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Drivers of electromobility / Yu Bin in KUNSTSTOFFE INTERNATIONAL, Vol. 110, N° 2 (02/2020)  

[article]  inKUNSTSTOFFE INTERNATIONAL > Vol. 110, N° 2 (02/2020) . - p. 8-13 Titre : Drivers of electromobility : Flame retardancy, heat and tracking resistance of electric vehicles Type de document : texte imprimé Auteurs : Yu Bin, Auteur ; Tamim Sidiki, Auteur ; David Zhu, Auteur Année de publication : 2020 Article en page(s) : p. 8-13 Langues : Anglais (eng) Catégories : Batteries électriques Ignifugeants Composé chimique utilisé pour réduire l'inflammabilité. Il peut être incorporé au produit durant sa fabrication ou appliqué ultérieurement à sa surface. Matières plastiques dans les automobiles Polyamide 6 Polyamide 66 Polymères ignifuges Résistance thermique Véhicules électriques Index. décimale : 668.4 Plastiques, vinyles Résumé : 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. The following article presents an overview of the most important changes. Note de contenu : - Flame protection is required - ID.2 reaches USD 100 per kWh - Without halogens, phosphar and halides - Reasons for electric breakdown - Figure : In electric vehicles, the change in engine technology also entails new requirements for the plastic materials used - Fig. 1 : Key components of the high voltage drive train system of a Chevrolet Bolt - Fig. 2 : PA is a very suitable material also for EV applications. For instance, PA6 and PA66 are used in HV connectors, HV PA 4T busbars and contactors - Fig. 3 : Terminal corrosion caused by outgassed heat stabilizers of migration of other ionic impurities in the plastic - Fig. 4 : In order to increase the the voltage rather than the current - Fig. 5 : The creep distance is often deliberately increased to prevent the flow of current between two contacts - Fig. 6 : Comparison of different polymer classes by tracking resistance. Colors indicate respective mechanical strength - Fig. 7 : Electric breakdown strength before aging at-elevated temperatures. Most polymers show a decline in breakdown strentgh at rising temperatures - Fig. 8 : Electric breakdown strength after aging at elevated temperatures. The curves of the materials are similar before and after aging. As a result of aging, the dielectric strength decreases as expected - Fig. 9 : DSM high-voltage material portfolio for high operating temperatures. Different materials are recommended depending on the temperature range - Fig. 10 : Functional diagram of the powertrain in a battery electric vehicle. Electrification adds further components - Table 1 DSM portfolio of compounds without critical halide salts or red phosphorous, which could lead to electro corrosion En ligne : https://drive.google.com/file/d/1odl1Mid1-bXu7zTe7Qf58lM9EpQhdHJF/view?usp=drive [...] Format de la ressource électronique : Pdf Permalink : https://e-campus.itech.fr/pmb/opac_css/index.php?lvl=notice_display&id=33974 [article]

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Polypropylene beats aluminum / Harri Dittmar in KUNSTSTOFFE INTERNATIONAL, Vol. 110, N° 2 (02/2020)  

[article]  inKUNSTSTOFFE INTERNATIONAL > Vol. 110, N° 2 (02/2020) . - p. 16-19 Titre : Polypropylene beats aluminum : Underbody protection for batteries in electric vehicles Type de document : texte imprimé Auteurs : Harri Dittmar, Auteur Année de publication : 2020 Article en page(s) : p. 16-19 Langues : Anglais (eng) Catégories : Bandes composites Batteries électriques Composites à fibres de verre Fibres à orientation unidirectionnelle Incendies -- Prévention Matières plastiques dans les automobiles Polypropylène Résistance thermique Véhicules électriques Index. décimale : 668.4 Plastiques, vinyles Résumé : Batteries in electric vehicles must be specially protected to counter the risk of fires. Battery trays made from aluminum frequently offer insufficient protection. The automotive supplier ElringKlinger has therefore developed underbody protection manufactured from glass fiber-reinforced PP. Note de contenu : - Sandwich structure with UD tapes - Underbody also protects against fire - Material reduces energy requirement - Figure : To be suitable for the underbody protection of electric vehicles, a material must first pass a bollart test - Fig. 1 : UD tapes made from PP with a high glass fiber content had much higher values than the other materials tested - Fig. 2 : Deflection under load (180 mm diameter, 100 kg. 84 J) : in contrast to aluminum, the PP sandwich structure transfers the energy fully elastically - Fig. 3 : After three repetitions of the bollard test, the aluminum sheet had significantly deformed by 12.2 mm, whereas the ElroSafe sheet was undamaged - Fig. 4 : The material must withstand temperatures of up to 800°C in the five test. This ensures that the battery does not catch fire - Fig. 5 : Temperature curves in the fire test : the temperatures measured on the aluminum frame are initially far higher than those measured on the ElroSafe sheet - Table 1 : Results of the bollard test on UD tapes with different glass fiber contents and an aluminum sheet En ligne : https://drive.google.com/file/d/13CwXrHuDMU8qKnbwQuDS9jspcHlANKuJ/view?usp=drive [...] Format de la ressource électronique : Pdf Permalink : https://e-campus.itech.fr/pmb/opac_css/index.php?lvl=notice_display&id=33975 [article]

