Panoramic roofs are a clear upward trend in all markets. The models incorporating spectacular panoramic openings are a clear example of that. This trend coexists with the need to reduce the weight of all automotive components to minimize CO2 emissions into the atmosphere.

Grupo Antolin, a global provider of technology solutions for the car interiors, has the answer to both trends with the development of new technical plastic parts for its interiors.

The Advanced Engineering of the Headliners Business Unit, together with Grupo Antolin project team and in collaboration with BASF, have successfully validated the use of material family Ultradur in plastic frames of solar and panorama headliners.

Ultradur S4090 High Speed grades – BASF’s very easy-flowing PBT – allow injection of large parts having very good dimensional stability, and low warpage at short cycle times.

Because of its high-speed property – meaning the markedly improved flowability in comparison to standard PBT/ASA – Ultradur S 4090 G6 HSP (PBT/ASA blend with 30% glass fibers) offers the possibility to design thin walled large structural components such as roof frames. Parts out of Ultradur S4090 High Speed grades withstand high mechanical stress even at elevated temperatures, also in the car interior.

BASF's easy-flowing PBT used in plastic frames for panorama headliners.

In addition, the company has made a novel design of these plastic frames, including technical details that allow lightening up to 60% the weight of the part compared to other traditional solutions on the market.

This solution is an example of the company's technological commitment to helping its customers develop more sustainable vehicles by reducing weight and emissions. CO2 savings can be up to 25,200 tons of CO2 emitted to the atmosphere during the complete life cycle of a model.

One of the main advantages of the design of the new plastic parts is the change in the process of attaching the frame to the headliner that allows eliminating additional process steps, to improve tolerances assembly and, ultimately, improve perceived quality of the final part. Besides, this new process is completely sustainable by not involving solvents or generating emissions.

PBT-ASA-PET, a material from the polyester family, is used. It is reinforced with fiberglass to increase the rigidity and stability of the part. The main advantages of this material are:

• High rigidity

• Ease of molding and processing

• Low total shrinkage and high dimensional stability

• Good resistance to high and low temperatures

To increase the mechanical strength of Ultradur PBT, it has been reinforced with fiberglass and modified with an Acrylonitrile and Styrene copolymer. The result is a rigid material that has low molding shrinkage, ensuring compliance with tolerances, especially in processes where the frame is stuck to the headliner in the mold at the same time the part is formed.

“Thanks to the great injection performance and optimal surface quality, the PBT-ASA-PET is well suited for producing large and slim interior trim parts. Besides, considering its unbeatable processing advantages, we have been able to reduce weight without losing stiffness or dimensional stability at high temperatures,” said Enrique Fernández, Director of Advanced Engineering of the Headliners Business Unit of Grupo Antolin.

Panoramic roofs are a clear upward trend in all markets. The models incorporating spectacular panoramic openings are a clear example of that. This trend coexists with the need to reduce the weight of all automotive components to minimize CO2 emissions into the atmosphere.

Grupo Antolin, a global provider of technology solutions for the car interiors, has the answer to both trends with the development of new technical plastic parts for its interiors.

The Advanced Engineering of the Headliners Business Unit, together with Grupo Antolin project team and in collaboration with BASF, have successfully validated the use of material family Ultradur in plastic frames of solar and panorama headliners.

Ultradur S4090 High Speed grades – BASF’s very easy-flowing PBT – allow injection of large parts having very good dimensional stability, and low warpage at short cycle times.

Because of its high-speed property – meaning the markedly improved flowability in comparison to standard PBT/ASA – Ultradur S 4090 G6 HSP (PBT/ASA blend with 30% glass fibers) offers the possibility to design thin walled large structural components such as roof frames. Parts out of Ultradur S4090 High Speed grades withstand high mechanical stress even at elevated temperatures, also in the car interior.

BASF's easy-flowing PBT used in plastic frames for panorama headliners.

In addition, the company has made a novel design of these plastic frames, including technical details that allow lightening up to 60% the weight of the part compared to other traditional solutions on the market.

This solution is an example of the company's technological commitment to helping its customers develop more sustainable vehicles by reducing weight and emissions. CO2 savings can be up to 25,200 tons of CO2 emitted to the atmosphere during the complete life cycle of a model.

One of the main advantages of the design of the new plastic parts is the change in the process of attaching the frame to the headliner that allows eliminating additional process steps, to improve tolerances assembly and, ultimately, improve perceived quality of the final part. Besides, this new process is completely sustainable by not involving solvents or generating emissions.

PBT-ASA-PET, a material from the polyester family, is used. It is reinforced with fiberglass to increase the rigidity and stability of the part. The main advantages of this material are:

• High rigidity

• Ease of molding and processing

• Low total shrinkage and high dimensional stability

• Good resistance to high and low temperatures

To increase the mechanical strength of Ultradur PBT, it has been reinforced with fiberglass and modified with an Acrylonitrile and Styrene copolymer. The result is a rigid material that has low molding shrinkage, ensuring compliance with tolerances, especially in processes where the frame is stuck to the headliner in the mold at the same time the part is formed.

“Thanks to the great injection performance and optimal surface quality, the PBT-ASA-PET is well suited for producing large and slim interior trim parts. Besides, considering its unbeatable processing advantages, we have been able to reduce weight without losing stiffness or dimensional stability at high temperatures,” said Enrique Fernández, Director of Advanced Engineering of the Headliners Business Unit of Grupo Antolin.