8:00 am – 11:00 am:
TH1-Electrical & Electronic and Advanced Energy-Room S320A
8:00 am – 8:30 am:
One-step Electrochemical Treatment of Metal Inserts for Tight Polymer-Metal Hybrid Applications
Tobias Kleffel, Institute of Polymer Technology
One common method for the manufacturing of electronic systems with a high resilience is the encapsulation of metal inserts using assembly injection molding. Due to the exposure of such parts to different mediums such as oil or saltwater during use, ensuring tightness still is a challenge. This paper deals with the assembly injection molding of tight electronic systems using microstructures on the metal insert introduced by a one-step electrochemical treatment. It can be shown that the electrochemical treatment increases both the tightness and the strength of the bond between metal insert and polymer component. Furthermore, the effects of the electrochemical treatment on the surface and geometry of the metal insert are presented.
8:30 am – 9:00 am:
Effects of Processing Variables on Crystallization Phases of P(VDF-TrFE-CFE) Thin Films
Hao Pan, Umass-Lowell
In this work, Poly (vinylidene fluoride-trifluoro-ethylene-chlorofluoroethylene) terpolymer [P(VDF-TrFE-CFE)] has been prepared as thin films with different processing conditions including coating temperature, annealing temperature and nanoclay loading level. The chain conformation of obtained films was studied by Fourier transform infrared (FTIR) and X-ray diffraction (XRD). It is shown that lower coating temperature is favorable for obtaining β-phase crystals, whereas higher annealing temperature leads to α-phase. Nanoclay can be added to increase total crystal amount.
9:00 am – 9:30 am:
New Transparent High Heat Polycarbonate Copolymer Resins for Thermo-optical Applications
Mark Van Der Mee, SABIC
SABIC has launched a new LEXANTM CXT resin portfolio designed to offer potential solutions for optical lenses with its unique combination of high heat resistance, water clear transparency and high flow in a broad processing window. The high heat resistance of these resins may allow the use of assembly processes like low temperature soldering of parts onto printed circuit boards, and/or demanding part operation conditions. The high flow capability of LEXAN CXT resins without excessive yellowing may allow significant benefits in productivity and system cost.
9:30 am – 10:00 am:
High Temperature Dielectric Film
Matthew Niemeyer, SABIC
A review of the key CTQ’s of high heat dielectric films and their relationship to the manufacturing process and electrical performance of a wound film capacitor. Clean energy, global CO2 reduction and the electrification of vehicles have been driving factors for the need for higher performing – higher temperature film products. SABIC has recently commercialized ULTEM UTF120 capacitor grade film, developed to meet the most stringent technical capacitor demands through a wide temperature range (-40 to +175 °C) and exhibits stable properties through temperature and frequency. Film is available for multiple applications requiring high temperature resistance during processing or end use.
10:00 am – 10:30 am:
Highly Filled Biochar/ultra-high Molecular Weight Polyethylene/linear Low Density Polyethylene Composites for Electromagnetic Interference Shielding
SUIYI LI, UW-Madison
Highly filled biochar/ultra-high molecular weight polyethylene (UHMWPE)/linear low density polyethylene (LLDPE) composites were prepared using extrusion and hot-compression methods. Bamboo charcoal (BC) carbonized at 1100 °C exhibited good electrical conductivity and had strong interfacial interactions with the polymer matrix. The addition of BC remarkably improved the electrical conductivity and electromagnetic interference (EMI) shielding effectiveness (SE) of the composites; the composite with 80 wt.% BC had a conductivity of 107.6 S/m and an ultra-high EMI SE of 46.7 dB at 1500 MHz. The loading of BC did not severely affect the crystal structure of the UHMWPE/ LLDPE blend.
10:30 am – 11:00 am:
Thermoelectric Properties of Open Cellular Polymer Templates Coated With 1D and 2D Carbon-Based Nanoparticles
Siu Ning (Sunny) Leung, York University
In this study, a novel technique was developed to fabricate organic thermoelectric (TE) materials with enhanced TE conversion efficiencies. The synergistic effects of multi-walled carbon nanotubes (MWCNT) and graphene nanoplatelets (GNP) as conducting nanofillers were investigated to enhance the TE properties of polymer nanocomposites. Polyvinylidene fluoride (PVDF) foams with open-cellular structures were employed as polymeric templates in combination with MWCNT and GNP as hybrid conducting fillers, to fabricate polymer nanocomposite foams for TE applications. The results of this study proved the template-assisted localization of conducting nanofillers within polymer matrices as an effective strategy to simultaneously tune all TE parameters of polymer nanocomposites and substantially promote their TE efficiency. Experimental results also revealed that utilizing hybrid nanofillers with optimized mixing ratio is beneficial for promoting the TE efficiency of polymer nanocomposite materials because of the synergistic effects of the 1D and 2D structures of the conducting fillers.
