Second Wave of Digitalization: From Plastics Machine Manufacturer to Platform Provider?

Second Wave of Digitalization

Thinking back to the last K-Show held in 2016 in Düsseldorf, Industry 4.0 and Industrial Internet of Things (IIoT) were all over the booths. This year at the K-Show we will see a lot about topics such as sustainability, circular economy, and recycling.

However, how did the Industry 4.0 story continue?

In the past three years, machine and equipment manufacturers, tool makers and plastic convertors connected their devices and started collecting data while making their products. This data allowed them to gain insights into their operations and make them more profitable. A major step stone was the introduction of Euromap 77 in 2018. This allowed data exchange between plastics converting machines e.g. injection moulding machines and manufacturing execution systems (MES). In this way, Euromap 77 enables a standardized way of connecting the entire production chain. Altogether, this first wave can be summarized under the term “efficiency innovation”. This was mainly driven to streamline internal processes and obtain cost reductions.

How does digitalization follow up?

Starting last year already, the second wave of digitalization [2] has arrived in Europe. In this second wave, investors focus on three main topics:

1. Artificial Intelligence (AI)

2. Platform based business models („platform economies“)

3. Mobility solutions

Artificial intelligence is the main game changer and impacts major traditional sectors such as banks and funds management. Adapting and changing your operations is major key to remain in business. For example, the most successful hedge funds managers, Ray Dalio with his Bridgewater Associates and Jim Simons with Renaissance Technologies have used sophisticated algorithms since the founding of their businesses. Now, the utilization of AI has enabled them to reach new levels of profitability.

Platform-based business models where profit is made by matching customers and producers belong to the most successful business models in the New Economy. There are several platform companies which are close or have already a stock valuation of 1 trillion USD. Microsoft (1.08 trillion Dollar) is the most valuable platform business followed by Amazon (961 billion Dollar), Apple (956 billion Dollar) and Alphabet (865 billion Dollar) [5].

Especially the third point “mobility solutions” is pushed by companies such as Amazon, which clearly places effort on having more vertical integration operations. For example, Amazon invested in the startup FlexPort to optimize its logistics so that the end consumer can be reached faster [3].

How is the plastics industry reacting to these three major drivers?

Plastic Industry 4.0 was and is all about making the use of things more efficient following the moto “faster, better, and cheaper.”

Apart of the efficiency steps, we see now first steps toward platform business models. For instances, the plastics machine manufacturer company, KraussMaffei, based in Munich set up his own market platform to tap into the material manufacturer pond. The platform is called “Polymore”. It represents a B2B marketplace to support sustainability in the plastics industry. It focuses mainly on compounds, recyclates and post-industrial waste, which serves plastic processors as well compounders. It will be launched at the K-Show in October later this year [1]. Although KraussMaffei is not producing resins or compounds, it can link polymer manufacturers and plastics convertors together and profit of the exchange. A similar platform is made by the company Matmatch (also Munich-based) which named its platform matmatch.com [4].

My interim conclusion

Plastics converting companies did not show exponential growth rates either, since fundamentally there was no change in their business models. Time will tell us, how the KraussMaffei approach will shake up the plastics industry. Creating a marketplace which not only offers materials, but also more and more plastics machinery, moulds and services combined with smart logistics and AI for sure hits the trend of second digitalization wave. With such platforms, companies gain access to customers and can leverage material capacities of other companies without having to own them. Market trends can be faster anticipated and customers better served. Traditional companies all along the plastics supply chain need now to re-think their business models.

Thanks for reading!

Till next time!

Best regards,

Herwig Juster

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Literature:
[1] https://www.polymore.com/en/home
[2] https://www.netzoekonom.de/2019/03/27/endspiel-um-die-digitalmaerkte/
[3] https://www.cnbc.com/2019/02/21/softbank-leads-1-billion-investment-in-logistics-start-up-flexport.html
[4] https://go.matmatch.com/materials-marketing-platform?utm_source=linkedin&utm_medium=paid+social&utm_campaign=Supp_Demo_SuppListsAll_EuropeNorthAmerica
[5] https://www.netzoekonom.de/plattform-index/

Take Me To The Moon – Celebrating 50 Years Moon Landing With High Performance Polymers

On July 20 1969, 50 years ago, Neil Armstrong and Buzz Aldrin touched ground on the moon. On this day, Neil Armstrong said the well known quote: “That's one small step for (a) man, one giant leap for mankind.”

The Apollo 11 crew was well equipped with latest technology. This included two high performance polymers constituting their helmet visors: polycarbonate (PC) and polysulfone (PSU).

Why were polycarbonate and polysulfone used for the helmet visors?

