Download - Cellasto ® : Cars love Quiet
cars love quiet
a broaD ranGe oF PoSSibilitieSFor oUr cUStoMerS
Innovation and our customer’s success is the driving
force behind our work. With our customers, we are
constantly searching for solutions to improve comfort
and convenience in daily life while simultaneously
conserving resources.
The drive to discover something new is a long
standing tradition at BASF. Even 75 years after
inventing engineered polyurethane, we continue
to innovate our product offerings. Our chemists
and engineers work with our customers to develop
new applications and areas of use, and to further
perfect them.
Vehicles are expected to offer increasing levels of
safety and comfort, while technical requirements
are becoming more and more complex. It is one
of many challenges faced by today’s chassis
engineers. These challenges have been met by
the versatile microcellular polyurethane elastomer,
called Cellasto®.
Under the brand name Cellasto®, BASF develops,
produces and markets components made from
special microcellular polyurethane (MPU) elastomers.
They are used in the automotive industry as spring
aids, coil spring isolators and top mounts and
signifi cantly enhance driving comfort and safety.
Cellasto® from BASF is highly resilient and has
outstanding high volume compressibility and low
compression set. In contrast to similar components
made of rubber, the polyurethane foam expands
only slightly under compression. Cellasto® offers
better damping performance and considerably
minimizes driving noise.
page 4 | 5 Unquestionably resilient – cellasto® spring aids
6 | 7 exceptionally quiet – cellasto® top mounts
8 | 9 Heavy loads feel light – cellasto® spring isolators
10 the versatility of cellasto®
11 baSF cellasto® Sites worldwide
12 | 13 Global network, local integration
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Nine out of ten car
manufacturers worldwide
use Cellasto® spring aids to
reduce noise, vibration and
harshness (NVH).
Cellasto®– the NVH solution.
This comparison demonstrates the volume compressibility of Cellasto® in enclosed spaces.
On the right, rubber expands laterally and shatters the glass.
On the left, with expansion low lateral Cellasto can be compressed to 40% remaining height.
Driving over a pothole is when spring aids soften the bump. Potholes impart enormous forces into the body and the spring aid stops its movement and minimizes energy peaks.
Volume compressible material offers invaluable advantages in the restricted spaces of the strut assembly.
UNQUESTIONABLY RESILIENT – CELLASTO® SPRING AIDSWhen the chassis is exposed to stress from rapid deformations and large spring travel, it absorbs
enormous amounts of energy within a short time. If the energy peaks are not absorbed, the dampers
and chassis may be damaged and vehicle occupants subjected to unpleasant vibration.
Energy peaks disappear
Cellasto® spring aids provide relaxed and
comfortable driving by eliminating energy
peaks. The volume compressibility of
Cellasto® permits large spring travel within
a confi ned space and is also abrasion and
fatigue resistant under high compressive
loading. It features excellent compression
set, a naturally progressive characteristic
curve, and superb energy behavior. No
other material offers this combination of
properties.
Made to meet the highest demands
At BASF, we are constantly working to meet
increasing demands placed on spring aids.
For example, using fi nite element analysis,
we can:
• identify stress concentrations in the
material at an early stage
• visualize and eliminate critical
deformation states
• implement shorter development times
• develop prototypes quickly and
accurately
Customized Cellasto® spring aids
Cellasto is distributed by our worldwide
production sites for high volume
manufacturing or a limited number of spring
aids for a small series – we offer customized
solutions. With global standards and a
complete portfolio of formulations, we can
meet any customer need.
4 Spring aids Cellasto® - the NVH Solution
Dynamic deflection of spring aids
Optimized spring aid characteristic curves
Non-optimized spring aid characteristic curves
0
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50 58 66 74 82
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Spring travel [mm]
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Spring travel [mm]
Our FEA simulations of Cellasto® components provide early design insight.
We supply top mounts, spring aids and dust tubes together in pre-assembled component groups.
Molded-in cups have a stabilizing effect and provide block height.
When the spring aid defl ects during driving, this impacts driving comfort. If the stiffness of the spring aid varies during such dynamic processes, loss of comfort may be the result. By optimizing the geometry, we offer spring aids that provide an extremely comfortable ride.
