For the successful implementation of electromobility, not only the vehicles but also the associated charging infrastructure play a decisive role. Various technologies are currently used to charge electric vehicles.

For the electronics of charging stations, Wevo offers temperature-stable adhesives and potting compounds based on silicone, epoxy resin and PU.

16:9

Silikone

Kunststoff Werkstoffe

Kfz-Elektronik

Elektronik

Harze, Epoxid

Duroplaste

Polyurethan

Klebstoffe

Verbindungstechnik Verfahren

Chemisches Fügeverfahren

Protection of Sensitive Charging Electronics

The processing of highly reactive resin systems requires a detailed understanding of the material behavior during component manufacture. The characterization of systems using DSC to date has reached its limits, especially in the case of polyurethanes. A specially developed measuring cell, on the other hand, delivers better results.

Measuring Cell Enables Characterization of Fast-Reacting Polyurethanes and Epoxy Resins

Messtechnik

Materialcharakterisierung

Software

Simulation

Sharp Look at Reactive Resins

The combination of injection compression molding, direct coating and partial film insert molding enables a novel design for the front module of the BMW iX electric vehicle. Important in the development were extensive trials carried out by plastics manufacturer Covestro in its technical lab.

Various production processes are combined to manufacture the front module of the BMW iX, known as the kidney.

Producing Large Exterior Parts with Integrated Functions and High-Quality Finishes

Technische Kunststoffe

Thermoplaste

Polycarbonat

Facelift for Electric Vehicles

Drawing on various joint projects conducted with customers, BASF will demonstrate how to significantly improve carbon emissions from products.

Vaude’s outdoor pants use a PA6 from BASF made from chemically recycled car tires. 

Messe K-Kunststoffmesse

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kunststoffe.de

Recycling

Umweltmanagement

Biokunststoffe

Kunststoff-Rezyklat

Calculating and Reducing the Carbon Footprint

All over the world, many polyurethane manufacturers are aligning production and assortment as well as upstream and downstream processes to the circular economy.

In wind turbines, polyurethane offers three major advantages over materials such as epoxy resins and improves two key criteria of the turbines. 

Polyurethane (PUR): Worldwide Demand for the Polymer Is Growing

Polyurethan-Schaumstoffe (PUR)

Halbzeuge und Zwischenprodukte

Kunststoff-Halbzeuge

Kunststoff-Recycling

Kunststoffverarbeitung: Verfahren

Kunststoff-Aufbereitung

Sustainability at Every Turn

In the last three years, global consumption of polyurethane has been growing by approx. 5 % per year. In 2012, it reached a volume of 15.3 million t. This encouraging growth trend can be expected to continue in both the middle and long term. The global factors strongly contributing to this include increasing urbanization and mobility, the economic growth driven by rising living standards, mainly in threshold countries, and last but not least, worldwide measures for saving energy. 

Stable Growth: Polyurethane (PU) 

An innovative process makes it possible for the first time to recover polyol from production scrap generated in standard flexible polyurethane foam block manufacture. Thanks to this process, the production scrap is suitable for recycling back into flexible foam manufacture, so bringing ecological and economic advantages. 

PU Recycling: Flexible Stays Flexible 

The rotor blades of wind power plants have to withstand enormous loads: Velocities of up to 300 km per hour are sometimes reached at the blade tips. And there is impact from rain, hail, snow, sand and UV radiation. Particular load acts upon the edges of the rotor blades. This is because rotor blades – which are mostly between 40 and 60, but sometimes even up to 90 meters long – consist of several components connected to each other. They are adhesion bonded, with the bond seam exactly at the blade edge. To protect the edge from erosion, sand and water, BASF SE, Ludwigshafen, developed the new Relest Wind LEP product. This new generation of polyurethane coating is due to protect the sensitive area of the rotor blade better than the known products. 

Shelter from the Wind and Storm 

Polyurethane Coating Relest Wind LEP 

Even though the solidification behavior of reactive polyurethane (PU) differs from that of thermoplastics, this material can be used for the projectile injection technique. The technology combines the excellent properties of PU with the economic benefits of injection molding and enables the production of complex elastomeric fluid-conducting hoses with adjustable flexibility and high impact strength. Additionally, the integration of a continuous fiber reinforcement leads to improved bursting strength in comparison to short fiber-reinforced thermoplastics. 

Fluid-Conducting Hoses with Complex Geometries Can Be Made of Reactive  Polyurethanes Now 

Glasfasern / -matten

Spritzgießen

Fluidinjektionstechnik

Improved Properties with Reactive Polyurethanes 

One-shot manufacturing of injection molded parts with high-gloss hard lacquer coatings, sophisticated depth effects or structured surfaces with a convincing tactile effect is no longer just a vision. After several years of development work, a project aimed at vehicle interiors is showing that the "ColorForm" process allows these aims to be met with virtually zero rejects and at favorable costs. 