8:00 am – 11:30 am:
TH2-Automotive: Design & Applications-Room S320E
8:00 am – 8:30 am:
KEYNOTE: Intelligent Automotive Design with Plastics
Jeff Helms, Celanese
There has never been a more exciting time to be in the Auto industry, with disruption and innovation occurring on many fronts. Electrification of the Powertrain, Autonomy, Regulation, and Connectivity are Megatrends impacting the future of mobility, and plastic materials play an important part in each of these large scale changes that will ultimately remake ‘what’ a light passenger vehicle is and does, and ‘how’ humans are transported in the future. This paper will touch on each of these trends and the potential impact on the Auto sector.
8:30 am – 9:00 am:
Innovations in Automotive Plastics “Applications”
Suresh Shah, Delphi -Retired
This presentation will discuss Innovations in Automotive Plastics “Applications” based on recent 2017 automotive innovations awards finalists and winners as well as recent innovations not submitted for awards.
9:00 am – 9:30 am:
Chemical Resistance of PMMA, ASA and ASA+PC for Automotive Exterior Trim Applications
Tom Pickett, SPE Automotive
This paper examines the chemical resistance of different grades of Polymethylmethacrylate material (PMMA), Acrylonitrile Styrene Acrylate (ASA) and Acrylonitrile Styrene Acrylate Polycarbonate (ASA+PC) that are commonly used in automotive exterior trim applications. The materials were exposed to automotive windshield washer solvent at different levels of strain.
9:30 am – 10:00 am:
Recycled and Waste Materials in Selected Automotive Applications
Karnik Tarverdi, Brunel University London
The objective of this project was to investigate the potential use of recycled and waste materials in automotive components. Few components were selected for the investigation. All of them had the potential to be manufactured from waste and recycled materials. The trial materials which included recycled polypropylene and an industrial particulate solid waste stream, were processed into prototype components that were evaluated and compared with the respective production counterparts. The overall results indicated a clear potential for the use of the project materials in their respective applications.
10:00 am – 10:30 am:
Hybrid Pedestrian-Safe Solution for the Automotive Industry
Pavan Puranik, SABIC
Pedestrian safety is one of the most important safety criterion that needs to be addressed by automotive OEMs. Additionally, increasingly aggressive styling of the vehicle has posed multiple technical and commercial challenges for OEMs. Having the spoiler positioned at the front end of the vehicle plays a key role in reducing the knee rotation and thus contributes largely to the design of a pedestrian-friendly front bumper system for a vehicle. Design of this spoiler largely depends on the vehicle architecture. This work captures efforts to understand the different vehicle architectures and to develop design strategies needed to meet lower-leg impact performance requirements of pedestrian safety. A hybrid lower member is proposed to meet the pedestrian safety requirements. The proposed solution not only eliminates an additional part in the vehicle front bumper system, but also provides integration possibilities with significant weight reduction potential.
10:30 am – 11:00 am:
Aerodynamic Optimization of a Day-cab Fairing
Carlos Pereira, SABIC
The current trend towards energy efficient commercial vehicles requires a substantial improvement in their aerodynamic performance. The development of a ducted fairing design for a Day Cab using computational fluid dynamics and scale wind tunnel evaluationis presented as well as the validation of the final design by means of a full scale prototype used for comparative testing with a commercial fairing in constant velocity track tests and highway coast down.
11:00 am – 11:30 am:
Computational Modeling of Impedance Tube and Validation for Tuning the Acoustic Transmission Loss of Polymeric Materials
Vasudev Nilajkar, SABIC
The need for lightweight solutions has increased the use of polymeric materials in many applications, with an aim of replacing multiple components with integrated multi-material and multi-functional polymeric parts. Apart from structural and thermal requirements, acoustic performance is an important functional requirement in many applications such as automotive, transportation, equipment enclosures and consumer electronics. The frequency-dependent acoustic transmission loss (henceforth referred to as TL) is one of the standard measures to understand the acoustic performance and is experimentally measured using an impedance tube setup. The process involves molding and preparing circular samples with two different diameters (for low frequency and high frequency impedance tube testing) and performing repeated tests. The tests are generally repeated for multiple samples of each material and averaged in order to compensate for uncertainties such as sound leakage from boundaries, fitment issues, sample variation, etc. Hence, experimentally determining the TL is expensive due to the labor-intensive and time-intensive sample preparation and testing. TL is a complex function of material composition, morphology, physical and mechanical properties, all of which can be modified for polymers (by using fillers) to achieve the desired TL values in the desired frequency range. As tuning the TL experimentally is a time and cost intensive affair, we have developed a computational model that has been validated with experimental measurements. It is a fully coupled structural-acoustic finite element model simulating the impedance tube. This model can be used to perform virtual design of experiments to arrive at the most likely properties of the polymeric material that will result in the required TL at the frequency range dictated by the application. Only this material configuration can then be prepared and the TL experimentally measured, enabling more quickly identifying a candidate material solution to meet the customer’s needs. In this study, we have experimentally validated the model using test data of TL from five samples of varying composition. This computational tool can be extended to estimate the TL from multi-layered laminates and sandwich panels with various core morphologies.