Borealis and Topas Advanced Polymers have started collaboration on the development of a new class of engineering materials for capacitor film applications that will bridge the current performance gap between standard polymers and high-end plastics.

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New Class of Engineering Material for Film Capacitor Applications

At the Fakuma-trade show, the additive manufacturer Quarzwerke is presenting fillers for plastics in electromobility, wind power and for films. They are intended to help processors manage the high requirements on the materials in these industries.

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Fillers Improve Batteries and Wind Power Plants

Bipolar plates are one of the key components of fuel cells and redox flow batteries. They consist of plastics compounds highly filled with electrically conductive materials. To save space, cut costs, and reduce weight, there is increasing demand for the production of thinner plates without compromising robustness and service life. This can be achieved using modified polymers. With a new technology, bipolar plate films based on these modified polymers can be processed as coils.

Modified Conductive Compounds Make It Possible to Manufacture Bipolar Plates from a Bipolar Film Coil

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Ultrathin Bipolar Plates for Fuel Cells

Not only the interest of tuning experts has recently focused on design in the engine compartment. Previously, the most conspicuous element – the motor cover – was expected primarily to meet acoustic demands, but to an increasing extent this component has now become an object for design. Decorative film layers can provide increased freedom of design whilst simplifying its implementation. 

Polyamide

Polyamide Films in the Engine Compartment: Design under the Hood 

Electrostatic charging may cause problems in the production of plastics and plastic semi-finished products. A new generation of ionizers meters the charge in an object, and then discharges it in a precise and reliable way. 

Oberflächentechnik

Static Eliminators: Controlling Discharge 

The demands placed on packaging films are so multifaceted that they can only be met by combining different raw material components. This in turn requires blown film dies that are able to process a wide range of materials and thus provide greater flexibility for the film manufacturer. 

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Barrier Film: Nine Super-Thin Layers 

Jointly organized by the Institut für Produkt Engineering (IPE) and Hanser Publishers on March 12–13 in Duisburg, Germany, and with well over 100 participants, the conference was a great success. The participants enjoyed highly topical subjects, top-class speakers, and lively discussions hosted by Professor Johannes Wortberg. 

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Duisburg Extrusion Conference: The Versatility of Films 

It was not only the 5-layer coextrusion blown film system itself that attracted around 100 visitors to the plant of Kuhne GmbH, in St. Augustin, Germany, at the beginning of April, but also the manner in which it was presented. Over a period of two weeks, the machinery manufacturer gave visitors the opportunity to participate in the first test and production runs of the 20 m high system, which stood completely assembled in the technical center. 

Blown Film Extrusion: Saint Augustin Displays Greatness 

About 20 percent of the 50,000 metric tons annual sheet output of the Danish company R. Færch Plast A/S in Holstebro will come from a new high-performance PP production line supplied by Battenfeld Extrusionstechnik GmbH in Bad Oeynhausen, Germany. For the continuously growing market for rigid foodstuffs packaging, Færch Plast operates a total of seven extrusion lines – mainly for PET, PP and PS film. Three of the lines come from Germany, and a fourth line has been ordered. Both the first and the second PET line, which was installed in 2002, work with a co-rotating twin-screw extruder. Thanks to effective melt degassing, high-quality sheet can be produced without material pre-drying. Battenfeld Extrusionstechnik accepted overall responsibility for both lines, so that the Færch Plast plant comes from a single source. According to Battenfeld, this kind of cooperation is also beneficial for the further development of machine components for the high-output flat sheet line with high-speed extruders. Færch was the first processor to decide for the installation of such a modern line. The high-speed BEX 1-75-34 is a comparatively small single-screw extruder but has an enormous output. With a screw speed of 1,500rpm, the machine has a three times higher output than a comparable conventional extruder of the same size. By means of adapted downstream equipment and a 75mm extruder, the line achieves an output of 1,400 kg/h when producing PP film. 

