pre- assembled component groups.
Molded-in cups have a stabilizing effect and provide block height. Another advantage is that Cellasto® and the mounted part are captively connect-ed to each other.
When the spring aid deflects during driving, this perceptibly impacts driving comfort. If the stiffness of the spring aid varies during such dynamic processes, loss of comfort may result. By optimizing the ge-ometry, we can offer springs that provide particularly high comfort.
Cellasto®– the NVH Solution Spring aids 7
Stronger, smaller
and more cost effective
Unlike rubber, Cellasto® top mounts are
volume compressible. The Cellasto®
structure makes it possible to imple-
ment the axial pathways of the insert
with a very narrow elastomer layer on its
face sides.
This volume compressibility means
that Cellasto® top mounts can be in-
stalled in a much smaller space. The
housing can then be made smaller and
the amount of expensive light metal
alloys used is reduced. Cellasto® top
mounts therefore sustainably reduce
costs, weight, and space requirements.
Not least, the enormous fatigue strength
of the high performance elastomer Cel-
lasto® also helps cut costs.
EXCEPTIONALLY QUIET –CELLASTO® TOP MOUNTSDriving Noise, Vibration and Harshness (NVH) considerably affect driving
comfort and dynamics. To keep noise out of the car interior, shock absorbers
are connected to the body by isolating rubber bearings. In this application,
however, rubber often comes up against its limitations. This is why car manu-
facturers worldwide are increasingly using top mounts made of Cellasto®.
Because, compared to rubber, Cellasto® offers not only convincing, but also
numerous advantages.
The cellular structure of Cellasto® means that, compared to a compact rubber bearing, less space is needed for the elastomer to expand. The result: The overall bearing is smaller but has the same spring travel.
Typical result of a long-run test with a rubber bearing and a Cellasto® bearing on a test rig. The high fatigue strength of Cellasto® is reflected in the long- term stability of the basic stiffness.
8 Top Mounts Cellasto®– the NVH Solution
Single-path bearings of Cellasto® are also outstandingly resilient.
Outstanding resilience
Another major advantage of Cellasto®
top mounts is that they function as a
pure compression mount. Compared to
conventional rubber bearings which are
usually shear loaded, the Cellasto® top
mount can be designed with greatly re-
duced radial stiffness. With very good
axial connection (axially coupled) of the
shock absorber, the overall transmis-
sion is reduced, which is reflected in the
effective decoupling of rolling noises of
the wheel-tire system and rumbling
noises from the shock absorber. This
substantially improves driving comfort.
In single path applications, Cellasto® is
also convincing as a pure compression
mount. Because of the low transverse
lateral expansion and high resilience, it
can permanently withstand the forces
of the spring aids.
Continuously optimized
To ensure that Cellasto® top mounts
meet the performance specifications,
we are continuously refining our pro-
duction processes, developing our
technical design resources and optimiz-
ing stiffness and hardening behavior.
Using FEA models, we record, improve,
and utilize the complex behavior of Cel-
lasto® to match practical requirements.
With our fast-track and pre cise proto-
type production, we can also manufac-
ture and validate different top mount
variants.
All-around solutions
Our well-proven standard approach is
to develop and implement the optimal
solution for each of our customers’
needs.
To do so, we record and discuss with
the customer the entire range of re-
quirements. Whether conical properties,
acoustic decoupling, ratios and pack-
age space conditions, radial forces,
body elasticity – we determine all influ-
encing variables to achieve an optimal
solution. We fully utilize the potential of
Cellasto® and take advantage of its in-
novative properties.
Numerous reference projects
prove the benefits of Cellasto®
solutions:
• drivingcomfortisimproved
• drivingdynamicsareoptimized
• componentweightisreduced
• fatiguestrengthisincreased
Our customers opt for Cellasto® be-
cause they directly experience the ma-
terial-specific benefits while driving.
Cellasto® and rubber top mounts usually differ in their mechanical mode of operation. Cellasto® utilizes compressive loading, rubber uses shear.
Design as functional parameter. Depending on the requirements, the function can be influenced via the geometry.
