issue 04/2023

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Intelligent materials are opening up new avenues in sound reproduction technology: lightweight loudspeakers, novel shapes for signal generators and applications involving noise cancelling textiles.

Sophie Nalbach conducted research on the smart foils as part of her doctoral thesis. They can replace electro- or permanent magnets in loudspeakers.

Silikone

Folien

Smart Films Make Loudspeakers More Energy-Efficient

Hennecke presents new high-pressure metering machine with high-end mixing head technology.

The Highline MK2, which celebrated its premiere at K, is equipped with high-end mixing head technology. 

Dosiergeräte

Polyurethan

Materialhandling

All-Rounder for PUR Applications

The K 2022 offered an immense range of innovations and application examples for – and with more – sustainable materials. Interestingly hereby was that bio-based versions were extremely popular.

Shoes made from waste gas: genetically modified bacteria produce ethanol from waste gas, which is then used to create plastic, e.g. for the Cloudprime shoes from On.

16:9

Thermoplastische Elastomere

Messe K-Kunststoffmesse

Masterbatches

Polyethylen

Streifinger, Florian

Polylactid

Polyamide

Biokunststoffe

Kunststoff Werkstoffe

Effektpigmente

Polypropylen

Faserverbundwerkstoffe

Kunststoff-Rezyklat

Additive

Silikonkautschuk

Is Bio the New Standard?

Direct recycling of cured thermosets as fillers in the injection molding process increases resource efficiency due to material recycling.

Recycling of sprue loss through shredding, blending with virgin material and direct recycling.

Direct Recycling of Cured Thermosets as Fillers in the Injection Molding Process

Spritzgießen

Nachhaltigkeit

Duroplast-Spritzgießen

Duroplaste

KFZ-Zulieferer

Sprue Recycling Conserves Resources

At the booth, baby bottle nipples will be manufactured on a 12-cavity mould on the Boy injection molding machine with 500 kN clamping force.

Boy Presents Silicone Application

At K 2022, it was clearly shown that with suitable materials not only can CO2 emissions be reduced, but also advantages in component design achieved.

The Japanese chemical company Asahi Kasei showed its concept vehicle at K 2022. The domed roof in particular could lead to a few changes in future automobiles.

With suitable materials CO2 emissions can be reduced and advantages in component design can be achieved.

Automotive Highlights of K 2022

Kunststoffe, biobasiert

Elektromobilität

Polymethylmethacrylat

Polycarbonat

Suitable Materials for Smart  Vehicle Design

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)

Kunststoff-Recycling

Sustainability at Every Turn

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. 

Recycling

Calculating and Reducing the Carbon Footprint

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

Facelift for Electric Vehicles

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

Harze, Epoxid

Materialcharakterisierung

Sharp Look at Reactive Resins

The battery system is one of the heaviest components in the powertrain of an electric vehicle. The use of lightweight materials and high-volume production processes according to requirements and functionality offers significant potential to reduce weight without compromising on safety or performance. A new technology concept shows the particular advantages of using a modified direct process with a tailored material selection.

Lightweight battery module with lithium-ion battery cells in pouch cell format and SMC module end plates.

Lightweight Traction Battery System for Electromobility

Composite-Halbzeuge

Verbundwerkstoffe / Werkstoffverbunde

Leichtbau

Harzsysteme für Composite-Herstellung

Energiespeichersysteme

Lightweight Construction  for Heavyweights

In a research project being carried out by the IKV and KTP, the influence of geometric and process parameters on the quality of the screw connection in the direct assembly of thermosetting plastics has been analyzed. The research results show that, in addition to the geometric design, the production parameters offer additional optimization potential for the reliability of the screw connection. The compactness and curing degree of the parts exert the largest influence.

Encapsulation protects the sensitive sensor technology from external influences. The direct screw connection enables secure mounting of the module.

Higher Process Quality through Adjustment of the Production Parameters

Verbindungstechnik

Schraubtechnik

Achieving a More Secure Connection with the Correct Design

Patient movements can severely affect the quality of MRI and CT images. A new approach detects the movements and subsequently incorporates them into the image evaluation by means of correction algorithms. This significantly improves the image quality. For the detection of the patient’s movements, the use of polymer optical fibers is suitable.

Polymer Optical Fibers Increase the Reliability of MRI Images

Fasern

LED / OLED-Systeme und Faseroptik

Lichttechnik

Medizintechnik

Lichtwellenleiter (LWL)

Motion Sensing Light Guides

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.

Kfz-Elektronik

Klebstoffe

Protection of Sensitive Charging Electronics

Within the “BarriFlex” joint project, novel nano-tailored materials with improved barrier properties against gas and water vapor were developed for packaging applications. These materials form the basis of new packaging concepts. Despite intensive research, much still remains to be done as regards diversity of materials, barrier specifications and more efficient manufacturing processes for new, inexpensive, easy-to-recycle and even renewable packaging products.

Production of a demonstrator for a mono-material packaging film.

Flexible and Sustainable Plastic Packaging Film thanks to Nanotechnology

Beschichtungsmassen

Photovoltaik und Solarthermie

Beschichten, Kaschieren, Laminieren

Lack

Nanoplatelets in a Barrier Lacquer

Avient Corporation, Cleveland, OH/USA, presents Gravi-Tech density-modified thermoplastics that enable advanced metal plating surface treatments to deliver both the look and feel of metal in premium packaging applications.

“These metallization-ready grades give premium packaging manufacturers a simpler way to incorporate the luxurious look and weight of metal into their products,” said Matt Mitchell, director, global marketing of Specialty Engineered Materials at Avient

Duroplastische Werkstoffe

Metallization Grades for Luxury Packaging

Thanks to a combination of polylactic acid and flax fabrics, Lanxess launches a full biocomposite in the Tepex range of continuous fiber-reinforced thermoplastic composites.

Demonstrator component with polylactic acid matrix and fabric reinforcement based on flax fibers. The component surface features a brownish bio-carbon appearance, which originates from the flax fibers

Biological and Suitable for Many Applications

At Fakuma, Momentive Performance Materials will be showcasing thermally conductive liquid silicone rubber (LSR) grades designed for high-temperature applications.

Processing of the low-temperature-cured LSR will be demonstrated at Momentive’s booth

Kautschuk / Elastomere

Messe Fakuma

Thermally Conductive LSR with Short Processing Time

Sabic has introduced Noryl GTX 9500 resin, a new addition to a range of unfilled Noryl GTX resin grades, which delivers excellent dimensional stability under hot and humid conditions, addressing the challenge for highly demanding automotive applications.

Sabic´s new Noryl GTX resin features superior dimensional stability in hot and humid conditions for auto applications

Harze

Stability under Hot and Humid Conditions

The process chain of the direct coating process has now been optimized. Self-healing, fast-curing PU casting coatings and polycarbonate compounds are now available for this manufacturing process.

The DC process makes it easier and faster to produce sophisticated-looking components with integrated sensors and light elements

Direct Coating with Polyurethane Coatings Creates Opportunities in Design and Functionality

Automotive

Oberflächentechnik

Kunststoff

Short Cycle Times and High Productivity for Smart Components

As a result of the Corona crisis, press manufacturer Wickert sees only a temporary slowdown in the growth forecasts for composite technologies. The company currently sees four trends in system engineering.

Composite press for research: for scientists at the Chemnitz University of Technology, Wickert developed a highly flexible four-column upper piston press which offers a high level of freedom and diversity in application

The Demand for Composites Will Keep Growing in the Future

Pressen

Automatisierungstechnik

Trends in Composite Manufacturing