• Automotive lightweighting: New epoxy and PU resins;
• Wind turbines: New PET foam for rotor blades.
One wind turbine and a blade profile, a fender demonstrator, a spoiler and a roof module will illustrate the wide spectrum of composite news. The new materials include a PET-based (polyethylene terephthalate) foam with the trade name Kerdyn® as well as new epoxy and PU (polyurethane) systems that can be used to produce composite parts by means of Resin Transfer Molding (RTM) processes. In addition, the BASF experts will be presenting coatings of wind turbine rotor blades.
Roof module, fender, spoiler - New composite materials for automotive lightweighting
With the aid of its multimaterial Lightweight Composite Team, BASF is intensively investigating composite concepts for the body and chassis of motor vehicles. The three plastic matrix systems based on epoxy resin, PU and polyamide, together with continuous-fiber reinforcement as well as high-volume processing by means of resin injection methods, especially RTM, provide the basis. Using a test component in the form of a carbon fiber-reinforced fender demonstrator, BASF will be exhibiting the new epoxy resin Baxxodur® System 2220 which was developed specifically for high-pressure RTM. The polyurethane side will be represented by a spoiler with RTM insert produced from the new Elastolit® R 8800. Both thermosetting resins employ novel curing mechanisms, allowing them to cross-link quickly. The transparent epoxy resin Baxxodur System 2220 offers a demolding time of only 2.5 minutes at 120°C while offering a high resin toughness. The custom formulated polyurethane system RTM Elastolit R 8800 is compatible with all established fiber sizings and offers exceptional fatigue strength. Its tolerance for damage is also very high. Both new resin systems have a wide processing window and can be demolded easily, through incorporated matched processing aids.
The convertible roof module being exhibited serves to demonstrate new concepts and BASF's versatile materials for the RTM process as well: The sandwich component, which was developed together with EDAG GmbH, consists of a closed-cell polyurethane foam core between two carbon fiber-reinforced skin layers. With a total weight of 2.9 kg, the roof segment achieves a 40% weight savings compared to an aluminum counterpart and more than 60% compared to a steel counterpart. Possible applications for such material and processing combinations include, in addition to attached parts such as doors, trunk lids and roof modules, structural vehicle components subjected to high loads as well.
Wind turbine rotor blades: Efficient and versatile processing
New PET structural foam
At the JEC, BASF will introduce for the first time a structural foam based on PET (polyethylene terephthalate). The new material with the trade name Kerdyn® is a high-performance foam supplied in form of panels that is used inside rotor blades, providing additional stability. As core material, PET foams offer exceptionally good mechanical properties and have a wide range of compatibility in terms of processing. With its ability to withstand very high temperatures and its very good chemical resistance, Kerdyn is extremely well-suited for use in composites. As part of the spectrum of lightweighting materials for composites, high-quality PET foam panels are also in demand in the transportation, marine, and building/construction sectors.
As one of its most attractive exhibits at the JEC, BASF will be presenting the cross-section of a wind turbine rotor blade that was manufactured using the wide range of BASF products available for rotor blade production: The glass fibers are embedded in a Baxxodur® epoxy resin system, the Kerdyn® structural foam provides stability, the paint finish is based on a RELEST® gelcoat system and the semi-structural Elastan® polyurethane adhesive comes from the BASF product line, too.
In addition to the BASF solutions represented in the rotor demonstrator, the company is presenting additional developments for customers involved in the wind power industry:
New infusion and structural adhesive systems
For vacuum infusion of ever larger rotor blades, BASF has developed the Baxxodur® System 5100 consisting of Baxxores® ER 5100 resin and Baxxodur® EC 5120 hardener. This new low- viscosity system does not only result in fast and complete impregnation of the fibers, but additionally offers a considerably longer processing time than standard systems. The company will also introduce a new epoxy resin-based structural adhesive system in Paris: the Baxxodur 4100 system consists of Baxxores ER 4100 adhesive resin and the standard Baxxodur EC 4110 hardener or alternatively Baxxodur EC 4105 for fast bonding. The system has been certified for rotor blade production by German Lloyd.
Protection from wind and weather with RELEST Wind In-mold Gelcoats
When it comes to coating rotor blades, resistance to erosion and UV radiation are essential. This protection is provided by the two RELEST® Wind In-mold Gelcoats from BASF. The semi-transparent two-component paint materials are very easy to sand and easy to use thanks to a colored hardener component with mixing control function. The integrated UV absorbers in the new generation prevent damage to the substrate from UV light.
The in-mold primer RELEST® Wind Gelcoat Transparent can be applied to a film thickness of up to 400 µm. RELEST® Wind ProcessCoat offers all of the benefits of an in-mold gelcoat at considerably lower usage. Both products are VOC-compliant (Volatile Organic Compounds) and easy to process. RELEST Wind In-mold Gelcoats are only one part of the extensive coatings assortment available from BASF for wind turbine rotor blades.
BASF (basf.com) is the world’s leading chemical company: The Chemical Company. Its portfolio ranges from chemicals, plastics, performance products and crop protection products to oil and gas. We combine economic success, social responsibility and environmental protection. Through science and innovation we enable our customers in almost all industries to meet the current and future needs of society. Our products and system solutions contribute to conserving resources, ensuring healthy food and nutrition and helping to improve the quality of life. We have summed up this contribution in our corporate purpose: We create chemistry for a sustainable future. BASF posted sales of about €73.5 billion in 2011 and had more than 111,000 employees as of the end of the year. BASF shares are traded on the stock exchanges in Frankfurt (BAS), London (BFA) and Zurich (AN).
Evelyn Naudorf, wind energy
P: +49 621 60-42223 - E: evelyn.naudorf[.]basf.com
Christof Jelich, Polyurethanes
P: +49 5443 12-2319 - E: christof.jelich[.]basf.com.
Marco Benen, Coatings
P: +49 2501 142040 - E: marco.benen[.]basf.com.