Inform122009EU1209BR1082E

inform 05 12 .

2009

Speed and qualitydetermine success

10 Productivity and performance

15 Interview with aircraft manufacturing expert

30 New from Ticona‘sresearch laboratory

T H E T I C O N A M A G A Z I N E

02

EDITORIAL CONTENTS

Dear readers,

The Fakuma in October served as a good indicator of the mood in the plastics industry. We all hope to see the signs of recovery materialize.

One thing is clear: Customers’ demands on processors will increase signifi cantly in the future. Business conditions will be defi ned in large part by manufacturers’ needs for more effi cient, faster and more economical solutions. And materials suppliers will also play a more important role as a result. The current situation requires a partner who, based on actual research and further development of his materials, can provide answers for an endless series of new applica-tions and is always there to help solve processing problems.

The direction we’re headed is also apparent at major industrial trade fairs such as the International Motor Show(IAA). People spoke of an environmental offensive – afterall, some of the highlights of this year’s premiere exhibitionincluded lighter, greener cars with alternative drive con-cepts. Basically it’s all about less CO2 today, not more horsepower. The topics of design and safety also remain top priorities.

A glance at the automotive industry leaves no doubt: Composite materials, metal replacement and green electro-nics are more important than ever in the advancement of technological developments such as lightweight construc-tion. And plastic solutions such as the brilliant, scratch-resistant MetaLX™ metal-effect polymers are also fully competitive with metal surfaces from a visual standpoint.

A broad, high-performance product portfolio is one thing – and application engineering advice is another. Ticona has an ample supply of both to offer. Count on us.

Kind regards,Henning Küll, Head of Communication Europe, Ticona

[email protected]

EDITORIAL

NEWS03 Welcome Maria Ciliberti 04 Armed for AdBlue® 04 Vectra® LCP enables accurate sound05 Additional impact protetion in vehicles05 MetaLXTM grades06 Tank and fuel system06 Plastics processing seminars07 Plastic meets metal08 First place for charge air pipe made of Fortron® PPS

RELOCATION NEWS09 Impressions of the new Ticona location

PRODUCTIVITY AND PERFORMANCE10 Cover Story: Speed and quality determine success

EFF IC IENCY WITH COMPOSITES12 Lightweights fl ex their muscle

D IALOG15 Aircraft manufacture:

Major breakthrough for PPS composites

GREEN ELECTRONICS20 Uncompromisingly halogen-free

EFFICIENCY THROUGH METAL REPLACEMENT22 Mobile without metal? Plastics go into high gear

APPEARANCE24 Strong on the inside, appealing on the outside

INNOVATION AND RESEARCH27 GUR® Vitamin E-enriched polymer

provides protection against oxidation28 Close to today‘s heartbeat: collective success30 New from Ticona‘s research laboratory

TECHNOLOGY AND SERVICE31 Technology FAQs

T ICONA CALENDAR32 Fairs and events32 Imprint

inform |05|

03

NEWS

Welcome Maria CilibertiNew Commercial Director

Maria Ciliberti was named the new Commercial Director for Europe in August, 2009. Maria Ciliberti has held positions of responsibility at Ticona since 2005. Among her other roles before moving to Kelsterbach, she was Global Automotive Director with responsibility for the development of Ticona’s worldwide automotive strategy.

In addition, Ms. Ciliberti is the Chair of the Automotive Division of the Society of Plastics

Engineers (SPE) where she also chairs the Inno-vation Awards Committee. She has established a solid reputation through a series of professional lectures and articles as well.

Having earned degrees in Chemical Engineering and Business Administration from Ohio State Uni-versity, Ms. Ciliberti has extensive experience in the plastics industry: over the course of the past 20 years she has worked for Dow Chemical, General Electric Plastics, Owens Corning and Composite Technologies Corporation. In her new European position, she heads a team of about 100 employees.

Four questions for Maria Ciliberti:

What is your goal for Ticona?My goal is for Ticona to be even closer to its customer. We can only be the best partner for our customers when we understand their existing needs and even anticipate their future needs. We aim to provide both consistent products and consistent support to our customers wherever their operations may be located.

How did you become so passionate about polymers? It’s amazing to watch so many things go from the initial idea to become a commercial reality. The solution to each and every new application represents a challenge whose commercial viability depends on engineering and design skills, materials expertise, application knowledge and business understanding. This is the essence of what makes it so exciting, because with plastics the possibilities are endless.

Are the polymer markets in America and Europe the same? Regardless of geography, I fi nd that our customers are un-der severe cost pressures. With this situation, we, Ticona must work even more closely with our customers to fi nd not only the best technical solution but also the most cost-effective solution to meet their challenges.

But I believe there are also some key differences, too. I see new polymer solutions being adopted by European carmakers in new applications that I haven’t seen before in the US. For me, the blow-molded Fortron® PPS charge air pipe on the VW Golf is a great example of this. I haven’t seen any blow-molded PPS parts being used in the US automotive market. But that’s what makes this fun, too. I’m sure blow-molded PPS will be used for under-the-hood applications in the US before we know it.

Do you have a motto for your work and your team?To put it simply: I believe in working hard, delivering on com-mitments, supporting the people, being open and having fun.

Maria Ciliberti

[email protected]

inform |05|

04

© 2

009

Jupi

terIm

ages

Cor

pora

tion

© R

ubbe

rBal

l Pro

duct

ions

Armed for AdBlue®*

Ticona materials suited for use in the SCR-system.

Tests have shown: The mechanical and chemical properties of the Ticona materials Fortron® PPS, Hostaform® POM and long-fi ber-reinforced Celstran® LFRT with PP- and PA-matrix are not changed, even when embedded in the reducing agent AdBlue®

in temperatures of up to 80 °C. The mate-rials can therefore be used in sensors, pumps, valves or valve body assemblies, for the polymers meet the requirements for plastics that are intended for use in emission control systems of modern diesel-engined vehicles. In SCR-systems (Selective Catalytic Reduction), plastics come into contact with diluted carbamide solutions. The solution is responsible for the reduction of nitric oxides. The nitric oxides, as well as particulate matter, are generated during diesel combustion. However, in contrast to several other plastics, Ticona materials are able to withstand the aggressive media and thus do not lead to damage to the catalytic converter.

*AdBlue® is a registered trademark of VDA, German Association of the Automotive Industry

Vectra® LCP enables accurate sound

The high-performance thermoplastic of the ”low warpage“ type enables a precise guidance of the laser.

Whether in a high-end system, an MP3-, DVD-, or CD-player – in premium home entertainment equipment the precise playback of picture and sound depends to a high degree on the laser. In the so-called lens holder Vectra® LCP E488i ensures an exactly controlled laser beam. In this application, the liquid crystalline polymer scores points in several areas, for example through stability even despite minimal wall strength. The low-warpage grade can thus provide the bracket with the necessary dimensional stability, in spite of its low weight. The new material, as all LCP-grades, is inherently fl ame retardant. It can withstand even temperatures as high as 260 °C, is compa-tible with all standard soldering processes and can be soldered lead-free, an environmentally friendly method. Vectra® LCP E488i thus meets the high fi re protection requirements (UL V-0), as well as the European environmental guidelines RoHS and WEEE.

Ticona developed the new LCP grade to minimize the warp tendency of fl at electronic components. Material attributes such as ease of fl ow allow for a high degree of design freedom and effi cient serial production. Low-warpage Vectra® LCP is the ideal material for environmentally friendly and highly precise electronic components, whether as a lens holder, a connector,

processor socket or in the form of other electronic components.

inform |05|

05

Additional impact protection in vehicles

The interior of an automobile places high demands on vehicle safety. Emissions and wear are strictly regulated. Hostaform® POM and Celstran® LFRT comply with these regu-lations and are therefore used in the crash-active headrests of BMW 3 series sedans.

According to a statistic of the Federal Statistical Offi ce, each year more than two million traffi c accidents take place on German roads. More than 400,000 persons are injured in these accidents. One of the most common injuries is whiplash caused by a rear-end collision. In rear-end collisions, the head of the person struck from behind is fi rst propelled for-ward and then back again.

Since last year, the safety of BMW’s 3 Series sedans has been enhanced through the addition of crash-active head-rests as standard equipment. In a rear-end collision of more than twelve kilometres per hour, a complex spring-driven mechanism shifts the front part of the headrests forward and upward within a fraction of a second, thereby reducing the risk of neck injury. This reduces the distance between the headrest and vehicle occupant’s head before the latter is propelled backward, thereby preventing neck injury due to hyperextension. The safety mechanism, which is triggered

by a collision, is a reversible system that can be reactivated with a few simple manual steps.

