Cellasto®

Components

Complete

Industrial

Products

Pe r f e c t p r o d u c t sa r e e i t h e r …

2

Contact discscoated with Cellasto are em-ployed for rough-ing and grindingwork carried out byautomatic grindingmachines. Cellastois highly resistantto abrasion and so its durability is several timesgreater than that of rubber.

When they reachtheir mechanicalend stop, cranebuffers made ofCellasto are com-pressed by up to75% of their origi-nal length. Thislarge spring excur-sion ensures thedesired short delayand thus safe oper-ation of the crane.

… p u r e l y n a t u r a l o r n a t u r a l l y o u t o f P U r e C e l l a s t o

3

l Modelled on nature

Why is an egg oval shaped and not

round or square? Why do certain kinds

of animals have their eyes on the sides

of their heads and others at the front?

Why is the coat of the Polar bear white

and that of the Grizzly a greyish-

brown?

Nature has adapted each detai l per-

fectly to suit the ›specif ic require-

ments‹ of l i fe. Only the best solutions

survive. The ›Survival of the Fittest‹

principle has successful ly establ ished

itself over mil l ions of years of evolu-

tion.

We at BASF work on the basis of a

similar principle. We want to improve

technical products, to perfect them and

to prepare them well for the ›batt le of

l i fe‹. This is what we are well armed to

do

� with the mult i-talented material

Cellasto, a special microcellular

elastomer made by BASF and

� with the know-how of our engineers

which has grown over decades

l BASF and Cellasto: since good

is just not good enough

We only develop solutions which are

both state-of-the-art and economical.

The units responsible for development,

construction, production and sales of

semi-f inished products and compo-

nents ensure that this motto is

observed at al l t imes through

� products which meet the require-

ments of the market

� r igorous product testing in accor-

dance with the application and

uti l ization of the f inished products

� employment of state-of-the-art tools

such as CAD and FEM MKS

� the competence of BASF, one of the

world’s leading companies in the

field of special microcellular elas-

tomers

This brochure aims to give you an

overview of the extensive variety of

applications in nearly al l areas of

industry.

Dirty bear-ings in-creasewear anddestroy

the precision-finished sliding surfaces. Remedy:seals made out ofCellasto.

Con-veyor belts coated with Cellasto excel due to their excel-lent grip and hightear propagationresistance thusrendering them extremely safe,particularly for thetransportation offlat glass.

Fillersmade ofCellastolevel out

rail grooves at levelcrossings thus enabling cyclists tocross tracks safely.Railway vehiclespress down thefillers with theirwheel flanges whendriving over them.

Impact energy ab-sorption and peakload damping com-bined with supremereliability: applica-tions for Cellasto.

All Cellasto componentsfrom one source: from development and production through tosales and distribution

N o i s e a n d v i b r a t i o n s c a n g e t o n y o u r n e r v e s …

4

Anti-vibration andend stop elementsmade of Cellastohave stood the testeven under themost difficult oper-ating conditions.

MouldedCellasto compo-nents are fitted intofriction dampers forvibration absorp-tion. Even whenused under perma-nent high pre-stressthe durability ofthese damping systems matchesthe durability of awashing machine.

The chain saw roars, the washing ma-

chine hums, the razor buzzes … Noise

and vibration everywhere: both at

home and at work. Our environment

is increasingly ›pol luted‹ with acoustic

›rubbish‹. Both acoustic and impact

vibrations have a negative effect on

our well-being.

l ›Environmental pollution‹

caused by vibrations can be

avoided.

General ly i t is impossible to el iminate

al l vibrations, yet i t is definitely possi-

ble to reduce their negative impact:

through sophist icated design of the

damping elements and through the use

of the vibration-absorbing material

Cellasto.

l Cellasto absorbs the vibra-

tions

Enhanced acoustic isolation has been

demanded for many applications in the

field of Noise, Vibration and Harshness

(NVH). The goal: on the one hand to

achieve low damping at low amplitudes

and high frequencies and on the other

to achieve rapid damping for strong

movement of large masses. Cellasto

meets the challenge of these seemingly

contrasting requirements.

l Good vibrations with Cellasto

In the f ield of vibration and noise isola-

t ion, Cellasto support elements dampen

impact noise. Cellasto makes its mark

due to its extremely low dynamic

st iffening even at high frequencies.

