Lifestyle with plastics and foams

On the occasion of K 2013 (stand C21/D21, hall 5), Basf is expanding its activities in the field of engineering plastics for automotive construction to include a completely new approach. For example, Ultracom is a package of three components: continuous fibre reinforced semi-finished products, adapted overmoulding compounds and the complementing engineering support. The key innovations in this new approach are laminates based on woven fabrics that are fully impregnated with the polyamide (PA) Ultramid or the PBT Ultradur. The overmoulding materials have been developed individually for use with these laminates. The third component covers the extensive engineering support provided by the Basf application engineering group.
As part of the Ultracom package, the company has installed a high-capacity composite production pilot plant in Ludwigshafen. Since March 2013, this equipment is being used to produce multifunctional composite test specimens by means of the in-mould forming/overmoulding process. Central element of the cell is a six-axis robot with specific gripper arm. Moreover, the company has developed its own multi-functional test part: the so-called CIFO part (derived from combination of in-mould forming and overmoulding) makes it possible to investigate continuous-fibre reinforced composite parts for volume production in the manufacturing cell. The simulation instrument Ultrasim is another part of the package.
Furthermore, one of the most heat-resistant polyamides is now also available as a blow-moulding grade: Ultramid Endure BM, with the same stabilization technology as the injection-moulding type. It also shows the same temperature resistance of 220°C in continuous use and peak temperature loads of 240°C. With this grade, Basf is closing a gap in the market: in the future, also pipes in the charge-air duct between the turbocharger and intercooler can be manufactured efficiently.
Another portfolio expansion covers the PA 610 product range. At the K 2013 the company is introducing two flexible grades of Ultramid Balance that are suitable for extrusion of pipe and tubing intended for use specifically in the automotive and machinery sectors as well as for oil and gas lines. In this way, Basf is reinforcing its position as a supplier of engineering plastics specialties for the extrusion field as well. Finally, the hydrolysis-resistant PBT Ultradur HR not only stands out in a positive way in customary static tests for damp-hot environments, but also passes the demanding climatic cycling tests of Uscar standard class 5. It could be shown that Ultradur HR is superior to competitor products and Basf now offers it with integrated flame retardant and laser transparency. The material is thus suitable also for applications in electric vehicles. Examples are control housings or charging plugs, but also parts that have to be laser-welded from several components.

Plastics for furniture, data transmission and water current
Plastics has also become a material of choice for furniture: Basf presents four new versions from its polyamide portfolio that are geared to the needs of the furniture sector. All four new Ultramid SI grades (SI: Surface Improved) combine high surface quality with the excellent mechanical and chemical properties of this class of materials - in a special case even joined with flame retardants. One of the first serially produced items made of the new Ultramid SI series is the MOVYis3 office swivel chair, which Basf developed in collaboration with the furniture manufacturer Interstuhl.
At the K exhibition the company also presents Infinergy, the world's first expanded thermoplastic polyurethane (E-TPU). This closed-cell particle foam shows an excellent resilience and an especially high durability over a wide temperature range. The first product making use of this innovative material is the new Energy Boost running shoe from adidas, which the German sportswear manufacturer has developed in close partnership with Basf. The midsole consisting of the new E-TPU with its combination of softness and high elasticity is responsible for the outstanding running characteristics of the Energy Boost running shoes. Their rebound is the highest of all available running shoes and remains stable even at low temperatures of minus 20°C.
Another news: the compostable plastic ecovio has found its first production application in a system solution for packaging. The Swiss Coffee Company's coffee capsules beanarella consist of the new injection moulding grade ecovio IS1335; at the same time the multi-layer composite system for the aroma-tight outer barrier packaging for the capsules is also ecovio-based. The capsules fulfil the demanding requirements for protecting the product and brewing coffee in high-pressure coffee machines, yet may still be composted; so does the barrier packaging. The system solution is predominantly based on renewable resources. The product which was jointly developed in only some 13 months, can contribute to sustainability while simultaneously addressing the latest trend in coffee drinking.
A new grade of Ultradur has been specifically developed for thin fibre-optic jacketing. With Ultradur B6550 LNX, Basf is expanding its existing line of PBT plastics for extrusion of protective sheathing for optical fibres. With the new material, the loose tubes can have a thinner sheath at the same protection against crush and kinking than with standard PBT grades. Because of its fine crystalline morphology it exhibits even faster crystallization than all previous materials and has a very high melt viscosity, especially at low shear rates.
On the other hand, two newly introduced materials are suitable for replacing metals in areas of applications where plastics were hardly found until now: Ultramid D3EG10 FC Aqua and Ultramid D3EG12 HMG. Thanks to its good chemical and hydrolysis resistance, the Aqua grade is well-suited for components that come into contact with drinking water or food (FC stands for Food Contact) as in the case of housings for water meters. The extraordinary mechanical properties of Ultramid D3EG12 HMG have led to the suffix HMG (High Modulus Grade). Moreover, the high surface quality opens up interesting application possibilities such as office chairs and ball shut-off valves.

Polyurethanes in all forms
The Elastocoat polyurea-based coating system is constantly conquering new fields of application. It is sprayed on surfaces and this process yields a protective coating that reacts to form a continuous membrane devoid of seams and joints. In the construction sector, the Basf material is used for coating concrete surfaces as car park floors, petrol tank pits and waste water shafts.
In industry, the electrostatic charging of plastics can cause severe damages. To address this problem, the company has developed an antistatic TPU granulate under the Elastostat brand name. Its exceptional properties are the permanent antistatic effect, mechanical properties and compatibility with non-polar polymers. The new TPU masterbatch opens up large fields of application, particularly for industrial packaging such as big bags and plastic drums or cans.
Last but not least, researchers of Basf have developed a unique high-performance insulation material that is scheduled for launch in just a few years. The product is a novel type of aerogel that will be offered as a mechanically strong panel. With a lambda value of below 16 milliwatts per meter and Kelvin (mW/m·K), the material displays exceptional insulation performance, is extra-slim, light and will be produced as a ready-to-use polyurethane panel that is easy to process. The company sees future applications of the product above all in construction and refrigeration.