MATERIALS | AUTOMOTIVE


IMAGE: SABIC


A SABIC concept for a two-component Lexan PC


front panel with transparent PU in-mould coating covering an


assembly moulded in Stamax long-glass


fibre PP. Lighting, sensors, illuminated logo and messaging units are mounted from behind


Right: The Covestro


Adelie car uses Covestro materials, including Makrolon TC in the heatsink in the headlamps


PC characteristics such as outstanding impact strength, weatherability and UV stability, as well as high freedom of design for unique shapes and brand or model differentiation. The part is manu- factured in an injection compression moulding (ICM) process as this provides wall thickness reductions and can accommodate longer flow paths by taking advantage of the compression stroke which enables lower clamp forces and the use of smaller tonnage machines.” Geert-Jan Doggen, Senior Business Develop- ment Manager, Automotive Marketing at SABIC, adds: “The overall decarbonisation of vehicles must also comprise end-of-life recyclability and the reuse of materials within a more circular economy. SABIC has developed long-glass fibre reinforced Stamax PP resins based on up to 30% mechanically recycled content. The technology combines outstanding strength-to-weight with enhanced impact resistance, high stiffness, and low warpage. While these and other long-term performance properties are similar to those of virgin PP-LGF, a cradle-to-gate life-cycle analysis shows major reductions in global warming potential and cumulative energy demand for the recycle-based grades. With specifications and material approvals from many OEMs already in place, vehicles with validated structural applications using these recycle-based grades are expected on the road soon.” Dhanendra Nagwanshi, Global Automotive


Leader, EV Batteries & Electricals at SABIC, says: “Besides battery module casings, end caps, busbars, enclosure covers and connectors, success- ful applications include the world’s first commercial all-thermoplastic battery pack cover that meets stringent international fire safety requirements like GB 18384-202. The 1.6 m² component is moulded in a halogen-free flame retardant PP-LGF com- pound, providing 40% weight reduction against comparable metal designs. In a recent study, a fire retardant PP-LGF compound was evaluated for use


38 INJECTION WORLD | November/December 2023 www.injectionworld.com


Full speed ahead In October, Celanese announced the global commercial launch of two new polyamide solutions for manufacturers of EV powertrain components and EV battery applications. The Frianyl PA W- Series of flame-retardant polyamide solutions enables the manufacturing of large, thick-walled, flame-retardant components for EV batteries, the solutions achieving V-0 flame retardance at 1.5 mm, combined with excellent flow characteristics. Compared to standard PA66 grades with 30% glass fibre reinforcement, the equivalent grade of the new W-Series offers a 10-20% improvement in flow in an injection mould, depending on the pressure applied. The solutions also exhibit an excellent Comparative Tracking Index (CTI) even after aging at 125°C for 1,000 hours. The specialty materials and chemical company


also introduced Celanyl PA B3 GF30 E, a new polyamide-based compound for semi- and structural EV powertrain applications. With this grade, the HB flame class is achieved, as well as a CTI of 600 even after 3,000 hours of aging at 150°C. The extremely low halide content in this solution makes it an electrically friendly option for applications like connectors, switches, relays, and sensors where malfunctions often occur because of surface moisture, elevated temperature, or traces


as a potential thermal barrier or separator material to mitigate the thermal runaway of battery cells in the event of a thermal event. A 5.5 minute horizon- tal flame test at 1,100°C showed that the HFFR compound forms an intumescent and self-extin- guishing char layer which prevents further flame propagation. The PP-LGF resin also excelled when tested according to the new UL 2596 standard, which combines defined pressure, ablative force, heat and fire conditions.”


IMAGE: COVESTRO


Page 1  |  Page 2  |  Page 3  |  Page 4  |  Page 5  |  Page 6  |  Page 7  |  Page 8  |  Page 9  |  Page 10  |  Page 11  |  Page 12  |  Page 13  |  Page 14  |  Page 15  |  Page 16  |  Page 17  |  Page 18  |  Page 19  |  Page 20  |  Page 21  |  Page 22  |  Page 23  |  Page 24  |  Page 25  |  Page 26  |  Page 27  |  Page 28  |  Page 29  |  Page 30  |  Page 31  |  Page 32  |  Page 33  |  Page 34  |  Page 35  |  Page 36  |  Page 37  |  Page 38  |  Page 39  |  Page 40  |  Page 41  |  Page 42  |  Page 43  |  Page 44  |  Page 45  |  Page 46  |  Page 47  |  Page 48