The wear resistance of Hostaform® POM copolymer makes it the ideal material for the functional components in the headrests of BMW’s 3 Series sedans. Hostaform® POM is predestined for the functional components, because the copolymer exhibits low wear. In addition, POM exhibits opti-mized slip-friction properties, so that no sound is generated when the headrests are adjusted.

The long-fi ber-reinforced thermoplastic Celstran® LFRT is used in the highly stressed structural components of the headrests. What is required here are light yet extremely strong materials. In the crash-active headrests of BMW Celstran® LFRT are designed to absorb a major share of the elastic strain energy and thus ensures added safety during impact.

MetaLXTM gradesTicona offers a broad range of plastics with attractive metallic look.

Polymers with integrated metallic effect permit desig-ners and processors to develop brilliant plastic solu-tions that resemble metal. The attractive look and feel is achieved without additional fabrication steps. And that reduces costs considerably, completely eliminating the need for further fi nishing processes. Along with the metallic variant of Hostaform® (POM), Ticona now also offers Celanex® thermoplastic polyesters (PBT), Riteflex® thermoplastic polyester elastomers (TPC-ET) and Vectra liquid crystal polymers (LCP) with metallic effect. That range includes unreinforced and glass-fi ber-reinforced grades (also available with a fl ame retardant system).

NEWS

inform |05|

06

NEWS

Tank and fuel system

Hostaform® POM and Fortron® PPS defy aggressive fuels

The proportion of organic fuels has risen con-tinuously in the past years. In 2007 alone, 4.6 million tons of bio diesel, vegetable oil and bio ethanol were added to conventional fuels. The share of organic fuels is expected to increase to ten percent by 2020. Most manufacturers have already provided for this development and use especially resistant technical thermoplastics in the fuel sector.

The infl uence of alternative fuels on materials and components was also a topic at the 5th inter-national CTI Forum ”Fuel tank and fuel systems“, which was intended for automobile manufacturers, system manufacturers, fuel producers and plastics manufacturers. Ticona also presented at the forum, which took place from March 31 to April 1, 2009, in Stuttgart, Germany.

”Our materials Hostaform® POM and Fortron® PPS are the right choice in fuel system applica-tions, where fuels in the future contain variable shares of organic fuels,“ says Ralf Langhammer, Emerging Markets Automotive. This was shown through long-term tests with a storage time of 5,000 hours. Even in gasoline with an 85-percent share of ethanol or in 100-percent bio diesel Hostaform® POM and Fortron® PPS demonstrated a high degree of durability.

Plastics processing seminars

Ticona instructed staff members of Robert Bosch and Continental Automotive

Since the beginning of the year Ticona has been training major customers in using and processing plastics. Staff members of Continental Automotive and Robert Bosch of the Czech Republic were among the fi rst training groups. The all-day semi-nars were structured in theoretical and practical sections. Priorities of the training sessions were general injection molding method, design guide-lines as well as the properties of the material Hostaform® POM.

”The seminars are being met with a positive response and offer a high degree of added value for our customers“, says Jörg Jander (Technical Service). It was demonstrated how costs can be reduced and manufacturing quality improved through processing optimisation. In the practi-cal session, the material was recorded with an infrared camera during processing so participants could clearly observe the temperature change over time.

The audience learns about the design guide-lines and properties of Hostaform® POM.

Seminars

inform |05|

07

NEWS

Joining together in a successful alliance – that’s what is happening now with plastics and metals. The fi rst Innovation Forum for Process Integration held in Dortmund at the end of June this year was dedicated to this forward-looking material combination.

Nearly 100 company delegates from the metal and plas-tics processing industries participated in a high-powered two-day program. Ticona plastics and their many different advan-tages in hybrid technology featured prominently at the forum.

In his presentation, hybrid expert Rochus Hiekisch provi-ded fascinating insights into the properties of Ticona’s plas-tics and illustrated these with successful practical examples. ”To achieve a high-strength bond, choosing the right primer or adhesion promoter, is crucial. That’s why, in addition to high-performance polymers, we also offer our customers information on the most suitable primer for each of our

individual materials,“ explained Hiekisch to the specialist audience.

Wanted – optimum material combinationProcess integration is one of the most important future topics for manufacturing industry. Technical solutions are required to combine the special properties of the comple-mentary materials metal and plastic. The advantages of plas-tics are light weight and lower costs, while metals contribute high stiffness and conductivity. ”By ideally harmonizing the two materials, there is enormous potential for companies to increase their productivity and effi ciency. But the prerequi-site for this, is to learn how to manufacture metal/plastic hybrid components intelligently in a single production line,“ concluded Hiekisch.The Innovation Forum for Process Integration took place in Dortmund on June 24 and 25, 2009. Under the umbrella of the Proform trade show, which is to open its doors every two years, the exhibition organizer, Messe Westfalenhallen Dortmund GmbH, will now arrange this high-powered con-ference in the years between the shows – with the assis-tance of the Lüdenscheid Plastics Institute (Kunststoff-Institut Lüdenscheid), the Institute of Forming Technology and Lightweight Construction (Institut für Umformtechnik und Leichtbau) at the Technical University of Dortmund (Technische Universität Dortmund) and the City of Dortmund Economic Development Agency (Wirtschaftsförderung Dortmund).

[email protected]

Plastic meets metalTicona at the fi rst Innovation Forum for Process Integration

Participants at the Innovation Forum for Processing Technology in Dortmund (fi fth from the right: Rochus Hiekisch, Ticona)

inform |05|

08

NEWS

Mid-June brought some very pleasing news. Röchling Automotive won not just one, but two of the coveted Automotive Awards from the Society of Plastics Engineers (SPE) for its charge air pipe made of Fortron® PPS: 1st place in the “Powertrain” category together with the “Grand Award” in the collective category “Parts & Components”.

VW uses this innovative component for two-liter diesel engines. It costs approximately 25 percent less than aluminum. “One of the reasons for this is the new processing method, which cuts reject rates in comparison to welding, integrates several manu-facturing steps, shortens cycle times, and increases the reliability of the production process,” says Dr Fabrizio Chini, R & D Mana-ger at Röchling Automotive. To manufacture these charge air pipes, Röchling has developed a method it calls JectBondingTM, a modifi ed blow molding process that has now also been paten-ted. It enables highly cost-effi cient manufacture of the pipes along with brackets at the same time.

This success owes much to the use of two different grades of PPS, Fortron® 1115LO and FX4330T7. Both grades offer excellent durability and a long service life as well as high melt strength and viscosity. Functional parts made from our material are extremely resistant to both mechanical and thermal stresses. They also weigh about 30 percent less than the aluminum com-ponents previously used. And that helps reduce both fuel con-sumption and CO2 emissions.

SPE: knowledge transfer for the plastics industrySome 20000 plastics experts in the fi elds of research, technology, marketing, and sales from over 70 countries belong to the SPE. Its goal is to support employees and companies in the plastics industry, especially through knowledge and know-how transfer, and to raise the industry’s profi le.

First place for charge air pipe made of Fortron® PPS

SPE ”Automotive Award 2009“ and ”Grand Award“

First place award for charge air pipe made of Fortron® PPS – the component was developed by Röchling Automotive and

Ticona in close collaboration. From left to right: Ludwig Huber, Dr. Fabrizio Chini, Frank Johänning, Matthias Schümann,

Dr. Bernhard Pfeiffer, Carsten Wörner.

[email protected]

www.4spe.org www.roechling-automotive.com

inform |05|

09

RELOCATION NEWS

Impressions of the new Ticona location

Construction work is proceeding at full speed, so the new production plant can go into operation on schedule. The relocation of Ticona in the Rhine-Main area from Kelster-bach to Höchst Industrial Park will be completed by mid-2011. The thorough pre-parations have paid off, and now building construction is well underway. Initial samples of Hostaform® POM are expected already next year.

Construction of the new Ticona works begins on ten hectares (25 acres) on the

west side of Frankfurt am Main, Germany

The plant is growing. By the time it’s completed, some 4,000 cubic meters of concrete, 600 kilometers of cable, 10,000 tons of steel and about 100 kilometers of pipe will have been used to build it.

Still computer simulation, but soon a reality

[email protected]

inform |05|

10

COVER STORY: PRODUCTIVITY AND PERFORMANCE

Today the demand for short production cycles is greater than ever before. And worse yet, products have to be ramped up from development to serial production in less and less time. This is primarily the result of fi erce competition along with rapidly changing trends. That’s why raising effi ciency and productivity is a top priority that OEMs, processors and ma-terial producers all have in common – so they can continue to provide the right means of creating competitive products in the future as well. Take Ticona, for example, which has set the stage for effi ciency improvements of this kind by cen-tralizing certain key in-house functions such as Supply Chain and Customer Service. A combination of broad expertise and high-performance polymers is letting customers realize cost-reduction potentials, improve effi ciency, and reduce the burden on people and the environment.