Cellasto® - the NVH Solution Spring aids 5
EXCEPTIONALLY QUIET –CELLASTO® TOP MOUNTSNoise, vibration, and harshness (NVH) has a considerable effect on driving comfort and dynamics. To keep noise out of the car interior, shock
absorbers are connected to the body by isolating rubber mounts. In this application, however, rubber often has limitations. This is why car
manufacturers increasingly use top mounts made with Cellasto®. Compared to rubber, Cellasto® is the clear choice in reducing NVH.
Stronger, smaller and
more cost effective
Unlike rubber, Cellasto® top mounts are
volume compressible. The Cellasto®
structure makes it possible to implement
the axial pathways of the insert with a very
narrow elastomer layer on its face sides.
This volume compressibility means that
Cellasto® top mounts can be installed in
a much smaller space. The housing can
then be made smaller and the amount of
expensive light metal alloys used can be
reduced. Cellasto® top mounts therefore
sustainably reduce costs, weight, and
space requirements.
Outstanding resilience
Another advantage of Cellasto® top mounts
is that they function as a pure compression
mount. Compared to conventional rubber
mounts which are typically shear loaded, the
Cellasto® top mount can be designed with
greatly reduced radial stiffness. With very
good axial connection (axially coupled) of
the shock absorber, the overall transmission
of NVH is reduced, which is refl ected in
the effective decoupling of noises from
the wheel-tire system and rumbling noises
from the shock absorber. This substantially
improves driving comfort. In single path
applications, Cellasto® is also convincing
The cellular structure of Cellasto® means that, compared to a compact rubber mount, less space is needed for the elastomer to expand. the result: The overall mount is smaller but has the same spring travel.
Cellasto® and rubber top mounts usually differ in their mechanical mode of operation. Cellasto® utilizes compressive loading, utilizes tension shear.
6 Top Mounts Cellasto® - the NVH Solution
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Cellasto® versus rubberChange in stiffness during fatigue strength testing
4 kN_4 Hz1 million cycles
Cellasto®
Rubber
Cycles
Sti
ffne
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kN/m
m]
1 million cycles
Typical result of durability test with a rubber mount and a Cellasto® mount on a test rig. The high fatigue strength of Cellasto® is refl ected in the long- term stability of the basic stiffness.
Depending on the requirements, the function can be infl uenced via the geometry.
Single path mounts of Cellasto® show outstanding resilience.
Cellasto® - the NVH Solution Top Mounts 7
as a pure compression mount. Because of
the low transverse lateral expansion and high
resilience, it can permanently withstand the
forces of the spring aids.
Continuous optimization
To ensure that Cellasto® top mounts meet the
performance specifi cations our customers
have come to expect, we are continuously
refi ning our production processes, developing
our technical design resources and optimizing
stiffness and stiffening behavior.
Using FEA models, we simulate the
complex behavior of Cellasto® to match
practical requirements. With our fast and
precise prototype production, we can also
manufacture and validate different top mount
variants quickly.
All-around solutions
To meet and exceed our clients needs,
we collaborate with our customers to
understand their range of requirements:
conical properties, acoustic decoupling,
ratios and package space conditions, radial
forces, body elasticity, etc.
Benefi ts of Cellasto® solutions:
• driving comfort is improved
• driving dynamics are optimized
• component weight is reduced
• fatigue strength is increased
HEAVY LOADS FEEL LIGHT – CELLASTO® SPRING ISOLATORSWhether steel coil or pneumatic springs – the chassis suspension must be very resilient. It has to bear the vehicle’s full static
weight when standing still and, in addition, supports the dynamic loads during motion. This generates strong vibrations
which become unpleasant for the vehicle occupants and subject the body to stress.
To provide protection against vibrations, the
automotive industry uses spring isolators to:
• dampen spring resonances
• reduce energy peaks and the
introduction of body noise
• absorb and isolate the reaction forces
of the spring and support bearing
• to isolate the relative movement of the
spring and spring seat during spring
compression
The ideal solution
Cellasto® spring isolators fulfi ll these
complex requirements. They reduce
resonance-related energy peaks and at the
same time, minimize body noise.
