JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 - 47

Foam materials New sandwich composites: for lightweight construction in the automotive industry Composite elements produced using the Baypreg® F polyurethane spray system are very light but still strong and rigid. Bayer MaterialScience has significantly extended the capabilities of this construction method, for which many production-line applications already exist in the automotive industry. The project was also facilitated by a development cooperation agreement with the polyolefin foam manufacturer Trocellen. similar way to that described for natural fibre composites (Fig. 1). It is sprayed on both sides with Baypreg® F placed in a , mould and pressed at around 130°C. The polyurethane spray system reacts at these temperatures and foams slightly, bonding the components to each other strongly and durably. This results in components that weigh less than three kilograms per square metre, i.e. up to 80% lighter than equivalent components made of conventional materials such as wood or sheet metal. MARCOS RAMOS BOSCH, HEAD OF BAYSYSTEMS COMPOSITES, POLYURETHANES BUSINESS UNIT, BAYER MATERIALSCIENCE AG he automotive industry is responding to spiralling fuel prices and rapid climate change – and their consequences in terms of energy and the environment – with a number of different strategies. One of these strategies involves reducing the weight of various modules and sub-assemblies. Bayer MaterialScience AG has been quick to react to this situation and has developed, either on its own or in cooperation with experienced partners, several production-ready solutions based on polyurethane. These form part of BaySystems®, the umbrella brand for the company’s worldwide polyurethane systems business. T For example, door liners made of natural fibres can be produced with Baypreg® F a two-component polyurethane spray system. , The liners weigh 30-40% less than their counterparts reinforced with, e.g., glass fibre. Production is simple and efficient. Flax or sisal mats are sprayed with the polyurethane system, placed in a mould and compressed to the shape of the door liner. As is essential for this application, the material is very stiff and has good impact resistance. It also scores points for safety. Should the material be destroyed in a serious collision, it breaks without leaving any sharp edges. The polyurethane spray system can also be used to produce sandwich elements that are lightweight but nevertheless very stress-resistant. They can be used as trunk floors, spare wheel covers or sliding roof cassettes. The components consist of a honeycomb core made of cardboard, overlaid top and bottom with an outer layer of glass fibres. This sandwich is treated in a Fig. 1: Production of polyurethane sandwich elements with Baypreg® F. The German supplier, Ideal Automotive GmbH, uses this process to manufacture the trunk floor of the Volkswagen Tiguan (Fig. 2). The part is approximately 80 cm deep, 1 m wide and 2 cm thick. Its fibre-reinforced facings (0.4 to 0.6 mm thick) provide very high flexural strength. Their modulus of elasticity is around 13,000 megapascals, so that they experience only moderate deformation even under high loads. Sliding roof cassettes must retain their shape even when exposed to high temperatures and major temperature fluctuations, otherwise they would be unable to slide properly along the guide rails. Sandwiches based on the polyurethane spray system have already proved they can meet these requirements very well in various production-line applications. No45 November-December 2008 / jec composites magazine

JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008

Table of Contents for the Digital Edition of JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008

Cover
Editorial
Market Place
Advertisers
CONTENTS
NEWS WORLDWIDE
- Companies
 - Innovations
 - Agenda of events
 - Innovations
BUSINESS
 - Market survey
 - Trends: Productivity
 - Human Capital: Designer
FEATURE - AUTOMOTIVE
 - Design
 - Raw material
 - Thermoplastics
 - Prepreg
 - Structural materials
 - Foam materials
 - Induction
 - Software
- Lighting
USERS' PLATFORM
 - Composites in the world
 - Successful partners
- Applications
KNOW-HOW
 - Biopolymer
 - Processing
 - Modelling
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 - Cover
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 - 2
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 - Editorial
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 - Market Place
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 - Advertisers
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 - CONTENTS
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 - 7
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 - - Companies
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 - 9
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 -  - Innovations
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 - 11
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 - 12
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 - 13
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 - 14
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 - 15
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 -  - Agenda of events
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 - 17
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 -  - Innovations
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 - 19
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 - 20
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 - BUSINESS
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 -  - Market survey
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 -  - Trends: Productivity
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 -  - Human Capital: Designer
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 - FEATURE - AUTOMOTIVE
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 -  - Design
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 - 27
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 -  - Raw material
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 - 29
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 - 30
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 - 31
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 -  - Thermoplastics
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 - 33
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 - 34
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 - 35
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 - 36
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 - 37
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 - 38
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 - 39
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 - 40
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 -  - Prepreg
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 - 42
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 - 43
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 -  - Structural materials
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 - 45
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 -  - Foam materials
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 - 47
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 - 48
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 - 49
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 -  - Induction
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 - 51
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 -  - Software
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 - 53
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 - - Lighting
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 - 55
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 - 56
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 - USERS' PLATFORM
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 -  - Composites in the world
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 - 59
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 -  - Successful partners
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 - 61
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 - - Applications
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 - 63
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 - 64
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 - KNOW-HOW
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 -  - Biopolymer
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 - 67
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 - 68
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 - 69
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 -  - Processing
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 - 71
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 - 72
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 -  - Modelling
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 - 74
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 - 75
JEC COMPOSITES MAGAZINE - Issue #45 - November/December 2008 - 76
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