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Automotive display : a matter of form / Martin Lenz in KUNSTSTOFFE INTERNATIONAL, Vol. 110, N° 2 (02/2020)  

[article]  inKUNSTSTOFFE INTERNATIONAL > Vol. 110, N° 2 (02/2020) . - p. 20-23 Titre : Automotive display : a matter of form : Large-area curved plastic panels with integrated displays Type de document : texte imprimé Auteurs : Martin Lenz, Auteur ; Kai Hohmann, Auteur Année de publication : 2020 Article en page(s) : p. 20-23 Langues : Anglais (eng) Catégories : Automobiles -- Tableaux de bord Décoration dans le moule Ecran de visualisation Ecrans tactiles Matières plastiques -- Moulage par compression Matières plastiques -- Moulage par insertion de film Matières plastiques dans les automobiles Polycarbonates Structures tridimensionnelles Index. décimale : 668.4 Plastiques, vinyles Résumé : 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. Note de contenu : - Continuous 3D plastic panel - Finding the right raw materials - 3D forming of large components - Increased tactile feedback - Advantages of the combined process - Fig. 1 : The plastic panel is manufactured in two separate processes, which are then merged together - Fig. 2 : The FIM machine for 3D heat forming of large-size polycarbonate arcs operates at 60 nar - Fig. 3 : The twelve-part tensioning frame for positioning the IMD film ensures precision fixing of the filmm before backmolding - Fig. 4 : Surface topographies on the panel make blind operation of functions in the display easier En ligne : https://drive.google.com/file/d/1Hs0A_-URoG8K3nglXe9D0kv0W0lnZuxK/view?usp=drive [...] Format de la ressource électronique : Pdf Permalink : https://e-campus.itech.fr/pmb/opac_css/index.php?lvl=notice_display&id=33976 [article]

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Easier to reach the destination / Georg Grestenberger in KUNSTSTOFFE INTERNATIONAL, Vol. 110, N° 2 (02/2020)  

[article]  inKUNSTSTOFFE INTERNATIONAL > Vol. 110, N° 2 (02/2020) . - p. 24-27 Titre : Easier to reach the destination : PP compounds for automotive lightweight construction Type de document : texte imprimé Auteurs : Georg Grestenberger, Auteur ; Markus Kralicek, Auteur Année de publication : 2020 Article en page(s) : p. 24-27 Langues : Anglais (eng) Catégories : Composites à fibres de carbone Composites à fibres de verre Matériaux -- Allègement Matières plastiques -- Propriétés mécaniques Matières plastiques dans les automobiles Mousses plastiques Polypropylène Index. décimale : 668.4 Plastiques, vinyles Résumé : 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). With the right reinforcements, it is also suitable for demanding vehicle components. This is demonstrated by its use in ‧vehicles such as the NIO ES8. Note de contenu : - Need for weight reduction drives innovation in automotive exteriors and structural parts - Carbon fiber-reinforced PP : when stiffness matters most - PP foams : keeping cool without draining the battery - Sustainability : higher on the agenda than ever before - Figure : The chines manufacturer NIO uses carbon fiber-reinforced PP compounds for the center console support of the ES8 electric SUV - Fig. 1 : PP compound Daplen EE001 Al has good scrtch resistance and surface quality despite its low material density of 0.95 g/cm3. Skoda therefore relies on this material for the door trim of its Scaa - Fig. 2 : Glass-fiber-reinforced PP is suitable as a PA replacement. For example, the front end module of Borealis is made of the material - Fig. 3 : Comparison of the bending stiffnes (E 1/3/p) of different lightweight materials (number in the bars indicates the density in g/cm3) : the filler content of all plastics is 40% - Fig. 5 : In order to be able to simulte components in a meaninful way, comprehensive material characterization by the manufacturer is necessary. This requires material tests such as tensile tests - Fig. 6 : Foamed components reduce the weight and thus also the energy consumption of the vehicles. Foaming is therefore an interesting option, especially for electric vehicles En ligne : https://drive.google.com/file/d/1iKNjgrobeYdrlq-AtJreWwytu0FPQ5fN/view?usp=drive [...] Format de la ressource électronique : Pdf Permalink : https://e-campus.itech.fr/pmb/opac_css/index.php?lvl=notice_display&id=33977 [article]

