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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

Compound

Brennstoffzelle

Brennstoffzellen

Kunststoff Werkstoffe

Kunststoff

Folien

Ultrathin Bipolar Plates for Fuel Cells

Teknor Apex presents three halogen-free FR glass-reinforced polyamide compounds with UL94 ratings of V0.

Elektronik

Automotive

Polyamide

Technische Kunststoffe

Faserverbundwerkstoffe

Glass-Reinforced and Halogen-Free Flame-Retardant

For lightweight applications e. g. in automotive engineering BASF developed carbon fiber-reinforced polyphthalamide (PPA) grades with fillings of 20, 30 und 40 %.

PPA Now with Carbon Fiber-Reinforcement

Lightweight Metal Replacement

The plastic components used for radar systems must not disturb the functioning of the sensors. Specialized measuring systems and test setups can greatly simplify to test the radar suitability of the components.

Straightforward Analysis and Characterization of Plastic Materials for Radar Systems

Fahrerassistenzsysteme / Automatisiertes Fahren

Werkstoffprüfung

Perfect Vision for Autonomous Vehicles

The ZKW Group manufactures premium lighting systems for automotive customers. In order to be able to produce trouble-free and in permanently high quality in the injection molding process, several hundred temperature control units from HB-Therm are also used, among others.

The ZKW Group Manufactures Innovative Lighting Systems for the Automotive Industry

Spritzgießen

Temperiergeräte

Temperiertechnik

Kfz-Leuchten, Beleuchtung

KFZ-Zulieferer

Where Night Becomes Day

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

Hochleistungskunststoffe

Getting Fuel Cell Vehicles Fit for Use

Leonhard Kurz’s “Iconic Space Grille”, does not only illustrates modern vehicle design but was also produced in a new production process.

Award-Winning Front Panel Combines Exciting Design with an Efficient  Manufacturing Process

Polyurethan

Polycarbonat

An Eye-Catching Addition  to Electric Vehicles

Replacing metal with polyamides (PA) in components can not only reduce weight and costs, but also offers developers greater design freedom. However, this requires materials with improved mechanical properties.

Special Polyamides 6 Match the Properties of Polyamide 66

Metal Substitution with Improved PA

The central issue in all polyurethane applications is the conversion from the past linear economy into a circular economy, and the use of sustainable raw materials in manufacturing. To do so, manufacturers are taking measures such as using bio-based raw materials, chemical recycling, and CO2 as a synthesis component. Digitalization, electromobility, autonomous driving and the construction industry are also driving PU development.

Polyurethane (PU)

Bauwesen

Bauchemie

Baustoffe

Polyurethan-Schaumstoffe (PUR)

Baubetrieb / Bauwirtschaft

Windkraft

Kunststoff-Recycling

Sustainable Growth

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

Medizintechnik

Medizinprodukte

Delivering Efficiency Even in  Harsh Environments

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

Polystyrol

Styrol-Copolymerisate

Diverse Shapes and Applications

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

Present in a Multitude of Trends

Because of its good temperature resistance, impact resistance and aesthetics appearance, acrylonitrile-butadiene-styrene is often used in household goods and in the automotive industry. The development of a circular economy also shows successes.

Acrylonitrile-Butadiene-Styrene (ABS)

ABS / ASA-Kunststoffe

In the production of plastic parts for the medical and pharmaceutical industry, the requirements for cleanroom environments are becoming increasingly stringent. In this area, not only the demand for all-electric injection molding machines is increasing. There is also an increasing use of electric drives for the implementation of mold movements, which meet the high requirements for cleanliness and reliability.

Electrical Drives in Injection Molds

Elektrische Antriebe

Spritzgießwerkzeuge

Mess- / Regel- und Prozessleittechnik

Mess-, Steuer- und Regelgeräte

Reinraumsysteme / -technik

Mold Technology

Plastic waste in the sea has been shaping the negative image of the industry for several years. Various initiatives and mergers of companies have therefore launched projects to tackle this Ocean-bound Plastics (OBP). Components made of OBP could become a symbol for a sustainable use of plastics.

