cars love quiet

Innovation and our customers’ success is the driv-

ing force behind our work. Together with our cus-

tomers, we are constantly searching for solutions

to improve comfort and convenience in daily life

while simultaneously conserving resources.

The ceaseless drive to discover something new

has a long tradition at BASF. And it is in the nature

of our engineering material polyurethane that it

has lost none of its fascination even 75 years after

it was invented. Our chemists and engineers are in

constant cooperation with our customers to de-

velop new applications and areas of use, and to

optimize and further perfect them. So naturally it

was only a matter of time before the advantages of

Cellasto® were discovered for the multiple, com-

plex requirements of the automotive industry.

Vehicles are expected to offer ever increasing

levels of safety and comfort, while technical re-

quirements are becoming more and more com-

plex. One of many challenges faced by today’s

chassis engineers. And one of many challenges

the versatile engineering material polyurethane

(PU) is helping us to meet.

Under the brand name Cellasto®, BASF devel-

ops, produces and markets components made

from special microcellular polyurethane (MPU)

elastomers. They are used in the automotive in-

dustry as spring aids, coil spring isolators and top

mounts and contribute significantly to enhancing

driving comfort and safety.

The premier product quality is based on our ex-

pert knowledge and has helped us achieve the

status of world market leader in this application

segment. This is why nine out of ten car manufac-

turers worldwide already use Cellasto® spring

aids. Because they know they have a solution to

reduce noise, vibration and harshness (NVH). NVH

is the study and modification of the noise and vi-

bration characteristics of vehicles and machines.

While noise and vibration can be readily measured,

harshness is a subjective quality, that is measured

either via “jury” evaluations, or with analytical tools

that provide results reflecting human subjective

impressions. These latter tools belong to the field

known as “psychoacoustics.”

Our premium brand Cellasto® convinces users

with its outstanding physical properties. The ma-

terial is highly resilient and has outstandingly high

volume compressibility and low compression set.

In contrast to similar components made of rubber,

for example, the polyurethane foam expands only

slightly under compression. Cellasto® offers better

damping performance, considerably minimizes

driving noise and enhances safety and driving

comfort.

Discover the many uses of Cellasto® and get to

know our global organization. We operate local

production facilities worldwide and offer solutions

custom-tailored to our customers and contact

partners around the world to meet their require-

ments. Discover more applications of this fasci-

nating material and challenge us to accompany

you along new paths.

PAGE 4 5 Globally networked, locally integrated

6 7 Unbeatably resilient – Cellasto® spring aids

8 9 Superiorly quiet – Cellasto® top mounts

10 11 Great loads borne lightly – Cellasto® spring isolators

12 13 The versatility of Cellasto®

14 15 Custom-tailored and high quality – the manufacture of Cellasto®

A FASCINATING RANGE OF POSSIBILITIES FOR OUR CUSTOMERS

Nine out of ten car manu-

facturers worldwide already

use Cellasto® spring aids.

Because they know they

have a solution to reduce

noise, vibration and harshness

(NVH): Cellasto®– the NVH

solution.

HA

RS

HN

ES

S

VIB

RA

TIO

NS

NO

ISE

I speak English

Je parle français

Eu falo português

Cellasto® stands for high quality, long-

lasting components. Because Cellas-

to® components have this in common,

we adapt them to meet each custom-

er’s requirements and the associated

production platforms.

Our local development and project

engineers are competent contact part-

ners closely integrated into BASF’s

global infrastructure. Thanks to our

global key account management, we

can respond rapidly and flexibly in all

regions of the world and offer compe-

titive solutions from a single source.

Our customers benefit from this ar-

rangement as they not only save on

development costs but also have a

single reliable local supplier who

speaks their language. BASF produces

Cellasto® at six sites worldwide, cur-

rently: Lemförde (Germany), Nansha

and Shanghai (China), São Paulo (Bra-

zil), Shinshiro (Japan) and Wyandotte

(USA).

Sharing know-how

Major elements of project work such as

tests, creation of drawings and quality

assurance are done by our develop-

ment centers linked with each other in a

worldwide network. Each of our devel-

opers can access a continuously avail-

able central database with all the im-

portant drawings, test orders, and other

development knowledge. The database

permanently offers guaranteed cutting

edge research and development infor-

mation.

It also serves as a calculation plat-

form for the preliminary design of differ-

ent products. These availabilities are

key factors ensuring fast and effective

work on global automotive platforms.

Location advantage

We find the suitable partners for our

customers’ projects and routinely offer

several options. Being familiar with the

local conditions, we know how to utilize

the economic advantages of regional

locations. We obtain outsourced parts

from all around the world, while the ma-

jor components are purchased from

local suppliers. This is another way we

guarantee cost benefits and security of

supply for our customers.

