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Currently, small wind turbines can hardly be operated profitably in landlocked regions. This drawback has now been overcome by the partners EAB Gebäudetechnik Luckau GmbH and the Chair of Polymer-based Lightweight Design at the BTU Cottbus-Senftenberg: passive smartblades made from 3D-printed molds adapt independently to wind conditions. This is achieved by an intelligent layer structure and its bending-torsion-coupling.

Additive Manufacture of FRP Injection Molds for FRP Components of Small Wind Turbines

Glasfasern / -matten

Faserverarbeitung

Simulation Produkt- / Formteildesign

Verbundwerkstoffe / Werkstoffverbunde

Finite Methoden

Harze, Epoxid

Windkraft

Analysetools, FEM

Additive Fertigung

Faserverbundwerkstoffe

Highly Efficient Adaptive  Fiber-Composite Rotor Blades

Thanks to new technologies and together with other chemical derivatives the greenhouse gas CO<sub>2</sub> can be converted into plastic precursors. Covestro is developing sustainable insulating materials for the construction sector based on this raw material.

Bauwesen

Baustoffe

Polyurethan-Schaumstoffe (PUR)

Baubetrieb / Bauwirtschaft

Kunststoff Werkstoffe

Dämmstoffe

Polyurethan

Kunststoff

Using CO<sub>2</sub> in Rigid Foam Insulation Boards

For a long time, chemical recycling was considered an unfinished addition to established material processes. In the meantime, however, some technologies are making the leap into large-scale industrial use: an overview of the various processes and providers.

Overview of the Various Processes and Suppliers

Recycling

Polypropylen

Kunststoff-Recycling

What Is Happening in Chemical Recycling?

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

Automotive

Polycarbonat

An Eye-Catching Addition  to Electric Vehicles

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

MCAM about its KyronMAX Structural Thermoplastic Compounds

Compound

Harze

Kunststoff-Erzeugung

Thermoplaste

Expanded Resin Formulations

To meet stringent flame retardancy demands of areas such as transportation and electronics, components based on thermosets increasingly require a soluble, non-powder flame retardant (FR) due to low layer thicknesses in the final product or due to liquid processing methods. Two flame-retardants developed by Clariant meet these requirements.

Completely Halogen-Free Flame Retardancy of Epoxy-Fiber Composite Components

Füllstoffe für Kunststoffe

Flammschutzmittel

Duroplastische Werkstoffe

Duroplaste

Additive

Avoiding Filter Effects of  Flame Retardants

The simple replacement of petroleum-based components with renewable alternatives in a well-established reactive extrusion process is a promising route to more environmentally friendly thermoplastic polyurethane elastomers (TPU). However, this requires a comprehensive understanding of the interactions between chemical reactions and material flow within an extruder, as well as a thorough understanding of the effects of heat and shear on polymerization and melt processing.

Production of Thermoplastic Polyurethanes with Reduced Carbon Footprint

Thermoplastische Elastomere

Extruder

Extrusionsanlagen

Reactive Extrusion of TPU

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)

Bauchemie

Sustainable Growth

The particle foam crowd cannot complain about a lack of interest by potential users. At least as far as demand for products with high-quality functional and optical surfaces is concerned.

A Glossy Surface Quality for Particle Foam Components

Beschichten von Kunststoffen

Spritzgießen

Mehrkomponenten-Spritzgießen

Partikelschäumen

Oberflächentechnik

Lacke für Kunststoff-Oberflächenveredelung

Foam Beads in Gliding Flight

By means of high-performance processes, chemical recycling converts plastic waste into high-grade material for new plastic products. Moreover, freedom of design results by selecting a suitable process and the matching waste material. Hereby, the right combination permits customized polyols to be created for the desired application area.

Solvolysis Using Different Solvents in Practice

Plastic Waste into  Custom-Made Polyols

At the first glance, this year’s K was clearly focused on recycling and the circular economy. However, apart from these topics, many novelties were also exhibited in the classical plastics fields such as automotive. And many materials producers showed exciting new developments for electromobility in particular.

Automotive Trends at the K 2019

Elektromobilität

Streifinger, Florian

Verbände, Institutionen, Messen

Polyamide

Electromobility and a Concept Vehicle

In the midterm, a worldwide increase in PU consumption of 4 to 5 % per year is to be expected. Growth drivers are the sound economic performance in the major industrialized nations so far, and in particular the increasing prosperity in China and emerging markets. In future, the PU business will be strongly influenced by digitalization and the development of closed material life cycles.

