Lucerne, September 2016. Sekisui Alveo has further expanded its product range: With Alveolen NLC LV & NLT LV, the manufacturer of polyolefin foams now offers two new foam types designed specifically for vacuum-forming parts. The new Alveolen NLC LV 1404.5 and NLT LV 1404 foams are ideal for vacuum forming automobile components like air ducts, cold air covers, headliner ducts, and seat belt covers. Both products have been proven in serial production in the car industry; Alveolen NLC LV is used for making air ducts for the Tesla Model X electric vehicle – the world’s most innovative SUV.

Superior technical performance
NLC LV foam is specially designed for the twin-sheet vacuum forming. The material heats up quickly and offers good weldability at low temperatures. This makes for very low cycle times for the customer. Temperature stability is up to 100°C. The material has a slightly rough surface.

NLT LV is a more rigid foam, with a smooth surface, and offers temperature stability up to 110°C. This can be useful in applications like headliner ducts or where higher temperature resistance or rigidity is needed. NLT LV has superior thermal stability properties compared with standard cross-linked PE foams.

Alveolen NLC LV and NLT LV foams have very good vacuumforming properties, and both possess the high elongation characteristics required for making challenging parts. Both foams have been designed to comply with the highest emission requirements such as DBL 5455 (VDA 278/2011) and VW 50180 standards and meet automotive flammability requirements.

Applications in the automotive industry
Foam parts are increasingly being used to replace solid plastic moulded parts in automobiles because they offer undeniable advantages such as light weight (up to 75% lighter, leading to better fuel efficiency and lower CO2 emissions), significantly better acoustic performance (as foam air duct up to 5dBA less noise) and excellent thermal insulation (for comfort, safety, energy savings, prevention of condensation, etc.). Furthermore, foam parts can eliminate squeaking and rattling noises, and the flexible parts are easier to assemble.

Sandro Glanzmann, Application Development Manager at Sekisui Alveo, says it’s the broad range of key properties of the new Alveolen foams that makes them ideal for vacuum-forming complex parts like air ducts: “Unique conversion properties like fast heat-up and excellent weldability make for short cycle times, and the low levels of VOC and FOG emissions, smell and fogging make for parts that meet the necessary environmental and comfort requirements.”

Because of their improved material and processing performance, Alveolen NLC LV and NLT LV foams are also suitable for many vacuum-forming applications in the consumer goods and industrial goods sectors.