Vehicle platforms are produced all around the world. With our Cellasto® sites

in North and South America, Europe and Asia, we’re where our customers

are. Whether for Chang´an, Citroën, Ford, GM, Hyundai, SAIC, Suzuki, Tata,

Toyota, or Volkswagen – we know the regional differences and our customers’

local needs.

GLOBALLY NETWORKED, LOCALLY INTEGRATED

4 Global Cooperation Cellasto®– the NVH Solution

Jag talar svenska

Ich spreche Deutsch

Io parlo italiano

90 %OF ALL CAR MANUFACTURERS USE CELLASTO® COMPONENTS WE PRODUCE WORLDWIDE

Why Cellasto® ?

Whether as spring aid, top mount or spring pad –

thanks to their outstanding physical properties,

Cellasto® components are the jackpot for the auto-

motive industry. Because Cellasto® offers:

• verygoodstaticanddynamic long-run behavior,

• highvolumecompressibilitywithminimal lateral expansion (ideal for restricted spaces),

• lowdynamichardeningand amplitude-selective damping,

• lowcompressionset,

• highabrasionresistance,

• resistancetocold,heatandmoisture,

• resistancetooils,greases,ozone and many other important media.

This special combination of characteristics distin-

guishes Cellasto® as an outstanding engineering

material that also decisively reduces noise, vibra-

tion, and harshness in vehicles. Hardly surprising,

therefore, that more than 90 % of all car manufac-

turers are already using Cellasto® components we

produce worldwide.

Cellasto®– the NVH Solution Global Cooperation 5

The chassis is exposed to special stresses. It has to respond to different driving conditions and road surfaces such

as potholes and constantly exercise a compensatory function. With rapid deformations and large spring travel, it

absorbs enormous amounts of energy within the shortest time. If the energy peaks are not absorbed, the dampers

and chassis may be damaged and vehicle occupants subjected to unpleasant jarring and vibrations.

UNBEATABLY RESILIENT – CELLASTO® SPRING AIDS

Energy peaks disappear

Cellasto® spring aids enable relaxed

and comfortable driving as they effec-

tively eliminate energy peaks. The vol-

ume compressibility of Cellasto® per-

mits large spring travel within a confined

space.

It is also abrasion and fa tigue resistant

under high compressive loading. It fea-

tures excellent compression set, a natu-

rally progressive characteristic curve,

and superb absorption behavior. No

other material offers this combination of

properties.

Made to meet

the highest demands

We are constantly working to meet in-

creasing demands placed on spring

aids. For example, using the finite ele-

ment analysis, we can:

Our FEA simulations of the Cellasto® compo-nents provide insights denied in rig testing. For example, optimizing the geometry is easier.

Driving over a pothole is when spring aids come into their own. The wheel speeds with enormous force towards the body. The spring aid has to stop its movement and minimize energy peaks.

Volume compressible material offers invaluable advantages in the restricted spaces of the strut assembly.

This comparison demonstrates the volume compressibility of Cellasto® in enclosed spaces. Rubber expands laterally and shatters the glass.

Cellasto® with its low transverse elongation can be compressed by up to 40 % of its original height.

• identifystressconcentrations

in the material at an early stage,

• visualizeandeliminate

critical deformation states,

• implementshorter

development times,

• anddevelophighmaturity

prototypes in early phases.

6 Spring aids Cellasto®– the NVH Solution

Customized

Cellasto® spring aids

Whether distribution to our worldwide

production sites for high volume pro-

duction with many variants or a limited

number of spring aids for a small

series – we offer customized solutions.

With globally identical standards and

the complete portfolio of formulations,

we can fulfill virtually all our customers’

needs.

We use different formulations, bulk den-

sities and contours, but also mounted /

attached parts that can be either direct-

ly foamed in or fitted. For example, with

a consistently low initial rate, a larger

block height can be implemented.

Efficient and fast

New car models and facelifts are cap-

turing the market at an increasing rate

and with ever shorter development cy-

cles. With efficient processes, we sup-

port our customers, operate with high

efficiency and supply premium quality.

But however efficient we are, our top

priorities are and will remain service and

personal contact.

We supply top mounts, spring aids and dust tube together in pre- assembled component groups.

Molded-in cups have a stabilizing effect and provide block height. Another advantage is that Cellasto® and the mounted part are captively connect-ed to each other.