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Replacing metal in the gearbox / Roger Kaufmann in KUNSTSTOFFE INTERNATIONAL, Vol. 110, N° 2 (02/2020)  

[article]  inKUNSTSTOFFE INTERNATIONAL > Vol. 110, N° 2 (02/2020) . - p. 28-31 Titre : Replacing metal in the gearbox : Production-ready plastic shifter fork offers a maximum of functional integration Type de document : texte imprimé Auteurs : Roger Kaufmann, Auteur ; Jana Horn, Auteur Année de publication : 2020 Article en page(s) : p. 28-31 Langues : Anglais (eng) Catégories : Automobiles -- Moteurs -- Pièces Boites à vitesse Composites à fibres de carbone Composites à fibres de carbone -- Propriétés mécaniques Essais de résilience Essais dynamiques Matériaux -- Allègement Matières plastiques dans les automobiles Polyphthalamide Index. décimale : 668.4 Plastiques, vinyles Résumé : Anyone seeking to replace a metal component by a plastic one, to reduce the number of component parts from eight to three and simultaneously cut both the weight and manufacturing costs needs to take great care to ‧ensure that all specifications are met – especially if the component is used in a hot gearbox and is subject to high mechanical stress. For developing a new shifter fork, GK Concept and its customer Koki Technik were awarded the 2019 GKV/TecPart Innovation Prize. Note de contenu : - Trojan work at up to 160°C - Systematic search for the right material pairing - A million windings for the insert - Functional integration brings decisive cost advantages - Endurance tests on automotive test rigs already passed - Figure : The shifter fork creates a positive lock between the gear wheel and the shaft so that the engine power can be transmitted to the wheels - Fig. 1 : An operating temperature of 120°C creates harsh conditions. The maximum permissible deformation of the fork-ends under an acting force of 1500N was well below 0.8 mm - Fig. 2 : Clearly visible : the reinforcement of the shifter fork with chopped carbon fibers - Fig. 3 : The filling simulation reveals the simultaneous melt flow into both fork ends. The carbon fiber insert is clearly visible on the right of the figure - Fig. 4 : The high degree of orientation of the fibers increases the load-bearing capacity of the part and reduces shrinkage in the direction of the fibers En ligne : https://drive.google.com/file/d/1juOPLXKtJeTkEjfS_tc6pOhxAGWEvoN_/view?usp=drive [...] Format de la ressource électronique : Pdf Permalink : https://e-campus.itech.fr/pmb/opac_css/index.php?lvl=notice_display&id=33978 [article]

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Runway lights for the seat belt / Sabine Kob in KUNSTSTOFFE INTERNATIONAL, Vol. 110, N° 2 (02/2020)  

