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2008-03-23 Manufacturing News

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Short Fiber polyurethane spray system for vehicle manufacture

Economical and simple production of lightweight radiator grilles and complex components for motor caravans with Multitec Short Fiber polyurethane spray system.

The Multitec* Short Fiber polyurethane spray system developed by Bayer MaterialScience enables efficient open mold processing. Any desired surface finish is possible - from "class A" to "soft touch". These advantages make the technology an attractive proposition for the automotive industry. For example, the system is currently being used to produce radiator grilles for motor caravans from Dethleffs GmbH & Co. KG. These components augment the state-of-the-art, expressive design of these increasingly popular vehicles.

Direct supplier PARAT AUTOMOTIVE Schönenbach GmbH + Co. KG produces these external bodywork parts by taking a thermoformable film, thermoforming it, and then back-injecting it in the open mold using Short Fiber technology. Robots are used to apply the Multitec Short Fiber polyurethane spray system in several layers, with short glass fibers being added for reinforcement. The polyurethane spray system typically consists of one isocyanate and two polyol components whose proportions can be varied, thereby allowing adjustment of the reaction speed. During finishing, the component is given its final form by milling its outer edges and apertures. This is followed by assembly, before the bodywork part – measuring 1.5 x 0.4 x 0.06 m – is packed and made ready for transport.

Economical production of lightweight radiator grilles for motor caravans with Multitec

Economical production of lightweight radiator grilles for motor caravans with Multitec. View High resolution image. photo: Dethleffs GmbH + Co. KG

Short Fiber technology offers considerable advantages over conventional methods and offers an alternative to long-fiber injection (LFI) technology. There is no need for coating, because the film already has a Class A surface. This means there is no danger of chipped coatings in the event of minor accidents, thus limiting the extent of any damage. The sprayed-on layers take only a few minutes to cure, which dispenses with the need for annealing. By eliminating processing steps, this technology shortens the cycle time and increases the productivity of the manufacturing process. The film is back-injected without the use of solvents, such as styrenes. Since the Multitec system is applied to a preshaped film, there is no need to construct and produce any foam molds. What’s more, the use of plastics reduces the weight of the bodywork part compared with the traditional production method, which uses steel.

Multitec Short Fiber technology from Bayer MaterialScience has also proven to be an economical and effective production method in the construction of instrument panels, fenders, door inner trim panels, and other applications both inside and outside of vehicles. The development of this technology is another example of the extensive customer collaboration and outstanding problem-solving expertise of BaySystems*, the umbrella brand under which Bayer MaterialScience manages its worldwide polyurethane systems business.

* Trademarks of Bayer MaterialScience.

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