BASF inaugurate pilot facility for innovative coating technology

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BASF inaugurate pilot facility for innovative coating technology

Operations have begun at BASF's pilot facility for Steron, a novel
coating process, at their Ludwigshafen plant.

This technology opens up a wide spectrum of possibilities for the
surface coating of diverse carriers, especially in matters of design.
Whether smooth or velvety, glossy or matt, a suede finish or a hint of
elegant embossing – the BASF technology imparts a high-quality surface
finish and can be produced cost-effectively, even in small amounts. A
unique property of the Steron coating is its breathability. This
ensures that coated materials offer more comfort – on surfaces ranging
from car seats to tennis racquet grips.

Steron was developed by the inventor Philipp Schaefer. The new coating
process can be used on a wide range of carriers including fleece
fabrics, woven fabrics, leather as well as wood or plastics. The
result: different materials bear an optically uniform design. This
holds an advantage for designers of vehicle interiors, who work to
incorporate all elements, from seat covers to the interior surfaces of
the doors, into a homogenous look. ‘We are pleased to be able to
include Steron in BASF’s service portfolio’, says Dr Jürgen Weiser,
project manager new technologies at BASF’s Performance Chemicals.

‘With BASF’s research and development expertise and infrastructure and
its partnership with Philipp Schaefer, we can unfold the full
innovative potential of this very promising new technology.’

BASF are planning to use their pilot facility to further develop the
Steron technology and work with customers to modify the process for
individual applications and needs.

In order to coat a carrier using the Steron technology, an aqueous
formulation of pigmented polyurethanes is first sprayed upon a silicon
matrix. Most of the water evaporates, leaving a gossamer-thin membrane
with micro-fine pores.

While still on the matrix, the membrane is then adhered to the carrier
and the finished product lifted from the matrix. Since the fine pores
of the coating ensure breathability, the Steron technology creates a
robust yet comfortable surface. The silicon matrixes allow for a great
versatility of design because, similar to a casting mould, they
structure the surface.

Depending upon the pattern set by the matrix, the coated material can,
for example, be made to look like the finest smooth or embossed
leather or velvet. Since the matrixes can be exchanged within a matter
of minutes, even small amounts of coated materials can be produced
cost-effectively with a certain design. This had not been possible
before and is thus a decisive competitive advantage in the face of
ever-shortening product cycles and ever faster-moving trends. Steron-
coated materials enable versatile processing. This is what the luxury
automobile segment is asking for with regard to the interior design of
vehicles. However, Steron can also be used in the production of
upholstered furniture and in the fashion, shoe or electronics
industries, one application being the coating of mobile phones and
joysticks.