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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12.5

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25

50 58 66 74 82

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ffne

ss [

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Spring travel [mm]

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ffne

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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

ss [

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:cellasto@basf.com 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: cellasto@basf.com

Follow us on:

facebook.com/basf twitter.com/basf

For more information on Cellasto® from

BASF, scan the QR Code above, or visit:

www.polyurethanes.basf.us

WHILE THE DESCRIPTIONS, DESIGNS, DATA AND INFORMATION CONTAINED HEREIN ARE PRESENTED IN GOOD FAITH AND BELIEVED TO BE ACCURATE, THEY ARE PROVIDED FOR GUIDANCE ONLY. BECAUSE MANY FACTORS MAY AFFECT PROCESSING OR APPLICATION/USE, BASF RECOMMENDS THAT THE READER MAKE TESTS TO DETERMINE THE SUITABILITY OF A PRODUCT FOR A PARTICULAR PURPOSE PRIOR TO USE. no warrantieS oF anY kinD, eitHer eXPreSSeD or iMPlieD, inclUDinG, bUt not liMiteD to, warrantieS oF MercHantabilitY or FitneSS For a ParticUlar PUrPoSe, are MaDe reGarDinG ProDUctS DeScribeD or DeSiGnS, Data or inForMation Set FortH, or tHat tHe ProDUctS, DeScriPtionS, DeSiGnS, Data or inForMation MaY be USeD witHoUt inFrinGinG tHe intellectUal ProPertY riGHtS oF otHerS. IN NO CASE SHALL THE DESCRIPTIONS, INFORMATION, DATA OR DESIGNS PROVIDED BE CONSIDERED A PART OF BASF’S TERMS AND CONDITIONS OF SALE. FURTHER, THE DESCRIPTIONS, DESIGNS, DATA, AND INFORMATION FURNISHED BY BASF HEREUNDER ARE GIVEN GRATIS AND BASF ASSUMES NO OBLIGATION OR LIABILITY FOR THE DESCRIPTIONS, DESIGNS, DATA OR INFORMATION GIVEN OR RESULTS OBTAINED, ALL SUCH BEING GIVEN AND ACCEPTED AT THE READER’S RISK.

Photography: BASF, © Okea-, © ArchMen-, © hfng-, © BezMaski-fotolia.com,motor cycle motive page 12/13: Böhringer, www.motorrad.kaernten.at, Getty Images.