The RadiciGroup High Performance Polymers Business Area is adding significantly to its global production capacity with new construction and installations in North America, Europe and China.

Compound

Kunststoff Werkstoffe

Thermoplaste

Compoundeure

Dienstleistungen

Handel

Kunststoff

Bauwesen

Baustoffe

Radici Increases Production Worldwide

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.

Batterien

Energiespeicherung

Elektromobilität

Mobilität

Füllstoffe, mineralisch

Füllstoffe für Kunststoffe

Messe Fakuma

kunststoffe-international.com

Füllstoffe, allgemein

Windkraft

Energieerzeugung

Erneuerbare Energie

Folien

Halbzeuge und Zwischenprodukte

Kunststoff-Halbzeuge

Additive

Fillers Improve Batteries and Wind Power Plants

Transparent polyethylene films can now be produced with antimicrobial and electrically conductive properties as well. This can be achieved by combining several films with the relevant property profiles. The surface conductivity of the films can also be increased by using a suitable new coating technique. The article describes the newly developed special compounds required for this and demonstrates their industrial feasibility. 

Special Compounds: Transparent, Conductive, and Antimicrobial 

With a newly developed process from Entex it was possible to compound an injection grade compound of PLA with a 50 % wood flour content.

Compounding PLA Formulations with a 50 % Wood Flour Content, without Premixing

Extrusion

Kunststoffverarbeitung: Verfahren

Extruder

Kunststoffverarbeitung: Maschinen und Komponenten

Extrusionsanlagen

Biokunststoffe

Compoundieren

Kunststoff-Aufbereitung

Direct to Highly Filled Bioplastics

There is still a need to catch up in terms of ion leaching and hydrolysis resistance of the materials used to date for fuel cells. Specially developed PPS represent one possibility for this.

Material Improvements Make Fuel Cells More Reliable

Automotive

Elektronik

Brennstoffzelle

Stromversorgung

Brennstoffzellen

Technische Kunststoffe

Fahrzeugbau

Hochleistungskunststoffe

Getting Fuel Cell Vehicles Fit for Use

Lightweight construction, functionality and design are characteristic of material development in all areas of application for PC compounds, composites and films. The range of materials has enormous opportunities when it comes to the mobility of the future, lightweight structural construction with continuous fiber-reinforced composites, 5G technology and medical technology.

Polycarbonate (PC)

Recycling

Umweltmanagement

Kunststoff-Recycling

Medizintechnik

Polycarbonat

Medizinprodukte

Present in a Multitude of Trends

Styrenics can be polymerized using different technologies and it can be modified with a range of copolymers. The resulting plastics offer a wide range of properties allowing to customize them for different applications. Because of this range of properties they are suitable for many industries. Strong demand is for example driven by the automotive industry, healthcare and the packaging industry.

Styrenic Polymers

Verpackungsmaterial

Logistik

Polystyrol

Styrol-Copolymerisate

Diverse Shapes and Applications

Due to its high-performing properties polyetheretherketone thermoplastic polymer is being used more and more frequently in many products.

Polyetheretherketone (PEEK)

Elektronik-Fertigung

Polyetherketon

Mikroelektronik

Delivering Efficiency Even in  Harsh Environments

Optics play an increasingly important role in plastic components. Glossy and even surfaces are decisive for an attractive appearance. With glass fiber-reinforced polyamides (PA), these requirements can usually only be achieved with an additional coating. A PA specially developed for surface design offers an alternative approach.

Aliphatic High-Performance Polyamide for Plastic Surfaces

Spritzgießen

Polyamide

Oberflächentechnik

Faserverbundwerkstoffe

Andere Werkstoffe

Kunststofffasern

Verstärkungsstoffe

Glossy Components without Painting

Renouncement is the trend that determines public perception of plastics today. Many consumers prefer products that are better for the environment, which is often equated to using less plastics. It is true, though, that plastics are important materials when it comes to finding answers to the challenges posed by the increase in population, high energy demand as well as growing urbanization and mobility.

