Raising the bar in lightweight construction

High performance materials are adding new dimensions in the automotive sector. The latest breed of concept vehicles are creating a buzz due to their improved interior and exterior features. One of them is the van of the future introduced by BASF through its VisionVenture, a vehicle that features lightweight construction and breakthrough design to create a new travel experience 

 

With its concept vehicle, VisionVenture, BASF demonstrates how its innovative materials and development expertise can open up new avenues in lightweight construction, independence, travel experience and design. Co-created by BASF and HYMER, VisionVenture, is a near-production glimpse into the future of van life. Using the development expertise of the BASF Creation Centre, the vehicle celebrated its world premiere at the Caravan Salon in August 2019. and was also presented at K 2019, both events were held in Düsseldorf, Germany

 

More than 20 high-performance plastics and a new painting technology of BASF are used in the concept camper and these materials brought a range of properties. For example, BASF and HYMER use various innovative lightweight materials and processes in the interior and exterior, providing greater comfort while also making the vehicle more robust. The VisionVenture also sets new benchmarks when it comes to design – for example by combining plastics with natural materials such as hemp and slate. Solutions include those for energy management, thermal insulation and electrical components, a tailored package of measures for preventing noises and vibrations, and more than 100 3D-printed components round off the vision of modern travel.

 

 

A lightweight approach

The VisionVenture's self-inflating pop-top roof is a world first and one of the van’s most striking features. It inflates in less than 60 seconds, creating more living space than ever before. The Elastollan® coating on the roof creates an outer wall that is resistant to water as well as wind and guarantees a peaceful night’s sleep at a pleasant temperature. The cushions and mattresses in the VisionVenture will also remain pleasantly fresh and cool even on the hottest day. This is down to the temperature-regulating effect of the Elastocoat® C Spray Gel, which adheres effectively to all PU foams and can be applied to different mattress surfaces, at different places and in variable thicknesses.

 

Combining the use of natural stone in interior design with a lightweight approach has never been possible before. But this is about to change thanks to the development of Veneo Slate®, manufactured using the compact, non-foamed polyurethane Elastocoat. This innovation has an exceptionally lightweight thin coating of real slate and with adding just 1mm, it is a space-saving and flexible material. The Elastoflex® polyurethane foam offers similar properties. With a unique combination of natural materials and plastic, this equally lightweight material utilises the structure of hemp fibres to produce cupboard doors and kitchen fronts. Like Veneo Slate, it can be applied to round and curved surfaces, eliminating the need for heavy alternatives like wood or chipboard.

 

BASF used a range of 3D printing techniques to realise more than 100 components for the interior and exterior of the VisionVenture, including wheel arch linings, bodywork parts, lampshades, handles, hooks and tablet-holders. The 3D printed wheel arches and other components such as the sills and balcony of the VisionVenture are protected by the polyurea spray coating Elastocoat C, which gives lasting protection from stains, scratches or impact damage from stones.

 

Independent, sustainable and smart

True freedom relies on independence – which the VisionVenture enables with its smart use of materials for energy management, insulation and electric components.

 

For the first time, BASF has combined its two innovative high-performance insulating materials SLENTEX® and SLENTITE® in the VisionVenture. The solid panel material SLENTITE is used in refrigeration equipment, door panels, window frame profiles and sub-floors. It can be easily cut to size and also provides the required stability for use in off-road vehicles. The highly efficient, safe and space-saving properties of SLENTEX provide heat protection for the battery, engine compartment, oven and hob in the VisionVenture. The high-performance insulating material is effective in preventing the spread of sparks or fire, thanks to its non-combustible properties. Another advantage: Both materials do not show any effects of ageing during their service life.

 

BASF’s semi-aromatic high-performance polyamides, known by the brand name Ultramid® Advanced, are particularly light and strong. The product group has exceptional rigid and solid properties, even when exposed to high temperatures. The polyamides also retain their mechanical stability, making them ideal for use in the engine or engine compartment. Ultramid Advanced T1000 and Ultramid Advanced N are additionally resistant to hydrolysis and therefore the perfect choice for the pipework in the VisionVenture’s kitchen and shower installations.

 

Strong accents – inside and out

The VisionVenture makes a strong design statement. A key contributor to the van’s cozy feel is Haptex®, a polyurethane system for imitation leather, which spans the entire interior. This material feels pleasantly soft and is available in a range of colours and textures. It is also extremely easy to clean and does not contain organic solvents. On top: Two pendant luminaires with diffusers made from the translucent material Ultramid Vision. As well as directing a focused light beam onto the table, the lights, which are hidden within the ceiling, also function as downlighters to brighten the entire interior. Ultramid Vision is scratch-proof and extremely resistant to chemicals.

 

The VisionVenture’s outer coating is something else that is new. For functional reasons, camper-vans are usually cream or white to avoid overheating during the summer. With their gray-green VisionVenture, HYMER and BASF are demonstrating that, in future, personal choice can also apply to the paintwork. The paint is based on Chromacool temperature-management technology. Chromacool is available in a wide variety of colours; it reflects the sun’s infrared light, thus reducing the build-up of heat in the vehicle body. This passive temperature management means that heating of the vehicle’s surface is reduced by up to 20°C, with the inside temperature dropping by as much as 4°C. Less energy is needed for air conditioning, which helps to reduce fuel consumption, or to increase the range of electric vehicles.

 

 

 

Maximum comfort – on the road and at the beach

Infinergy®, primarily associated with the Energy Boost running shoe from adidas, appears in jet black for the first time in the VisionVenture. In the steps and the bed frame, the expanded thermoplastic polyurethane (E-TPU) gives pressure point relief together with pleasing aesthetics. As a connection module, it holds the slats in the slatted base together, resulting in an excellent, individually adjustable mattress base on account of its high material resilience. This effect is also maintained in the event of a continuous load; this is known as “rebound.”

 

To make traveling as relaxing as possible, the pillows and mattresses used in the VisionVenture are comfortable. The memory effect of the CosyPUR® moulded flexible foam ensures optimum comfort. The polyurethane material has special properties that can be set using cell morphology from ultra-soft to viscoelastic. The material is also air-permeable, breathable and machine-washable, and retains its properties even after long-term use.

 

To avoid any compromises in comfort on the open road, BASF and HYMER have come up with a customised NVH (noise, vibration, harshness) package for the VisionVenture. The compact, microcellular polyurethane Cellasto® is used to reduce vibrations and block noise in the interior, drive or chassis. Specifically for off-road adventures, the developers have fitted the VisionVenture with a special Cellasto solution for vibration decoupling and structure support of the chassis, combining driving safety with dynamics and comfort.