BASF's New Elastollan® AC 55D10 HPM TPU Finds Application in Citroën C4 Cactus' Airbumps

As a manufacturer of thermoplastic polyurethane (TPU), BASF has successfully optimized the material so that it can be applied extensively and unpainted on the vehicle exterior. The automotive manufacturer PSA Peugeot Citroën uses the new TPU grade Elastollan® AC 55D10 HPM (High Performance Material) for cladding the Citroën C4 Cactus with so-called Airbumps®. These are large air-filled cushion bumpers in contrasting colors: They are fitted on the sides as well as on the front and rear of the vehicle, protect the car exterior from impact and scratches and give the vehicle its distinctive look. This world first is the result of many years of development work between the French automotive manufacturer, the supplier Rehau, Switzerland and BASF. Rehau manufactures the side Airbumps®, while the company Faurecia, France produces the bumpers at the front and back.

"With their characteristic Elastollan® surface, Airbumps® embody the philosophy of the Citroën C4 Cactus perfectly — they have style and are multifunctional. Together with BASF and the suppliers of the Airbump® parts, we have shaped material development and the manufacturing process in such a way that the two have resulted in models offering the optimum combination of quality, aesthetics and costs", explains Jérôme Vinot Préfontaine, Purchasing General Manager for the C4 Cactus program at PSA Peugeot Citroën. The advantage of Elastollan® HPM lies in its freedom of design and long-term durability together with attractive haptics and a high-class appearance. The new material combines the properties of conventional TPU, such as good tensile strength and abrasion resistance, elasticity, excellent impact resistance at low temperatures and high media resistance, with new features: It has outstanding surface properties even at low wall thicknesses, it is scratch-resistant, UV- and weather-resistant, is easy to clean and has a high service temperature of 120 to 150°C.

Good assembly properties

This makes it an ideal surface for the impact-absorbing Airbumps® which give the C4 Cactus its characteristic graphic looks. The injection-molded Elastollan® component is mounted to a polycarbonate and acrylonitrile-butadiene-styrene (ABS) support shell, thus forming flexible cavities that can be dented and bounce back again. The entire structure is fixed to the metal chassis. Because of the good mounting properties of the HPM grade a tight assemblage is possible which conventional trim materials such as polypropylene do not achieve.

Elastollan® HPM can be pigmented, so the Airbumps® do not have to be painted. Thus, they do not require any special maintenance and in case of an accident help reduce the repair costs for the vehicle. The bumpers are available in four contrasting colors (black, brown, light and dark gray) and contribute to the harmonious individual color design with the automotive coatings, primers and clearcoats from BASF's Coatings Division.

Processing: short cycle time and good flow properties

BASF has also further developed the processing properties of the new Elastollan® grade. The material can be injection-molded within a wide process window with a cycle time that is 50% shorter compared with conventional TPU. It has excellent flow properties, which means that low wall thicknesses of 1.5 to 1.8 mm can be produced without affecting the surface quality. "Because of the high demands on surface and color, hardness and flexibility the close cooperation with BASF in material formulation and application development was a decisive factor for us", explains Bernard Delles, Project Head at the automotive supplier Rehau which manufactures the side Airbumps®. Faurecia uses the new Elastollan® HPM for manufacturing the bumpers at the front and back of the C4 Cactus. "The innovation lay not only in the material but also in the mounting. BASF has developed a plastic that required a new assembly technology. We worked closely to meet the requirements for the industrial mass production of these unusual parts", says Sébastien Bret, Development Manager at Faurecia.

Up to now, Elastollan® has been used in the automotive industry as cable sheathing, in the engine compartment and in the vehicle interior, e.g. for door handles, gear knobs and cupholder linings. BASF's TPU can be injection-molded, extruded or blow-molded.

Meet BASF at Fakuma 2014, Friedrichshafen, October 14-18, 2014, hall B4, booth 4306.

Airbump® is a registered trademark of PSA Peugeot Citroën.

Source: BASF

LANXESS Achieves Process Innovation in Production of Tepex Continuous FRT Composites

LANXESS has achieved a process innovation in the production of continuous fiber-reinforced thermoplastic Tepex composites. The subsidiary company Bond-Laminates, which manufactures these composites, is now able to continuously series-produce large semi-finished composite products in which the continuous fiber layers can be oriented at almost any conceivable angle. Until now, the continuous fibers in Tepex could only be lined up in the direction of production or perpendicular to it (0 degrees or 90 degrees). This process innovation means the designer can use the differently oriented composite continuous fibers to help him react more specifically to the force transmission in the target component. Even quasi-isotropic constructions can now be fashioned using Tepex. "This means Tepex can be used to design lighter-weight composite components that are tailored even more specifically to the load in question. So the new-generation Tepex strengthens our position as a leading supplier of thermoplastic high-performance composites for lightweight design," says Dr. Dirk Bonefeld, head of Research and Development at Bond-Laminates.

