Düsseldorf, October 15, 2024 – Envalior is expanding the performance of its Tepex® continuous fiber-reinforced thermoplastic composites. These products are now available to its customers with matrices made from polyetherimide (PEI), polyphenylene sulfide (PPS), polyamide 4.6 and 4.10 (PA4.6 and PA4.10) as well as thermoplastic copolyester elastomers (TPC-E). Envalior will present the new composite range at the Fakuma 2024 trade show booth in Hall B4, number 4302.
“The new structural materials boast typical strengths of special and high-performance composites. This gives rise to attractive new areas of application – for instance, in mechanical and equipment engineering, running shoe production and aircraft construction or special applications in automotive engineering such as structural components of the body,” explains Dr. Lisa Tölle, material developer at the Envalior subsidiary Bond-Laminates, which produces Tepex®.
Stable at high temperatures, yet flame retardant and low in flue gas
Thanks to their matrix polymers, the composites based on PEI and PPS have outstanding mechanical strength and stiffness that are barely compromised even in intense heat. For instance, the heat deflection temperatures (HDT, DIN EN ISO 75-1,-2,-3) are 210 °C and 275 °C, respectively. In addition, the composites are highly resistant to chemicals. Both matrix materials are inherently flame retardant and barely flammable. Furthermore, in a fire, they hardly emit any toxic substances and flue gases that restrict visibility. Consequently, Envalior expects these two composite ranges – as well as their matrices – to comply with most current industrial standards for components in aircraft and railway vehicles. These include the European standard DIN 45545 on fire protection in railway vehicles, the US fire test FAR 25.853 (Federal Aviation Regulations) on the flammability of materials for aircraft, and Airbus standard ABD0031, which tests aspects such as the toxicity and density of flue gases. “Potential applications could therefore include components inside airplanes and railway vehicles such as backrests, seat shells, lids of luggage compartments or table structures,” says Tölle.
PEI is an established material in 3D printing. Thus, the new composites based on these thermoplastics can also be easily combined with this generative process. Formed semi-finished products of the composites can be printed with functions such as ribs, guides or mounts and converted into components. “When working with the small production volumes that are typical of the aircraft industry, for example, this is much more flexible and cost effective than investing in elaborately designed tools for the back-injection of inserts,” Tölle explains.
Based on castor oil
Further variants of the new composites are based on the PA4.10 EcoPaxx® from Envalior. Their carbon footprint is around 50 percent smaller than those of comparable fossil-based polyamide 66 types. Around 70 percent of their matrix consists of raw materials that are derived from castor oil in a resource-saving manner, meaning that they do not compete with food production. At the same time, the level of their mechanical characteristics is around 10 to 20 percent higher than that of polyamide 6 or 66. Further strengths of the composites are their high scratch resistance, low water absorption and good melt flowability. “This makes them suitable for the production of highly stiff, high-strength, heat-exposed housings with a decorative, hard-wearing surface and an intricate internal structure,” Tölle explains.
Wear resistant and low friction, even at high temperatures
The new composites with a matrix made of the PA4.6 Stanyl® from Envalior exhibit outstanding mechanical properties at operating temperatures of up to 220 °C. In particular, the products are highly resistant to wear and abrasion and have low susceptibility to friction. They are therefore ideal for the production of moving parts. “We see major potential for application in metal substitution in transmission systems components such as gear wheels, actuators and coil carriers,” says Tölle.
Elastomers with a wide range of hardness
The composites based on TPC-E from Envalior’s Arnitel® product range are particularly intended for applications in the production of sporting goods, such as components for shoe soles. Their matrices cover a wide hardness range, with Shore hardnesses from 74D and 55D to 33D. The benefits of the composites include their high thermal stability and their largely consistent mechanical properties across a wide temperature spectrum, from -45 to 150 °C, such as high tensile strength and abrasion resistance. Although the new composites have elastomeric properties, they are easy to recycle as thermoplastic materials. For instance, used components can be shredded and processed into recompounds.
The harder, carbon-fiber-reinforced composite variants are highly suitable for use in so-called power plates for running shoes, for example. Behind this are midsole elements made from a thermoformed composite plate with high rebound elasticity that is combined with shock-absorbing foam layers.
Carbon-fiber-reinforced product types, too
All new composites are available with continuous glass-fiber and continuous carbon-fiber reinforcements. The carbon variants have even better mechanical properties, such as much higher tensile moduli and flexural strength.
Successful use of synergies
The Tepex® business is part of Envalior’s Specialty Materials division, which is also responsible for high-performance thermoplastics such as EcoPaxx®, Stanyl®, Arnitel® and Xytron® (PPS). “The development of the new Tepex® variants with matrix materials produced in-house demonstrates the synergies generated from the wide range of high-performance thermoplastics in the Specialty Materials division for the development of innovative products,” says Tölle.
Fakuma will take place from October 15 to 19, 2024, at Friedrichshafen Exhibition Center. You can find Envalior’s stand in Hall B4, number 4302.
For more information on the products and services provided by Envalior, visit www.envalior.com/en-us/products/tepex.html.
Tepex® is now also available with matrices made from polyetherimide, polyphenylene sulfide, polyamide 4.6 and 4.10 as well as thermoplastic copolyester elastomers.
Photo: Envalior
About Envalior
Envalior is a global leader in Engineering Materials with over 4,000 employees worldwide. It was established in 2023 through the merger of Lanxess Performance Materials and DSM Engineering Materials. With a long track record of customer-driven innovation, Envalior specializes in developing sustainable and high-performance material solutions. Focus markets include Automotive, New Mobility, Electronics & Electrical, and Consumer Goods. For more information, visit www.envalior.com.
Forward-Looking Statements
This company release contains certain forward-looking statements, including assumptions, opinions, expectations and views of the company or cited from third-party sources. Various known and unknown risks, uncertainties and other factors could cause the actual results, financial position, development or performance of Envalior GmbH to differ materially from the estimates expressed or implied herein. Envalior GmbH does not guarantee that the assumptions underlying such forward-looking statements are free from errors, nor does it accept any responsibility for the future accuracy of the opinions expressed in this presentation or the actual occurrence of the forecast developments. No representation or warranty (expressed or implied) is made as to, and no reliance should be placed on, any information, estimates, targets and opinions contained herein, and no liability whatsoever is accepted as to any errors, omissions or misstatements contained herein, and accordingly, no representative of Envalior GmbH or any of its affiliated companies or any of such person’s officers, directors or employees accepts any liability whatsoever arising directly or indirectly from the use of this document.
Candace Roulo
