Thermoplastics | The lightweight, sustainable all-rounders

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Details: Released: 25.01.2023; Last updated: 31.08.2024; Hits: 29046

The demand for new sustainable plastics that are also recyclable is increasing. This also applies to thermoplastics, which is common in the Automotive industry be used. In addition to a material modeling technology that measures the proportion of carbon in Plastic Reduced by 60%, you will find further thermoplastic innovations here, with which, among other things, weight can be saved and other advantages opened up.

Hexagon Sumika Thermoplastics

Content

Thermoplastics 2024 – The most important things in brief
Thermoplastic innovations
Frequently Asked Questions

Thermoplastics 2024 – The most important things in brief

Current developments show a strong trend towards improving Sustainability of thermoplastics. Bio-based and biodegradable thermoplastics are gaining importance to reduce the ecological footprint. A prominent example of innovation is polylactic acid (PLA), a bio-based thermoplastic made from renewable raw materials and used in packaging and 3D printing. PLA is at the forefront of developments as it offers a promising alternative to traditional petroleum-based plastics.

We also see progress in high performance Thermoplastics such as polyetheretherketone (PEEK), which is used in demanding applications such as aerospace and Medical Technology is used.

Thermoplastic innovations

Follow the development of thermoplastics and discover numerous applications:

Thermoplastic injection molding process makes components 70% lighter

Fried Thermoplastic Injection Molding 30.08.2024 | The advantages of metal components such as stability and strength cannot be replaced by classic plastic injection molding. The TSG process from fried combines the advantages of metal casting with those of thermoplastic injection molding. Despite their lower weight, the components have high rigidity. This is achieved through high wall thicknesses and the heat generated during the TSG process. The economic precision and stability with high design freedom can be seen on the Fakuma 2024 convince.

injection molded parts up to a weight of 35 kg can be manufactured on machines with a clamping force of up to 32.000 kN. The tools, which weigh up to 60 t, are manufactured with international toolmaking partners. In the TSG process, a blowing agent is added to the plastic. This releases a gas, usually CO2, at processing temperatures.

Temperature, pressure and injection speed are coordinated in the manufacturing process so that Wall thicknesses from 5 to 8 mm An almost solid outer layer of 1,5 to 3 mm surrounds a foamed core zone of 1 to 4 mm thickness. The resulting integral foam has a lower average density than normal injection-molded components - with no sink marks. The cellular structured inner core weighs very little, but ensures high rigidity and strength of the component. The cellular structure can also absorb noise and shocks.

Sustainable thermoplastics digitized for the automotive industry

24.01.2023 | Sumika Polymer Compounds Europe (SPC Europe) and Hexagon Manufacturing Intelligence are working together to digitize the performance of new sustainable thermoplastics (PP) for the automotive industry. Engineers can develop recyclable components based on these thermoplastics and thus reduce the carbon footprint of future vehicles.

Plastic recycling from and for industry and other uses

The materials Thermofil HP made of short glass fiber polypropylene (GF-PP) and Thermofil Circle Sumika Polymer Compounds' recycled polypropylene (GF-rPP) grades benefit from sustainable manufacturing and recycling practices, offering automotive manufacturers properties such as performance comparable to traditional engineering plastics. However, the new thermoplastics offer up to 60% less carbon footprint.

An increasing proportion of today's PP plastics will compared to Polyamides (PA) recovered and recycled. Of this, up to 70% is used in waste-to-energy initiatives or ends up in landfills. There is still considerable room for improvement here. Sumika's new recycled thermoplastics are designed for the circular economy. The plastics contribute to the reduction of plastic waste at the end of the vehicle life cycle.

Thermoplastics reduce weight and increase energy efficiency

Plastics can be up to 20% of the total weight of a car. Their applications are increasing as the replacement of metals to. The advent of electromobility has increased the need for lightweight components. This maximizes vehicle energy efficiency and reduces the significant weight of battery packs. In addition, the developers must also consider properties such as environmental compatibility throughout the entire life cycle.