… C e l l a s t o c a n s o o t h e t h e m

5

With moulded Cellasto compo-nents, vibrations intumble driers canbe dampened directly at the pointof origin.

Reliable enginebearing in confinedstructural space.Noticeable benefitsfor the user: the razor is much quieter and its vibrations are reduced.

Fatigue-free workwith the vibrationcompactor: damp-ing elements madeout of Cellasto reduce unpleasantvibrations to handsand arms.

Vibrationscaused by loadchange of engines are effi-ciently reducedthrough torquesupports madeof Cellasto.

Amplitude Selective Damping

loss

an

gle

[G

rad

]

amplitude [mm]

Clearly visible: the steeprise in loss angle with in-creasing amplitude for allmaterial densities.

MH 24-35

MH 24-45

MH 24-55

MH 24-65

E v e r y t h i n g h e c a n d o . . .

6

Maintenance-freesuspension sys-tems for industrialtrucks: the Cellastosuspension ele-ments absorb severe impacts, re-duce vibration andnoise whilst main-taining driving dynamics.

Optimal tuning ofdriving comfort inhigh-performanceshock absorbers of mobile homesthrough progres-sive Cellasto springaids.

A double linkaxle withCellastosprings:good damp-ing effect

with both full andempty tanks. Level-ling is not neces-sary as the springtravel differencebetween full andempty load is minimal.

l When powerful energies bump

into one another

When Sumo wrestlers bump into each

other colossal impact forces are

released. Weighing 180 to 200 kg the

wrestlers try to bounce off the bulk of

their opponents whilst putt ing more

force into their own attack. What these

flesh and blood giants can do by occu-

pying a lot of space, a l i t t le lump of de-

l ightful roly-poly made of Cellasto can

do much better and in a much smaller

space.

l The trump card is volume

compressibility

Due to its cel lular structure Cellasto

can be compressed so much that the

cells virtual ly disappear and a homoge-

nous-elastic structure is achieved. This

property al lows for a spring deflection

of 80 % of their original height for

Cellasto components whilst hardly

changing its transverse dimension. This

volume compressibi l i ty gains impor-

tance against the background of a con-

fined surrounding structural space,

such as inside a spring strut. Both vol-

ume compression and energy absorp-

tion of the material can be adjusted

through the density of the Cellasto

springs. Remember: compact materials

such as rubber are not compressible

and therefore show extreme transverse

expansion when under pressure. Even

steel coi l springs attain well below the

values achieved by Cellasto.

l Second to none

Apart from its volume

compressibi l i ty the

polyurethane elas-

tomer Cellasto also

stands out with a

number of further

properties:

� high tensi le

strength and

breaking strain

� excellent impact strength

� high abrasion resistance

� maintenance of elasticity at low tem-

peratures and resistance against

oi ls, grease, petrol, ozone and

ageing

� high impact resi l ience

� high reset force – even under long-

term loads

� low compression set

� no coagulation of cel l walls

Cellasto is extremely well suited for

spring and damping elements in road

and rai l vehicles.

. . . C e l l a s t o c a n d o b e t t e r

7

It limits the axlemechanisms anddampens the start-ing impact. Cellas-to in aircraft towingtractors.

More comfort andsafety on twowheels: this sus-pension fork damp-ens the effects ofuneven road sur-faces through Cellasto spring elements.

Cellasto as a multi-functional spring system toadjust the positionof both seat andbackrest, as endstop and in height-adjustable gaspressure springs.

G r i p , d y n a m i c s , s e n s i t i v i t y, r e s i l i e n c e , e l a s t i c i t y …

8

Extremely high re-silience at minimalsetting behaviourrenders Cellastoejectors suitableeven for high-speed punchingmachines.

