issue 04/2022

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Alternative powertrains, autonomous driving and the urge for more sustainability impact the vehicle design and driving experience.

 The USB connector system enables space saving of up to 60 %. The used PBT allows tight tolerances regardless of the ambient conditions.

16:9

Polybutylenterephthalat

Elektronik

Kfz-Elektronik

Kunststoff Werkstoffe

Technische Kunststoffe

Steckverbinder

Smaller, Faster, Lighter

The interfacial tightness of hybrid polymer-metal parts such as injection-molded connectors represents a decisive quality characteristic. Until now, however, there has been a lack of suitable measurement technology with which to quantify the media tightness of such molded parts. A new method delivers significantly more accurate results than previous test methods.

The DDP method enables more accurate determination of the tightness of polymer-metal hybrids

Measurement Method for the Exact Leakage Determination of Polymer-Metal Hybrid Parts

Messtechnik

Verbundwerkstoffe / Werkstoffverbunde

Prüfen von Kunststoffen

Stecker

Kunststoff

How Tightly Sealed are Connectors Really?

Aside from offering high mechanical strength, versatility and durability, polymer materials are ideal for applications in the electrical industry because of their ability to isolate electrical current.

For the conduction cooled MicroTCA systems, Harting processes LCP, a material that is flame-resistant, dimensionally stable at high temperatures, chemically resistant, and has only a low thermal expansion

Connectors for Industrial Lifelines: High-Tech Injection Molding at Harting

Hybridtechnik

Polymere, flüssigkristalline

Spritzgießen

Spritzgießwerkzeuge

Heißkanalsysteme

Stanzen

Hybrid-Spritzgießen (Metall / Kunststoff)

Well-Balanced Hot Runner Technology for LCP Processing

The non fossil fuel-based portfolio offers same high quality and performance for applications in all industries.

The Bornewables portfolio is suitable for the production of the most demanding applications, including hygiene and food-contact

Gehäuse aus Kunststoff

Polyethylen

Polystyrol

Kunststoff-Aufbereitung

Standardkunststoffe

Polypropylen

Kunststoff-Regenerate

Kunststofffasern

Kunststoff-Recycling

Borealis Launches Portfolio of Circular Polyolefins

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

PEEK can replace fluoropolymers in cryogenic applications. Advanced Engineering Valves uses PEEK from Victrex for sealings in ball valves

Polyetheretherketone (PEEK)

Elektronik-Fertigung

Polyetherketon

Mikroelektronik

Medizintechnik

Hochleistungskunststoffe

Medizinprodukte

Delivering Efficiency Even in  Harsh Environments

Touch-sensitive lighting modules that are the size of a palm and about as thin as a matchbox can create varying light mosaics thanks to digital control. The electronics behind this construction are situated in a flat plastic housing and are securely welded using laser technology for their protection.

When the mosaic surface is swiped, the modules light up in the desired colors in the touched areas

Luminous Mosaics with Laser Welded Electronic Modules

Verbindungstechnik Verfahren

Verbindungstechnik

Laserschweißen

Laserschweißanlagen

Colors at Your Fingertips

In-mold labeling is the ideal solution for today’s customer requirements in the packaging industry. Companies need high-quality, durable machines with maximum availability that can produce a wide range of packaging designs with flexibility and economic cycle times. To implement such systems efficiently, Swiss specialty machine manufacturer Beck Automation implements PC-based control and drive technology from Beckhoff as its standard automation platform.

With IML systems from Beck Automation, a broad range of plastic containers and lids can be labeled efficiently and flexibly

PC-Based Control in an In-Mold Labeling System Helps Decorate Plastic Lids

Steuerungen (Hardware und Software)

Folientechnik (IMD, IML, FIM, u.a.)

Servomotoren

As Flexible as Required

Housings not only protect the inner workings of medical equipment, but also protect patients from electric shocks, for example. This function is very important for the increasingly widespread medical wearables, which are often in constant contact with the patient. When designing such devices, it is therefore important to select the appropriate housing material.

Housings play an important role in medical wearables. They protect their inner workings, but at the same time protect the users of the devices

Materials for Medical Wearable Housings

Polycarbonat

Protection and Attractive Design

Harmoniously integrating displays into the lines of a vehicle cockpit has always been a real challenge. Continental now uses a combination of film insert molding, in-mold decoration and injection-compression molding to produce large, three-dimensionally formed plastic panels.