Guest Commentary by Dr. Michael Zobel

Kunststoffe

Photonik

Optik

Leichtbau

Kunststoffhandel

Werkstoff

The Answer to Many Questions

In this interview with Kunststoffe, Alfred Stern, CEO of Borealis, explains why he considers fixed recycling quotas to be necessary and why voluntary commitments do not work.

Alfred Stern, CEO of Borealis, Talks about the Circular Economy

Schröder, Susanne

Streifinger, Florian

Kunststoff-Rezyklat

“Unfortunately, the Only Globally Accepted Ideology Is Money”

Bio-based plastics can lock away vast quantities of CO<sub>2</sub> in durable, recyclable applications and make a real contribution to climate protection. All that is needed for this is the right product design and a functioning circular economy. By focusing more on this approach, the plastics sector has the chance to evolve into a key industry of a green economy.

How Bio-Based Polymers Can Help Sequester CO<sub>2</sub> for the Long Term

Kunststoffe, biobasiert

Kunststoffe, bioabbaubar

Into the Future with Biopolymers

Dow expertise and Endurance insulation system supports Saudi cable manufacturers supplying power grid upgrade.

Elektrotechnik

Ingenieurwissenschaften

Bau- / Elektroinstallation

Baubetrieb / Bauwirtschaft

Elektrokabel, -leitung, -drähte

Elektrotechnik, Elektronik

Dow and NGSA Cooperate on Ambitious Grid Upgrade

The company presents new formulas of structural thermoplastic materials reaching 414 MPa tensile strength.

MCAM about its KyronMAX Structural Thermoplastic Compounds

Harze

Duroplaste

Kunststoff-Erzeugung

Expanded Resin Formulations

The so-called M·Vera grades can be processed in the injection molding process and in the extrusion process.

Bio-Fed’s Contribution to the EU Green Deal 2030

Masterbatches

Sustainable PLA-Based Compounds

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

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.

Sustainable energy sources are of vital importance for society’s future power supply. Since wind and solar power are subject to fluctuation due to changing weather conditions, the generated energy must be held in medium or long-term buffer storage. The ideal solution for this task is provided by so-called redox flow batteries. These generally take the form of 40-ft containers which, as electrochemical converters, can store and deliver large amounts of energy. Another possibility is fuel cells that convert fuels such as hydrogen into electrical energy. This technology is becoming increasingly popular for mobile and portable applications and is already being used for trucks, cars, trains, boats, domestic energy supply (cogeneration), and independent power supply units, e. g. for data centers.

For these technologies to become established in the market, further development of bipolar plates, as the central functional elements of fuel cells and redox flow batteries is necessary. Bipolar plates are a key component of fuel cells and redox flow batteries. Conventional carbon-containing bipolar plates usually consist of thermoplastic or thermoset matrix materials with a high content of conductive fillers such as graphite, carbon black or carbon nanotubes. Although made from plastics, bipolar plates must have very good electrical and thermal conductivity. To achieve suitably high conductivity, the plastic must be filled with up to 80 or 90 wt. % conductive material. Here, the binding polymer plays a crucial role in preventing the compound from becoming brittle and ensuring optimum processability, although it only makes up 10 to 20 wt. % of the compound. For long and economical use of bipolar plates, high electrical conductivity, resistance to degradation, and mechanical stability under load are required.

Polypropylene (PP) and polyolefins in general are frequently used as the polymers for bipolar plates. But for special requirements, other materials such as polyphenylene sulphide (PPS), polyvinylidene fluoride (PVDF), and phenolic resins are also used. Although highly filled graphite bipolar plates based on PP, polyethylene (PE), PVDF, and PPS offer high durability and can be manufactured economically, users are also increasingly demanding thinner, weight-optimized components to save space, reduce weight, and cut material costs. Low thickness and high durability are very conflicting requirements for such high conductive-filler loadings and make the achievement of this goal even more challenging.

By modifying the plastics used in bipolar plates such as PP, PE, PVDF, and PPS, their mechanical properties can, at least within certain limits, be adapted to the required specification and, through impact strength improvement, for example, be made more flexible or ductile. This is essential for the manufacture of thin plates. By using special impact modifiers, Eisenhuth GmbH & Co. KG has been able to produce thin, highly filled, very conductive bipolar plate films as coils in a continuous process (Fig. 1). In this process, polyolefin block copolymers additionally containing ethylene-propylene-diene-monomer rubber (EPDM) were produced with varying graphite content.

