Today's KNOWLEDGE Share : Reckless product design and failed systems engineering

Today's KNOWLEDGE Share

A father and his two daughters burned to death in their Tesla because the doors wouldn’t open

September 7, 2025.

Schwerte, Germany.

A Tesla hits a tree and bursts into flames.

Inside: a 43-year-old father and his two 9-year-old daughters.

A witness tries to open the doors.

He can’t.

All three burn to death.

Tesla’s flush door handles are designed to pop out electronically when you approach the car or pull the interior release.

When the crash damaged the electrical system, the handles stayed retracted—flush with the body, offering nothing to grip.

↳ The 12V battery likely failed on impact

↳ Without power, the solenoids controlling the handles don’t activate

↳ The handles remain mechanically locked inside the door

Manual releases exist in the front seats—a mechanical cable behind a small panel—but most people don’t know they’re there.

In the rear seats of many Tesla models, there’s no manual release at all.

Or it’s hidden under the seat mat, requiring knowledge and steps no one performs under stress.

The German fire service is now demanding visible, mechanical handles that work without power.

Tesla announced design reviews after this incident and multiple lawsuits.

But the core issue is simple:

A door handle that requires electricity to become a door handle isn’t a safety system.

It’s a failure point.​​​​​​​​​​​​​​​​

This is reckless product design and failed systems engineering

source : Lukas Timm

LYB launches Pro-fax EP410C: A breakthrough in polypropylene performance

LyondellBasell a leader in the global chemical industry, has introduced Pro-fax EP410C, a new polypropylene grade designed to meet the evolving needs of packaging and industrial manufacturers.  

This new grade is a direct response to what our customers need most versatility, strength and durability,” said Derek Dever, LYB commercial manager. “Pro-fax EP410C empowers manufacturers to push boundaries in packaging and industrial design.

Pro-fax EP410C combines exceptional impact strength, cold temperature durability and high melt strength, making it ideal for demanding applications such as rigid and flexible #foodpackaging, industrial containers and sheet and profile extrusion. With its low odor and general-purpose additive package, it also supports consumer products with reliable performance. 

The launch of Pro-fax EP410C is an example of how LYB is expanding its product portfolio of differentiated #polypropylene solutions. By targeting high-value applications and new market segments, LYB aims to drive growth, strengthen customer relationships and reinforce its position as a trusted innovator in the plastics industry. 

Key applications include: 

Rigid food packaging – blow molding and thermoforming conversion processes 

Flexible food packaging – specialty and blown films 

Industrial containers and housings – sheet, profile extrusions and specialty injection molded parts 

Polypropylene compounding feedstock – variety of broad end-use applications 

Product highlights: 

High melt strength 

Exceptional impact toughness at ambient and cold temperatures resistance 

Good stiffness 

Excellent organoleptics; low to no odor

source : Lyondellbasell

Today's KNOWLEDGE Share : Polyurethane Spray Foam – Formulation Challenges

 Today's KNOWLEDGE Share

Polyurethane Spray Foam – Formulation Challenges & How to Solve Them

Rigid PU spray foam is one of the best thermal insulation materials — but many of the problems seen on-site aren’t only about equipment or spraying technique.

Here are the most common formulation-related issues and their solutions:

1. Poor Adhesion

Low adhesive promoter content

Incompatible blowing agents or additives

Other Key Factor:

Substrate conditions (temperature, surface cleanliness)

Solutions:

Increase adhesion promoters in the polyol blend

Adjust catalyst package

Use Advanced MDI Variants

Tailor Polyol Properties for Substrate Compatibility

Test adhesion on multiple substrates before finalizing the recipe

Ensure substrate is clean, dry, and at recommended application temperature

2. Excessive Shrinkage or Cracking

Imbalanced isocyanate index (too high →brittle, too low →unstable)

Incorrect crosslinker ratio

Other Key Factor:

Type of isocyanate (Different Polymeric MDI) and curing conditions can impact dimensional stability.

Solutions:

Optimize NCO/OH ratio (index ~100–110 depending on application)

Fine-tune polyol blend with proper chain extenders

Consider post-curing or selecting an isocyanate type better suited for the application

3. Voids, Cavities, or Uneven Cell Structure

Inadequate surfactant balance

Poor blowing agent compatibility

Other Key Factor:

Silicone surfactant type and concentration are critical (typically 1–3 pphp, depending on system).

Solutions:

Optimize surfactant package to stabilize foam rise

Match blowing agent type/ratio with desired cell morphology

Use lab foaming tests to calibrate rise profile before field application

4. Moisture Sensitivity (Collapsing / Bubbling)

Too much water as chemical blowing agent

Lack of moisture scavengers

Other Key Factor:

Storage and handling: pre-dried polyols and proper sealing of raw materials reduce moisture ingress.