When the spring aid deflects during driving, this perceptibly impacts driving comfort. If the stiffness of the spring aid varies during such dynamic processes, loss of comfort may result. By optimizing the ge-ometry, we can offer springs that provide particularly high comfort.

Cellasto®– the NVH Solution Spring aids 7

Stronger, smaller

and more cost effective

Unlike rubber, Cellasto® top mounts are

volume compressible. The Cellasto®

structure makes it possible to imple-

ment 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 in-

stalled in a much smaller space. The

housing can then be made smaller and

the amount of expensive light metal

alloys used is reduced. Cellasto® top

mounts therefore sustainably reduce

costs, weight, and space requirements.

Not least, the enormous fatigue strength

of the high performance elastomer Cel-

lasto® also helps cut costs.

EXCEPTIONALLY QUIET –CELLASTO® TOP MOUNTSDriving Noise, Vibration and Harshness (NVH) considerably affect driving

comfort and dynamics. To keep noise out of the car interior, shock absorbers

are connected to the body by isolating rubber bearings. In this application,

however, rubber often comes up against its limitations. This is why car manu-

facturers worldwide are increasingly using top mounts made of Cellasto®.

Because, compared to rubber, Cellasto® offers not only convincing, but also

numerous advantages.

The cellular structure of Cellasto® means that, compared to a compact rubber bearing, less space is needed for the elastomer to expand. The result: The overall bearing is smaller but has the same spring travel.

Typical result of a long-run test with a rubber bearing and a Cellasto® bearing on a test rig. The high fatigue strength of Cellasto® is reflected in the long- term stability of the basic stiffness.

8 Top Mounts Cellasto®– the NVH Solution

Single-path bearings of Cellasto® are also outstandingly resilient.

Outstanding resilience

Another major advantage of Cellasto®

top mounts is that they function as a

pure compression mount. Compared to

conventional rubber bearings which are

usually shear loaded, the Cellasto® top

mount can be designed with greatly re-

duced radial stiffness. With very good

axial connection (axially coupled) of the

shock absorber, the overall transmis-

sion is reduced, which is reflected in the

effective decoupling of rolling noises of

the wheel-tire system and rumbling

noises from the shock absorber. This

substantially improves driving comfort.

In single path applications, Cellasto® is

also convincing 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.

Continuously optimized

To ensure that Cellasto® top mounts

meet the performance specifications,

we are continuously refining our pro-

duction processes, developing our

technical design resources and optimiz-

ing stiffness and hardening behavior.

Using FEA models, we record, improve,

and utilize the complex behavior of Cel-

lasto® to match practical requirements.

With our fast-track and pre cise proto-

type production, we can also manufac-

ture and validate different top mount

variants.

All-around solutions

Our well-proven standard approach is

to develop and implement the optimal

solution for each of our customers’

needs.

To do so, we record and discuss with

the customer the entire range of re-

quirements. Whether conical properties,

acoustic decoupling, ratios and pack-

age space conditions, radial forces,

body elasticity – we determine all influ-

encing variables to achieve an optimal

solution. We fully utilize the potential of

Cellasto® and take advantage of its in-

novative properties.

Numerous reference projects

prove the benefits of Cellasto®

solutions:

• drivingcomfortisimproved

• drivingdynamicsareoptimized

• componentweightisreduced

• fatiguestrengthisincreased

Our customers opt for Cellasto® be-

cause they directly experience the ma-

terial-specific benefits while driving.

Cellasto® and rubber top mounts usually differ in their mechanical mode of operation. Cellasto® utilizes compressive loading, rubber uses shear.

Design as functional parameter. Depending on the requirements, the function can be influenced via the geometry.

Cellasto®– the NVH Solution Top Mounts 9

GREAT LOADS BORNE LIGHTLY – CELLASTO® SPRING ISOLATORS

To provide protection against these vi-

brations, the automotive industry uses

special spring isolators that have to per-

form a range of functions:

• Thesteelspringtwistsondeflection.This produces relative movements between the spring and spring cup that generate friction. The purpose of the spring isolator is not only to dampen the resulting noises. It also protects the anticorrosion coating of both steel parts from abrasion and contributes to their long service life.

• Springisolatorsalsohave to effectively dampen spring resonances.

• Spring isolators additionally have to reduce energy peaks and the introduction of body noise, caused by uneven road surfaces, into the chassis.

• In pneumatic suspensions, spring isolators also have to absorb and isolate the reaction forces of the spring aid and support bearing.

The ideal solution

Cellasto® spring isolators fulfill these

complex requirements particularly well.

They reduce resonance-related energy

peaks and at the same time, isolate the

body noise.