Cellasto®– the NVH Solution Top Mounts 9
GREAT LOADS BORNE LIGHTLY – CELLASTO® SPRING ISOLATORS
To provide protection against these vi-
brations, the automotive industry uses
special spring isolators that have to per-
form a range of functions:
• Thesteelspringtwistsondeflection.This produces relative movements between the spring and spring cup that generate friction. The purpose of the spring isolator is not only to dampen the resulting noises. It also protects the anticorrosion coating of both steel parts from abrasion and contributes to their long service life.
• Springisolatorsalsohave to effectively dampen spring resonances.
• Spring isolators additionally have to reduce energy peaks and the introduction of body noise, caused by uneven road surfaces, into the chassis.
• In pneumatic suspensions, spring isolators also have to absorb and isolate the reaction forces of the spring aid and support bearing.
The ideal solution
Cellasto® spring isolators fulfill these
complex requirements particularly well.
They reduce resonance-related energy
peaks and at the same time, isolate the
body noise.
Because of their excellent fatigue
strength, Cellasto® spring isolators can
be made far softer than other elasto-
mers used in components subject to
pressure loads. Furthermore, Cellasto®
spring isolators are characterized by
high abrasion resistance, negligible
creep and low compression sets.
Whether steel coil or pneumatic springs – the chassis suspension must be very resilient. It has to
bear the vehicle’s full static weight when standing still and, in addition, supports the dynamic
loads during motion. This generates strong vibrations which become unpleasant for the vehicle
occupants and subject the body to stress.
The wide range of design options take into account not only the optimal function but also the requirements for steel spring assembly and positioning.
10 Spring aids Cellasto®– the NVH Solution
Customized applications
Depending on our customers’ require-
ments, we can also combine the spring
isolators with an end stop or spring aid
so as to integrate vibration damping
with limitation of spring travel in one
component. This reduces assembly ef-
fort and saves additional costs.
The multicomponent construction
technique can also be worthwhile in
certain cases. Our customers benefit
from our expertise because BASF
knows how to chose materials that work
together. For example, with particularly
heavy automobiles it can be advanta-
geous to use spring isolators made from
a combination of several polyurethanes.
The combination of a volume compress-
ible polyurethane like Cellasto® as a
spring isolator on the upper part of the
spring with a thermoplastic polyure-
thane (TPU) spring isolator, for example,
Elastollan® on the lower part of the
spring can significantly reduce the gen-
erated peak energies.
Skilful combination of Cellasto®
and Elastollan® TPU reduces the maximum forces in
the car body by up to 25 %.
Driving over rough sur faces stimulates the resonances of the steel spring, causing rumbling noises inside the vehicle. Acoustic measurements confirm the subjective impression: Cellasto® spring isolators signi-ficantly reduce these noises.
Depending on the requirements, the spring isolator can be
integrated in the spring aid.
This produces a cost effective component that saves assembly effort and improves the vehicle’s
NVH characteristics.
Cellasto®– the NVH Solution Spring aids 11
NVH reduction
Vehicles are becoming technologically
ever more complex, while expectations
of their ease of use, long service life
and driving comfort are increasing.
Driving comfort consists mainly of qui-
etness in the passenger compartment
despite high speeds, potholes or curv-
ing roads.
Noise, vibrations, and harshness are
considerable stress factors for car driv-
ers. Chassis engineers have long been
searching for ways of reducing them.
The use of Cellasto® spring aids, spring
isolators and top mounts is the right
choice for this purpose. But Cellasto®
can also decisively minimize NVH in oth-
er areas:
For all these applications, Cellasto® of-
fers adequate spring travel even in con-
fined spaces. Its abrasion- and com-
pression-resistant long-term functionality
and ability to absorb high loads even on
small bearing surfaces are convincing
properties. It also eliminates whining
noises and isolates excitations at high
frequencies.
Damping elements
and differential bearings
The temperature resistance of Cellasto®
also allows its use in applications involv-
ing elevated temperatures. For example,
Cellasto® components are also used as
damping elements in the transmission
shafts of BMW motorcycles. Cellasto®
components are also suitable as differ-
ential bearings because of their high re-
silience and volume compressibility.