The starting point was the production of highly filled compounds. Compounding was carried out on twin screw extruders from Collin, Leistritz, and Battenfeld. On these machines, various modified PP, PE, PVDF, and PPS compounds with a carbon content of about 80 wt. % were produced and pre-conditioned for the shaping process. The next important step comprised processing them into thin films on a suitable continuous production unit.

Modified Films Achieve the  Required Values

The average thickness of the films was well below 1mm and for the most part between 0.5 and 0.8 mm (Fig. 2).

During production, however, the film can be precisely adjusted to the specification so that the required thickness can be ensured to a tenth of a millimeter in serial production. The tensile strength of the plates produced was between 4 and 11 N/mm² (Fig. 3), which is lower than that of the reference material.

It should be remembered, however, that the measurements were not carried out on a standard test bar but on the film itself, which is only about 0.6 mm thick. Further trials to improve tensile strength are currently in progress. The electrical resistivity values of the different material types are higher than those of the reference material (Fig. 4). However, it should be borne in mind that thinner plates compensate for the somewhat poorer electrical conductivity.

The films also open up new processing options. Until now, suitable shaping methods for producing bipolar plates have been hot pressing and injection molding. In these processes, the preconditioned material is generally fed into a heated compression or injection mold. In the case of compounds with a thermoset matrix, a chemical curing reaction under heat must take place before the plate can be removed from the cavity.

With thermoplastic matrices, on the other hand, the compound must first be melted and then brought below the melting or glass transition temperature of the particular plastic before demolding. In hot pressing or injection molding, the technically challenging options consist in directly shaping the required structures or producing unstructured sheet blanks instead.

With the latest technology, graphite compound films can now be processed as coils (Title figure). In a similar way to stamping, the films are drawn down from a coil and processed by stamping/bending to produce the final structured plate (Fig. 5).

The new technology represents a further important step in automated manufacture of conductive compound films to achieve the economy of scale effect.

In this way, the overall costs of fuel cell or battery systems can be significantly reduced. The mechanical properties obtained are comparable with those of graphite-filled, pressed or injection molded bipolar plates. Electrical conductivity, too, lies within a range that is suitable for the application. In view of the current legal framework conditions specified in particular by the EU Commission, there is an ever more pressing need for action to make mobility emission-free. The films described can make an important contribution towards greater acceptance of fuel cell technology.

Eisenhuth GmbH & Co. KG  

https://www.eisenhuth.de

Ausgabenartikel

The modified polymers enable films to be processed  as coils

Fig. 1. By modifying the highly filled plastics, considerably thinner bipolar plate films can be produced than was previously the case 

Fig. 2. Film thickness of the processed compounds and comparison with reference materials (filling degrees in brackets): the thickness of the plates ranges between about 0.5 and 1 mm

Fig. 3. The tensile strength of the different films is lower than that of the reference materials. However, the reference materials are also considerably thicker (3 mm) 

Fig. 4. The electrical resistance of the compounds (filling degrees in brackets) is higher than that of the reference materials. However, this is compensated for by the lower thickness of the films

Fig. 5. Stamped graphite compound film: the bipolar plate is produced by the stamping/ bending process 

KU 6-21_Eisenhuth - Hauptartikel

 Dr. Thorsten Hickmann is CEO of Eisenhuth GmbH & Co. KG, Osterrode, Germany; <a href="mailto:t.hickmann@eisenhuth.de">t.hickmann@eisenhuth.de</a>

Dr. Thorsten Derieth works in marketing and application technology in the Fuel Cells and Batteries Department of Eisenhuth; <a href="mailto:t.derieth@eisenhuth.de">t.derieth@eisenhuth.de</a>

Read the German version of the  article in our magazine Kunststoffe or at  <a href="https://www.kunststoffe.de/a/fachartikel/duennere-bipolarplatten-fuer-brennstoffz-326015" target="_blank">www.kunststoffe.de</a>