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BASF Develops New Load Floor With Dayton Polymeric Products, Georgia-Pacific

BASF’s Automotive Polyurethane Systems business developed an advanced composite for automotive load floors with Dayton Polymeric Products, Dayton, Ohio, and Georgia-Pacific, Atlanta, Ga., that weighs less, has comparable strength and is more efficient to produce than standard products for this application.

The new load floor composite can be used in trunks, bays and other automotive flooring areas. Dayton Polymeric Products produces these strong, lightweight load floor components by combining Georgia-Pacific’s Superwood® hardboard with BASF’s custom-formulated rigid polyurethane system to create a composite.

“The inherent properties of the hardboard / polyurethane composite enables us to produce load floor parts that have demonstrated as much as 40 percent lower weight and 60 percent improved deflection compared to glass-filled polypropylene,” said Kathy Bassett, Vice President of Engineering for Dayton Polymeric Products.

“The composite parts also demonstrate improved dimensional stability, making this technology a means to create stronger, lighter load floor components than those typically made with other plastics.”

In addition, said Bassett, the adhesive qualities of the polyurethane system are used to consolidate manufacturing steps by serving as the glue to directly adhere carpet to the load floor during the sandwich panel construction process. Eliminating the laborious step of laminating carpet to the load floor composite helps to reduce costs. A further enhancement is achieved by backing the underside of the load floor with BASF’s polyurea spray, which adds more stiffness, abrasion resistance and moisture resistance to the composite.

“Producing more lightweight parts supports the automotive industry’s goal to improve the fuel efficiency of vehicles,” said Todd Green, Market Development Manager for BASF’s Automotive Polyurethane Systems business in North America.

“We are also supporting their efforts to remove costs by enabling a more efficient manufacturing process to produce the innovative load floor composites. These activities are all part of our global strategy of helping make our customers more successful.”

More information on Dayton Polymeric Products is available on the Internet at

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