Processing steps: Less is moreMajor cost and time savings are obtained through functional integration, for example, where elements such as switches or fastening clamps are directly integrated into the plastic component during production instead of adding them after-wards. Manufacturing costs can also be reduced through the use of plastics with a brilliant metallic appearance. That’s because this approach eliminates additional painting or coating operations otherwise necessitated by the cost-inten-sive processing of metals. And that also reduces, in turn, the burden on the environment and people, as it ultimately eli-minates the need to handle pollutants that were previously

required in order to achieve a special fi nish. Further cost re-duction potentials can be realized through the shape, color and quality of the fi nal component. The resulting reduction in handling and logistics requirements can have a perceptible impact on productivity.

Manufacturing: Effi cient and innovative This explains to some degree why high-performance plastics are conquering more and more application areas. Processed into tapes and composites, for example, they are enabling the effi cient and cost-effective implementation of lightweight construction trends in the aircraft and automotive industries. Composites based on plastics are also being used to create energy-effi cient solutions in the construction of fans and fl exible piping systems. Here they provide longer service life or lower maintenance costs than metal assemblies used in the corresponding applications. These materials feature very high chemical resistance and mechanical strength, and their lower weight is also benefi cial during transport to the actual place of use, whether by land, sea or air.

The high-tech materials can be processed effi ciently by means of established processing techniques – primarily in-jection molding. As they fl ow well in the mold, for example, these polymers permit short cycle times. If cleaning intervals can be extended as a result, then the processor saves hard cash: they don’t have to interrupt the production process nor do they have to provide personnel. Other methods used to process engineering thermoplastics include extrusion and

Speed and quality determine success

Processors and system suppliers are under tremendous pressure to maintain and increase productivity. Their customers – in the automotive industry, for example – expect effi ciency improvements year in and year out together with optimal product quality. Processors face complex challenges in the market as a result. In the production process, every second counts – provided the fi nished product ultimately meets the performance specifi cations.

inform |05|

11

COVER STORY: PRODUCTIVITY AND PERFORMANCE

blow molding. Blow molding is also used to create complex geometries – ranging from charge air pipes in vehicles to water tanks in ovens – and reduces the number of manu-facturing steps at the same time: there is no need to weld individual components like the water tanks together, and cycle times are shorter. A modifi ed blow molding process makes production of the charge air pipes even more effi -cient despite their complex geometry, as brackets and clips are integrated directly. And there’s an added benefi t: reject rates are lower than with welding. (See also ”inform“ page 8.)

Special solutions promote productivityThe ability to increase effi ciencies in this way, however, de-pends on the selection of a suitable material for the specifi c application. Qualifi ed application engineers and process de-velopers offer just the right advice here. Their aim is to provide suppliers, OEMs and injection molders with a plastic that has the ideal properties tailored to meet the specifi cations already before processing. Additives of all kinds permit mate-rials to deliver halogen-free fl ame retardancy (if not already inherently fl ame retardant), for example, or conductivity right from the outset. Engineering polymers can also be modifi ed with UV protection, helping components subjected to ultra-violet rays maintain their function and appearance for years and years. In addition, Ticona plastics can be dyed in the mass with virtually any color – and special effects such as metallic or matt fi nishes are also possible.

More function and performance, less costIn the face of huge pressures from markets and competitors, long-lasting materials with good mechanical properties offer major advantages. They make it possible to square the circle, enabling the development of thin-walled components such as instrument panel carriers made of the long-fi ber-reinforced compound Celstran® PP-LGF (long glass fi ber). This permits designers to reduce wall thicknesses from 2.5 – 3.0 mm to

just 2.5 – 1.5 mm in some places. Less plastic is required and the production process uses less energy at the same time.

In this way, these high-performance materials meet the designers’ high expectations while giving them more design latitude to develop innovative products effi ciently – products that would be impossible or prohibitively expensive to make from metals or other plastics. One particularly important consideration in the automotive and aerospace industries is the low weight of engineering polymers. An optimization of just 0.5 mm as in the example above already yields a weight savings of some 20 percent. And in aircraft construction, individual components such as the lumbar support in a seat backrest weigh as little as half as much as the comparable metal counterpart. With up to eight times less weight, these polymers ultimately result in lower fuel consumption and less CO2 emissions.

Speed and quality without compromiseThe implementation of effi cient solutions in combination with increased productivity has its limits in everyday life – and that applies in geographic terms as well. Because if a material made from the identical recipe is not available in the markets of America, Europe and Asia, then the time-con-suming preliminary work starts all over again for companies with global operations: clarifying application engineering questions, identifying suitable materials, verifying processing, comparing costs and quality, etc. When materials suppliers operate global infrastructures, on the other hand, and en-sure long-term recipe uniformity in their materials all over the world, global players can develop and implement new products faster. Optimized processes also contribute to this acceleration no less than the actual performance character-istics of the materials used. That’s why polymer manufac-turers like Ticona are continuously working on the further development of advanced materials, thereby setting the stage for new trends or else applying them when the right moment comes along.

inform |05|

12

© F

otos

earc

h

E FF IC IENCY WITH COMPOSITES

Lightweights fl ex their muscle

The low weight of fi ber composites combined with their very high strength and stiffness is making them the material of choice for more and more demanding light-weight design applications – in aeronautics, the automotive industry, construction, piping and even sports equipment.

Production of the wing leading edge nose assemblies of the Airbus A380 at Stork Fokker in the Netherlands. The composite sheets are made from carbon fi bers and Fortron® PPS from Ticona.

inform |05|

13

EFFICIENCY WITH COMPOSITES

Nature has perfected the art of lightweight con-struction for millions of years. Every honeycomb, every bone is stiff and strong and located preci-sely – and exclusively – where the load is high. Areas that bear lighter loads are all trimmed con-sistently to reduce weight. Material and compo-nent developers have long recognized nature as an ideal teacher. They have very successfully emu-lated nature’s designs for many years now, in order to satisfy the most demanding applications with a minimum of raw material. One means of achieving this is through fi ber composites – or “composites” for short – where fi bers made of glass or carbon are embedded in a thermoplastic matrix. Composites are stiffer and stronger than nonrein-forced plastics. They offer a weight advantage of up to 25 percent over aluminum – and up to 60 percent over steel. The interest in composites is correspondingly high in all industries where weight is a critical factor – especially in aeronautics.

Along with low weight and reasonable raw materials costs, two further aspects are of key importance to industry in the replacement of esta-blished metallic or thermoset materials: rational processing and broad design latitude. Ticona has a very wide range of products to offer here, ranging from Fortron® PPS as basic material, Celstran® LFRT pellets or Celstran® LFRT composites in the form of tapes and semi-fi nished products. They can be combined with virtually any polymer (e.g. PP, PA or ABS) as a matrix material and with a variety of reinforcement fi bers (glass, aramid, carbon, etc.).

Celstran® LFRT: Thermoplastic compositesCelstran® LFRT long-fi ber-reinforced pellets pro-vide impressive results, not only with their specifi c technical properties, but also with short cycle times and broad design latitude – using established pro-cessing techniques. Moreover, so-called “tapes” (unidirectionally reinforced semi-fi nished products) are in increasing demand among processors: available in a variety of standard sizes as well as

customized dimensions, tapes based on different polymers and reinforcement fi bers can also be processed easily and particularly cost-effi ciently. Ticona’s latest customer-friendly semi-fi nished products are rods developed especially for metal replacement applications.

Lightweight construction in many fi eldsThe advantages of composites are readily appa-rent – not only in the air, but also on the ground: in automotive construction, fi ber-reinforced Celstran® LFRT grades from Ticona are used for different structural components such as instru-ment panels and door modules.

In bridge construction, the low weight of com-posites permits the prefabrication of very large components, which can be installed subsequently at the construction site. Load-bearing assemblies made of composites are perfectly able to compete with concrete or steel bridges: depending on fi ber content, their strength in the direction of the fi bers is comparable to that of steel. Unlike traditional ma-terials such as steel, reinforced concrete or wood, they neither corrode nor weather, thereby guarantee-ing long service life and low maintenance costs.

