New grades for critical automotive application

ELIX Polymers has developed a range of specialty grades of ABS and PC/ABS to reduce the squeak that is generated by the contact of plastic parts with other plastic parts, leather, PVC-foil or other products. These undesirable noises can negatively affect the driver´s comfort and the quality impression of a car. Automotive interior parts affected include door handles, seating parts, cup holders, and air vents. However, these newly developed grades may also be suited for other segments such as E&E, white goods or consumer goods.

 

The new grades were submitted to stick-slip tests at several premium Automotive OEMs according to VDA230-206 at testing machines from Ziegler Instruments with very positive test results: a 10 point scale is used where 10 is the highest risk level. The newly developed ELIX grades managed to score 1 – the lowest risk level. Tests were conducted with different forces (10N, 40N) and speeds (1mm/s and 4mm/s) at several temperatures.

 

The new grades use ELIX Polymers base polymers: standard ABS, high heat ABS, ABS/PC or PC/ABS - and because their key properties remain the same, this does not affect existing OEM approvals of ELIX grades. Furthermore, as the shrinkage of the materials stays the same, current moulds can be used without further need for modifications.

 

According to Mr. Fabian Herter, Industry Manager Automotive at ELIX Polymers, with these new grades, significant cost savings are possible: “Until now, in many instances, fabrics or grease had to be added afterwards to reduce squeak and rattle. However, this involves additional costs and manual labour – and therefore is not ideal. Now, thanks to these new ELIX grades, we are able to offer a more competitive solution when compared to other resins that are currently available.”

 

Mr. Herter added: “This new development is the result of our close partnership with leading OEMs. Together we identified the need to address this issue and we were able to develop tailor-made solutions. This approach is fully in line with our strategy to focus on specialty added-value materials.”

 

ELIX Polymers - ELIX Polymers is a leading manufacturer of ABS (Acrylonitrile-Butadiene-Styrene) resins and derivatives in Europe. Operating from its head office in Tarragona, Spain, and with Sales support teams in all key markets, the company is a specialist provider of tailor-made solutions for high quality thermoplastics applications. With a 40-year track record, ELIX Polymers is an expert in ABS polymers, and it has the resources, the expertise and the experience to create value for its customers through highly individual solutions. 

 

ELIX Polymers’ specialty grades can reduce the squeak due to the contact of plastic parts with other parts made of  other materials.  

 

 

Novel solutions for hydrogen storage tanks

DSM recently introduced a material solution for high-pressure composite tanks for hydrogen storage in its continuing mission to help reduce CO2 emissions.

 

Hydrogen tanks are the next step in fuel storage, as such storage is a key enabling technology for advancing hydrogen and fuel cell technologies in applications that include stationary power, portable power and transportation.

 

Hydrogen has the highest energy per mass of any fuel. One kg of hydrogen is equivalent to 33.3 kWh, which means it delivers three times more energy than conventional fuel. But hydrogen’s low ambient temperature density results in a low energy per unit volume. This requires the development of advanced storage methods that have the potential for higher energy density.

DSM is working to apply its materials expertise to make safe, effective and very lightweight hydrogen tanks.

 

“We had already developed this technology for compressed natural gas (CNG) tanks, and now we are testing the same material and design principles for hydrogen tanks to meet the needs of the automotive industry,” said Mr. Bert Keestra, Application Development Engineer at DSM.

 

The two-part tank design features a proven, blow molded liner made of Akulon® Fuel Lock, a polyamide 6-based engineering plastic with a very high barrier to hydrocarbons. The tank can then potentially be further reinforced by wrapping it in unidirectional (UD) continuous fiber-reinforced thermoplastic tapes made of EcoPaXX® polyamide 410. This combination of commercially available materials has already proven to be very effective in CNG tanks, and DSM is now actively testing the concept in hydrogen tanks.

 

The result would be the lightest-weight plastic tank available for hydrogen storage applications. Reducing weight is key, since every 10 kg removed from a vehicle roughly translates into a reduction in CO2 emissions from the vehicle on the road of one gram per km.

 

For the liner, Akulon Fuel Lock greatly reduces weight compared to metal. It also offers improved permeation versus polyolefin liners, meaning that the gas stays in the tank. The liner material, which is 100% recyclable, is safe with no debuckling.

 

Furthermore, the material is optimized to remain ductile and tough, even at extremely low temperatures (-40°C). This was important for CNG, but is even more vital for hydrogen storage, as the working pressures are much higher.

 

DSM  unveils material solution for high-pressure composite tanks for hydrogen storage

 

High impact bumper guards  

INEOS Styrolution has been selected by Goldsun Auto Pvt. Ltd. as a thermoplastics supplier for its range of automotive components such as spoilers, luggage carriers and footsteps for four-wheelers in India. The Coimbatore, India, based company lives up to a strong commitment to quality, right from sourcing raw materials all the way to final fitting. For a wide range of applications, they turn to INEOS Styrolution to provide the best ABS solution per respective application.

 

Goldsun employs innovative methods such as special blow molding, plasma cutting (cutting electrically conductive materials by means of an accelerated jet of hot plasma), cold anodizing (electrolytic passivation process increasing the thickness of the natural oxide layer on the surface of metal parts) and powder coating to create high quality and visually appealing components. They are one of the first companies to start a dedicated ABS bumper guard production unit in India. The blow molding technology ensures dimensional accuracy, high volume production, high surface finish and repeatability factors.

 

Mr. G Ramachandran, Managing Director at Goldsun, says: “We are happy with the E 502 BML grade, as it gives a better result in blow molding products. Absolac shows good flexibility that helps in proper molding. Its high melt strength and broader processing window contributes to produce good quality bumper guards weighing 17 to 18kg, with good impact strength, dimensional stability and consistent product wall thickness”. He particularly appreciates the proactive approach of the INEOS Styrolution representatives. The Absolac line of ABS solutions is produced in India for the Indian market.

 

Goldsun uses a broad range of Absolac ABS solutions in their production. One is Absolac E 502 BML, which is a blow molding grade that became the latest addition to the portfolio used by Goldsun. It is used for the production of the Goldsun Xtent Defender and Trishul range of bumper guards for SUVs like Tata Hexa and parcel trays for Datsun redi-GO. Goldsun chose this particular grade for its high melt strength and good mechanical properties. Another grade is Absolac 120 HR, which is used for the production of the Goldsun Footrail suitable for all SUVs. Absolac 200 EP is an easy flow electroplating injection-molding grade is used for automotive plating parts. 

 

Mr. Rajiv Verma, Lead Automotive India at INEOS Styrolution, enjoys the partnership with Goldsun. He comments: “We are glad to work with this strong local automotive company in India, and we are looking forward supporting Goldsun to stay at the top of the industry.” Mr. Thangamayan Prabharan, Manager Sales and Marketing, adds: “Due to our close cooperation, we are able to make suggestions early in the development process of a new application.”