World's first urban bike made from recycled plastic

“Limited data on the behavior of the material is hampering sustainable innovations in electromobility because automobile developers are developing new Materials could not undergo the rigorous virtual durability and safety tests required for automotive approval,” said Guillaume Boisot, Head of Center of Excellence Materials at Hexagon. “Our unique multi-scale materials modeling technology accelerates the adoption of SPC Europe's breakthrough recycled thermoplastics. It allows product developers to precisely simulate components and subject them to the tests and validations established in the automotive industry.”

Software evaluator design of thermoplastics

With the technical data provided, developers can evaluate thermoplastics in new designs. If they then replace conventional engineering plastics, they can be used to produce more sustainable vehicles. “Our Thermofil short glass fiber reinforced thermoplastics offer equivalent performance to traditional engineering plastics while at a much lower level CO₂ footprint. With them, the design challenges that come with sustainable e-mobility can be met in the best possible way,” said Bruno Pendelio, Marketing Manager for SPC Europe. "By weighting our customers' automotive components, physical material testing and prototyping can be reduced."

Material and filament 3D printer - durable!

The cooperation partners carry out a detailed and strict test and physical validation program to create highly accurate multi-scale behavior models for the thermoplastics on recycled PP grades. Each material grade has a model that simulates the mechanical and environmental performance of the thermoplastics over the entire life cycle of a component. SPC Europe's customers can access the encrypted proprietary material models via Hexagon's Digimat software. Digimat is compatible with common CAE software tools such as MSC Nastran, Marc and third-party software. Accurate analyses can be carried out using established digital engineering workflows.

Colour-stable, tailor-made polyamide for electric cars

11.05.2022/XNUMX/XNUMX | With the Ultramid A3U44G6 DC OR (PA66 - GF30 FR) extended BASF the portfolio of flame-retardant engineering plastics for the manufacture of electric vehicles. With the already proven Ultradur (PBT), color stability can be largely guaranteed, especially in the orange (RAL 2003) color that is in high demand throughout the industry.

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Thermoplastic polyimide for high temperature applications

01.09.2021 | The thermoplastic Polyimide Aurum is a highly heat-resistant super-engineering plastic with high production efficiency in the injection molding sector. The thermoplastic challenges the conventional wisdom that polyimide performs very well but is difficult to process. flexible presents the PI portfolio as a distributor for PI Meldin from Saint-Gobain.

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Low-corrosion polyamides with very long tool life

15.06.2020/XNUMX/XNUMX | The halogen-free, flame-retardant (HFFR) Technyl One Polyamide from Domo (Distribution: Ultrapolymers) enable very long tool service lives in the second generation. The corrosivity of the polyamides is considerably lower than that of comparable types. The HFFR polyamides enable particularly long tool service lives.

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Polymer-specific plastic solutions for electromobility

Rowa Masterbatch offers polymer-specific solutions for e-mobility. 17.10.2019 | Rowa Masterbatch has polymer-specific solutions for almost all plastics – 160 different polymer carriers are currently used. New requirements and product needs from the e-mobility market can already be met on a customer-specific basis.

An example is this Plastic PBT, which is used for the high voltage identification color orange. But high temperature resistant thermoplastics such as PA66, PPA, PPS etc. are also used here.

Another area of application for Rowalid-Masterbatches in electric vehicles are the on-board networks that are installed with cable harnesses via connectors. These connectors are manufactured in corresponding signal colors to ensure simple, error-free connection. Common plastics for this are PBT and TPU.

The company is already delivering the desired color settings in this sector. For special color coding in combination with the respective polymers in components in electric cars, polymer-specific color concentrates can be produced within a very short time.

Flow improver for the full range of polyamides

25.09.2019/1810/XNUMX | "Bruggolen TP-PXNUMX" by Bruggemann allows for the first time a significant improvement of the often critical Flow properties of polyphthalamides (PPA, such as PA6T, PA6T/6I, PA6T/6.6 etc.) while retaining the mechanical property profile. Compounders and injection molders can thus significantly broaden the processing window.