For more than 50 years, we have been using polyurethane in the automotive industry. And of one thing we
are certain: this is just the beginning. Whether as spring isolators, spring aids or top mounts – Cellasto®
contributes decisively to enhancing driving comfort and safety, especially by its ability to substantially re-
duce noise, vibration and harshness. But these are far from all the advantages offered by Cellasto®. The
outstanding physical properties of this material can also be utilized for other structural components such
as damping elements or differential bearings. Discover the other fascinating applications of this multi-
talented material.
Cellasto® absorbers damp load alterations in the transmission shaft of BMW motorcycles.
THE VERSATILITY OF CELLASTO®
• asanendstopfor trunk lids and doors,
• asafrictionelementinarmrests,
• forseattrackdecoupling,
• asaspringelementin seat height adjustment,
• asadecouplingelement for wiper blade mechanics,
• asadampingring for the handbrake lever,
• asadampingelementinlocks,
• asabearingforelectricmotors and transmissions,
• asanadditionalelement(endstop)for motor bearing systems,
• asadifferentialand transmission bearing,
• asatorquesupport,
• asatransmissionshaftbearing.
12 New applications Cellasto®– the NVH Solution
New applications based on
Verbund technology
To manufacture more complex parts
such as differential bearings, technolo-
gies are needed that allow permanent
bonding with metal mounted parts such
as an aluminum core. In this area, we are
using our well-proven expertise to series
produce Cellasto® components to meet
your requirements. For example, we
produce composites of Cellasto® with
metal parts that last an entire vehicle
lifetime and have excellent durability.
Another example are two-component
adhesive technologies which ensure
outstanding adhesion.
We have also developed a special
casting resin (Elastolit®) with which we
can cast Cellasto® parts onto other ma-
terial. One example of these composite
structures are the clips that allow a Cel-
lasto® stop to engage firmly in seat
tracks. This application offers designers
great freedom and the option of replac-
ing metal parts with lightweight, more
cost effective plastic components.These
technologies demand a high level of ex-
perience and competent expert knowl-
edge. At BASF, we have both.
The good high-frequency transmission properties and compression resilience distinguish Cellasto® differential bearings.
Cellasto® seat track buffers can be clipped into metal tracks by casting on a resin. This plastic composite tech-nology significantly contrib-utes to weight savings and reduces the need for expen-sive metal parts.
Cellasto® buffers intercept engine movements in load alteration processes and have a long service life at elevated temperatures.
Cellasto®– the NVH Solution New applications 13
Thanks to the outstanding dynamic
properties of the special cellular PU
elastomer, every Cellasto® formulation
satisfies the extremely high require-
ments of the automotive industry. We
have developed special test methods
for the manufacture of new compo-
nents because many of the existing
methods originate from the non-com-
pressible elastomer field and are not
applicable to the volume compressible
Cellasto®.
In high-efficiency test laboratories we
evaluate the dynamic and static mate-
rial properties such as resistance to
tear propagation, tensile and expansion
behavior, compression set, and chemi-
cal resistance. From the results, we de-
rive material laws for simulating the
mechanical properties of the compo-
nents. Using the simulation method, we
can develop optimal Cellasto® compo-
nents to meet our customers’ specific
needs.
This makes describing Cellasto® de-
manding, but worthwhile. BASF has
also set itself the task of further evalu-
ating the potential of the multitalented
material Cellasto® and solving our cus-
to mers’ future tasks even better and
more sustainably than at present.
The production process
Cellasto® is fabricated into cellular
moldings in a closed mold in the hot
casting process.
In the first step, intermediates known
as prepolymers are produced from
polyols and isocyanates in a special
process which offers significant higher
characteristics compared to a one-shot
system. These are then mixed with oth-
er intermediates, the crosslinkers, on
the casting machine and then filled into
a mold which is then closed. Here the
chemical reaction takes place: The
foam begins to rise until it finally fills the
mold completely. After mold removal,
the components undergo thermal cur-
ing and the chemical reaction is termi-
nated.