Fiber-reinforced plastics are also suitable for use in wind turbines, shipbuilding and piping systems. With their excellent processing charac-teristics, short cycle times and low creep, they are the material of choice for use in the fabrication of rotor blades for wind turbines, for example. In addition, components such as these have a long service life – after which they can also be easily recycled. Fiber-reinforced Celstran® LFRT can be used as a substitute for metal and metal alloys in the production of pipes for fl owlines, pressure lines and underwater pipelines: In oil and gas production, piping systems made of PPS also of-fer signifi cant advantages over metal pipes. With aramid reinforcement, for example, they are up to 90 percent lighter than metal, permit rapid, inex-pensive installation and prevent paraffi n build-up.

Pipes made of Celstran® LFRT composites offer high strength and require little maintenance.

inform |05|

14

EFFICIENCY WITH COMPOSITES

That’s why pressure losses are up to 50 percent lower, which means piping with smaller diameter can be used. In sum, the greatest possible effi cien-cy in terms of performance and costs – from in-stallation right through to maintenance.

Today composites are even used in sports equip-ment. A leading manufacturer of golf clubs, for example, is marketing three new models with shafts made of carbon-fi ber-reinforced Fortron® PPS. This composite increases the stability of the golf club on impact and improves energy trans-mission, thereby optimizing precision and range. With their wide range of extraordinary property profi les, composites made from Ticona polymers give the start signal for the cost-effi cient imple-mentation of many demanding lightweight struc-tural design solutions.

Fortron® PPS – proven in the aeronautics industryComposites based on the polyphenylene sulfi de Fortron® PPS from Ticona are already common-place in aircraft construction. Inherently fl ame-retardant, this thermoplastic combines high hard-ness and impact strength with excellent resistance to heat, chemicals and fuels. It maintains its pro-perties across a very broad range of temperatures – from minus 40°C to plus 240°C. Ideally suited for subsequent thermoforming and welding pro-cesses, these composites consist of alternating layers of Fortron® PPS fi lms and carbon fi ber mats, which have been baked into an inseparable sandwich in an autoclave.

Current aircraft applications include the large area profi le components of the wing leading edge nose assemblies for the Airbus A380 jumbo airliner and the A340-500/600 series. With a length of

26 meters, the wing leading edge nose assembly of the A380 weighs just 200 kilograms – about 20 percent less than a comparable assembly made of aluminum. Moreover, the design latitude that resulted from conversion to composite construc-tion made an entirely new forming technique possible: the new ‘J nose’ is more aerodynamic than the conventional ‘D nose’ made of aluminum and also leaves room to house electrical cables, de-icing systems and other equipment.

Will composites soon make up half of all parts?A total of more than 1,000 separate parts used in the Airbus A380 are made of PPS composites. Integrated into seat backrests, the new type of lumbar support made of Fortron® PPS weighs all of 150 grams. “A comparable support made of aluminum would weight nearly twice as much,” says Peter Radden, Technical Marketing Manager Composites at Ticona.

“With 555 seats in all, that amounts to a weight savings of 72 kilograms.” For airlines that want to reduce fuel consumption, extend carrying capacity and range, and ensure economical operation, every kilogram truly does count – even in a large, heavy commercial jetliner that weights about 550 tons at takeoff.

Composites dampen vibrations better than steel and concrete,

and their corrosion resistance lowers operating costs in the construction

of bridges and buildings.

Fortron® PPS makes it possible to reduce weight economically with these seats too.

inform |05|

15

DIALOG

Aircraft manufacture

Major breakthrough for PPS compositesGulfstream G650: Fortron® PPS composites used in primary structural aircraft components for the fi rst time

Arnt Offringa smiles. For good reason. Stork Fokker has written another chapter in its 90-year history and the evolution of aircraft manufacturing. In an inter-view with ”inform“, the R&D director takes a look at the most recent successes and explains what develop-ments may be expected in future. In his view, thermo-plastic composites and innovative technologies will be at the cutting edge of these advances.

Inform: The new business jet from Gulf-stream, the G650, recently completed its fi rst fl ight. Can you briefl y describe what part Fokker has played in this?A. Offringa: Among other things, we developed the G650’s rudder and elevator. When it fl ew for the fi rst time on November 25, 2009, the event marked the maiden fl ight of the world’s fi rst aircraft to rely on PPS thermoplastic composites for these control surfaces. This is a very major breakthrough in the aircraft industry. Until now, those assemblies had been made from a combination of thermosets and metal.

Inform: Why are aircraft manufacturers using the new material combination instead of thermosets?A. Offringa: There are two key reasons for using ther-moplastic composites. Firstly, they save time and handling costs in production, because they eliminate the very labor-intensive riveting and bonding opera-tions required in individual component assembly. The second advantage of thermoplastic composites – which, in the case of the G650, are based on Fortron PPS polyphenylene sulfi de – is that they can be used to produce large profi le sections that are some 20 per-cent lighter than those made from conventional mate-rials such as metal and light alloys. All manufacturers today want to and must design lighter aircraft to cut fuel consumption per passenger. Inform: Thermoplastic composites have been used for quite some time in aircraft construction. What have been the im-portant milestones in your opinion?A. Offringa: These composite materials have been used since the mid-1980s, although only in very small quantities at fi rst. The material primarily employed in those early days was a carbon fi ber-PEEK (polyethe-rether ketone) composite. Dassault and Airbus used it, for example, in the vertical fi n. At the end of the 1980s, PEI composites, i.e. polyetherimide, also arrived on the scene. They were used in applications such as fl oor panels inside the Airbus “Beluga” super

Thanks to high-performance composites in the form of prepregs and new welding methods, we can produce large, strong, homo-geneous structural components without the usual additional costs for drilling and riveting work.

inform |05|

16

© S

tork

Fok

ker

transporter and in aircraft manufactured by Fokker and Dornier. And in 1995, Gulfstream brought out an aircraft that relied on a carbon fi ber-PEI composite in primary structural components.

Inform: And when did the fi rst aircraft fl y containing a carbon fi ber-PPS composite?A. Offringa: That was the Fokker 50 in about 1997. It had a landing gear door made from PPS composites. But this had been preceded by discussions since 1992/93 between TenCate Advanced Composites, the Technical University of Delft in the Netherlands and Ticona. At about the same time, the developments that would later lead to the new wing leading edge nose on the A340 500/600 started at Airbus in the UK. Profi le sections based on composites from TenCate and Fokker made it possible to design a new wing leading edge nose shape, the “J nose”. This has seve-ral advantages over the old “D nose” shape produced from aluminum. The components are reinforced with curved ribs made from PPS-carbon fi ber composites in a way that makes them exceptionally stiff in the direction of fl ight but able to accommodate wing vibrations in the transverse direction. In addition, the

“J nose” is aerodynamically shaped and designed to house electric cables, deicing equipment and other systems. Instead of the usual fi ve aluminum compo-nents, only two structural elements are now required for the wing leading edge nose.

Inform: What was the next crucial step?A. Offringa: The next great milestone without any doubt was the A380, the largest passenger plane to-day. Around 25 percent of the aircraft structure and components are produced from composites. And in the next generation of aircraft, the content of compo-sites will double. For example, the A350 is expected

to take off for the fi rst time in 2011 with over 50 per-cent of its total weight made up of fi ber-reinforced composite materials. And also in the Dreamliner, the Boeing 787, which is due to make its maiden fl ight in 2009, half of the components are produced from composite materials. A measure of the trust now placed in lightweight structures can be seen in the advance orders: over 860 for the Dreamliner and nearly 500 for the A350.

Inform: What has driven this development over the past years? A. Offringa: This rapid development has been driven by the signifi cant advances made in technologies and materials but also, of course, by economic and ecolo-gical pressures. Metals such as aluminum weigh more and, as I have already said, are more costly to process.

Inform: How then are these large profi le sections produced from thermoplastic composites?A. Offringa: PPS composites (so-called prepregs) are produced from Fortron® fi lms, PPS matrix material and reinforcing fi bers at a temperature of about 300°C under high pressure. Specialized suppliers to the aircraft industry such as Ten Cate or also Airbus itself manufacture ribs, stiffeners and other elements from the prepregs. The individual components are welded together to form a strong, inseparable unit. This pro-cess eliminates the need for costly drilling and riveting operations and achieves higher strength and safety – while at the same time reducing weight. It also saves time and money.