Cellastoconveyingrolls have along operat-ing life andfold even wafer-thinpaper quickly andwithout creasing.

. . . C e l l a s t o c o m p o n e n t s w i t h f e e l i n g …

9

Goodgrip, ab-solute reliability andgood durability arethe demandingspecifications Cellasto transportand counting rollsmeet, e.g. in cashdispensers.

Mortice dead lockwith a multi-func-tional Cellastospring element forsoft stops andsilent spring deflec-tion.

Printing rolls needcompressible coat-ings out of Cellastofor a consistentand high resetforce.

l ... for sensitive machines

There are machines with a sensit ive

touch, cash dispensers, for instance.

The sensit ive ›f ingers‹ inside them

never make a mistake and always hand

out the correct sum.

For cash dispensers absolute rel iabi l i ty

is crucial. For this reason manufactur-

ers bank on Cellasto for their counters.

The durable Cellasto rol ls and conveyor

belts always have the right sensit ivity.

How is this feel ing created? The sensi-

t ive grip is the result of the vacuum ef-

fect between the microscopic structure

of Cellasto cel ls and the fr ict ion coeff i-

cient of the banknote.

l Even under pressure: soft and

elastic

Even during deformation, caused by

compression, for instance, the hard-

ness and thus the grip of Cellasto re-

mains nearly unchanged, an advantage

for the transportation of paper on con-

veyor belts with Cellasto coating.

l Ejectors at the service of die

cutters

When packaging material has been

punched out of cardboard it needs to

be pushed out of the die cutt ing tool.

The material which is designed for

the job on the die cutter is Cellasto.

Cellasto shows the lowest dynamic

load-related creep of al l elastomers.

The low increase in deformation means

that Cellasto parts return to their origi-

nal posit ion as soon as the compres-

sion phase is terminated; and this for

over a mil l ion cycles without any loss

of performance:

l When Cellasto starts rotating

When Cellasto coatings rotate, for

instance on fast moving rol ls in the

printing industry, Cellasto never loses

its shape. Being both abrasion-proof

and l ightweight, Cellasto simply runs

and runs and runs.

Dynamic load-related creep

Co

mp

ress

ion

[%

]

A l ternating load

Cushioning comfortfor Nordic walkingsticks through a linear coil springcombined with aprogessive Cellastospring.

0

10

20

30

40

50

60

70

80

102

2 5 103

2 5 104

2 5 105

2 5 106

2

F i r s t C l a s s – o f f t h e p e g

10

Foils which are up to 10 mm thickand 400 mm wideare sliced out ofcylinders.

The basis for agreat number oftechnical items:Cellasto blocks andslabs. The partsand plates areformed by punch-ing as well as waterjet and convention-al cutting.

C e l l a s t o P r o d u c t s – t a i l o r m a d e

11

Cellasto cylindersare used for fin-ished parts whichare given their finalshape by cutting,turning and milling.

Cellasto tubes arethe preferred mate-rial to punch orturn tubes andseals.

The Cellasto prod-uct portfolio forlifts: overrun andcable buffers, guide shoes andguide shoe hous-ings tested and approved by theGerman TechnicalInspection Authori-ty (TÜV).

Pre-fabricatedspring elementsmade of Cellas-to for applica-tions which areutilised to cush-ion impact gently and toabsorb high energies.

I t does not matter whether you are tal l

or short, big or sl im: many fashion

houses provide f irst class garments

directly off the peg in the ›standard‹

sizes men and women wear. The advan-

tage is obvious: the clothes f i t as

if they were tai lor-made, whilst being

much less expensive and prêt-à-porter.

l If it is good enough for fashion

houses, it is good enough for

Cellasto

Our ›ready-to-wear‹ range comprises

1,500 different products which were

original ly developed and produced for

the automotive industry world-wide,

90 % of which has opted for Cellasto

damping elements in their under-

carriages.

We can draw from this pool of 1,500

geometries of moulded parts and

spring characterist ics to develop a

solution for any task you ask us to

accomplish.

