BASF Develops Material for Window Shapes with High Thermal Insulation

BASF SE hasdeveloped new a material for window profiles with high thermal insulation based on engineering plastic Ultradur.

Ultradur (PBT, polybutylene terephthalate), modified for co-extrusion with PVC, that replaces steel in PVC windows as the stiffening element.

The outcome is impressive because the window is equally strong while being lighter and more cost-effective. Its insulation performance is also superior, with the Uf value being significantly reduced by 0.1 W/(mK).

Ultradur simplifies production and cuts costs

The BASF plastic Ultradur is put to use in numerous industry applications in high-grade and highly stressed technical components. The material specially developed from an Ultradur blend reinforced with glass fibres offers profile manufacturers and window constructors numerous advantages.

“With its simplified production and cost-effectiveness, our new Ultradur gives both profile manufacturers and window constructors a competitive edge in the marketplace,” said Dr Kay Brockmuller, project manager construction at BASF.

Benefits for profile manufacturers and window constructors

An attractive feature for profile manufacturers is the possibility of co-extrusion with PVC. Highly rigid Ultradur binds with PVC and, in the right position, can replace conventional steel stiffeners in profiles. The co-extruded profile is weldable and undergoes the same downstream treatment as other profiles. The process also permits the best-possible reinforcement geometry for the profile in question.

For window constructors, the production effort is reduced considerably, as all the steel-associated activities are eliminated. In the chain from purchase through to processing, several steps are omitted, thus avoiding the potential for error in steel handling at the same time. Handling – be it during the dyeing of the corners or installation in the building – is additionally simplified, as the profile reinforced with Ultradur is much lighter. A further positive feature for the ultimate customer, in addition to improved insulation performance, is that the profile shows high dimensional stability and virtually no tendency to shrink after installation.

Fast track to the mass-produced item

BASF offers profile manufacturers technical support with the development of new Ultradur profiles. Greiner Extrusion Group, the Austrian supplier of extrusion lines, tooling and complete production plants for profile extrusion, can deliver dependable series tooling for the co-extrusion of Ultradur with PVC at short notice.

Leopold Weiermayer, technical manager at the Greiner Extrusion Group, sees huge potential in this: “With the expertise developed by Greiner for the necessary pronounced forward orientation of the fibres in the direction of extrusion combined with smooth running, we can offer tooling for this promising co-extrusion market.”