Skip to main content
Sister Publication Links
  • Middle East Foam & Polyurethane
  • UTECH Asia/PU China
  • UTECH Europe
  • UTECH Las Americas
Subscribe
  • My Account
  • Login
  • Subscribe
  • Ukraine
  • News
    • Asia
    • Americas
    • Europe
    • M & A
    • Financial results
    • Automotive
  • Data
  • Information
    • Country Overview
    • Market Sector overviews
    • Technical articles
    • Company profiles and strategies
  • Events
    • Exhibitions
    • Conferences
    • Webinars / Livestreams
    • Become a Speaker
    • UTECH Europe 2021
  • Advertise
  • Contact Us
  • Issues
  • Subscribe
MENU
Breadcrumb
  1. Home
  2. News
October 21, 2010 12:00 AM

An innovative roof for cutting-edge automobiles

Utech Staff
  • Tweet
  • Share
  • Share
  • Email
  • More
    Print

    Leverkusen, Germany - Polyurethanes experts at Bayer MaterialScience have developed a material for making very light but stiff car roofs with excellent thermal insulating properties.

    The properties were achieved by using Baypreg and Multitec polyurethane systems from BaySystems, the company's global polyurethane business, with a coated Makrofol film giving the roof modules a high-quality surface, BMS said in a 20 Oct announcement.

    The combination gives the new-generation roof modules a low weight per unit area of just 4.5 kg/m2. The modules' low thermal conductivity also reduces heating energy requirements, especially in winter, BMS pointed out.

    All vehicles can benefit from these properties, but weight-saving is particularly beneficial for electric vehicles powered by batteries or fuel cells, and for solar-powered vehicles. This is because their practicality and range depend to a great extent on the drive energy being used efficiently. The modules' low thermal conductivity also reduces heating energy requirements, especially in winter.

    The modules also provide superior drive comfort to conventional designs as they boast excellent acoustic properties. They are also highly resistant to hailstones and other mechanical influences, BMS claims.

    "State-of-the-art polyurethane processing technologies enable highly cost-effective production in both small and large volumes, despite the multilayer structure," explains Detlef Mies from Bayer MaterialScience. The polyurethane experts work with automakers and component manufacturers in projects aimed at series application.

    Module structure
    The sandwich construction of the roof module's support structure delivers excellent flexural strength and dimensional stability. It is made up of two glass-fibre mats with a lightweight core layer between them - a polycarbonate or paper honeycomb, for example.

    The mats and the core layer are bonded to the Baypreg polyurethane system by compression moulding. At the edges of the roof, the sandwich construction's support function is taken over by the Baypreg polyurethane spray system, which is processed in solid form and reinforced with long glass fibres, BMS continued.

    The solid area at the edges is used to create a bond to the roof frame of the bodywork. It is also easy to integrate inserts such as handles, and the entire roof module is able to withstand even higher mechanical loads, according to the BMS statement.

    Working outward, the support structure is followed by a multifunctional intermediate layer of the highly reactive two-component polyurethane system Multitec. This prevents glass fibres or cavities from appearing on the roof surface and has very low linear expansion and excellent tensile strength. It also ensures good adhesion between the support structure and the Makrofol polycarbonate film forming the roof's surface. In addition to its impressive brilliance, the film is highly resistant to scratches, cleaning agents and chemicals.

    Bayer MaterialScience develops coated films for the external bodywork in a contrasting colour (black). With transparent coating films it is also possible to use printing processes for coloured designs or to create functional prints.

    At this stage, the coatings applied to the films only undergo physical drying and, once cut to size, the films can be stored until the next processing step. Only when the roof panel has been shaped by thermoforming is the coating fully hardened by UV radiation. The films' clear-coat structure gives them an excellent deep gloss finish.

    "Starting with a thermoformed film and having prepared the sandwich support structure, the entire roof module can be produced in a single manufacturing step using just one mould," explains Mies. He qualified this statement by saying that it is not necessarily the most cost-effective production method. "The larger the volume, the more worthwhile it is to think about separating the production steps," he concluded.
    "

    Recommended for You
    US government backs 3D printing initiative
    US government backs 3D printing initiative
    henkel adhesive recyclable packaging 800
    Henkel adds adhesives for recyclable food packaging
    formlabs 3dp pu resin 800
    Formlabs adds PU 3D printing resins
    Latest Issue
    April/May 2022 issue
    Click HERE for Free Download
    View All Archives
    Get our newsletters

    Breaking news and in-depth coverage of essential topics delivered straight to your inbox.

    Subscribe today

    Register to access our archive of leading information on the polyurethanes industry.

    Subscribe now
    Connect with Us
    • Twitter
    • LinkedIn
    • Facebook
    • Youtube

    Follow us on social media for the latest polyurethanes industry news and event updates.

    Logo
    Contact Us

    Office 127,
    61, Willow Walk,
    London
    SE1 5SF
    E-mail us
    +44 (0) 203 287 5979

    Customer Service:
    +1 313 446 0450

    Resources
    • Advertise with Us
    • Media Kit
    • Staff
    • Careers
    • Ad Choices Ad Choices
    • Sitemap
    Legal
    • Terms and Conditions
    • Privacy Policy
    • Privacy Request
    Copyright © 1996-2022. Crain Communications, Inc. All Rights Reserved.
    • Ukraine
    • News
      • Asia
      • Americas
      • Europe
      • M & A
      • Financial results
      • Automotive
    • Data
    • Information
      • Country Overview
      • Market Sector overviews
      • Technical articles
      • Company profiles and strategies
    • Events
      • Exhibitions
      • Conferences
      • Webinars / Livestreams
      • Become a Speaker
      • UTECH Europe 2021
    • Advertise
    • Contact Us
    • Issues
    • Subscribe