And this is how we work: in close

co-operation with you we develop the

specif ications to get a ›blueprint‹ for

your product. Then we check if we

already have a product with similar

features in our pool. I f necessary we

can modify i t to meet your require-

ments.

Special requests from customers are

turned into real i ty without delay. For

custom-made products our team of

designers is at your service.

l Tailor-made products off the

shelf

Small quantit ies of rotation-symmetric

parts are manufactured at low cost

from Cellasto tubes and bars through

cutt ing, mil l ing and turning.

Plane-surface parts are shaped by

water-jet and conventional cutt ing as

well as punching. For special applica-

tions Cellasto is also avai lable as

sl iced foi l up to 10 mm thick.

Both spring elements and standard

springs with foamed-in mounts, which

can be used for a wider range of appli-

cations, are avai lable from stock. This

also applies to our complete range of

mounts for l i f ts and crane buffers.

12

Tr i v i a he lps t o h i t t he bu l l s eye …

. . . y e t h i t t i n g t h e t a r g e t i s n o t a t r i v i a l m a t t e r

13

Physical testingof Cellastocomponentswith the droptester or hydropulser. De-pending onspecificationsup to severalmillion cycles.

The chemicaldevelopment iskey to successof Cellastocomponents.

l The whole is only as good as

the sum of the parts

The f inished product is only as good as

its individual components. For this rea-

son you can obtain our products from

one source only: from development and

construction to component optimisation

and production to sales and distr ibution

all steps are both executed and closely

monitored in-house.

l The quality of the components

As an active part icipant in the auto-

motive industry BASF meets str ict

guidel ines and specif ications. This

means in turn that we operate at a

level of quality which goes far beyond

what is demanded of other industries.

To accomplish such demanding tasks

BASF draws on a long tradit ion of

expert ise and experience in both engi-

neering and chemistry. State-of-the-Art

calculation and testing equipment sup-

ports our engineers during their work.

The facts:

� acoustics laboratory

� FEM (Finite Elements Method)

� FFT (Fast Fourier Transformation)

analyser

� hydropulser

� shaker

� Adams simulation software

� test vehicles

� specif ic technology for component

testing

l Perfection plus innovation

Striving for perfect solutions and

products: our heart beats faster when it

comes to innovative products. Our goal

is to make the seemingly impossible a

real i ty with our customers. Our offer:

you explain your problem. We make

your task ours and together we devise

an innovative solution.

t ime [h]

co

mp

ressi

on

[%

]

Static load-related creep

14

l Leader in its Field

BASF is the leading supplier of

polyurethane basic products, systems

and specialt ies. With its global network

of 35 polyurethane System Houses and

its comprehensive product and service

portfol io, BASF is the preferred partner

of i ts customers in many industries.

With its world-scale plants BASF

secures its leading market posit ion in

the manufacture of polyurethane basic

products in al l regions of the world.

In the European Economic Area BASF

Polyurethanes GmbH is running the

BASF polyurethane business via i ts

14 System Houses. In Europe, BASF is

both the market and technology leader

of polyurethane systems and poly-

urethane specialty elastomers.

l Working hand in hand with our

customers

In the highly service-oriented

polyurethane systems and specialt ies

business, experience and expert ise are

what customers require. With its net-

work of System Houses, BASF offers

fast local support in the development of

individual solutions, including technical

service, sales and marketing. BASF

ensures rel iable supply of basic

polyurethane products l ike MDI, TDI

and polyols on a global scale from the

company's world-scale plants.

l Individual Innovations

No matter which PU application is

involved – BASF turns the apparently

impossible into an innovative real i ty.

In close project-related co-operation

with the customer our special ist teams

of chemists, physicists, engineers

and sales experts develop tai lor-made,

creative and economic solutions. We

create a sol id and rel iable base with

our customers through both active dia-

logue and combined experience. Our

sectoral applications technology which

stretches throughout Europe is str ict ly

focused on value added benefit.