Because of their excellent fatigue

strength, Cellasto® spring isolators can

be made far softer than other elasto-

mers used in components subject to

pressure loads. Furthermore, Cellasto®

spring isolators are characterized by

high abrasion resistance, negligible

creep and low compression sets.

Whether 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.

The wide range of design options take into account not only the optimal function but also the requirements for steel spring assembly and positioning.

10 Spring aids Cellasto®– the NVH Solution

Customized applications

Depending on our customers’ require-

ments, we can also combine the spring

isolators with an end stop or spring aid

so as to integrate vibration damping

with limitation of spring travel in one

component. This reduces assembly ef-

fort and saves additional costs.

The multicomponent construction

technique can also be worthwhile in

certain cases. Our customers benefit

from our expertise because BASF

knows how to chose materials that work

together. For example, with particularly

heavy automobiles it can be advanta-

geous to use spring isolators made from

a combination of several polyurethanes.

The combination of a volume compress-

ible polyurethane like Cellasto® as a

spring isolator on the upper part of the

spring with a thermoplastic polyure-

thane (TPU) spring isolator, for example,

Elastollan® on the lower part of the

spring can significantly reduce the gen-

erated peak energies.

Skilful combination of Cellasto®

and Elastollan® TPU reduces the maximum forces in

the car body by up to 25 %.

Driving over rough sur faces stimulates the resonances of the steel spring, causing rumbling noises inside the vehicle. Acoustic measurements confirm the subjective impression: Cellasto® spring isolators signi-ficantly reduce these noises.

Depending on the requirements, the spring isolator can be

integrated in the spring aid.

This produces a cost effective component that saves assembly effort and improves the vehicle’s

NVH characteristics.

Cellasto®– the NVH Solution Spring aids 11

NVH reduction

Vehicles are becoming technologically

ever more complex, while expectations

of their ease of use, long service life

and driving comfort are increasing.

Driving comfort consists mainly of qui-

etness in the passenger compartment

despite high speeds, potholes or curv-

ing roads.

Noise, vibrations, and harshness are

considerable stress factors for car driv-

ers. Chassis engineers have long been

searching for ways of reducing them.

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 oth-

er areas:

For all these applications, Cellasto® of-

fers adequate spring travel even in con-

fined spaces. Its abrasion- and com-

pression-resistant long-term functionality

and ability to absorb high loads even on

small bearing surfaces are convincing

properties. It also eliminates whining

noises and isolates excitations at high

frequencies.

Damping elements

and differential bearings

The temperature resistance of Cellasto®

also allows its use in applications involv-

ing elevated temperatures. For example,

Cellasto® components are also used as

damping elements in the transmission

shafts of BMW motorcycles. Cellasto®

components are also suitable as differ-

ential bearings because of their high re-

silience and volume compressibility.

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 beginning. Whether as spring isolators, spring aids or top mounts – Cellasto®

contributes decisively to enhancing driving comfort and safety, especially by its ability to substantially re-

duce 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 bearings. Discover the other fascinating applications of this multi-

talented material.

Cellasto® absorbers damp load alterations in the transmission shaft of BMW motorcycles.

THE VERSATILITY OF CELLASTO®

• asanendstopfor trunk lids and doors,

• asafrictionelementinarmrests,

• forseattrackdecoupling,

• asaspringelementin seat height adjustment,

• asadecouplingelement for wiper blade mechanics,

• asadampingring for the handbrake lever,

• asadampingelementinlocks,

• asabearingforelectricmotors and transmissions,

• asanadditionalelement(endstop)for motor bearing systems,

• asadifferentialand transmission bearing,

• asatorquesupport,

• asatransmissionshaftbearing.

12 New applications Cellasto®– the NVH Solution

New applications based on

Verbund technology

To manufacture more complex parts

such as differential bearings, technolo-

gies are needed that allow permanent

bonding with metal mounted parts such

as an aluminum core. In this area, we are

using our well-proven expertise to series

produce Cellasto® components to meet

your requirements. For example, we

produce composites of Cellasto® with

metal parts that last an entire vehicle

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 ma-

terial. One example of these composite

structures are the clips that allow a Cel-

lasto® stop to engage firmly in seat

tracks. This application offers designers

great freedom and the option of replac-

ing metal parts with lightweight, more

cost effective plastic components.These

technologies demand a high level of ex-

perience and competent expert knowl-

edge. At BASF, we have both.

The good high-frequency transmission properties and compression resilience distinguish Cellasto® differential bearings.

Cellasto® seat track buffers can be clipped into metal tracks by casting on a resin. This plastic composite tech-nology significantly contrib-utes to weight savings and reduces the need for expen-sive metal parts.

