PRODUCT DESIGN | MATERIALS
undesired ambient noises and – in the case of external components such as battery boxes on two-wheelers – ensure a weatherable and water-tight enclosure. This is opening attrac- tive new application opportunities for thermo- plastic elastomers, says Kraiburg. “For the anti-rattle cover of the battery connector and the sealing of the redesigned battery box on our bikes and scooters, we were looking for a material that would provide the right balance of gasketing, mechanical and moulding performance,” says Paolo Trabuio, Project Man- ager Scooter, for Askoll. “Kraiburg TPE went a long way in supporting our efforts from concept to market, with qualified assistance in material selection, design optimisation, adhesion testing and moulding trials.” Both TPE applications are injection moulded in a two-component process, which required excellent direct adhesion to the glass-filled polybutylene terephthalate (PBT) resin used for the battery box. In addition, the chosen Thermolast K compound also had to offer good flowability to ensure a precise, tight and faultless fit of the gasket on the narrow contact surface of the lower box compo- nent. In addition, the compound lends the critical long-life mechanical properties required to withstand the shocks and vibration of the box when driving, as well as the wear and tear during frequent removal for charging the maintenance- free battery on the electric grid at home or at work. Kraiburg TPE has also collaborated to develop second skin breathable body protectors with lightweight padding using a flexible TPE com- pound. French company Hexaflex has developed a padding technology based on hexagonal-pyram- idal shapes moulded with TPE. The thermoplastic elastomer compound provides the flexibility, light weight and full articulation characteristics of the modular system that lends itself to many shock and vibration absorbing applications, from sportswear and personal protection equipment to healthcare and other demanding industries. In a first application, the creative technology is used for a dorsal protection product covered with high-strength aromatic PA stretch fabric for bikers and motorcyclists. The lightweight material combination acts like a second skin, and the Hexaflex padding with its interlocking shapes in Thermolast K is fully articulated to follow body motion while ensuring maximum shock absorption. “Innovative concepts like our Hexaflex system need innovative materials to take them from idea to reality,” says Stephane Desnoyers, Founder and CEO of Hexaflex. “Although we knew it would have
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Left: The flexible, inter- locking and fully articu- lated Hexaflex shapes moulded in Thermolast K TPE result in a modular padding technology for many applications, including sportswear, personal protection equipment and healthcare
to be an elastomeric solution rather than foam, the success of this project was essentially driven by the expertise found in collaborating with Kraiburg TPE. Besides helping us specify the most suitable thermoplastic elastomer, they supported us with comprehensive assistance from early on in the design phase through to series production.” The Hexaflex shapes can be moulded in various
sizes, thicknesses and custom colours. Thermolast is claimed to deliver the long-term flexibility required for reliable articulation of the assembled padding throughout the life time of the protectors. The material has also been shown to minimise rebound when the padding is flexed, which results in good shock absorption performance. Further specifications to be met included good mechanical strength and durability over a wide range of temperatures, ease of recycling, as well as the absence of substances of very high concern (SVHC) in the compound. In addition, the padding is fully washable and waterproof but breathable due to integrated ventilation features in the design. Following its successful use in dorsal protectors,
Hexaflex is planning to extend the technology to other sportswear in the near future, including knee and elbow pads for activities such as skateboarding, snowboarding, skiing and horseback riding. The company also sees broad application possibilities in personal protection equipment, from helmet inserts to breathable harnesses, as well as in anti-vibration floor padding and various healthcare products.
CLICK ON THE LINKS FOR MORE INFORMATION: �
www.eastman.com �
www.solac.com �
www.sabic.com �
www.basf.com �
www.wilkhahn.com �
www.covestro.com �
www.embrlabs.com �
www.kraiburg-tpe.com �
www.askoll.com �
www.hexaflex-technology.com
January/February 2019 | INJECTION WORLD
Below: Askoll, an Italian manufacturer of electric
two-wheelers, has specified the use of Thermolast K from Kraiburg TPE for two precision gasketing applications on the new battery boxes of a growing range of power-assist- ed bikes and electro-scooters
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