Anmerkung für

Litho: Flagge

sauber freistel-

len.

Portfolio:

BASF develops, produces and

sells:� PU elastomers as thermo-

plastic specialty elastomers� PU elastomers as cellular

specialty elastomers� PU base products, such as

isocyanates, polyols, cata-lysts, auxillary materials

� PU systems, divided into system groups such as rigid,flexible, integral, compact

Sites (EMEA)� Germany (headquarters)� France� The UK� The Netherlands� Italy� Russia� Sweden� South Africa� Spain � Turkey� Hungary� Slovakia� Dubai

Research and Development

World-wide BASF Polyurethane

Research for PU systems and

PU special elastomers has been

centralized in the newly created

Research Centre in Lemförde.

Nearly 200 specialists work in

this think tank of expertise and

creativity for the fields of

Research, Development and

Applications Technology. With

the know-how of this inter-

national technology centre we

provide our expertise to other

BASF Group companies in Ameri-

ca and Asia which are active in

the field of polyurethane.

A b o u t Po l y u r e t h a n e s a t B A S F

15

l Quality Management

Customer satisfaction is the basis for

sustained business success. There-

fore, we want to meet the customers'

requirements for our products and

services now and for the long term

futures.

To ensure success in a rel iable way,

we introduced a quality management

system several years ago including al l

divisions.

Each business process is regularly

assessed and further developed based

on informative performance indicators.

The target is to reach optimum eff i-

ciency and almost perfect coordination

of al l activit ies and operations. Each

employee is asked to make a contribu-

tion to quality assurance and continu-

ous improvement with its capabil i t ies

and ideas at i ts workplace.

Our quality management system is

based on the international standard ISO

9001, supplemented by the addit ional

requirements of the automotive indus-

try ISO/TS 16949.

l Responsible Care�

BASF supports Responsible Care, the

worldwide init iat ive of the chemical in-

dustry, and thus commits itself to con-

tinual safety, health and environmental

protection.

For us Responsible Care is an issue

for safety, health and environmental

protection, which – for the sake of

environmental sustainabil i ty – is

considered as being a corporate value

as important as economic criteria for

boosting the company's success.

The whole process of development,

production and storage of our products

as well as their transport, application

and f inal ly also their disposal or

recycl ing is evaluated and continually

further developed with respect to the

reduction of possible environmental

impact.

This includes, in part icular, the protec-

tion of resources as well as prevention

of emissions and waste. We appropri-

ately inform customers, partners and

neighbours about environmental as-

pects of products and processes. Our

environmental management system is

geared to the guidel ines of Responsible

Care and meets the requirements of

the international standard ISO 14001.

l Recycling

Methods for recycl ing polyurethanes

are as diverse as their use. In order to

f ind the right method, i t is necessary to

clarify their specif ic origin and use.

Alongside thermal re-uti l isation of PU

products, the recycl ing of production

waste also plays an important role. The

fol lowing processes are already being

introduced on a practical scale:

� Flock-bond

� Particle-bond

� Chemical recycl ing

� Raw material processes

It is general ly not possible to state

whether such processes are more

ecological ly beneficial than thermal

re-uti l isation.

A c t i n g w i t h R e s p o n s i b i l i t y

BASF Polyurethanes GmbH

European Business Management

Microcellular Elastomers (Cellasto®)

P.O. Box 1140

49440 Lemfoerde

Germany

Phone +49 54 43 12-23 02

Fax +49 54 43 12-21 05

www.pu.basf.eu KU

/WM

, 2

57

-10

-10

/GB

® = registered trademark of BASF Polyurethanes GmbH

The data contained in this publication is based on our

current knowledge and experience. In view of the many

factors that may affect processing and application of our

product, this data does not relieve processors from

carrying out their own investigations and tests; neither

does this data imply any guarantee of certain properties,

or the suitability of the product for a specific purpose.

Any descriptions, drawings, photographs, data, proporti-

ons, weights etc. given herein may change without prior

notice and do not constitute the agreed contractual qua-

lity 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. (10/10)