BASF has licensed Pune-based AIM Filtertec for the production and application of Steron coating in India. In-line with BASF's policy to offer a company to produce Steron as a complete package under a licensing agreement, AIM Filtertec is located in a city that is better known as home to global automakers like Tata Motors, Bajaj Auto and others. Having a considerable presence of automotive suppliers, AIM Filtertec has been supplying non-wovens for automaking. Synergies are quite possible therefore. AIM is procuring the production equipment from the German machinery manufacturer Venjakob in Rheda-Wiedenbrück (North Rhine-Westphalia).
While production is likely start up in a new, similarly sized system in Germany early in 2014, Steron was an outcome of the BASF's endeavour to create completely new ways to give surfaces an extremely unusual look and feel through use of a polyurethane dispersion. The Steron coating system (AIM Filtertec is also licensed to apply Steron) combines the different characteristics of leather, artificial leather, fabric and soft-touch materials. It permits creation of surfaces with a structure and design that at present cannot be achieved in any other way. BASF has automated the technology, and with the help of partners, is launching the first production applications in the automotive and furniture industries.
Versatile coating material
Steron can be used on a wide variety of substrates. For instance, leather and fabric as well as cardboard, paper and plastics such as PVC and polyurethane can serve as the substrate material. Moreover, the design freedom is almost limitless - regardless of whether technical, natural or soft-touch structures are involved. Quick design changes present no difficulties. Textures from leather graining to the appearance of velvet and even geometric patterns and impressions can be achieved with minimum effort. Finally, coating in any colour is possible.
New production technology
Production of Steron is based on the transfer process. The process was refined over the past two years and has been automated. The starting point for production is a silicone mould half into which the desired surface structure is engraved by a laser. A thin layer of the polyurethane dispersion is sprayed onto this surface in a manner similar to the technique used when working with a casting mould and assumes the desired shape. This topcoat is followed by a base coat and then the adhesive. Finally, the substrate is laminated to the adhesive layer and the two are pressed together. Following this, the finished product can be removed from the mould. Modern laser technology permits fast and economical production of moulds with any custom design. The benefit of silicone as the mould material is that it can be engraved readily by means of a laser, while the substrate with the Steron coating releases easily. The polyurethane dispersion is microporous and, in contrast to conventional leather finishes, can breathe, improving the comfort of the coated materials.
Steron in concept cars and future production applications
Due to its many characteristics and very wide design spectrum, Steron is ideal for use in many fields. In the case of automotive applications, leather and plastic serve as the substrate material. New design structures can be developed for seats, headrests, steering wheels and interior surfaces - with a smooth, soft or velvet like feel as desired by the customer. Steron complements the trend toward creating a sense of well-being when seated in a car - a trend that contributes towards an increasing demand by vehicle buyers for more comfort.
Designers of concept cars have been inspired by the new options. For instance, the new coating is used in seat covers in the Smart Forvision and in side panels for the new Hyundai models HED-7 and Ioniq with laminated parts for seats and vehicle interior components.
The automotive industry is now also showing great interest in the possibilities and benefits of Steron for high-volume production. Another aspect that is important for automakers looking to save every kilogram is the fact that the material is very light. Thus, compared to leather, which accounts for up to 25 kg in every vehicle, weight savings of more than 50% are possible. Offering completely new design opportunities for high-quality packaging, where new patterns and previously unknown sensory effects can be expected, Steron promises to be a substance of the modern times. The experts involved with Steron are convinced that co-operation with flexible, medium-sized companies like AIM Filtertec will foster rapid development in their respective fields of activity, because these companies often combine a great deal of creativity with market savvy.