[article]  inKUNSTSTOFFE INTERNATIONAL > Vol. 110, N° 2 (02/2020) . - p. 32-34 Titre : Runway lights for the seat belt : Twin-turn pool provides solution to production problem with a double turn Type de document : texte imprimé Auteurs : Sabine Kob, Auteur Année de publication : 2020 Article en page(s) : p. 32-34 Langues : Anglais (eng) Catégories : Automobiles -- Eclairage Matières plastiques dans les automobiles Polycarbonates Rayures Résistance à l'abrasion Terpolymère acrylonitrile butadiène styrène Index. décimale : 668.4 Plastiques, vinyles Résumé : 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. Note de contenu : - A small rotary plate on the fixed side - Absolute uniform illumination necessary - The scratch-resistant coating does not tolerate any cracks - Figure : No need to fiddle for the seat belt buckle anymore : an integrated light guide provides orientation for car passengers. Nonetheless, the production process proved to be quite a task - Fig. 1 : The inner contour and exterior cover of the light guide (in reality bot black, in the graphic green, and orange for better differentiation) cannot be formed in one process - Fig. 3. Small rotary plate on the nozzle side : the twin-turn tool is also partly movable on the usually fixed side. The complete tool rotates on the ejector side - Fig. 4 : The rotary plate does a 180° turn so that the freshly molded PC light guide ends up on the ejector side in station 2. There the inner contour with assembly elements is formed from black PC+ABS En ligne : https://drive.google.com/file/d/1EJ62pHC0gOFgsPqHfCH9w4Ms5F7SdbUM/view?usp=drive [...] Format de la ressource électronique : Pdf Permalink : https://e-campus.itech.fr/pmb/opac_css/index.php?lvl=notice_display&id=33979 [article]

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Rattle-free part in KUNSTSTOFFE INTERNATIONAL, Vol. 110, N° 2 (02/2020)  

[article]  inKUNSTSTOFFE INTERNATIONAL > Vol. 110, N° 2 (02/2020) . - p. 35-37 Titre : Rattle-free part : Flexible turnkey system for multi-variant roller blinds Type de document : texte imprimé Année de publication : 2020 Article en page(s) : p. 35-37 Langues : Anglais (eng) Catégories : Automobiles -- Pièces Matières plastiques -- Moulage par injection Matières plastiques bi-composant Matières plastiques dans les automobiles Store enrouleur Index. décimale : 668.4 Plastiques, vinyles Résumé : 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. The individual slats of the roller blind are manufactured on a large two-component injection molding machine and, while they are still in the turnkey system, are combined with externally supplied parts to form the finished roller blind. Note de contenu : - Central Selogica controls processes - A large and a small six-axis robot as assembly team Figure : The center console of the Mercedes GLE class, which are equipped with a roller blind. The individual slats of the roller blind are injection molded using a two-component machine and combined with externally supplied parts to form the finished subassembly - Fig. 1 : A two-component injection molding machine with a clamping force of 5000 kN and two six-axis robots integrated into the machine controller form the heart of the system En ligne : https://drive.google.com/file/d/1zxR9XN0nWiFu00-z4kTtfwqsKdNLnqon/view?usp=drive [...] Format de la ressource électronique : Pdf Permalink : https://e-campus.itech.fr/pmb/opac_css/index.php?lvl=notice_display&id=33980 [article]

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New application areas for cube molds on standard machines in KUNSTSTOFFE INTERNATIONAL, Vol. 110, N° 2 (02/2020)  

[article]  inKUNSTSTOFFE INTERNATIONAL > Vol. 110, N° 2 (02/2020) . - p. 38-39 Titre : New application areas for cube molds on standard machines : Compactcube reduces initial capital outlay and maintenance requirements Type de document : texte imprimé Année de publication : 2020 Article en page(s) : p. 38-39 Langues : Anglais (eng) Catégories : Matières plastiques -- Appareils et matériel Moules d'injection Outillage Index. décimale : 668.4 Plastiques, vinyles Résumé : The newly developed Compactcube mold system from Foboha can be used on slightly modified standard machines in the low to medium clamping force range. This means that the advantages of cube mold technology are now also available for applications with smaller production volumes. Note de contenu : - Space requirements, energy consumption, number of cavities : advantages everywhere - Figure : The Compactcube is attractive to the automotive, electronics, and medical technology industries En ligne : https://drive.google.com/file/d/1TFRXWrEdIh1j9Eh_KTSlmbQGTZkNKc0N/view?usp=drive [...] Format de la ressource électronique : Pdf Permalink : https://e-campus.itech.fr/pmb/opac_css/index.php?lvl=notice_display&id=33981 [article]

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The switchover problem and its consequences / Christian Hopmann in KUNSTSTOFFE INTERNATIONAL, Vol. 110, N° 2 (02/2020)  