Because of their excellent fatigue strength,
Cellasto® spring isolators can be made
far softer than other elastomers used in
components subject to compression loads.
Furthermore, Cellasto® spring isolators are
characterized by high abrasion resistance,
negligible creep and low compression sets.
Customized applications
Depending on our customer’s requirements,
we can also combine the spring isolators with
an end stop or spring aid. This integrates
vibration damping by limiting spring travel in
one component, reducing assembly effort
and saving additional costs.
The wide range of design options take into account not only the optimal function but also the requirements for steel spring assembly and positioning.
8 Spring isolators Cellasto® - the NVH Solution
The wide range of design
Driving over rough surfaces stimulates the resonance of the steel spring, causing rumbling noises inside the vehicle.
Acoustic measurements confi rm the subjective im-pression: Cellasto® spring isolators signifi cantly reduce these noises.
Noise level in the passenger compartmentSpring isolator variation on the rear axle on cobblestones
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Cellasto®
Rubber
Cellasto® - the NVH Solution Spring isolators 9
UP TO
25%REDUCTION OF MAXIMUM FORCES INTO THE CAR BODY
Depending on the requirements, the
spring isolator can be integrated into
the spring aid.
This produces a cost effective
component that saves assembly
effort and improves the vehicle’s
NVH characteristics.
The combination of Cellasto®
and Elastollan® TPU reduces the
maximum forces in the car body
by up to 25%.
Depending on the requirements, the
spring isolator can be integrated into
the spring aid.
With particularly heavy automobiles it can
be advantageous to use spring isolators
made from a combination of several
polyurethanes. The combination of a
volume compressible polyurethane like
Cellasto® on the upper part of the spring
with a thermoplastic polyurethane (TPU)
spring isolator, for example, Elastollan® on
the lower part of the spring can signifi cantly
reduce the generated peak energies.
2500
NVH reduction
Vehicles are becoming technologically more
complex, while expectations of their ease of
use, long service life and driving comfort are
increasing. The use of Cellasto® spring aids,
spring isolators and top mounts is the right
choice for this purpose. But Cellasto® can
also decisively minimize NVH in other areas:
• as an end stop for trunk lids and doors,
• as a friction element in armrests
• for seat track decoupling
• as a spring element in seat height
adjustment
• as a decoupling element for wiper
blade mechanics
• as a damping ring for the
handbrake lever
• as a damping element in locks
• as a mount for electric motors
and transmissions
• as an additional element (end stop)
for motor mount systems
• as a differential and transmission mount
• as a torque support
• as a transmission shaft mount
Damping elements and
differential mount
The temperature resistance of Cellasto®
also allows its use in applications involving
elevated temperatures. For example,
Cellasto® components are also used as
damping elements in the drive shafts of
BMW motorcycles. Cellasto® components
are also suitable as differential mount
because of their high resilience and volume
compressibility.
New applications based on
integrated technology
To manufacture more complex parts such
as differential mounts, technologies are
needed that allow permanent bonding with
metal mounted parts such as an aluminum
core. To meet this need, we are using our
well-proven expertise to produce Cellasto®
components. For example, we produce
composites of Cellasto® with metal parts
that last a vehicle’s lifetime and have
excellent durability. Another example are
two-component adhesive technologies
which ensure outstanding adhesion.
We have also developed a special casting
resin (Elastolit®) with which we can cast
Cellasto® parts onto other materials. One
example of these composite structures are
the clips that allow a Cellasto® stop to engage
fi rmly in seat tracks. This application offers
designers great freedom and the option of
replacing metal parts with lightweight, more
cost effective plastic components.
THE VERSATILITY OF CELLASTO®
For more than 50 years, we have been using polyurethane in the automotive industry. And of one thing we are certain: this is just the begin-
ning. Whether as spring isolators, spring aids or top mounts – Cellasto® contributes to enhanced driving comfort and safety, especially by its
ability to substantially reduce noise, vibration and harshness. But these are far from all the advantages offered by Cellasto®. The outstanding
physical properties of this material can also be utilized for other structural components such as damping elements or differential mounts.
Discover the other unique applications of this multi-functional material.
Cellasto® absorbers dampen load alterations in the drive shaft of BMW motorcycles.
