BASF’s hydrolysis-resistant PBT and know-how in ultrasonic welding enabled the company Rosenberger Spritzguss und Formenbau to develop a new type of carrier for hall effect sensors.

For gearboxes that breathe easily

Posted on May 04, 2016
    Functional integration of housing and electronics: sensor carrier made from hydrolysis-resistant Ultradur® HR by BASF
    Rosenberger Spritzguss und Formenbau manufactures sensor carrier for charge air cooler in one process step and without any weldlines


Combine the right material and technical expertise to integrate functions, streamline production processes and increase the lifespan of components: With BASF’s hydrolysis-resistant PBT (polybutylene terephthalate) Ultradur® HR and BASF’s know-how in ultrasonic welding, the company Rosenberger Spritzguss und Formenbau has now managed to develop a new type of carrier for hall effect sensors. It combines the housing and printed circuit board in one component andisinjection-molded in a single, fully automated production step.A PET membrane, which is welded into the housing, provides the pressure compensation required in the event of climate changes. When combined with the BASF PBT that is resistant against air humidity, the service life of the component is thus extended. The carrier completes the control gearbox; the welded hall effect sensor measures the position of the valve in the exhaust gas recirculation. The whole component is mounted as a cover on exhaust gas recirculation modules which are fitted as standard in many automobiles in Europe.


Highly hydrolysis-resistant Ultradur® HR for damp-warm environments


Materials used for exhaust gas recirculation modules (EGR) have to withstand high thermal, mechanical and chemical loads and must therefore be highly creep and corrosion resistant. Ultradur® B 4330 G6 HR (HR = hydrolysis resistant) is noted for its high resistance to hydrolysis in damp-warm environments and thus extends the service life and tightness of the component considerably – including in the temperature range from -40 to 140°C which is demanded by automotive manufacturers as a result of an ever more compact design in EGR and the engine compartment. Ultradur® B 4330 G6 HR also shows a substantially increased resistance to alkaline media, which trigger stress corrosion cracking. The plastic can be processed without anyproblems.


Welded-in membrane for pressure compensation


The sensor cover measuring 10 x 8 cm is extremely tight, particularly because of the single-stage injection-molding process and the unique design: The printed circuit board is inserted into the mold for the housing and fixed in place so that it can be overmolded without any external holding-down devices. This avoids weld lines which could leak in the event of fluctuations in temperature or air pressure. However, as these climate variations are unavoidable and trigger pumping effects in the housing, a thin PET membrane is welded into the sensor cover:The membrane, which has a diameter of around 1.3 cm, is attached to the PBT housing by ultrasonic welding. It is permeable to air, but water-tight and thus provides the required pressure compensation.


“Ultrasonic welding with this material combination is high-precision work: BASF’s outstanding expertise helped us to fine-tune the complex welding and establish a stable process for serial production,” says Axel Gutzmer, operations manager at Rosenberger Spritzguss und Formenbau. “Together with the tailor-made plastic for the housing, we thus managed in a short development time of just twelve months to successfully produce the sensor cover and meet the automotive manufacturer’s specifications for leak tightness and process  reliability.”  The  combination  of  housing,  connector and conductor tracks could previously only be produced in a multi-stage, complicated injection-molding process: First the conductor tracks were separately overmolded with plastic and then placed in another mold which is used to manufacture the entire housing component. In order to ensure that the conductor tracks do not shift in this injection- molding process, they were generally secured with external holding- down devices.


BASF offers several HR-modified Ultradur® grades,with 15% or 30% glass fiber reinforcement as well as impact-modified, laser-markable or flame-retardant. Typical applications can be found primarily in automotiv eelectronics, e.g.housings of control units, connectors and sensors.


Further information:


About BASF’s Performance Materials Division


BASF’s Performance Materials division encompasses the entire materials’ know- how of BASF regarding innovative, customized plastics under one roof. Globally active in four major industry sectors - transportation, construction, industrial applications and consumer goods – the division has a strong portfolio of products and services combined with a deep understanding of application-oriented system solutions. Key drivers of profitability and growth are our close collaboration with customers and a clear focus on solutions. Strong capabilities in R&D provide the basis to develop innovative products and applications. In 2015, the Performance Materials division achieved global sales of € 6.7 bn. More information online:


About BASF


At BASF, we create chemistry for a sustainable future. We combine economic success with environmental protection and social responsibility. The approximately 112,000 employees in the BASF Group work on contributing to the success of our customers in nearly all sectors and almost every country in the world. Our portfolio is organized into five segments: Chemicals, Performance Products, Functional Materials & Solutions, Agricultural Solutions and Oil & Gas. BASF generated sales of more than €70 billion in 2015. BASF shares are traded on the stock exchanges in Frankfurt (BAS), London (BFA) and Zurich (AN). Further information at

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