Suitable for large-scale series production with minimal waste

These multiaxial Tepex semi-finished products are fully impregnated and consolidated. Despite being formable to quite extreme angles, their impregnation means the fibers are unlikely to slip. As in the past, Bond-Laminates will consult closely with the customer regarding cutting the semi-finished products into pre-contoured profiles for forming and overmolding or compressing. Special nesting programs help keeps wastage to a minimum in almost all cases. "Thus the processor receives a fully constructed, made-to-measure composite material that can be shaped into highly load-resistant, complex components in very short cycle times without generating wastage," says Bonefeld.

Unidirectional properties

Thanks to the continuous fibers' high degree of orientation, the individual fiber layers demonstrate almost unidirectional properties. The stiffness and strength of the individual layers based on polyamide 6 and continuous glass fibers are 37 GPa and 780 MPa respectively in the direction of the fibers.

Broad spectrum of applications

Their high-quality mechanical set of properties, which can be tailored to meet specific requirements, makes multiaxial Tepex semi-finished products the perfect material for manufacturing high-strength structural components and semi-structural components for automobiles in particular. "For example, we are currently working on front end carriers, pedal and seating components, carriers for electrical and electronic modules, engine compartment guard plates, airbag housings and components used in underbody protection. We are also looking at components that require custom construction for meeting a combination of torsional and flexural load requirements," Bonefeld adds.

Source: LANXESS

DSM's Dyneema® UHMWPE Fiber-based Fishing Trawls Improve Sustainability of Fishing Industry

Fishing Company Cornelis Vrolijk, based in IJmuiden, The Netherlands, and its subsidiary Jaczon, based in Scheveningen, The Netherlands, are specialized in pelagic fishing. The fishing trawls on board of their trawlers, which are used for catching pelagic (schooling) species, are traditionally made of nylon. Cornelis Vrolijk and Jaczon are now replacing their nylon trawls by trawls made from DSM's light and exceptionally strong UHMwPE (ultra high molecular weight polyethylene) fiber, branded as Dyneema®.

The use of this far thinner material in pelagic trawls offers immediate and tangible environmental advantages. The reduced resistance of the trawls in the water translates into a significant reduction in CO₂ emissions, thus reducing the CO₂ footprint of the pelagic fishing fleet. In this way Dyneema® makes a substantial contribution to improving the overall sustainability of the fishing industry.

The innovative trawls made from Dyneema® were developed by Maritiem BV in Katwijk, The Netherlands, in close consultation with DSM. Around 90% of the trawl material is Dyneema®. During both the design and use of the trawls, Maritiem worked closely with the relevant departments of both fishing companies and with the officers on board the vessels.

Dyneema® fiber is used in hand-spliced front sections of the trawls, from mesh size 800 mm and up. According to Maritiem some of these sections were previously made of knotted netting, but the knots were prone to slip. This does not happen with hand-spliced trawls. Dyneema® can be used for these sections. Dyneema® is also used for the selvedge lines and the frame ropes.

In order to allow for a proper comparisons, identical trawls made of predominantly conventional materials such as nylon, were also carried on board some of the vessels. This made it possible to compare the performance of the different materials used in trawls of an identical design. The fishing company's assessment of the new trawls was extremely positive.

Eric Roeleveld, Operations Manager of Jaczon says: "As a company specialized in pelagic trawling, we are profoundly aware of the environmental impact of our activities. One of our key drivers is to continuously look for increased sustainability in our fishing methods. We try to reduce our CO₂ footprint wherever possible and support the FAO code of conduct for sustainable fisheries."

Cornelis Vrolijk and Jaczon now have eight of the trawls made with Dyneema® in use. The size and shape of the trawls depends on the targeted species, fishing area and the dimensions of the vessel.

The newly developed trawls offer a number of specific benefits in comparison to traditional nylon versions. The lighter material makes them easier to handle and therefore safer in use for the crew.

Feedback on the new fishing trawls has been favorable: "Positive results are coming in from all quarters." says Johan Müller, Cornelis Vrolijk's Fishing Fleet Manager, "We can also confirm a substantial reduction in fuel consumption and subsequent CO₂ emissions."