Solutions:

Reduce water and partly replace with physical blowing agents (e.g., pentane)

Add desiccants or adjust catalyst system to slow down side reactions

Use pre-dried polyols and store materials in dry, controlled environments

5. Inconsistent Foam Density

Imbalanced blowing agent /catalyst ratio

Inadequate viscosity control of polyol blend

Other Key Factor:

Temperature control of mixing and heating equipment also affects density

Solutions:

Optimize catalyst mix to synchronize gelling vs. blowing reactions

Adjust polyol viscosity with plasticizers or pre-blending

Monitor raw material and equipment temperatures for consistent sprayability

Spray foam issues are often formulation-driven, not just equipment-related.

Here’s what really matters:

- Adhesion → Add coupling agents+ensure clean substrates

- Shrinkage/Cracking →Keep isocyanate index ~100–110

- Cell Structure →Optimize silicone surfactant & blowing agent match

- Moisture Control →Use pre-dried polyols +reduce water

source : F Homayouni

#Polyurethane

Today's KNOWLEDGE Share : Linen takes pole position in Skoda’s new electric concept car

Linen takes pole position in Skoda’s new electric concept car

The 100% electric Škoda Enyaq RS Race 2025 concept car uses Bcomp’s ampliTex and powerRibs technologies. The vehicle weighs 316 kg less and produces up to 85% less CO₂ emissions than its carbon fibre equivalent.

The Škoda Enyaq RS Race 2025 electric concept car is the result of a collaboration between Swiss natural fibre composites specialist Bcomp and the Motorsport division of car manufacturer Škoda.

This experimental vehicle weighs 316 kg less than the production model Enyaq Coupé RS, while reducing its carbon footprint by nearly 85% thanks to flax components replacing carbon fibre.

Designed as a technology demonstrator, the Enyaq RS Race is based on ampliTex and powerRibs materials developed by #Bcomp. Engineers replaced sixteen components of the car with #biocomposite equivalents: bumpers, wings, dashboard, door panels, footrests, roof air intake, spoiler and even the panoramic roof panel.

These components, which combine rigidity, lightness and vibration damping, demonstrate the versatility of #flaxfibre in both indoor and outdoor applications.

The ampliTex fabric, woven from long flax fibres, forms the skin of the composite. Its natural architecture, which is both strong and shock-absorbing, provides a specific rigidity comparable to that of #carbonfibre while improving acoustic comfort.

Combined with the powerRibs system, a network of three-dimensional reinforcements on the inside of the parts, it increases #flexuralstiffness without adding mass.

Photos: Skoda / Bcomp/ Jeccomposites

Braskem Approves Investment to Expand Ethylene and Polyethylene Production at Rio de Janeiro Facility

With an estimated investment of R$ 4.2 billion, the project reinforces the company's industrial transformation and consolidates a strategic partnership with Petrobras, strengthening Braskem's competitiveness.

Braskem announces that its Board of Directors has approved an estimated investment of R$ 4.2 billion to increase the capacity of its petrochemical complex in Rio de Janeiro by 220,000 tons of ethylene per year, along with equivalent volumes of polyethylene. The initial phase of basic engineering, with a budget of R$ 233 million, had already been approved in February of this year.

The project marks another step in the company's strategy for industrial transformation and competitiveness and is part of its Transformation Program. Scheduled for completion by the end of 2028, the project is subject to securing additional financing beyond the resources already approved under the REIQ Investments - Special Regime for the Chemical Industry - for the years 2025 and 2026. This strategy is part of ongoing analyses and discussions regarding the ideal capital structure for the company.

"Despite the current challenging global scenario, we must ensure that Braskem remains competitive in the new global petrochemical landscape, securing its survival and long-term sustainability. The investment in the Rio de Janeiro petrochemical complex demonstrates our confidence in Brazil's potential and Braskem's commitment to contributing to a sustainable reindustrialization of the sector, driven by innovation and value creation," says Stefan Lepecki, Vice President of South America Business at Braskem.

To enable the project, the Board also approved the procurement of additional volumes of ethane through a long-term supply agreement with Petrobras, which is currently in the final stages of negotiation. This measure ensures supply security and operational competitiveness, strengthening the strategic partnership between the two companies.

The project aims to increase the use of gas in Braskem's feedstock matrix, reducing costs and emissions, and making the company's industrial park more modern, sustainable, and competitive. "We are taking an important step in Braskem's energy transition and in the transformation of the chemical industry in Brazil. This is an investment focused on the future-with efficiency, sustainability, and value generation at its core," concludes the executive.

source : Braskem