Flame Retardant for Compounds Based on Recycled Ocean-Bound Plastics

Polybutylenterephthalat

Polyethylenterephthalat

Flammschutzmittel

Additive

From the Sea to Electronics

Threaded inserts ensure a secure connection of hybrid components. Under continuous load, effects can occur with thermoplastics due to pressure and temperature, which means that a durable screw connection is no longer guaranteed. Such effects can be prevented by thread inserts with a special surface structure.

Structuring of Surface Ensures Reliable Anchoring of Thread Inserts in Organic Sheets

Verbundwerkstoffe / Werkstoffverbunde

Reduced Settling Behavior in Multi Material Components

Interview with One of this Year’s Winners of the Nobel Prize in Chemistry, Dr Akira Yoshino

Interview with One of this Year’s Winners of the Nobel Prize in Chemistry,  Dr Akira Yoshino

Batterien

Elektromobilität

“Plastics Play a Key Role in  Lithium-Ion Batteries”

Batteries in electric vehicles must be specially protected to counter the risk of fires. Battery trays made from aluminum frequently offer insufficient protection.

Underbody Protection for Batteries in Electric Vehicles

Polypropylen-Platten

Glasfasern / -matten

Aluminium

Polypropylen

Polypropylene Beats Aluminum

The transformation from the combustion to the electric engine entails several imponderabilities for the plastics industry. In part, electric drives have completely different material requirements which are becoming specifically evident with the increasing use of appropriate vehicles.

Flame Retardancy, Heat and Tracking Resistance of Electric Vehicles

Elektromotoren

Elektronische Bauelemente

Leistungselektronik

Drivers of Electromobility

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.

Large-Area Curved Plastic Panels with Integrated Displays

HMI, Bedienelemente, Displays

Display im Automobil

Thermoformanlagen

Automotive Display: A Matter of Form

Weight reduction is one of the major requirements of automotive components. Regardless of the vehicles in which they are used. One of the lightest materials that can be considered is polypropylene (PP).

PP Compounds for Automotive Lightweight Construction

Polypropylen-Compound

Easier to Reach the Destination

Ambient lighting has captured the car interior – and facilitated orientation for the passengers. There is no need for anyone to fumble for the seat belt buckle in the dark in the Audi A7, as an integrated light guide shows the way. Kunststoff Helmbrechts produces the 3-component part and also developed the tool concept. The trick:  a so-called twin-turn tool which rotates on both sides. The company was awarded the GKV TecPart Innovation Prize for it at the K 2019.

Twin-Turn Tool Provides Solution to Production Problem with a Double Turn

Mehrkomponenten-Spritzgießen

Runway Lights for the Seat Belt

At the US location in Auborn Hills, Michigan, fischer automotive systems produces kinematic components for the center console of the Mercedes GLE class, which are equipped with a roller blind.

Flexible Turnkey System for Multi-Variant Roller Blinds

Montage

Industrieroboter

Industrieroboter klein

Montageeinrichtungen

Rattle-Free Part

The voltage test of the comparative tracking index is limited to 600 V so far. In many areas the voltages increase, especially for electrical vehicles. Therefore, it is interesting to know what the real limits of isolating materials are. These are considerably higher. To test these, a modified test set-up is necessary.

Testing Isolating Materials above 600 V

Prüfen von Kunststoffen

Beyond the Limits of the Comparative Tracking Index

Currently, recyclates are in high demand, including the automotive industry. Previously, component suppliers had reservations about using recyclates in safety-related areas, because mechanical properties varied too widely. Now, materials producer JSP has developed an expanded polypropylene with 25 % recyclate content precisely for these application areas. But to ensure high quality, close cooperation with the recycling company is essential.

Circular Economy for Expanded Polypropylene (EPP)

Automotive Components  Made of Packaging