Lines from a Single Source 

Extrusion lines 

Use of renewable resources is currently being actively researched. Before they can be used, the environmental compatibility, economic aspects and social impact over the entire life cycle, including production and disposal, must be investigated. If the results are not positive, there are alternatives that do not rely on biomass, since innovative petrochemical plastic products are saving enormous amounts of energy and thus lowering CO2 emissions already today – and the potential is not yet exhausted. 

Kunststoffe, bioabbaubar

An Eco-Efficiency Evaluation: Bio – Sense or Nonsense 

Extruders from Leistritz Extrusionstechnik GmbH, Nuremberg, Germany, are used in the production of BOPP (bi-oriented polypropylene) films. Now, a ZSE 135 Maxx extruder has been delivered to the Austrian-French company DMT. DMT is a supplier of machines and equipment for producing biaxially stretched plastic films, which, among other applications, are used as packaging materials in the food industry. The ZSE 135 Maxx has a screw diameter of 140 mm and enables extremely high torques together with a large free screw volume. DMT employs the extruder as part of a direct extrusion line. A total of 16 machines from Leistritz, with screw diameters of 75 to 140 mm, are now in operation at DMT. 

Large Format 

Extruder ZSE Maxx Series 

In October 2008 the plant and equipment manufacturer Kuhne GmbH hosted the first “Kuhne Autumn Week“. The very latest developments in blown and flat film manufacture were presented to an international audience at their headquarters in Sankt Augustin, Germany. A range of informative presentations by guest speakers rounded off the in-house exhibition. Alongside issues relating to specific materials, aspects of measurement and control technology were discussed. 

Extrusion: Spotlight on Film 

Until now, materials and processes have been colored holograms in large print runs. This could all change thanks to a new holographic photopolymer. A specially developed polycarbonate film with application-oriented material properties has proved a suitable carrier material for this photopolymer in the high-security holograms sector. 

Polycarbonat

Full-color Photopolymer: 3-D Image Holograms in Large Print Runs 

The current range of packaging films extends from shrink wrapping film via synthetic paper through films made from biopolymers. From these materials packagers can themselves design a packaging unit to suit their needs. This survey points out the possibilities, including advantages and disadvantages, that the various materials and their associated processing methods afford for the production of an economical and attractive package. 

Film Design: Packaging with the Right Film 

It is not possible to detect flaws on surfaces with complex texture patterns, e.g. artificial leather, using commercially available film inspection systems. By incorporating texture analysis algorithms into the film inspection system, comprehensive quality control is now also possible for these products. 

TQM / Null-Fehler-Strategie

Film Inspection: Focus on Textured Films 

Borealis and Topas Advanced Polymers have started collaboration on the development of a new class of engineering materials for applications that will bridge the current performance gap between standard polymers and high-end plastics.

The EPN (ethylene-propylene-norbornene) material now in development will increase the temperature resistance of film capacitors significantly – by 20°C to 35°C – in comparison to capacitors made of standard polymers. This will close the current gap between conventional polymers and costly high temperature plastics by enabling the use of polymeric film capacitors at endurance temperatures of up to 140°C. Combining the highest electrical purity with superior homogeneity, the new material should be designed for the production of ultra-thin and highly consistent films in the range of 2 to 6 microns gauge. Provided the appropriate processing parameters are in place, the new material is targeted to be suitable for use on BOPP (biaxially oriented polypropylene) film processing machines.

Higher-performance film capacitors are a crucial element in all power transformation systems that bring about the green-energy transition in a cost-efficient way. The new material class now being jointly developed by Borealis and TOPAS Advanced Polymers will be used in electric mobility units, particularly when higher endurance temperature resistance and consistent frequency control is essential, such as in electric vehicles and high-speed trains. It will also help address one of the major challenges of the green-energy transition by enabling the large-scale provision of more cost and energy-efficient capacitors for inverters that transform HVDC power generated from renewable sources on and offshore, such as from windfarms or photovoltaic arrays, into HVAC and back – with minimal energy loss.

Borealis AG  

https://www.borealisgroup.com

Higher-performance film capacitors are a crucial element in all power transformation systems that bring about the green-energy transition in a cost-efficient way

2021-10-05 Borealis+Topaz

issue 08/2021

issue 07/2021

issue 06/2021

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