As well as easier, safer use and savings on fuel, the development of lightweight fishing trawls has brought about a major improvement in sustainable fishing techniques. "This is good for the environment and good for the fishing industry." says Johan Müller. "We would definitely encourage other fishing companies to adopt this strategy and the use of this new material as well."

Dyneema® and Dyneema®, the world's strongest fiber™ are trademarks of DSM. Use of these trademarks is prohibited unless strictly authorized.
All other trademarks are the property of their respective owners.

Source: DSM

Braskem Provides Sugarcane Ethanol Derived Green PE-based Packaging for Organic Bread

Eureka! Organic Bread is introducing three bread varieties on the East Coast. The new flavors are certified Vegan and USDA Organic, and the renewable bag demonstrates the company's commitment to sustainability. Braskem and Bimbo packaging engineers have been working to produce bio-based packaging using Braskem's Green Polyethylene, which is produced from sugarcane ethanol, a 100 percent renewable raw material. The sugarcane used is non-GMO (genetically modified organisms) based. The bread packaging is made with 36 percent bio based material; verified using ASTM D6866, Eureka! Organic Bread bags are the first packaged bread in North America to use this renewable and sustainable technology.

For each ton of plastic produced, green plastic sequestrates approximately 2.15* tons of CO₂ from the atmosphere. To help consumers recognize green plastic in stores, Braskem created a seal, which guarantees the renewable content of the plastic.

Braskem has been making Green Polyethylene since 2010 at its Triunfo Petrochemical Complex, in the state of Rio Grande do Sul, in the south region of Brazil. The plant's capacity is 200 kton/year and the total investment amounts to US$290 million.

Source: Braskem

Momentive's Lightweight CF Epoxy Door Structure Wins SPE's ACCE's 'People's Choice' Award

Momentive Specialty Chemicals Inc. ("MSC") won the "People's Choice" Award for the "Most Innovative Composite Part" at the annual Society of Plastics Engineers Automotive Composites Conference & Exhibition (ACCE) last month in Novi, Michigan. The lightweight carbon fiber epoxy door structure submitted by MSC was singled out by vote of conference attendees.

Judging for the competition was based on the impact and trendsetting features of each application, including construction materials, processing methods, assembly methods, and other technologies that made the application possible. Design benefits, weight and cost reduction, parts consolidation, functional integration, and improved performance were also taken into consideration.

The winning component was a light-weight, carbon fiber epoxy door and window frame profile produced by Benteler-SGL for 2013 and later Porsche 911 GT3 Cup coupes. The composite was manufactured by high pressure resin transfer molding (HP-RTM) using MSC's EPIKOTETM 04695-1/EPIKURETM 05357 epoxy resin system, carbon fiber (Sigrafil® type C40 supplied by SGL Group) and polyester fiber. The component's Class A surface was finished in the body color.

Innovative features of this part include a simplified, integrated 2-piece design with a single structural inner piece incorporating the header, and a Class A outer panel. The door is a light-weight, trimmed body structure weighting 5.5 kg, compared to 15.0 kg for the standard series door. The raw body of the door weights 4.0 kg and the polycarbonate window and paint weight 1.5 kg. The inner and outer shells are manufactured via HP-RTM, and the outer shell is designed as a "micro-sandwich" to achieve the requisite buckling strength and performance at the minimum weight.

Design benefits of this MSC epoxy resin composite part are: a greater than 60% weight reduction, compared with metal; lower vehicle center of gravity; Class A appearance; and short cycle-time production. The HP-RTM process is set up in automated steps, accommodating build rates from low volume (500 pieces/year) to high volume (up to 100,000 pieces/year) with a fully automated process line.

Source: Momentive Specialty Chemicals Inc.

Braskem, Amyris & Michelin Collaborate to Develop & Commercialize Renewably-sourced Isoprene

Amyris, Braskem and Michelin announced recently that Braskem is joining a collaboration already launched in 2011 between Michelin and Amyris. This collaboration was initiated to develop and commercialize renewable isoprene, sourced from various biomass as an additional sustainable pathway to produce isoprene.

Under the terms of the agreement, Braskem, Michelin and Amyris will work together to develop a technology to utilize plant sugars, such as those found in Brazilian sugarcane or cellulosic feedstocks, to produce renewable isoprene. Adding the expertise of Braskem, the largest petrochemical company in the Americas and one of the global leaders in the production of biopolymers, Amyris and Michelin will accelerate the industrialization of renewable isoprene.

