Window Encapasulation BBG Innovation Day 2019 Dominik Kohlhoff, - - PowerPoint PPT Presentation

“New Generation PU Material in Window Encapasulation”

Dominik Kohlhoff, Technical Development Transportation BASF Polyurethanes GmbH

BBG Innovation Day 2019

Outline of Presentation

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 Short Introduction  Kinetics of PU- Reaction  Material Properties  Material Approval of OEMs  Improved Testing of Material  Conclusion

Short Introduction

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History:

• The actual aromatic systems have been developed already mid 90’s

ELASTOLIT R8919/101/OA48 ELASTOLIT R8919/100/WE35 ELASTOLIT R8919/102/WE45

• At that moment, they were fully fulfilling the requirements, as most

sunroofs had a limited weight of PU

• More recently, more and more large parts (in weight of PU) are

coming into production

 This requires longer shot times. Thus, improved flowability/ kinetics required Challenge:

• Development of systems having improved flowability for bigger molds,

global recipes, lower emissions, being REACH conform, and keeping machine parameters at customers` constant

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Kinetics of PU- Reaction

• Tests were conducted using ViskoPakt

by HiTec Zang GmbH

Kinetics of PU- Reaction

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• Flowability of serial material

is limited by increasing viscosity even before hardening

• f material
• Early increase of viscosity

makes higher shot weights and filling of complex molds difficult

Determined under laboratory conditions

Kinetics of PU- Reaction

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Determined under laboratory conditions

Completely new formulation with novel raw materials led to delayed reaction onset → viscosity is kept low and flowability could be improved

Kinetics of PU- Reaction

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ELASTOLIT R 8919/107 ELASTOLIT R 8919/108 ELASTOLIT R 8919/109 ELASTOLIT R 8919/101/OA48 ELASTOLIT R 8919/100/WE35 ELASTOLIT R 8919/102/WE45

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Property Test method unit Serial Material New Generation Moulded density ISO 1183-1 Kg/m³ 1060 1060 Shore A ISO 7619-1

• 87

88 Tensile strength DIN 53504 MPa 12 13 Elongation DIN 53504 % 215 200 Tensile modulus DIN 53504 MPa 28 26 Tear resistance ISO 34-1,B (b) N/mm 28 27 shrinkage

• %

1,25 1,2

Material Properties

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Material Properties

Property unit Serial Material New Generation Peel test 7 days N/cm 88 90 Peel test after cataplasm ageing N/cm 81 80

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Serial Material (averaged values): New Generation (averaged values): VOC 200 ppm FOG 830 ppm Nonylphenol is detected VOC 120 ppm FOG 370 ppm no Nonylphenol

Material Properties

→ lower emissions and absence of Nonylphenol are nowadays OEM requirements for new encapsulation projects

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Material Properties

72 144

Watercontent in wt%

96 120 Absorption [h] in Water at 2 °C

Watercontent after absorption in Water (2°C) for Serial Material (dark grey) and New Generation (light grey)

4,5 4 3,5 3 2,5 2 1,5 1 0,5

Material Approval of OEMs

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→ Further OEMs made specific project approvals, evaluate material,

• r purchase aliphatic material

Improved Testing of Material

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• Manual testing of start and rise time is conducted
• Precise results for one operator
• Reproducibility for more operators

is lower than in case of automatized testing

• Automatized QM apparatus for outgoing

PU material needed

• Requirement: automatized in-situ stirring and

kinetic testing

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Improved Testing of Material

• Torque meter for kinetic testing already

built up at BASF`s Lemförde site

• Implementation will be done

in 2nd half of 2019

New Generation PU Material → global PU systems with improved flowability, reduced emissions, and REACH conformity were successfully developed → OEMs with interest in aromatic material already approved New Generation material → BASF supports customers in questions of material approval at OEMs` Improved QC Material Testing → Novel testing method for quality control was developed → Implementation as criterion for outgoing inspection is ongoing → BASF supports customers in questions of material testing

Conclusion

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Thank you for your attention!

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