Jeffrey Milliner :
Bayer MaterialScience provides new material, Baypreg F, a two-component polyurethane system, for sunshade of GMT 900 series SUVs and trucks.
Jeffrey Milliner :
When it comes to its GMT 900 series SUVs and trucks, GM has it made in the shade, thanks to a novel sunshade made from a unique two-component polyurethane system from Bayer MaterialScience.
The sunshade was designed and manufactured by G&G Industries of Shelby, Mich. using Stabilicore, a new material manufactured with Baypreg F, a two-component polyurethane system from Bayer MaterialScience. The Bayer system gives Stabilicore its key benefits, including high strength-to-stiffness weight ratio, complete design flexibility, and a competitive cost.
Stabilicore is unique because it is manufactured using an automated spray application of modified Baypreg F system over a composite core of paper honeycomb and fiberglass. By adjusting the glass content and core thicknesses, a wide range of parts can be produced. According to Bruce Gantner, president of G&G Industries, Stabilicore is extremely versatile. While the GM sunshade represents a thin, lightweight, full trimmed part application, the same material is used in a thicker, load-bearing application for the BMW Load floor panel.
G&G liked the fact that Bayer’s technology allows them to mold the Stabilicore sunshade into complex shapes, with varying thicknesses for unique part applications. The parts can be covered with a wide range of textile materials, and offer tremendous weight savings over traditional materials.
Typically, sunshades have been made from PUR, which offers a comparable weight, but lacks the dimensional stability or strength; aluminum, which is costly and does not attenuate sound; SMC, which is stiff but carries both weight and cost penalties; and Thermoformed PolypropyleneGlass (Azdel Superlite), which lacks strength and stability. All of these other materials require complex guidance systems and sometimes additional reinforcements to achieve performance requirements.
In working with Bayer technicians, G&G engineers learned that they could minimize the number of parts involved in the sunshade assembly including the reinforcements and certain parts of the guide system because of the stability of the Baypreg F system. This not only eliminates additional assembly time, but reduces the overall weight of the shade.
The production system developed by Bayer’s Hennecke Machinery Group and G&G is capable of high volume production runs, with less than average maintenance as compared to other delivery systems, making it ideal for the high-volume GM product.
The sliding sunshade is a critical component in any sunroof, because it is the only part that the end customer actually touches and operates. Although functionality is very important, there is a demand for an aesthetically pleasing trim, fit, and finish as well. Stabilcore was chosen because of its ability to meet or exceed these requirements, while keeping costs – and weight – down.
“Thanks to all of the hard work by the G&G team, the invaluable core technology of the Baypreg F urethane system, and the assistance given by the Bayer MaterialScience folks, we have had one of the most successful product launches ever,” claimed Gantner. “I’m told that our customer has not had any complaints, returns, or rejections for this part application, which has been one of the most important GM vehicle launches ever.”
For more information about Stabilicore, contact G&G Industries at 586-726-6000 or visit www.gandgindustries.com.
For more information about polyurethane technology from Bayer MaterialScience, call 1-800-662-2927 or visit www.rimmolding.com
Bayer MaterialScience LLC is one of the leading producers of polymers and high-performance plastics in North America and is part of the global Bayer MaterialScience business with nearly 19,000 employees at 40 sites around the world and 2005 sales of 10.7 billion euros. Our innovative developments in coating, adhesive and sealant raw materials, polycarbonates, polyurethanes and thermoplastic urethane elastomers enhance the design and functionality of products in a wide variety of markets, including the automotive, construction, electrical and electronics, household and medical industries, and the sports and leisure fields. Our inorganic basic chemicals unit produces chlorine and related essential products for the chemicals industry.