The choice of raw materials, addi-
tives and processing technologies de-
termines the properties of the materi-
als. For Cellasto®, for example, mainly
1,5-napththylene diisocyanate (NDI) is
used, which differs greatly from other
isocyanates by its molecular structure,
and contributes significantly to creating
the outstanding properties of Cellasto®
components.
Sharing know-how
and global infrastructure
We develop, produce, and market high
quality Cellasto® components world-
wide. We can confidently guarantee the
long-lasting quality and success of our
products, because
Cellasto® is the successful synthesis of modern high tech polyurethane and BASF expertise. On this basis we pro-
duce first-class components adapted to our customers’ needs and requirements. Whether resilient with low com-
pression set or flexible at low temperatures – we produce Cellasto® components on a project basis and according to
our customers’ needs.
CUSTOM-TAILORED AND HIGH QUALITY – THE MANUFACTURE OF CELLASTO®
• wehaveaparticularlybroad range of raw materials and auxiliaries available in-house;
• withourglobalnetworkof production sites, we guarantee consistently high quality worldwide;
• Cellasto® is part of BASF’s research and development effort;
• ourownpilotplantoperates with specially developed and legally protected plants and process technologies;
• ourchemical-technicalinfrastructureis constantly researching to further develop the Cellasto® property profiles.
14 Cellasto® formulations Cellasto®– the NVH Solution
BASF POLYURETHANES – CELLASTO® SITES WORLDWIDE
Demanding applications and customer oriented solutions with Cellasto® worldwide.
Get in touch with us:[email protected] www.cellasto.basf.com
NORTH AMERICA
BASF Corporation
1609 Biddle Avenue Wyandotte, MI 48192, USA Phone +1 734 324 - 6285
SOUTH AMERICA
BASF Poliuretanos Ltda
Av. Papa João XXIII, 4502 - A, 09370-904 Mauá, SP, Brazil Phone +55 11 4542 - 7260
EUROPE
BASF Polyurethanes GmbH
Elastogranstraße 60 D-49448 Lemförde, DeutschlandPhone +49 5443 12 - 2302
INDIA
BASF India Limited
Navi Mumbai HO II, Plot No. 12, T.T.C Area, Thane Belapur Road, Turbhe, Navi Mumbai, Maharashtra, 400 705, India Phone +91 22 6712 7663
CHINA
BASF Polyurethane Specialties (China) Company Ltd
No. 2333, Gangcheng Road, Shanghai, 200137, ChinaPhone +86 - 21 - 3865 5556
JAPAN
BASF INOAC Polyurethanes Co. Ltd (BIP)
441-1347 1-196 Hongudo, Kawada, Shinshiro, Aichi, JapanPhone +81 536 23 5599 - 231
KOREA
BASF Company Ltd.
14F, KCCI Bldg., 45, 4-ga, Namdaemunro, Jung-gu, Seoul, 100-743, KoreaPhone +82 2 3707 7853
Cellasto®– the NVH Solution Cellasto® sites 15
BASF Polyurethanes
BASF has established a firm position in
the field of polyurethanes in numerous
applications by technically mature pro-
duct qualities, acknowledged good ser-
vice, and continuous further develop-
ment. With our knowledge and long ex-
perience, we want to contribute to your
success: with the multitalented material
Cellasto® and innovative problem solu-
tions tailored to your needs.
The data contained in this publication are based on our current knowledge and experience. In view of the many factors that may affect processing and application of our product, these data do not relieve processors from carrying out their own investigations and tests; neither do these data imply any guarantee of certain proper-ties, nor the suitability of the product for a specific purpose. Any descriptions, drawings, photographs, data, proportions, weights etc. given herein may change without prior information and do not constitute the agreed contractual quality of the product. It is the responsibility of the recipient of our products to ensure that any proprietary rights and existing laws and legislation are observed. (09/11) Photography: BASF, © Okea-, © ArchMen-, © hfng-, © BezMaski-fotolia.com, motor cycle motive page 12/13: Böhringer, www.motorrad.kaernten.at, Getty Images.
BASF Polyurethanes A unit of BASF Coordination Center Comm. V.
Drève Richelle 161 E/F B-1410 Waterloo Belgium
Email: [email protected] www.cellasto.basf.com
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2011
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