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Polyamide sets standards for the fuel cell

12.03.2019 | Joma Polytec and Mercedes Benz Fuel Cell has succeeded in making some components of the fuel cell system from the technical plastic "Ultramid" from BASF to manufacture. It is used as standard in the new "Mercedes GLC F-Cell", which is equipped with a combination of fuel cell and rechargeable Lithium Ion Battery Is provided.

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Novel fillers for thermoplastics and duroplastics

The effectiveness of the thermally conductive Silatherm filler is obvious: Shortly after areas 3 and 4 were touched simultaneously with the fingertips of one hand, area 4 containing Silatherm showed significantly less residual heat thanks to the improved heat dissipation. 19.09.2016/XNUMX/XNUMX | The use of electrical components with high energy density requires efficient dissipation of the heat generated while at the same time maintaining the electrical insulator properties of the plastic materials used. HPF The Mineral Engineers has developed novel filler concepts for thermoplastics and duroplastics.

Thanks to many years of experience in processing and finishing mineral fillers With Silatherm and the further developments Silatherm Plus and Silatherm Advance, it has now been possible to develop fillers that cause a significant increase in thermal conductivity in plastics.

With a specially surface-modified Silatherm Plus Type, for example, in epoxy resin castables Values of over 4 W/mK can be achieved. At the same time, these fillers give thermoplastics and duroplastics better mechanical strength.

Thermoplastic for the charge air duct in the combustion engine

12.10.2016/XNUMX/XNUMX | the BASF responds to the Further development of engine concepts with a coordinated portfolio of polyamide PA6 and PA66 types that meet the increased requirements for the materials used, their mechanical properties and temperature resistance.

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Hard molded plastic and alternative to POM

31.07.2014/XNUMX/XNUMX | Of the PET-P material “Ertalyte” by Quadrant has better properties than the widely used POM and can replace it in many cases. Compared to POM, PET-P has less wear and better dimensional stability. In the Polymer Center of Sahlberg The material is cut and further processed according to the individual wishes of the customer.

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Food plastic for 3D printers

Polypropylene for 3D printers 14.01.2014 | with PP (polypropylene) closes German Rep now fills an important gap in the supply of 3D printer consumables. This means that plates, cups or other containers for Food and children's toys are printed. The exclusively manufactured material is food safe and complies with US food safety regulations (FDA) and the corresponding EU standards.

Polypropylene (PP) is a semi-crystalline, thermoplastic material. That food safe material is suitable for the production of objects that come into contact with food or are used as toys for children. Comparable to many everyday PP products (lunch boxes, kitchen utensils, etc.), the material has a slightly soapy feel and is slightly flexible.

PP can be best layer adhesion print very well at 210 °C. The material also adheres very well to a cold printing bed, whereby the first layer has to be applied deeply. Adhesion is ideal on a hot print bed at 80° to 90°C. Parts printed with PP are very elastic and quite stable even with thin structures. PP can be used with all printers that have a 3mm hot end. However, PP requires a special print bed, which is available in 460 x 400 x 2 mm and in 230 x 230 x 2 mm for Protos V2 and other printers from the supplier. The PP filament is available in black and in a strand thickness of 3 mm.

Lauramid receives new DIN designation

24.05.2012/XNUMX/XNUMX | The high-tech art stuff Lauramide from Handtmann Elteka has a new material abbreviation. The cast polyamide previously designated "PA 12 G" according to DIN is now called "PA 15860 C" according to the current EU DIN EN 12. The high-performance plastic polyamide Lauramid shows its advantages over simpler plastics, among other things due to its special manufacturing method.

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Cable sheathing for 1000 volts high voltage in electric cars

16.07.2010 | This is how these Cables from Electric cars and hybrid vehicles Due to high voltages of up to 1000 volts and correspondingly high currents, they have to withstand significantly higher temperatures and overheating than their predecessors. BASF has a robust cable sheathing its thermoplastic Polyurethanee (TPU) was supplemented with Elastollan 785 A 10 HPM (high performance).