Polycarbonate as protective helmet visor:

Polycarbonate can be regarded as the benchmark for all existing impact resistant plastics. It got its name from the containing carbonate groups (−O−(C=O)−O−) in its backbone. These promote temperature and high impact resistance as well as an amorphous macromolecular structure which leads to excellent optical properties. High energy is needed to tear its chains apart. For these reasons, an ultraviolet-stabilized polycarbonate visor was used for protecting the heads of astronauts against impact and micrometeoroids. The protective visor could be moved independently of the sun protection visor. Back then, the Apollo mission used the newly developed polycarbonate Lexan® from GE Plastics [1].

Polysulfone as sun protection helmet visor:

Commercialized in 1965 by Union Carbide, Udel® Polysulfone (PSU) was right in time to be used as the external helmet visor. Polysulfone has a high service temperature (Tg = 190°C) in combination with reduced creep and dimensional stability. Among non-reinforced thermoplastics, polysulfone affords top high-temperature creep resistance. Another superior property of this plastic is that it retains its transparency after prolonged exposure to temperatures up to 200°C. This high temperature resistance property is to great extent imparted by the contained diphenyl sulfone groups. These characteristics made polysulfone suitable to be used as the sun protection visor (outer visor) in astronauts’ helmets [2,3], which main function was to protect the astronaut from sun exposure and high temperatures. For this, the inner surface of the polysulfone-based visor was also coated with gold for extended sun visor protection capabilities. The gold coating supported the protection against generated heat inside the helmet as well.

Thank you for reading this recap history!

Greetings,

Herwig 

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Literature:

[1] https://www.hq.nasa.gov/alsj/alsj-LEVA.html
[2] https://www.space.com/26630-apollo-11-vintage-tech-innovations.html
[3] https://www.ge.com/reports/post/74545208407/ge-phone-home-ge-technology-helped-fly-humans-to/

[4] https://omnexus.specialchem.com/tech-library/article/apollo-11-moon-landing-plastics-applications

High Performance Polymers in Electrification: A Must-Have Or A Nice-To-Have (Part 3: Autonomous Driving)

Welcome back to the third part of the high performance plastics for electrification series. In the previous parts, we have discussed the polymeric materials used in battery systems and traction motors. Now, we a look at the high performance plastics used for autonomous driving applications.

Autonomous driving

• Connectors

Connectors need to be reliable while driving (manual and autonomous driving mode) as well as when the OEM is assembling the different parts of the car in the manufacturing line. Therefore, connectors need to fulfil different requirements:

• JEDEC MSL1 level of shelf life (=infinite);
• no corrosion (especially pins; plastic parts need to be free of halogens, red phosphor, and ionic heat stabilizers);
• continuous use temperatures of 140°C-180°C;
• high chemical resistance;
• high electric strength;
• and CTI of 600 Volts (PLC0).

Connectors need to have a high ductility level too. Easy identification of high voltage connectors, insulators, and circuit breakers is achieved by coloring polymers in orange (color coding compulsory above 60 V). Polymers such as polyphthalamide (PPA) with a Tg of 120°C and above (Tg of 140 up to 180°C are possible) can handle the requirements listed above offering high mechanical strength with low moisture uptake, similarly to polyesters. Apart of aliphatic polyamides and polyesters, semi-aromatic polyamides such as PPA and polyarylamide (PARA) can be obtained in a non-halogenated flame retardant compound. Advantages of PARA are the high stiffness, excellent low creep, low moisture uptake and impact properties.

• Light Detection and Ranging (LiDAR) and Radio Detection and Ranging (Radar) sensors

High performance plastics play an important role in connectors on the one hand as well as in sensors for autonomous driving on the other. An aliphatic polyamide absorbs water and moisture. This absorption is linked to a dimensional and mechanical change. LiDAR and radar housings need to be dimensional stable since their job is to scan the environment and create an accurate picture of the surrounding. Therefore, using polymers such as polycarbonate (PC), polyethersulfones (PESU), and polyphenylene sulfide (PPS) ensure the high dimensional stability combined with nearly no moisture uptake. Those polymers ensure safe communication of the different sensors over the life time of the vehicle.

• Battery temperature sensors

Minimal temperature changes (+/- 1 °C) in the Li-ion batteries can impact their loading efficiency. Therefore, accurate management of the temperature by sensors is essential for keeping the batteries at their highest effectiveness level. For this type of sensors, polyethersulfones are best suited since their Tg is around 220°C and they show excellent dimensional stability. Furthermore, this stability is needed for keeping the sealing performance of the sensor’s O-ring seals.

• 5G communication sensors

With the arrival of 5G mobile technology, our cars will be able to communicate with each other and the environment. Requirements for 5G related applications are mainly high speed data transmission, infrared transmission, retention of environmental influences and dimensional stability. Polymers such as polyether imides (PEI) and polysulfones are suitable to fulfill these requirements since their amorphous structure allows for tight tolerances and low CLTE, creep resistance and good IR transmission.