Cellasto® buffers intercept engine movements in load alteration processes and have a long service life at elevated temperatures.

Cellasto®– the NVH Solution New applications 13

Thanks to the outstanding dynamic

properties of the special cellular PU

elastomer, every Cellasto® formulation

satisfies the extremely high require-

ments of the automotive industry. We

have developed special test methods

for the manufacture of new compo-

nents because many of the existing

methods originate from the non-com-

pressible elastomer field and are not

applicable to the volume compressible

Cellasto®.

In high-efficiency test laboratories we

evaluate the dynamic and static mate-

rial properties such as resistance to

tear propagation, tensile and expansion

behavior, compression set, and chemi-

cal resistance. From the results, we de-

rive material laws for simulating the

mechanical properties of the compo-

nents. Using the simulation method, we

can develop optimal Cellasto® compo-

nents to meet our customers’ specific

needs.

This makes describing Cellasto® de-

manding, but worthwhile. BASF has

also set itself the task of further evalu-

ating the potential of the multitalented

material Cellasto® and solving our cus-

to mers’ future tasks even better and

more sustainably than at present.

The production process

Cellasto® is fabricated into cellular

moldings in a closed mold in the hot

casting process.

In the first step, intermediates known

as prepolymers are produced from

polyols and isocyanates in a special

process which offers significant higher

characteristics compared to a one-shot

system. These are then mixed with oth-

er intermediates, the crosslinkers, on

the casting machine and then filled into

a mold which is then closed. Here the

chemical reaction takes place: The

foam begins to rise until it finally fills the

mold completely. After mold removal,

the components undergo thermal cur-

ing and the chemical reaction is termi-

nated.

The choice of raw materials, addi-

tives and processing technologies de-

termines the properties of the materi-

als. For Cellasto®, for example, mainly

1,5-napththylene diisocyanate (NDI) is

used, which differs greatly from other

isocyanates by its molecular structure,

and contributes significantly to creating

the outstanding properties of Cellasto®

components.

Sharing know-how

and global infrastructure

We develop, produce, and market high

quality Cellasto® components world-

wide. We can confidently guarantee the

long-lasting quality and success of our

products, because

Cellasto® is the successful synthesis of modern high tech polyurethane and BASF expertise. On this basis we pro-

duce first-class components adapted to our customers’ needs and requirements. Whether resilient with low com-

pression set or flexible at low temperatures – we produce Cellasto® components on a project basis and according to

our customers’ needs.

CUSTOM-TAILORED AND HIGH QUALITY – THE MANUFACTURE OF CELLASTO®

• wehaveaparticularlybroad range of raw materials and auxiliaries available in-house;

• withourglobalnetworkof production sites, we guarantee consistently high quality worldwide;

• Cellasto® is part of BASF’s research and development effort;

• ourownpilotplantoperates with specially developed and legally protected plants and process technologies;

• ourchemical-technicalinfrastructureis constantly researching to further develop the Cellasto® property profiles.

14 Cellasto® formulations Cellasto®– the NVH Solution

BASF POLYURETHANES – CELLASTO® SITES WORLDWIDE

Demanding applications and customer oriented solutions with Cellasto® worldwide.

Get in touch with us:cellasto@basf.com www.cellasto.basf.com

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

EUROPE

BASF Polyurethanes GmbH

Elastogranstraße 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 15

BASF Polyurethanes

BASF has established a firm position in

the field of polyurethanes in numerous

applications by technically mature pro-

duct qualities, acknowledged good ser-

vice, and continuous further develop-

ment. With our knowledge and long ex-

perience, we want to contribute to your

success: with the multitalented material

Cellasto® and innovative problem solu-

tions tailored to your needs.

The data contained in this publication are based on our current knowledge and experience. In view of the many factors that may affect processing and application of our product, these data do not relieve processors from carrying out their own investigations and tests; neither do these data imply any guarantee of certain proper-ties, nor the suitability of the product for a specific purpose. Any descriptions, drawings, photographs, data, proportions, weights etc. given herein may change without prior information and do not constitute the agreed contractual quality of the product. It is the responsibility of the recipient of our products to ensure that any proprietary rights and existing laws and legislation are observed. (09/11) Photography: BASF, © Okea-, © ArchMen-, © hfng-, © BezMaski-fotolia.com, motor cycle motive page 12/13: Böhringer, www.motorrad.kaernten.at, Getty Images.

BASF Polyurethanes A unit of BASF Coordination Center Comm. V.

Drève Richelle 161 E/F B-1410 Waterloo Belgium

Email: cellasto@basf.com www.cellasto.basf.com

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