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FROM CLASSIC TO MODERN SUPERCAR: FORD UTILIZES BAYER MATERIALSCIENCE LLC’S BAYFLEX® RRIM SYSTEM IN UPDATED 2005 FORD GT
The Ford GT design and engineering teams worked hard to strike a delicate balance in creating a slightly updated Ford GT featuring new technology. Making their job a little easier was Bayer MaterialScience LLC’s Bayflex® 180 RRIM (Reinforced Reaction Injection Molding) system. The Bayflex 180 RRIM system is used to mold the front fascia, which covers the bumper, goes up to the hood and wraps around to the wheel wells; the rear fascia, which wraps around to the wheel wells and comprises the entire back end of the vehicle; the left and right rocker panels; rear bumper cover; and the spoiler of the Ford GT. The Bayflex 180 system had the right combination of properties for this challenging application. 'Some of the advantages of going with the Bayflex 180 system are that you get high heat resistance, superior surface quality and rigid parts,' said Norman Fortier, general manager, Moon Roof Corporation of America, Inc., which molds the components. The ability to mold complex shapes was another reason for the selection of the Bayflex 180 RRIM system. 'The GT adds some rather complicated features to the fascias such as fog lamps, a grill area and return flanges,' said Terry Seagrave, market channel representative, Bayer MaterialScience. 'Molding such complex designs is more of a challenge for other composite materials,' he added. However, the Bayflex 180 RRIM system is ideal for molding such complex geometries, according to Seagrave, who also notes that another Bayflex formulation – Bayflex 110-35 IMR (internal mold release) elastomeric polyurethane RIM system – is used to mold the splitters that mount to the bottom of the rocker panels. Lightweight, Yet Strong Components molded with Bayer’s Bayflex 180 system feature reduced weight without sacrificing part strength and durability, good low-temperature impact strength, energy-elasticity, good dimensional stability and low coefficient of linear thermal expansion. Another important property for this application was the material’s high heat resistance. This is important because the material has the ability to handle the temperatures at the rear of the car, where the engine and exhaust system are located. Additionally, the Bayflex 180 system offers excellent surface quality and adhesion properties for painting, mar and chip resistance, and long-term durability. In the front fascia, the material is reinforced with mica under a technology patented by Bayer, while the rear fascia, rocker panels, rear bumper cover and the spoiler are reinforced with wollastonite to enhance stiffness and strength. These mineral fillers are added directly to the polyol blend to produce the RRIM parts. All of the parts have an average wall thickness of about 3mm. To mold the components, Moon Roof injects the Bayflex 180 system at low-pressure into a two-piece, closed mold. After the parts are molded, Moon Roof sends them to pgam Advanced Technologies AG for post-curing, power washing and priming. The parts are then sent to the paint facility and then to the assembly plant line. 'This combination of material properties and aesthetics of materials made with Bayflex 180 made it a good choice for this demanding application,' said Seagrave. http://www.bayermaterialscience.com
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