10 New applications Cellasto® - the NVH Solution
baSF cellaSto® SiteS worlDwiDeProviding customer oriented solutions for demanding applications
Get in touch with us:[email protected] www.polyurethanes.basf.us
nortH aMerica BASF Corporation 1609 Biddle Avenue Wyandotte, MI 48192, USA Phone +1 734 324 - 6285
SoUtH aMerica BASF Poliuretanos Ltda Av. Papa João XXIII, 4502 - A, 09370-904 Mauá, SP, Brazil Phone +55 11 4542 - 7260
eUroPeBASF Polyurethanes GmbHElastogranstraße 60 D-49448 Lemförde, DeutschlandPhone +49 5443 12 - 2302
inDia BASF India Limited Navi Mumbai HO II, Plot No. 12, T.T.C Area, Thane Belapur Road, Turbhe, Navi Mumbai, Maharashtra, 400 705, India Phone +91 22 6712 7663
cHina BASF Polyurethane Specialties (China) Company Ltd No. 2333, Gangcheng Road, Shanghai, 200137, ChinaPhone +86 - 21 - 3865 5556
JaPan BASF INOAC Polyurethanes Co. Ltd (BIP)441-1347 1-196 Hongudo, Kawada, Shinshiro, Aichi, JapanPhone +81 536 23 5599 - 231
korea BASF Company Ltd.14F, KCCI Bldg., 45, 4-ga, Namdaemunro, Jung-gu, Seoul, 100-743, KoreaPhone +82 2 3707 7853
Cellasto® - the NVH Solution Cellasto® - sites 11
12 Global cooperation Cellasto® - the NVH Solution
Global network, local inteGrationVehicle platforms are produced around the world. With Cellasto® sites in North and South
America, Europe and Asia, we are close to our customers. Whether for Chang´an, Citroën,
Ford, GM, Hyundai, SAIC, Suzuki, Tata, Toyota, or Volkswagen – we know the regional
differences and our customer’s local needs.
Cellasto has always stood for high quality,
long lasting components for the automotive
industry. That’s why 90% of all car
manufacturers use Cellasto® components.
Thanks to our global key account
management, we can respond quickly in
any region around the globe to offer our
customers competitive solutions from a
single source. BASF produces Cellasto® at
six sites worldwide: Lemförde (Germany);
Nansha and Shanghai (China); São Paulo
(Brazil); Shinshiro (Japan); and, Wyandotte,
Michigan (USA).
Sharing know-how
BASF’s worldwide network of development
centers share major elements of project
work, such as tests, creation of drawings and
quality assurance. Each of our developers
has access to a central database containing
drawings, test orders, and other development
knowledge. The database guarantees
cutting edge research and development
information is at the developer’s fingertips. It
also serves as a calculation platform for the
preliminary design of different products. This
ensures fast and effective solutions without
duplication of effort.
location advantage
Familiarity with local conditions allows us
to utilize the economic advantages of the
region in which our customers are located.
We locally source major components used
in many of our products. This is another way
that we provide cost benefits and secure
supply for our customers.
i speak english
Je parle français
eu falo português
Cellasto® - the NVH Solution Global cooperation 13
90%oF all car ManUFactUrerS USe cellaSto® coMPonentS
why cellasto®?
Whether as a spring aid, top mount or coil spring isolator – thanks
to outstanding physical properties, Cellasto® components are the
ideal solution for the automotive industry. Because Cellasto® offers:
• very good static and dynamic characteristics
• high volume compressibility with minimal lateral expansion
• low dynamic stiffening and amplitude dependent damping
• low compression set
• high abrasion resistance
• resistance to cold, heat and moisture
• resistance to oils, greases and ozone
This special combination of characteristics differentiates Cellasto®
as an outstanding engineering material that also reduces noise,
vibration, and harshness in vehicles.
Je parle français
io parlo italiano
ich spreche Deutsch
Jag talar svenska
cars love quiet
baSF corporation
1609 Biddle Avenue
Wyandotte, MI 48192
Phone: 734-324-6285
E-mail: [email protected]
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For more information on Cellasto® from
BASF, scan the QR Code above, or visit:
www.polyurethanes.basf.us
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