With the Gulfstream G650, aircraft control surfaces made of thermoplastic composites will take off for the fi rst time in the history of aircraft construction. Aircraft manufacturer Stork Fokker uses Fortron® PPS to manufacture the rudder and elevator of the new business jet from Gulfstream Aerospace.

inform |05|

17

© S

tork

Fok

ker

DIALOG

Inform: In the Gulfstream 650, you are going a step further because here ther-moplastic composites are being used in exterior primary structural aircraft com-ponents. Does a new technology or material lie behind this?A. Offringa: New technology, yes, new material, no. Because of its specially suitable property profi le, Fortron PPS is the only thermoplastic, apart from PEI, PEKK and PEEK to be approved for aircraft composite structures by the US Federal Aviation Authority and other national authorities. Components made from PPS composites remain hard, impact-resistant, stiff and dimensionally stable, even when exposed to temperature variations of more than 100°C. Fortron® PPS is also resistant to aggressive media such as aviation fuel, engine and hydraulic oils, solvents and antifreezes. With its inherent fl ame retardancy, the material also meets the very high safety standards

specifi ed by the aircraft industry, such as the FST (fi re, smoke and toxicity) requirements.

Inform: So essentially something has chan-ged in the technology or processing …A. Offringa: That’s right! The PPS components for the rudder and elevator of the Gulfstream 650 are pro-duced using a welding method that is new to aircraft construction, known as induction welding, which has been developed by the Dutch KVE Composites Group. In simple terms, this is a very precise welding method, in which the components are only welded at the points where it is necessary. This method is used, for

example, to weld PPS ribs to large, fl at PPS compo-nents. Now we have moved forward another step and the relevant components are in serial production.

Inform: Is this another reason for the surge in the use of fi ber-reinforced ther-moplastics in aircraft construction and does it even spell the end for aluminum? Which material will win out your opinion?A. Offringa: Aluminum will certainly have to give an enormous amount of ground. But in the near future, it will not disappear completely – even though Bomba-dier, for example, has developed an all-composites fuselage structure for the Learjet LJ85. Tape techno-logy has a future as a production process simply because it offers important advantages. In this techno-logy, long tapes are ultrasonically compressed and shaped. Other parts can be directly joined to the tapes in a fully automated process. Once again, this saves

time. For this reason, this is the technology of the future in my opinion. In terms of materials, however, there will probably still be some departure from the present route. I am fi rmly convinced that the future lies “between” the properties of PPS and PEEK. Although it is an excellent material, PPS comes up against certain limits here and there. PEEK is a very good but also very expensive material with a very high melting point in an autoclave. If we could succeed in producing a combination that exploited the advantages of both materials, we would have the perfect basis for new tapes.

inform |05|

18

© G

ulfs

tream

Aer

ospa

ce C

orpo

ratio

n

DIALOG

Inform: Have you set up special research or partner programs to help translate the increasing but very complex know-how surrounding lightweight construction from theory to practice in a quicker and more targeted way?A. Offringa: We are conducting research in many directions. But we cannot cover or take forward everything on our own. We are therefore cooperating, for example, with Boeing, TenCate Advanced Compo-sites and the University of Twente in the Netherlands. We plan to establish a “Thermoplastic Composites Research Center (TPRC)” to accelerate innovations based on affordable, lightweight, eco-friendly ther-moplastic composite technologies. And Airbus, too, is working in this area with the Dutch aircraft industry and therefore with us under the auspices of TAPAS, the “Thermoplastic Affordable Primary Aircraft Struc-ture” project. This does not mean, of course, that all knowledge is thrown into one pot and mixed up. A couple of secrets remain because our aircraft manu-facturing competitors are also pushing ahead with innovations and lightweight construction, so we are all eagerly awaiting future developments.

Inform: Can you reveal to us neverthless what new things the near future might bring in aircraft construction?A. Offringa: It is certainly no secret any more to say that not only in the new A350 fuselage brackets but also in the new military transport plane from Airbus Military, the A400m, the fuselage ice protection plates are to be produced from this material. The horizontal tail is also in the development engineers’ sights.

All in all, and this is not just my opinion, the future lies in the production of thermoplastic composites by the new tape technology I have already mentioned. This will allow more compact design and require less material, so that further considerable weight reduc-tions can be achieved. In addition, tape technology will open up whole new design opportunities. For example, large structural components can be produ-ced more cost-effectively.

Inform: Will these developments exhaust the future of thermoplastic composites?A. Offringa: By no means. Then we can really take off in the aircraft industry and develop far more than the 1000 structural and non-structural interior and exterior parts installed on the A380, for example. Our designers’ eyes light up at the very thought, as no doubt do those of the material manufacturers, to whom rosy times will certainly come. And, of course, there are other industry sectors that benefi t from good lightweight construction materials. And I’m not thinking just of the automotive industry here. For wind farms, trains, buses or trucks, high-performance composites are also the lightweight material of choice.

Inform: Thank you very much for the interview.

The interview with Arnt Offringa was conducted by Henning Küll, Communications Manager Europe, Ticona.

Further links www.airbus.com www.fokker.com www.gulfstream.com www.kve.nl www.tencate.com

Delivery of the fi rst Gulfstream G650 is currently scheduled for 2012.It logged its maiden fl ight in late November 2009.

inform |05|

19

EFFICIENCY WITH COMPOSITES

PEEKPolyether ketones (PEK) are high-temperature-resis-tant thermoplastics. The best known and most im-portant representative of this group is polyetherether ketone (PEEK). Its melting point is 335 °C.

Polyether ketones are resistant to virtually all organic and inorganic chemicals. They are also re-sistant to hydrolysis up to about 280 °C. On the other hand, they are not resistant to UV radiation, concentrated nitric acid, general acid-oxidizing con-ditions and some halogenated hydrocarbons. With a typical price per kilo for prepregs of about 350 € (April 2009), PEEK is one of the most expensive engineering plastics.

PEIPolyetherimide (PEI) is a high-performance thermo-plastic belonging to the high-temperature-resistant plastics group (up to about 200 °C).

Polyetherimide is inherently fl ame-retardant with low smoke development. Even in the unreinforced state, it has very high strength, which can be further increased by the addition of glass or carbon fi bers. PEI has high dielectric strength, is resistant to hydro-lysis and very resistant to UV and gamma rays.

Fortron® PPSSpecifi c properties of polyphenylene sulfi de and its compounds: inherent fl ame retardancy, excellent hardness, stiffness and dimensional stability, high heat resistance with continuous service tempera-tures of up to 240 °C, very good chemical and oxidation resistance, minimal water absorption, good electrical properties, low creep and excellent mechanical properties.

Fortron® PPS is an ideal high-tech thermoplastic for production with short cycle times. PPS is recyclable and consumes relatively little energy during processing.

Braided cable sleeves made of Fortron® PPS are used in many applications in aircraft construction.

20

© S

tock

byte

/Get

ty Im

ages

h

EFFICIENCY WITH T ICONA GREEN ELECTRONICS

IT products are getting greener and greener. Three out of four buyers are now willing to dig deeper into their own pockets for such goods. A repre-sentative survey carried out by Pricewaterhouse-Coopers in 2008 came to this conclusion. When purchasing computers, televisions or cell phones, every second consumer indicated that they would agree to pay up to ten percent more for eco-friendly models than for conventional ones.

Most consumers can’t quite fathom what the term ‘green’ actually means in the context of electrical and electronic products, however. This buzzword is generally associated with nothing more than low energy consumption. Hardly any-one thinks about material selection based on

environmental considerations. Their use – com-bined with clear, easily traceable identifi cation for consumers – opens up considerable opportunities for manufacturers to differentiate themselves from their competitors.

Clear regulations from BrusselsThe requirements of environmentally compatible materials are clearly defi ned. The EU’s RoHS and WEEE regulations impose tight limits on heavy metals and certain brominated fl ame retardants. Relevant requirements and restrictions apply for all materials used in production. That applies to the plastics as well as to the solder materials, with their extremely high solder bath temperatures.

In its conversion to forward-looking, ‘green’ solutions, the industry faces a series of complex tasks. It is looking for so-called ‘drop-in’ materials that meet the ambitious sustainable development requirements. The new materials must also offer performance characteristics that are equal to, if not better than, those of the materials they replace – while enabling environmental compatibility cost-effectively at the same time. As a leading supplier of sustainability-conscious, high-performance thermoplastics, Ticona is prepared to assist

Uncompromisingly halogen-free

Heightened ecological awareness on the part of consumers and new international environmental regulations are increasing demand for eco-friendly electrical and electronic equipment.

Microswitches made of Fortron® PPS and Vectra® LCP meet the requirements of “Green Electronics”.

inform |05|

21

© F

otos

earc

h

companies as they develop and refi ne their pro-ducts through the optimization of materials, application and processing.