• Outlook

In next steps, automotive exterior designers start to seamlessly integrate LED lighting systems with infrared transparency for LiDAR sensor systems [1]. In such application concepts, polycarbonates can play an important role. The integration of LiDAR systems into the car bumper will lead to another challenge: having clean lenses. This may be ensured by using fluorinated coatings which are based on fluoropolymer chemistry (e.g.  perfluoropolyether - PFPE).

• Wrap-up

Electrification brings a whole mix of performance plastics in several applications. I have listed the material requirements and applications we discussed in this post including the previous two parts in two tables, which can serve as guidance through selecting the optimal polymer for your application.

Electrification application matrix for supporting polymer material selection



Material requirements of high voltage components in electric vehicles

Thank you for reading this third part of the electrification blog series! If you enjoyed it please do like and share it with your network.

Till next time!

best regards,

Herwig Juster

If you liked this post, share and like! Interested in my monthly blog posts – then subscribe here.
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Literature:

[1] https://www.magnetimarelli.com/press_room/news/magneti-marelli-showcase-its-latest-technology-and-innovation-electronics-lighting

Polyphenylene sulfide (PPS) – The Conquering of Electric Car Parts



In this blog post I explain why polyphenylene sulfide (PPS) is conquering more and more key parts in higher voltage electric cars. In my electrification series, I have discussed the requirements of certain parts already in detail as well as which advanced polymers can be used. A major one is PPS.

Currently, a typical internal combustion engine (ICE) has around 700 grams of PPS polymer on board. New numbers form Asia reveal that there will be 3 to 4 kg of PPS in electric vehicles (EVs) and hybrid electric vehicles (HEVs). This is a huge increase. Let’s find out why it is so heavily in use.

Reason number 1: Elevated temperatures during usage over a long lifetime (over 6000 hours)

Applications such as capacitor cases, invertor cores, motor cores and housings have to withstand elevated temperatures during use and need to have excellent heat cycle performance. PPS can fulfill these set of requirements in an economic manner.

Reason number 2: Thermal management systems

Cooling of the battery and the electric motor requires water pumps. The latter need to perform when constant exposed to the water-glycol mixture. The outstanding thermal and chemical performance of PPS makes it a very suitable candidate for any application inside the water pump, e.g. impellers. Cooling of the battery is necessary when the car is charging as well. As such the lifetime expectation of (plastic) parts is also higher.

Reason number 3: Good metal overmolding capabilities

Busbars are usually thick copper lines which need to be overmoulded. Here again, processing of PPS due to good flow properties is an advantage together with its good electrical insulation properties.

Reason number 4: Dimensional stability at ambient conditions

Exterior positioning sensors in electrical vehicles need to be dimensional stable at various ambient temperatures and humidity. This ensures accurate positioning detection. In this context, PPS exhibit negligible water uptake which makes them suitable for external positioning sensors. For instances, Nylons would be less of suitable candidates here due to their inherent higher hydrophilicity.

Reason number 5: Price level suitable for automotive market

With PPS you will get a lot of value for a reasonable price, i.e. continuous use temperature of 200-240°C, UL94 V0 rating, chemically resistance up to 200°C and dimensional stability at ambient conditions. Price is a major advantage in comparison to other high performance polymers.

A short word on linear vs cross-linked PPS:

There are three major routes to obtain PPS. First one is called flash process with curing. The curing step is needed to increase molecular weight [2]. This process results in branched PPS. The second route encompasses the flash process and metal carboxylates and results in linear PPS [3]. The third route is over the quench process and results in linear PPS as well [3]. Leaders in the industrialization of the PPS polymerizations were Chevron Philips and Kureha back in the 1980s. For electric vehicles, linear types of PPS are optimal. These show superior toughness and improved weldline strength. In general, linear PPS does not process as well as cross-linked PPS. However, less moulding flash is generated by linear PPS types.

What are the potential downsides of using PPS for e-mobility applications?

One aspect to consider is the comparative tracking index of PPS which is between 250 and 275 Volts. This is low compared to PPA which can easily reach 600 Volts. Another point is its low thermal conductivity, 0.3 -0.5 W/mK and finally its brittleness.

Besides PPS, what are next best candidate materials?

In the table below, I have listed polymers which can be in competition for applications using PPS: syndiotactic polystyrene (sPS), polybutylene terephthalate (PBT), and polyphthalamide (PPA).

Conclusion:

PPS, branched or linear, are in the lead for e-mobility applications, especially for high temperature electronics. Automotive, regardless of ICE or EV, will be the main driver for using PPS. This was a wrap up on PPS used in electrification applications.

I hope you have enjoyed it!

Till next time!

best regards,

Herwig Juster

If you liked this post, share and like!

Interested in my monthly blog posts – then subscribe here.
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Literature:
[1] https://www.plasticstoday.com/automotive-and-mobility/chinaplas-pps-recording-explosive-growth-evs/50108596960874
[2] Nexant Chemical Systems
[3] Solvay Specialty Polymers – Ryton PPS https://www.solvay.com/en/brands/ryton-pps