K2016 Materials Review The K2016 show saw various materials advancements, especially for the automotive sector • A new concept race car jointly developed by German chemicals firm BASF and Hyundai Motor, RN30, has moved away from carbon fibre-reinforced polymer (CFRP) to reduce weight, utilising BASF’s Elastolit rigid integral foam and reaction injection molding (RIM) systems developed for body panels. The latter are said to permit challenging designs like the fender and spoiler of the RN30 and allow for painting. The RN30 also features BASF’s Elastoflex E, a spray impregnation PU for light and stiff sandwich structures consisting of a long fibre-reinforced surface layer and a paper honeycomb. Its Infinergy is the world’s first expanded TPU, which combined with an elastic coating is used in the roll bar padding of the RN30 for durability and resilience. As for the braking system, BASF says it developed a breakthrough technology, Hydraulan 406 ESI, which fulfills legislative requirements by extending the durability of the brake elastomer. For electronic assemblies of the RN30, BASF’s new Ultramid Advanced N allows for miniaturisation and functional integration. Other features undertaken by Hyundai include a bucket seat for racing, fitting the driver’s body and an integrated roll cage, which increases the vehicle body strength and protects the driver in precarious situations. For the seat shell and pan, BASF offers Ultracom, a thermoplastic composite system while its near infrared-reflective films, protect windows against solar heat and its waterborne ColorPro IC basecoat “Performance Blue” is used on the exterior with a layer of iGloss clearcoat.
RN30 concept racing car, a collaboration between BASF and Hyundai
• Solvay launched Technyl REDx, a new heat performance PA66 integrating a “smart molecule” self-reinforcement technology, said to outperform conventional speciality polymers in demanding thermal management systems. It includes a patented self-strengthening technology present in the polymer chain without affecting its structure. This technology remains inactive during moulding of car parts, leaving the material behaving like a high-flow PA66. During
Solvay’s latest PA66 incorporates technology ideal for charge air coolers
the vehicle’s use, the elevated temperatures activate the smart technology, leading to rapid cross-linking that boosts the mechanical properties far beyond their initial values. Technyl REDx can be processed at temperatures below 100°C. Ageing tests over 3,000 hours at 220°C demonstrate high retention property as well as tensile property gain of more than 50%, without degradation of elongation at break. It is said to help meet growing demand for downsized engines. Solvay also launched Technyl 4Earth, a postindustrial PA66 sourced from automotive airbags. Industrialised in Poland, the patented process is able to separate the nylon from the airbag's silicone. It had on display an automotive oil filter made of the material.
• What’s next for a company that has proven that a solar-powered plane is possible? An electric concept car! Germany-based Covestro’s featured car, developed in collaboration with design students from Sweden and Finland, showcases a wrap-around glazing made of transparent PC, a new lighting concept as well as seamless integration of the PC body with the PC lighting. For the rear of the vehicle, together with lighting and electronics supplier Hella, Covestro developed a solution based on holographic films, where various light functions can be integrated. Said to be an industry first, Hella developed the holograms before Covestro then incorporated these into a transparent holographic film, which retains the design and is laminated onto a 3 mm glass plate. For series applications, plastic will be used instead of glass. The holographic film is illuminated from behind using LED light sources and reflectors, resulting in a 3D effect. Other new developments are the 70%-biomass coating hardener while another hardener enables plastic automotive add-on parts to be coated at low temperatures. Covestro says the wraparound glazing on its car provides for better allaround visibility
NOVEMBER / DECEMBER 2016
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