Amyris will share its rights to commercialize the renewable isoprene technology developed under this collaboration with Braskem. Michelin will maintain certain preferential, but not exclusive, access to the renewable isoprene to be produced by this technology. The companies will not disclose details of the agreement, including the financial contributions of each party.

This joint project, with Amyris and Braskem, will give Michelin an additional sustainable sourcing channel for poly-isoprene for the production of quality tires, providing a high-performance, environmentally responsible material.

“With this new partnership, we join forces with Amyris and Michelin in the development of an innovative technology that strengthens our commitment to improve people’s lives, creating solutions through sustainable chemistry,” said Luciano Guidolin, Vice President for Polyolefins and Renewables of Braskem. With a proven track record in leading research in sustainable chemistry, Braskem has already an experience in the development of 100% renewable polyethylene.

“Braskem is an ideal partner to join our isoprene project with Michelin. They bring the right expertise and share in our commitment to transform the chemical industry through sustainable product innovation and superior performance,” said John Melo, President & CEO of Amyris. “Amyris has led the way in producing long-chain hydrocarbon molecules via fermentation, from anti-malarial drug precursors to long-chain hydrocarbon molecules used in cosmetic emollients and even fuels. Building on the success of this proven technology to produce tailored hydrocarbons, we are revolutionizing the way products are made, one molecule at a time,” concluded Melo.

“We are pleased to have a strong industrial partner join our ongoing collaboration with Amyris. Braskem’s chemical industry experience, coupled with Amyris’s biotechnology expertise, will support Michelin’s goal of addressing the long-term needs of the tire industry for sustainable sourcing with renewable chemicals,” said Jean-Christophe Guerin, Head of the Materials Division of Michelin.

Source: Amyris

DSM Unveils Dyneema Purity® Radiopaque UHMWPE Fiber for Devices Used in Orthopedic Trauma

DSM, among the global leaders in biomedical materials science and regenerative medicine, announced the launch of its Dyneema Purity® Radiopaque fiber, one of the radiopaque ultra-high-molecular-weight-polyethylene (UHMWPE) medical fibers in the world. The fiber is the newest addition to DSM's medical Dyneema Purity® fiber portfolio.

Dyneema Purity® Radiopaque fiber is designed to support the development of medical devices for use in orthopedic trauma. The fiber contains a radiopacifier, which makes it the only UHMWPE fiber currently available that is visible in x-ray images. This feature helps surgeons with medical device and implant visualization both during and after surgical interventions.

The fiber will initially be used as a replacement for metal surgical cables that are used in procedures to treat bone fractures. The fiber is 15 times stronger than steel but maintains high pliability and increased flexibility, which may help lower the risk of bone damage. Steel does not conform well to the natural contours of the human body. A small contact point between the bone and metal wire leads to high levels of pressure in a concentrated area during surgery. On the other hand, UHMWPE fibers conform directly to complex bone anatomy, which increases surface contact and spreads force more evenly, reducing the risk of the cable cutting into the bone. The fiber is biocompatible and chemically inert, which can help reduce tissue inflammation, irritation and complications associated with metal allergies. All of these factors can increase patient comfort and promote shorter healing times.

UHMWPE fiber has additional advantages for cable construction. If a steel cable is wrapped around portions of a bone that require repairs, both ends of the cables must be guided through a tensioning device. Once fixation is complete, no incremental adjustments are possible and a re-adjustment can only be accomplished by cutting the cable and starting all over again. In contrast, a cable construction made from UHMWPE fiber promotes more flexibility and allows for re-tensioning after primary fixation without the need to start from scratch.

"With its impressive durability, flexibility and X-ray visibility, our Dyneema Purity® Radiopaque fiber gives device manufacturers the opportunity to use UHMWPE fiber in new applications," said Carola Hansen, Director of Biomedical Polyethylenes, DSM Biomedical. "Creating quality and innovative materials that help patients and surgeons is of the utmost importance to DSM."

"As an orthopedic surgeon, I have firsthand knowledge of the current challenges presented by traditional, steel cable solutions," said Professor Dr. Lodewijk van Rhijn, head of the department of orthopedic surgery at the University Hospital Maastricht, The Netherlands. "DSM's new Dyneema Purity® Radiopaque fiber has high flexibility which has the potential to reduce the chance of patients suffering from neurological damage. Further, the radiopacity would allow me to check instrumentation stability using x-ray imaging." Dyneema Purity® Radiopaque fiber is available worldwide.

Source: DSM