A Combined Injection Molding and Reaction Process Generates High Gloss, Depth and Structure in One Operation 

Oberflächentechnik

One Surface, Three Effects 

Large-surface components reinforced with natural fibers, which are used for the interior trim of vehicles must be light and strong. In addition, they must be fitted with integral functional elements, and have high-quality surface coatings. Intelligent combination of the processing methods thermoforming, injection molding, and reaction technology enables these complex requirements to be met efficiently. Initial close-to-production tests have confirmed the compound strength of the three processes, and demonstrate their potential for industrial applications. 

Processing Combinations Smooth the Way for Manufacturing Lightweight Fiber-Reinforced Components with High-Grade Surfaces 

Faserverarbeitung

Warmformen / Thermoformen

Spritzgieß-Sonderverfahren

Beschichten, Kaschieren, Laminieren

Schäumen / Reaktive Verarbeitung

Oberflächenveredelung

Getting Results Faster 

The world market for PU grew at an above-average rate in 2013, with total sales reaching 16.4 million t. Prognoses indicate that in the medium term it will continue to grow globally at an annual rate of about 5 %. For years, investments by PU manufacturers have concentrated on the largest PU regional market, the Asian-Pacific region. However, other regions are also displaying solid growth.  

Custom-Formulated All-Around Resin for Numerous Innovative Applications  

Polyurethanes (PU) 

Epoxy resins and polyurethanes are outdoing each other with ever shorter cure times. There is downright competition as to which of them will serve in the large series of automotive production. In-situ polymerization remains an exciting issue. Most types of composites now sail in calmer waters, though. Ecological aspects and resistance to flames are the outstanding features of the new developments. 

Fiber Reinforced Plastics Finally Ready for Series Production 

Harze

Reaktionsharze

Verbundwerkstoffe / Werkstoffverbunde

Resins and Reactive Systems 

In an on-site presentation, Sonderhoff Engineering GmbH, Hörbranz, Austria, will showcase its Smart - DM 402 dosing cell designed for gasketing, adhesion bonding and casting of polyurethanes (Fig.). The integrated 3-axis linear robot positions the mixing head at a part-to-part consistency of ± 0.1 mm. The basic size of the component to be processed may be up to 500 x 500 mm, at 200 mm maximum height. The dosing cell has a compact design and is entirely composed of modules, thus allowing for flexible and simple adaption to the respective production concepts. 

Sonderhoff 

Flexible in Sealing and Adhesion Bonding 

The plant engineering company from Sankt Augustin, Germany, will also present their improved versions of state-of-the-art, as well as classical, processing techniques. At the focus of the presentations of Hennecke GmbH, a new energy saving technology will be on display at the trade show. Named "blue intelligence", this technology bundles several measures aimed at energy saving for reaction injection molding machines. Optimized machine stand-by management and an adapted tempering concept, along with high-efficiency, state-of-the-art nozzle technology, make it possible to reduce energy consumption considerably. Highline is the first machine series to comprise all of these measures (Fig.). 

Hennecke 

Energy Efficient Operation 

Specialty Chemicals Company Launches Production Line

Lanxess put a new production line for the manufacture of water-based compounds into operation in Nantong, China.

Lanxess put a new production line for the manufacture of water-based compounds into operation in Nantong, China. The business belongs to the Urethane Systems (URE) business unit which is also producing polyurethane dispersions, an important ingredient of the compounds.

Under the Pellart brand these products are used in many functional coatings applications where high requirements in terms of haptics, chemical resistance, gloss level, temperature and abrasion resistance and, above all, the lowest possible content of volatile organic compounds (VOC) are required.

Typical areas of application are flat materials for automobile interiors, i.e. instrument panels, seats and door panels, but also decorative foils for consumers and industry.

Water-based and therefore environmentally friendly products are a strong trend globally. “As the automotive industry will continue to switch from solvent-based to environment-friendly water-based coatings, we see strong potential with attractive growth rates,” says Michael Timm, Head of Marketing & Development Cast Elastomers at URE.

With the new production line, the company will be able to supply customers in Asia with modern and environmentally friendly Pellart products. Fast developments and customer proximity are provided by the coupling with the application development center, which was opened by Lanxess in Shanghai in June 2021, as well as by the backward integration into its PU dispersions.

Lanxess produces polyurethanes and lubricants at its Nantong site, which covers over 100,000 m2. The urethanes products include hot-cast prepolymers, which are components of specialty polyurethanes that are used primarily in the construction, mining, oil, gas, athletic equipment and electronics industries. These polymers are used, for example, to manufacture rollers, tires and wheels, conveyor belts, screens, seals and so on.

LANXESS Deutschland GmbH  

The specialty chemicals company put a new production line for the manufacture of water-based compounds into operation

At its Nantong site, China, which covers over 100,000 m2, Lanxess produces urethanes and lubricants

2021-11-24 Lanxess

issue 09/2022

issue 08/2022

issue 07/2022

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