The consultants from Ticona have a broad range of products at their disposal. Modifi ed for specifi c applications, RoHS and WEEE-compati-ble grades of Celanex® PBT, Fortron® PPS and Vectra® LCP withstand high temperatures during processing, assembly and use. In so doing, they retain their dimensional stability and do not give off any substances that could damage sensitive electronic components. And thanks to their inher-ent fl ame retardancy, Fortron® PPS and Vectra®

LCP also help impede the spread of fi re. Despite miniaturization and reduced wall thicknesses,

designers need not compromise on strength. Easily processed, these materials enable high productivity, and their environmentally compatible composition facilitates recycling.

Ticona’s eco-friendly approachWith its RoHS-compliant grades, Ticona underscores its consistent focus as a company for which eco-friendly solutions represent both an objective and a core competence.

Celanex® PBT is a polybutylene terephthalate with high strength, stiffness, dimensional stability, im-pact strength and creep strength as well as good chemical resistance. Recent additions to this product range include non-reinforced and glass-fi ber-reinforced grades of the XFR series. Flame-retardant (UL94 V-0 at 0.8 mm), halogen and an-timony-free, and lightweight, they can be processed without emitting

corrosive substances and offer high electrical tracking resistance properties at the same time. Their patented fl ame retardant system is based on highly effective, organic phosphor compounds (so-called ‘metal phosphinates’) that remain stable at temperatures of up to 300 °C.

Fortron® PPS (polyphenylene sulfi de) is an inherently fl ame-re-sistant, high-temperature thermo-plastic with a melting point of 285 °C that exhibits an outstan-ding combination of thermal, me-chanical and chemical resistance.

Liquid crystalline Vectra® LCP is fl ame retardant without any ad-ditives whatsoever and has a low thermal expansion coeffi cient. Its

dimensional stability and chemical resistance, on the other hand, are very high. Vectra® LCP’s outstan-ding heat resistance permits lead-free soldering. Its excellent fl owa-bility in the melt in combination with the molded parts’ high strength let designers create thin-walled components, thereby saving material, reducing cycle times and increasing productivity. The ability to produce parts with up to 50 percent regrind content also offers cost-reduction poten-tials. Typical applications include connector strips, lamp sockets and bases, coils, switches, connectors, chip carriers and sensors.

Memory module sockets made of halogen-free Vectra® LCP E471i are used in products such as laptops.

The Ticona label stands for the use of halogen-free and fi re-safe polymers.

EFFICIENCY WITH TICONA GREEN ELECTRONICS

inform |05|

22

© V

olks

wag

en A

G

The evolution of Volkswagen’s 1974 Golf I to the current Golf VI has been far more than just a facelift: it has also en-dowed the model with highly enhanced active and passive safety systems and more dynamic handling characteristics, not to mention a comfort-oriented, upscale ambiance in the interior. But now the new generation has a problem: it has developed a ‘prosperity paunch’ – and a substantial one at that. It weighs in just short of 1.3 tons, a full 50 percent more than the founding member of the Golf dynasty. Much of the blame lies with luxury equipment like power steering or air conditioning and safety systems such as ABS and airbags – features that today’s drivers consider absolutely indispensable. Over the past 15 years, passenger cars have become about 30 percent heavier on average solely as a result of such features.

Modern gasoline and diesel engines are certainly far more fuel effi cient than their predecessors. But the price of fuel at the pump has nearly doubled since 2004 and legis-lators are in the process of tightening climate protection regulations, so the issue of fuel consumption is more urgent than ever. Beginning from 2012, for example, new cars sold in the European Union may not emit more than 120 grams of CO2 per kilometer. This corresponds to a fuel consumption

rate of about 5 liters of gasoline or 4.5 liters of diesel per 100 kilometers (47 mpg and 52 mpg, respectively). Compare that with the CO2 emissions of the top 14 automakers’ fl eets in 2006, which still averaged 162 grams per kilometer. “In view of these requirements, vehicle weight reduction will be a major development priority,” says Johannes Winterhagen, Editor in Chief of ATZ. Because according to a study by the European Federation for Transport and Environment (T&E), every percentage point of weight reduction corresponds to about 0.8 percent less CO2.

Lightening the load with more plasticModern engineering polymers like the ones Ticona has been developing and delivering to the automotive industry for more than 40 years are helping reduce the weight of vehicle components by an average of 30 percent. The share of plastic in today’s vehicles is about 15 percent. According to experts, the weight of a mid-size car containing about 900 kilograms (2000 lbs.) of steel and metal parts can be trimmed by another 300 kilograms (700 lbs.) through the consistent use of plastics in place of metal and through appropriate composite or hybrid solutions.

Mobile without metal? Plastics go into high gear

Engineering polymers are pioneering our automotive future: offering customized properties and light weight, they are replacing components made of metal, improving both perfor-mance and safety, and helping reduce fuel consumption and therefore CO2 emissions.

23

EFFICIENCY THROUGH METAL REPLACEMENT

And plastics provide other benefi ts as well: they enable highly versatile product design, can be colored in many dif-ferent ways, and make it possible to create even extremely complex components cost-effectively. Injection molding is a particularly useful means of producing material and com-ponent combinations in a single operation. This so-called ‘assembly injection molding’ helps reduce fabrication costs signifi cantly. Another special bonding process developed by Röchling Automotive known as JectBondingTM is also making a major contribution here.

Ticona diet plan From among the broad range of Ticona materials, Celstran® LFRT, Hostaform® POM and Fortron® PPS are the most widely used by a large number of automakers in structural, functional and aesthetic components. They feature excellent mechanical properties along with resistance to chemicals, corrosion and high temperatures. Three examples illustrate the diversity of applications – in exterior and interior components and even in components used in the engine compartment.

Take Celstran®+PP long-fi ber-reinforced polypropylene, for example, which is particularly well suited for automotive structural components such as front end carriers, door mod-ules and instrument panel carriers or control unit boxes and seat shells. This material exhibits an advantageous combina-tion of high impact strength and notched impact strength – an important factor for passenger protection in the event of a crash. It is also characterized by high stiffness and strength as well as low creep and warpage. In the case of the front end used on Mercedes’ most recent Vito and Viano models, it enabled designers to cut the weight of the component to half that of its predecessor. Through the integration of further assemblies such as headlamps, radiator and fenders,

it has also facilitated assembly and reduced production costs. The simple and inexpensive fabrication of metallic-effect

components for vehicle interiors includes a new special grade of Hostaform® POM polyacetal copolymer. One example of a current application is the door handle of the Honda Accord in high-quality metallic look, which is durably colorfast and scratch-resistant. These injection-molded parts have this fi nish right out of the mold. This has eliminated the need for the additional operations that were necessary in the past, such as coating, painting or vacuum metallization – along with the considerable costs associated with them.

Fortron® PPS linear polyphenylene sulfi de offers high hardness and stiffness, resists aggressive media such as fuels and lubricants, and even withstands continuous service temperatures of over 200 °C. Application areas in the en-gine compartment include air intake modules and charge air pipes in turbocharger systems. Moreover, a charge air pipe made of Fortron® PPS weighs only 500 grams, for example, which represents a weight savings of 30 percent over the comparable aluminum component. At the same time, the production costs are about 25 percent lower.

A safe, roadworthy, high-quality ‘lightweight car’ is a feasible objective – and the keys to achieving that goal in-clude engineering plastics that are currently available and under continuous further development. Ticona is playing an active role in shaping this development as a system partner to automakers and their system suppliers. The material expert’s range of services includes support in the selection and development of materials as well as extensive advice on engineering applications – from component design to mold layout and CAE modeling right through to the optimization of production processes.

From left to right:(1) Door handles made of POM metaLX: no sub-

sequent painting or metallizing operations required

(2) Door module made of Celstran® LFRT saves up to eight kilograms.

(3) Charge air pipe made of Fortron® PPS weighs 500 grams (made of aluminum: 870 grams)

inform |05|

24

APPEARANCE

Product designers and marketing experts appreciate the manifold design- and processing options, the mechanical attributes such as good slip and abrasion properties, excel-lent heat resistance, high durability even versus aggressive substances or an improved environmental record. But it is not just the inner values that are pivotal when choosing the right material, the ”external” characteristics are also impor-tant. ”Plastics provide us with extensive freedom in the design of components or the fi nished product. This concerns colors, surface feel and shapes. New features can also be easily integrated with the aid of plastics. The materials of the twenty-fi rst century eliminate existing constraints and give us additional space for creativity,” says professor Andreas Schulz from University of Applied Sciences and Arts in Hildes-heim, Germany.

