Foaming simulation of PU systems

for the automotive interior

Dr. Matthias Wohlmuth

Team Head Process Analysis for Reactive Systems,
Simulation Engineering & Ultrasim®, Europe
Dr. Katrin Nienkemper
Segment Manager Interior, Transportation Europe
Polyurethane: the ideal material for a variety of
transportation interior applications

Main reasons for polyurethanes

 Product diversity
 Product flexibility
 Comfort
 Acoustics
 Haptics

 Seating  Steering wheel  Durability

 Acoustic  Surfaces  Weight reduction
 I & D panels  Trunk floor
 ...
 Headliner and many more

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Polyurethane formation: two-component approach

 PUs formed by reaction of

two liquid components
HO OH
Polyol (A)
 Polymerization and part production
in one step at the customer site O O

=
+ (C─N─
H
─N─C─O
H
O)

 Product properties determined by Urethane

PU system and processing conditions Exothermic
O=C=N─ ─N=C=O
Isocyanate (B) polyaddition
reaction
 PU systems tailored to the detailed
tier and OEM requirements

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Polyurethane formation: the most important reactions

+ Alcohol + Amine + Water

-
urethane urea

Gelling reactions Blowing reaction

 Sequence of gelling and blowing reactions determined by formulation, temperature and processing
 Foam formation and expansion evolving differently at each point in the mold
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BASF approach: technology leadership and excellent
customer service

Tailored products Technical service Deep market understanding

 PU systems for individual  Fine tuning of system solutions  Clear industry focus
tier & OEM requirements  Support of process  Strong key account management
improvements  BASF is No.1 chemical supplier
to the automotive industry

PU foaming simulation as additional CAE service

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PU foaming simulation as additional CAE service

CAE model of customer part BASF foaming simulation

BASF material model

 Visualization of foaming process (flow front)

 Void prediction
Material characterization
 Understanding of foaming process
 Optimization of injection pattern, injection point (vents)
 Optimization of mold design
 Adjustment of PU system
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Example Elastoflex® E: polyurethane solutions to improve
car interior comfort
Elastoflex® E –
Global semi-rigid foam solutions for soft interior surfaces
Key benefits of Elastoflex® E
 Robust processing, excellent flowability
 High mechanical properties
 Good ageing properties
 Low emission and odor
 Adhesion to all relevant skins (PVC, TPO, PU)
Main applications
 Dashboard PU foam

 Door panel
Market and customers
 Elastoflex® E globally available and in use at all relevant OEMs Skin Carrier

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PU foaming simulation as CAE service
Example: BMW X1 (2015) manufactured by Yanfeng Automotive Interiors

Preliminaries
 PU system: Elastoflex® E 3595/100
 Processing technology: open mold

Objective
 Robust process settings through
optimized injection and venting concept

Customer feedback (Yanfeng Automotive

Interiors)
 Simulated foam flow confirmed by production trials
 Speed-up of process development
 Reduction of scrap rates
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PU foaming simulation as CAE service: open mold process
optimization

Mold settings Initial process

settings
 Mold orientation
 Closing times Foaming
 Venting system simulation
 Mold pivoting
Adjusted
settings
Injection settings
 Injection rate
 Injection time
Result evaluation
 Nozzle path
with customer
 Nozzle orientation Optimized  Filling patterns
settings  Flawed regions
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Process simulation established as CAE service

Simulation service established for instrument panels and Elastoflex® E systems

Expanding foaming simulation to

 new applications: steering wheel, engine cover, seating, window encapsulation

 more PU systems: integral skin and flexible foams, duromer and rigid foams, compact systems

 final part properties: head impact, shore hardness, crash, warpage

Collaborate with us to steer the process to where it creates value!

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BASF: your partner for PU system solutions used
in the transportation industry

BASF approach: close customer interaction

 Tailor-made systems
 Superior technical support
 Global network and production in all regions
 BASF Verbund with strong automotive competence

PU foaming simulation identifies critical aspects at an early stage of a

project and thus can increase production efficiency at our customers!
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