Two displays are seamlessly integrated into the continuously 3D-formed instrument panel

Large-Area Curved Plastic Panels with Integrated Displays

HMI, Bedienelemente, Displays

Display im Automobil

Thermoformanlagen

Automotive Display: A Matter of Form

Mold breathing provides useful information about the processes that occur in the mold and the cavity. Mold-maker Schneider Form and injection molding machine-maker Engel have recognized the potential which this process variable offers and have worked intensively on it for several years, albeit by adopting different approaches. They recently carried out joint tests on bumper molds using a two-platen injection molding machine with a clamping force of 40,000 kN and then swapped experiences.

Bumper molds were the focus of mold-breathing studies aimed at process optimization. The photo shows an example from the bumper portfolio of Schneider Form

Comparative Methods for Determining Mold Breathing

Energiemanagement / Smart Home

Industrie 4.0 für die Kunststoffverarbeitung

Druck- / Kraftsensoren

Spritzgießmaschinen

Using Breathing Signals for  Process Optimization

The aesthetically and mechanically outstanding properties of styrene polymers are extensively enhanced by different blending partners. New developments include weather-resistant grades, laser surface structuring and fiber reinforcement. The newly founded “Styrenics Circular Solutions” industry association recently started a chemical recycling initiative for polystyrene.

The radiator grille of the Peugeot 208 is hot-stamped from Luran S 778 T acrylonitrile styrene acrylic ester (ASA). The material is pre-colored, unpainted and suitable for long-lasting outdoor applications

Polystyrene and Copolymers Combine Aesthetics with Technical and Sustainable Properties

Polystyrol-Platten

Styrol-Copolymerisate

Styrene Copolymers

The production costs for complex injection molded parts not only depend on material costs but also to a considerable extent on cycle time. The cycle time is divided into the injection, holding pressure, (residual) cooling phases and the tool movements. The cooling phase takes up 60 to 90 % of cycle time, depending on the particular plastic material and part component. Adequate cooling can therefore reduce not only cooling time but also cycle time.

This mold determined the maximum cycle times (rendering)

Improving Conformal Cooling with Design, Simulation, and Processing Know-How

Werkzeug- und Formenbau

Konturnahe Kühlung

Werkzeuge für die Kunststoffverarbeitung

Kühlelemente, aktive

Fine Channels, Maximum Efficiency

Efficient thermal management is needed for the drive batteries, electric motors and power electronics in electric vehicles. Due to their wide range of consistencies and their robustness, silicone-based thermal interface materials prove indispensable in this field.  

Silicone-Based Thermal Interface Materials for Electric Vehicles  

Elektromobilität

Abdeckmassen (Elektronik)

Silikone

Efficient Heat Dissipation 

Static mixers are compact, but they cannot lower the melt temperature. Combining a static mixer with a powerful cooler in a single unit opens up new possibilities in process engineering. 

Combining Intensive Static Mixing with Effective Heat Exchange 

Polyethylenterephthalat

Schaumstoffe und Vorprodukte

Mischer

Schäumen / Reaktive Verarbeitung

A Cool Mix 

Good fire resistance is important in technically demanding applications. However, the use of suitable additives reduces the mechanical properties of a material, e. g. impact resistance and tensile strength. It can now be shown that this effect can be counteracted by means of regenerated cellulose fibers. 

PBT Compounds Modified with Natural Fiber Reinforcement as Flame Retardant 

HV-Anwendungen / Hybridisierung / Elektrifizierung

Celluloseester, -ether

Flammschutzmittel

Fasern

Naturally Non-Flammable 

Nothing defines the current generation more than the smartphone. Premium, classy metal devices are the current trend. In order for the numerous integrated antennas to work notwithstanding the conductive housings, they must be electrically insulated against each other. Two newly developed polyphthalamides that join especially well with titanium and stainless steel alloys are suited for this purpose.  

Polyphthalamides for Hybrid Connections in Metallic Smartphone Housings 

Aluminiumlegierungen

Verbindungstechnik, hybride

Icons of the Modern Era 

A low-warpage, flame-retardant PBT-ASA material has been developed for the housings of a battery management unit and two cell monitoring units. Both assemblies have recently been used in the lithium-ion battery systems of a small compact car. The material has low warpage and is flame-retardant. It also offers high chemical resistance, low emissions, and high toughness and stiffness. 

PBT Blend Developed for Battery System Components in Mass-Produced Electric Vehicles 

Energiemanagement / Ladetechnik

Thermoplaste

Compound

New Plastic Housing Material for e-Power Units under the Hood  