Through continuous advancements product designers possess a limitless variety of materials. Ticona alone offers a portfolio of some 400 different polymer grades. Among these are full-color plastics of diverse hues, plastics with a particular surface feel or special appearance, such as MetaLXTM variants, which possess a metallic look. Additives provide polymers with further characteristics, for example the long-term resistance of a material against UV irradiation. Additives also optimize plastics for additional processing steps, such as durable labeling through laser marking or assembly with decor elements using so-called In-Mold-Decoration.

True beauty comes from withinOften it is the combination of several strengths that makes

a plastic the material of choice. For example, shower heads manufactured with Hostaform® POM would hardly win a beauty prize, would they not also be able to withstand lime-scale, chlorine and aggressive cleaning agents. Baking dishes made of Vectra® LCP must be suitable for foodstuffs and be able to withstand temperatures of 280 °C. The surface quali-ty of oven handles made of Celanex® PBT makes little sense without low heat conduction. And metallic shimmering door handles in automobiles can’t have a tendency toward hair-line fi ssures and have to withstand cockpit cleaning agents as well as temperature fl uctuations in the vehicle interior.

Environmental considerations also play a role when using technical plastics. Manufacturing surface materials with polymers lowers the number of processing steps. This saves resources in raw materials, energy and logistics. Pollutants such as specifi c lacquers or metals are avoided altogether to protect man and the environment.

However, the existing portfolio is not the only thing that is available for designers and manufacturers. Plastics experts target existing materials for modifi cation or are developing additional products for new applications. ”Almost always, we have the option to individually tailor the properties of high performance plastics. This provides thermoplastics with very many and very specifi c application options,” explains Dr. Tilo Vaahs, Manager Market Development at Ticona. ”The future will show which products will be successful in the market. Of one thing we can be certain: high performance polymers will play a role.”

High functionality with a perfect visual appearance at an acceptable price – consumers make high demands. Increased quality, durability, environmental friendliness, lowered weight and increased cost effi ciency in production are key reasons to bet on high per-formance polymers during the development of new products or components.

Strong on the inside, appealing on the outside

inform |05|

25

© N

eope

rl

APPEARANCE

Plastics bring color into playBefore processing even begins, pellets and granulated material are mixed on a molecular

level. This provides the component or product with the appropriate hue. Colored through and through, they are less susceptible to visible scratches. Cost intensive paint work or surface coating, which also usually burden the environ-ment, are thus superfl uous.

Lasers make permanent marksSpecial plastics types can be marked with a laser for functional or decorative applications. Even after a long

time, the abrasion-proof and high-con-trast characters and labeling can be read as readily as on the fi rst day. The highly precise laser labeling takes place immediately after

the injection molding. Even components with complex geometries can be processed rapidly with this method.

Glittering effects with MetaLXTM

MetaLXTM-polymers provide designers with glit-tering metallic plastics solutions that cannot be distinguished from real metal surfaces – neither visually nor through surface feel. The appropri-ate appearance is achieved without additional processing steps. This lowers costs signifi cantly and helps avoid elaborate fi nishing processes altogether. As the components are colored in the mass, they are particularly scratch-resistant and their paintwork does not crack.

Beauty from within Attractive appearance and pleasant touch on their own are not enough. Inner qualities are no less important. Take oven handles made of Celanex® PBT, for example: the low thermal conductivity of this plastic makes it suitable for use on ovens and in other heat-related applications.

Defying the sunThe sun bleaches plastics and makes them brittle. Components made from UV-resistant polymers withstand ultraviolet rays. Even after years of use, they maintain their functionality and appearance through the use of specifi c additives.

IMD: inseparably bondedIn-Mold-Decoration (IMD) offers extensive design freedom for complex components. With this method materials such as metals, fabric, wood veneer or glass can be bonded into one formed component with technical plastics. Using IMD, one can manufacture completely new decors and surface effects such as Cool Touch, a metallic look as well as scratch-proof, heat-resistant or structured surfaces with a specifi c surface feel.

inform |05|

26

© P

lush

Stu

dios

/Get

ty Im

ages

INNOVATION AND RESEARCH

Artifi cial knee joints and prosthetic hips are fabricated from GUR® UHMW-PE.

inform |05|

27

Dr. Walkenhorst, when our readers think of vitamin E, they tend to think of food and not plastic. What was the idea behind mixing this vitamin with a plastic? When working with polymers for use in medical applications, this isn’t nearly so far-fetched as it might seem. Half of the compounds we know under the collective term vitamin E have an anti-oxidative effect. After all, they’re really nothing more than fat-soluble substances known as toco-pherols. One of these is the alpha-tocopherol that we use.

What exactly is the vitamin E in implants designed to do?Many implants are pre-treated with modern radia-tion techniques, in order to sterilize them and im-prove their effectiveness. This can generate free radicals in the material, possibly causing oxida-tion and thereby accelerating the rate at which implants age. This might, in turn, adversely affect mechanical properties and reduce wear resistance. A plastic modifi ed with vitamin E improves oxida-tion resistance.

Mr. Redeker, does this impair the me-chanical properties of the plastic?No, according to the information we have today, this is not the case. The new material complies with ASTM* F648 and ISO 5834-1. All of its mechanical properties are comparable with those of UHMW-PE Premium, which are already widely known. Here GUR® 1020-E and 1050-E meet the requirements relative to purity and processabil-ity, and furthermore exhibit excellent vitamin E homogeneity.

How is the plastic produced?The polymer is produced using the Ziegler-Natta polymerization process and takes the form of a powder. Due to its high viscosity, it cannot be processed like other thermoplastics. Instead, com-pression sintering or ram extrusion is used to process it into sheets and bars. The implant is machined into its desired form through chip re-moval during subsequent processing operations.

“The vitamin E-enriched polymer provides protection against oxidation”

At the beginning of this year, Ticona released two new ultra-high-molecular polyethylenes for test purposes: GUR® 1020-E and 1050-E. Orthopedic implants made from these vitamin E-modifi ed grades do not oxidize or age. “inform” met with Dr. Rainer Walkenhorst and Gunther Redeker, both of Technical Marketing GUR, and asked them for details.

INNOVATION AND RESEARCH

*ASTM = American Standard Test Method

[email protected] [email protected]

inform |05|

28

INNOVATION AND RESEARCH

Today, better quality, decreased weight and lower costs are core reasons for companies to place their bets on high-performance plastics instead of metals, ceramics or other materials. Whether processed as composite materials in airplanes or automobiles, as fi laments in technical textiles or as a primary material for the manufacture of parts from large to very small – Ticona materials satisfy the most discerning customers through their individually tailored attributes. Today, the company, which belongs to Celanese, provides more than 400 speciality grades worldwide. Selecting the correct material is, however, just one side of the coin – albeit a very important one. The other comprises a number of factors which, in total, play a key role in economic success. For example, companies benefi t by having a partner who can competently advise them regarding innovations and entry into new markets, as well as one who offers well-founded expertise and is present in the important regions.

Innovations: Breaking new ground using best practice methodsThere is no single key to successfully entering a new market. Knowledge of existing markets and experience offer a good basis. Effort, expenditures and risks in developing potential markets are thus signifi cantly reduced. Ticona offers specially developed innovation workshops for exactly this scenario. Participating customers can more readily recognize the strengths of their company and (learn to) use those strengths more intensively. For the potential of an idea increases dispropor-tionately if entrepreneurial skills are taken into account from the start when searching for new business models. This allows for utilization of existing know-how and appropriate knowledge transfer.

Innovations become especially ”cutting edge” if societal megatrends, which are intensively scrutinized by Ticona, are considered during this knowledge transfer phase. Using existing markets

Close to today’s heartbeat: collective success

The business climate in the German economy has brightened, as the Ifo-Index (Ifo-German institute for economic research) shows in November. There are increasing indicators for an end to the crisis. However, economic recovery is not yet stable. Now, more than ever, a competent partner is needed. A partner with whom one can set the correct course for sustained business success – through initiative, market knowledge and imagination as well as processing- and technology know-how and a global presence.

Ticona hosts innovation workshops for customers.

inform |05|

29

INNOVATION AND RESEARCH

as a launching point, new, profi table markets can be developed – for example, in the automotive industry trends such as safety, the environment and lightweight construction, comfort or individual appointments can be considered.

Processing- and technology know-howSetting the course for the success of a plastic component or product takes place as early as the planning phase. Because of this, Ticona offers its extensive process and technology expertise from the outset in development partnerships in the form of consultancy, seminars and troubleshoot-ing. Which material is best for the planned com-ponent? Which processing technology is best suited for the job? How must the component and consequently the mold be designed to be appro-priate for the particular plastic used?