The Global PU Sales Reached a New Record in 2018 with just over 20 Million Tons

Schaumstoffe und Vorprodukte

Schaumstoffe

Standardkunststoffe

The traditional markets for glass fiber-reinforced thermoplastics remain stable. Thermoplastic composites are gaining fast with 3D-printing and hybrid processing techniques. The fiber composite industry is tackling the recycling issue with pragmatic ideas.

The Manifold New Collection of Reactive Systems and Thermoplastic Composites

Reaktionsharze

Kohlenstofffasern / -matten

Sekundärfasern

Fasern

Aramidfasern

Harzsysteme für Composite-Herstellung

Phenolharze

Harzwerkstoffe

Hochleistungskunststoffe

Fiber-Reinforced Plastics

Often pure plastic materials are not able to fulfill the increasing demands of plastic component. It is therefore necessary to adapt the properties of the plastics by adding other polymers or additives.

Comparison of Two Techniques to Produce Thermoplastic-Nanoparticle-Composites

Compoundieren

Agglomerate-Free Compounding

Thanks to a patented plastic alloy based on nanotechnology, PPS compounds can be created that are tracking-resistant, even at very high voltages. These compounds prevent the undesired process of carbonization that can lead to an electrical short on the material surface. The PPS is especially suited for high-voltage applications in electric vehicles.

Toray Develops PPS with CTI 600 Volts or Performance Level 0 for Electrical Applications

Elektronik

Abdeckmassen (Elektronik)

Elektronische Bauelemente

Polysulfone / Polysulfide

Werkstoff

Immune to Electrical Breakdown

Cordless, mobile, networked devices promise comprehensive in vitro diagnostics. However, for applications in biological surroundings, the toxic electronic components must be carefully encapsulated. Therefore, cost-effective coating materials were examined regarding their interaction with biological systems. 

Barrier Effect of Polymer Coatings for Encapsulating Smart Biomedical Devices 

HV-Anwendungen / Hybridisierung / Elektrifizierung

Beschichtungsmassen

Medizintechnik

Protective Coat for Electronics and Body 

Henkel AG & Co. KGaA, Düsseldorf, Germany, is extending its Loctite Max range of polyurethane matrix resins with epoxy-based versions. While Loctite Max 5 NextGen offers high transparency for an attractive carbon look, Loctite Max 6, which is soon to be launched, combines high heat resistance with good fracture toughness. In particular in the field of wheel rims, the new resin systems could save component weight, increase productivity and improve the thermal, mechanical and optical properties, according to the manufacturer. 

Henkel Presents Two New Resin Systems 

Crystal-Clear Mesh 

Not only on Earth do elastomers make an important contribution to everyday life in demanding applications but they are also in demand for satellites or probes. Alongside typical worldly properties such as temperature and chemical resistance, materials deployed in space are subject to other conditions specific to this environment, such as enormous centrifugal and gravitational forces. These place special demands on the polymers we are familiar with.  

Properties of and Demands on Silicone Rubbers in the Space and Aerospace Industry 

Kautschuk / Elastomere

Silikone

Compoundeure

Galactic Compounds 

The combination of fiber-reinforced face layers with a lightweight foam core combines high strength and stiffness with low part weight. However, when processing, it is anything but easy to combine anisotropic FRP materials with lightweight, cost-effective foams. A tailored material system now makes processing by high-pressure resin transfer molding possible at low temperatures and pressures, with short cycle times. 

Rapid and Cost-Effective Sandwich Parts with PU Resin and PET Core Foam 

Polyethylenterephthalat

Hard Shell, Lightweight Core 

In a joint project, seven companies developed a combination of technologies for manufacturing electronically functionalized high-quality surfaces, e. g., for applications in and on the car. Demo parts were shown in public for the first time at Fakuma 2018.  

Combination of Technologies for Manufacturing Electronically Functionalized Plastic Parts 

HMI, Bedienelemente, Displays

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

Laserstrukturieren

Lackieren

Premium Surfaces by the  One-Shot Process 

The colorful logo and the name Covestro are already well known. New to the team since summer is Dr. Markus Steilemann who heads the manufacturer of polycarbonates, polyurethanes and specialty chemicals. In our interview he talks about the transformation of the former Bayer division into an independent plastics producer, the pitfalls of large-scale chemistry and what sets him apart from his predecessor other than the consuption of Cola light and coffee. 

Covestro CEO Dr. Markus Steilemann Emancipates the Group, Makes it Digital and  Globally Agile 

Kunden-Lieferanten-Verhältnis

Unternehmenskultur

The Decathletes 