[article]  inKUNSTSTOFFE INTERNATIONAL > Vol. 110, N° 2 (02/2020) . - p. 40-43 Titre : The switchover problem and its consequences : Phaseless process control should revolutionize the switchover process Type de document : texte imprimé Auteurs : Christian Hopmann, Auteur ; Katharina Hornberg, Auteur Année de publication : 2020 Article en page(s) : p. 40-43 Langues : Anglais (eng) Catégories : Matières plastiques -- Moulage par injection Moulage par injection -- Défauts Procédés de fabrication Qualité -- Contrôle Index. décimale : 668.4 Plastiques, vinyles Résumé : The switchover process from the injection phase to the holding pressure phase is frequently the cause of ‧reduced part quality in injection molding. An alternative process control concept aims to remedy this by completely eliminating the switchover process. For this purpose, the cavity pressure curve is predetermined and controlled for the entire filling process. Note de contenu : - Which switchover method is best ? - Part quality is process-dependent - How the switchover affects the quality - The solution to avoid the break between the controlled variables - Figure : Typical injection molding defects, caused by incorrect switchover from injection toholding pressure phase - Fig. 1 : The parts were manufactured on an injection molding machine (type: Allrounder 370A, manufacturer : Arburg GmbH + Co KG, Lossburg) using a polypropylene (grade : PP579 S) - Fig. 2 : The regression analysis describes the change in length of the part when the machine setting variable is varied by one unit - Fig. 3 : A pressure peak can be identified in the cavity pressure curve for the screw position-dependent switchover method - Fig. 4 : The control loop consists of a superordinate quality control, which generates the target trajectories for a subordinate process control - Fig. 5 : The cavity pressure curve steadily converges to the reference trajectory of 250 bar En ligne : https://www.kunststoffe.de/en/journal/archive/article/phaseless-process-control- [...] Format de la ressource électronique : Pdf Permalink : https://e-campus.itech.fr/pmb/opac_css/index.php?lvl=notice_display&id=33982 [article]

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Foam beads in gliding flight / Erwin Bürkle in KUNSTSTOFFE INTERNATIONAL, Vol. 110, N° 2 (02/2020)  

[article]  inKUNSTSTOFFE INTERNATIONAL > Vol. 110, N° 2 (02/2020) . - p. 45-48 Titre : Foam beads in gliding flight : A glossy surface quality for particle components Type de document : texte imprimé Auteurs : Erwin Bürkle, Auteur ; Thomas Schwachull, Auteur Année de publication : 2020 Article en page(s) : p. 45-48 Langues : Anglais (eng) Catégories : Billes de mousse Mousses plastiques Ondes électromagnétiques Polyuréthanes Sellerie Surfaces (technologie) Technique des plasmas Température -- Contrôle Vélo -- Matériaux Index. décimale : 668.4 Plastiques, vinyles Résumé : 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. However, development has stagnated since the joint research project SamPa sponsored by the German Federal Ministry of Education and Research reached its conclusion. There is an urgent need for action. Note de contenu : - Skin forming for better surface quality - Electromagnetic waves instead of steam - Advantages of variotherm mold temperature control - Using plasma to render EPP surfaces "compilant" - Process monitoring requires complex sensor technology - Figure : Before flow coating with PU, the EPP surface must be activated - Fig. 1 : In the Wave Foamer, electromagnetic waves cause the polymer chains to oscillate, so that the foam beads are heated from the inside outward - Fig. 2 : A-pillar of particle foam with textured surface - Fig. 3 : Schematic representation of the skin formation in five steps - Fig. 4 : Section through an A-pillar produced by the IMPFC process - Fig. 5 : To activate the EPP surface, the chemical and physical interaction between the plasma and plastic causes, a) reaction of an isocyanate functional group with the PU layer, and b) a fixed atomic bond between the PU layer and EPP - Fig. 6 : After pretreatment with plasma, EPP can be flow-coated with a semi-rigid foam, with which this pattern is flow-coated with a further PU system - Fig. 7 : EPP saddle as a technology demonstrator : functionalized with a printed circuit and flow-coated with clear coat to investigate the depth effect (le) ; flow coated with "piano black" PU (right) in different layer thicknesses (0.5 mm, 1.5 mm and 2.5 mm), in order to illustrate the color intensity En ligne : https://www.kunststoffe.de/en/journal/archive/article/a-glossy-surface-quality-f [...] Format de la ressource électronique : Pdf Permalink : https://e-campus.itech.fr/pmb/opac_css/index.php?lvl=notice_display&id=33983 [article]

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