The most commonly used processing method for plastics is injection molding. Just one fault when setting up the machine can already create a component that does not meet requirements. If extensive knowledge of the material exists, then a simple visual check is sometimes all that is needed to decide what needs to be changed. Especially im-portant: When using the injection molding method, the tools must be tailored exactly to the particular plastic, the component to be manufactured as well

as location of operation and intended function. To avoid lasting diffi culties or even faults during sub-sequent production, the mold designer and mold maker rely on data existing for Ticona plastics.

Global presence in the important regionsSo that know-how and the right products are available in fast-growing locations, Ticona is com-mitted to regions such as Asia. Customers who manufacture products there, can access polymers and services locally and profi t from quicker de-livery times, increased fl exibility and decreased costs. Today, Ticona manufactures Hostaform® POM, GUR® UHMW-PE, and Celstran® LFRT locally. The main pillar is China. In addition to world-scale monomer-, polymer- and compounding facilities, a development center for customer applications has been in operation in Shanghai since 2008. The center is an important element of the global support network, which also includes similar centers in Kelsterbach, Germany, Auburn Hills, Michigan and Florence, Kentucky, USA.

[email protected]

inform |05|

30

© F

otos

earc

h

INNOVATION AND RESEARCH

Unbeatably tough and effi cient: Hostaform® S 9362 and S 9363

As POM market leader, Ticona has been continuously optimizing its Hostaform® POM range already for nearly half a century. Now two new high-impact-strength grades of the next generation raise production effi ciency while offering an improved property profi le at the same time.

In order to meet growing demands also in the future, Ticona has done more than merely expand the property profi le of the Hostaform® S product family. Hostaform® S 9362 and S 9363 also permit processors to increase their productivity considerably: Cooling times can be shortened by up to 30 percent and reduced mold deposit minimizes downtime, thereby yielding signifi cant cost savings over processes that use competitors´ impact-modifi ed POM products.

Product developers at Ticona have also managed to improve the perfor-mance profi le of these new grades. They provide up to 200 percent higher weld line strength versus other TPU impact-modifi ed polyacetals and feature signifi cantly greater heat de-fl ection resistance, a higher elastic mod-ulus and enhanced mechanical per-

formance properties. The modifi cation also gives Hostaform® S 9362 and S 9363 more favorable slip/friction pro-perties and improved chemical resis-tance. Typical application areas for these new products include automo-tive safety systems, fastener elements, and clips and buckles as well as sports and leisure articles.

[email protected]

Lower chlorine content for a broader range of applications

Ticona introduces a new grade of Fortron® PPS.

The production of eco-friendly pro-ducts has long been one of Ticona’s top priorities. That’s why certain mate-rials are already inherently fl ame retar-dant and free of fl ame-retarding agents that contain halogens. These special polymers include Celanex® PBT XFR and Vectra® LCP, for example – and now the new generation of Fortron® PPS “Low Chlorine” joins their ranks. Fortron® PPS “Low Chlorine” reduces bromine and chlorine content to below 900 ppm. The 1140LC6 grade can also be used as a drop-in solution in eco-friendly components.

“Fortron® PPS is part of our range of plastic grades whose qualities can

benefi t nearly every industrial segment in the development and production of molded parts designed to withstand high mechanical and thermal stress,” says Frank Johänning, Marketing Manager LCP. That’s why Fortron® PPS “Low Chlorine” is also used in the electrical/electronics sector, and especially wherever robust properties are required, such as in switches, con-nectors, relay parts, etc. “In electronics applications, the material’s extremely low ionic contamination represents a distinct advantage over other products,” explains Johänning. Fortron® PPS “Low Chlorine” is suitable for use wherever fl ammability class V-0 is required.

European and American manufacturers are already complying with the international environmental regula-tions of RoHS (Restriction of Hazardous Substances Directive), which prohibits the use of brominated fl ame retar-dants. And many manufacturers also monitor chlorine content in production now. Fortron® PPS “Low Chlorine” offers them yet another opportunity to make their products eco-friendlier.

[email protected]

New from Ticona’s research laboratory

*impact-modifi ed POM products of competitors

inform |05|

?31

TECHNOLOGY AND SERVICE

Technology FAQs

Is mold wear generally higher with LFRT?Mold wear is lower with long-fi ber-rein-forced products than with comparable short-fi ber-reinforced grades. At equal fi l-ling ratios, long-fi ber-reinforcement leaves fewer free fi ber ends, thereby reducing the abrasive effect.

What is the minimum required length of the fi bers in the fi nished part?In order to ensure superior properties versus short fi ber products, the mean fi ber length in the component must exceed a critical length. With Celstran® LFRT PP, for ex-ample, the mean fi ber length in the component after the injection molding process must be at least two millimeters. At the same time, full impregnation of the long fi bers (pul-trusion process) during Celstran® LFRT production ensures optimal fi ber/matrix bonding.

How can the customer determine the fi ber length in the component?There are several possibilities. With Celstran® LFRT PA and PP, the easiest method by far is to analyze the fi ber structure after ashing the component. In this case we recommend the following temperatures: heating for one hour at 400 °C and then one more hour at 600 °C.

Don’t long fi bers cause higher warpage and greater shrinkage than short fi ber products?Long fi bers tend to align themselves less in the direction of fl ow than com-parable short fi ber products. So proper processing techniques form a fi ber structure without a prevalent fi ber orientation. This results in a reduced tendency to warp. The fi ber structure also impedes shrinkage at the same time, so shrinkage behavior is also better than that of short-fi ber-reinforced thermoplastics.

Interest frequently focuses on long-fi ber-reinforced thermoplastics. “inform” asked Ticona’s Technology and Service Department which questions are posed most often.

Short-fi ber-reinforced

Celstran® Long-fi ber-reinforced

[email protected]

32

inform |05| TI-B

R 10

82-D

E-12

.200

9

TICONA CALENDAR

IMPRINTPublished byTicona GmbH

Editorial team Monika Besant (V.i.S.d.P.),Beate Sauer, Marcel Rzymann(SWK Semnar & Wolf Kommunikation GmbH)

Editorial addressTicona GmbH, Monika Besant,B2B Communications, Prof.-Staudinger-Straße, 65451 Kelsterbach/Germany

Design/layoutSWK Semnar & Wolf Kommunikation GmbH, Frankfurt/Germany, www.swk-ffm.de

PrintingJD Druck- und Medienhaus GmbH, Lauterbach/Germany

Picture creditsTicona GmbH, unless otherwise stated

Ticona productsHostaform® POM, Celcon® POM, GUR® UHMW-PE, Celanex® PBT, Impet® PET, Vandar® (polyester alloys), Ritefl ex® TPC-ET, Vectra® LCP, Fortron® PPS, Celstran® LFRT, Compel® LFT

Notes for usersThe information contained in this publication should not be construed as an agreement or guarantee regar-ding certain properties of our products. It is the sole responsibility of the user to determine the suitability of a particular material and component design for a specifi c application. We strongly recommend to users that they obtain the latest manufacturers’ instructions on the use of the selected materials and to follow these. With the exception of GUR® UHMW-PE, our products are not intended for use in medical or dental implants. Any existing industrial property rights must be observed.

Fairs and events

October

October 13-17, 2009FakumaInternational Trade Fair forPlastics ProcessingHall B1, Stand B1-1117Friedrichshafen, Germany

Ticona at Fakuma 2009Under the banner “Productivity & Performance”, Ticona had its own stand for the fi rst time at this year’s FAKUMA. In four main areas – Composites, Metal Re-placement, Green Electronics and Appearance – the plastics pro-ducer from Kelsterbach showed manufacturers and suppliers in different industries how to take full advantage of plastics tech-nologies and high-performance materials. Exhibits highlighted concrete competitive edges like weight and CO2 reduction through lightweight construction, and cost and energy-effi ciency, as well as innovations in pro-ducts, manufacturing processes and design. The Ticona stand presented new materials and applications, including major exhibits from the aeronautics and automotive industries.

January

January 27, 2010ZVEI Working Group “Halogen-Free Products”Frankfurt am Main, Germany “Halogen-free fl ame-retardant plastics”Dr. Alexandra Jacobs-HattwigTicona GmbH,Kelsterbach, Germany

February

February 24-25, 2010SKZ WürzburgEngineering polymersPerformance potentials and trendsProfessional conference including, among other topics:“POM, a surprisingly versatile engineering polymer”Dr. Kai-Uwe Tönnes, Ticona GmbH, Kelsterbach, Germany“LCP, the sophisticated material class“Dr. Achim Hofmann, Ticona GmbH, Kelsterbach, Germany

SKZ WürzburgSKZ uses its facilities to host, among other things, professional conferences and seminars cover-ing all facets of plastics and interdisciplinary topics.www.skz.de