BASF's Ultradur® High Speed ​​enables lightweight and emission-reducing roof frames

● The new design effectively improves the production process while reducing the weight of the components

● New material with high fluidity and temperature resistance

In the automotive industry, the trend of panoramic sunroofs is still in the ascendant
.
As an added bonus to the vehicle, many consumers put the panoramic sunroof at the top of their wish list when purchasing a new car
.
At the same time, cars also need to reduce the weight of components to minimize carbon dioxide emissions
.
To meet these challenges, BASF and Grupo Grupo Grupo Antolin successfully developed new engineering plastic components
.
The newly developed panoramic sunroof has an integrated design with the roof trim, also known as the headliner, which is made of ultra-light polyurethane Elastoflex® E 3943/134
.
Skylights in the ceiling are supported by the structural skeleton
.
Traditional skeletons are made of heavy duty steel, this new skeleton uses Ultradur® High Speed ​​as a metal alternative
.
In addition to high dimensional stability, this engineering plastic also imparts excellent mechanical properties to the skeleton
.

Collaboration is the key to success   

After close cooperation, both parties have successfully demonstrated that Ultradur® High Speed ​​polybutylene terephthalate (PBT) can be used in the production of plastic frames for panoramic sunroof roofs
.
The bold new design reduces the weight of the part by 60% compared to conventional solutions
.
This special material has a unique set of properties, such as excellent dimensional stability, low warpage in short cycles, high stiffness, high temperature resistance, and excellent flow properties, enabling injection molding of large parts
.

Enrique Fernandez of Grupo Grupo Grupo explains: "One of the main advantages of this newly designed plastic part is the manufacturing process
.
We fit the frame into the ceiling
.
During production, the reinforced frame of the panoramic sunroof is integrated into the ceiling.
The trim is fixed, allowing the part to be formed in the mold
.
As a result, the assembly tolerance of the part is improved due to the elimination of additional process steps, and the quality of the final part is also improved
.
In addition, this new process does not use any solvents, Nor does it produce any harmful emissions
.
"

Ultradur® High Speed ​​supports customers worldwide

Dirk Salzmann, Key Account Manager Performance Materials at BASF, said: “The new Ultradur® High Speed ​​is rheologically modified and has excellent flow properties, which are essential for the production of thin and light large interior parts
.
In addition, thanks to its unprecedented With the processing advantages, we can reduce part weight without compromising part stiffness and dimensional stability at high temperatures
.
”

The pre-development of the component was completed at a German customer, followed by the first pilot projects on a best-selling model, with remarkable results
.
Globally, several automotive original equipment manufacturers (OEMs) are taking notice of the opportunities this solution presents
.