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Frequently Asked Questions

What are thermoplastic examples?

Thermoplastics are plastics that can be plastically deformed when heated and then solidified when cooled. They can be melted and molded repeatedly, making them ideal for numerous industrial applications. Here are some of the main types:

Polyethylene (PE)
- LDPE (Low-Density Polyethylene) is used for plastic bags, films and bottles.
- HDPE (High-Density Polyethylene) is used in pipes, containers and tanks.
Polypropylene (PP) is used in the automotive industry, for packaging, textiles and household goods.
Polyvinyl chloride (PVC)
- Hart-PVC is used in pipes, window frames and profiles.
- Soft-PVC is used in hoses, cable sheathing and floor coverings.
Polystyrene (PS)
- Expanded polystyrene (EPS) can be found in packaging and insulation materials.
- High impact polystyrene (HIPS) is suitable for housings, toys and display packaging.
Polyethylene terephthalate (PET) is used in beverage bottles (PET bottles), food packaging and textile fibers.
Acrylonitrile butadiene styrene (ABS) is used in automotive parts, toys (e.g. LEGO) and housings for electrical devices.
Polymethyl methacrylate (PMMA) is known as acrylic glass and is found in lighting, signs and optical lenses.
polycarbonate (PC) is high-strength and transparent and is used for protective glasses, CDs and electronic housings.
Polyamide (PA, Nylon) is used in textiles, gear and ball bearings, as well as technical components.
Polyoxymethylene (POM) is known for its high strength and rigidity, used in precision parts such as gears and bearings.

What happens when thermoplastics are heated?

When thermoplastics are heated, they go through a phase of plastic deformation. There are three main stages:

softening: When heated moderately, thermoplastics reach their glass transition point. In this state, they begin to become softer and more flexible. This process is reversible, which means that when cooled, the materials regain their original strength.
Schmelzer who: When the temperature is increased, thermoplastics reach their melting point. They become liquid and can be poured or extruded into different shapes. This state allows the plastic to be processed for different applications.
application and Solidification: In their liquid state, thermoplastics are easy to shape and process. After the desired shape has been achieved, they are cooled, causing them to solidify and retain their new shape. They can be reheated. This process can be repeated as often as required without significantly affecting the material properties.

These thermoplastic properties make materials such as polyethylene (PE), polypropylene (PP) and polyvinyl chloride (PVC) extremely versatile and reusable in a wide range of industrial applications.

Thermoplastics are characterized by their ability to be repeatedly softened and hardened, a difference between the material and thermosets and elastomers, which harden or decompose irreversibly when heated.

Are thermoplastics elastic?

Thermoplastics are generally not as elastic Their mechanical properties vary greatly, but they typically have the following properties: malleability when heated, stiffness and hardness, limited flexibility. In contrast to thermoplastics, elastomers are highly elastic and return to their original shape after stretching.

How stable is thermoplastic?

Thermoplastics are very stable and offer excellent mechanical strength and rigidity. They are chemically resistant to many acids, alkalis and solvents. They also show good thermal stability in the normal operating temperature range and, depending on the type, can also be UV and weather resistant.

What do Van der Waals forces have to do with thermoplastics?

Johannes Diderik van der Waals is important for thermoplastics through his discovery of van der Waals forces because he recognized the weak intermolecular forces that act between molecules. These forces significantly influence the physical properties of thermoplastics because they contribute to the stability and behavior of the polymer molecular chains. Thermoplastics such as polyethylene and polypropylene benefit from these forces, which hold the molecular chains together and determine their mechanical and thermal properties. The van der Waals forces are therefore fundamental to the understanding and development of thermoplastics.

Source: This article is based on information from the following companies: BASF, Bieglo, Brüggemann, Fried, HPV, German-Raprep, Handtmann, Hexagon, Lehvoss, Quadrant, Rowa, Sahlberg, Sumika, Ultrapolymers.