ZIM project - new flame-retardant polymer composites

In order to obtain flame protection for different applications, it is necessary include high amounts of flame retardants into a polymer system. The good flame retardant-properties result in reduced strength and impact resistance. For many applications the mechanical properties are important, e.g. for lightweight construction, metal replacement etc. The mechanical properties are obtained through reinforcement materials such as glass or carbon fibres.
In the ZIM-project FlamZation innovative surface modifications are to be combined with classical fillers with the aim to fulfil the fire protection regulations of the different application areas and to eliminate the disadvantages of a significant deterioration of the mechanical properties.

In the research project FlamZation the DTNW uses his experience to developed flame-retardant systems as additive for different polymers. In combination with the required additive the flame-retardant requirements for different applications areas, without the disadvantage of losing the mechanical properties, should be reached.
The production of the flame retardants in laboratory scale for screenings as well as in pilot and production scale is implemented by the abcr GmbH.
Material development is carried out by the Gemeinnützige KIMW Forschungs-GmbH, which contributes its expertise in the fields of compounding, injection molding and material validation.
The upscaling behavior of the new material systems is qualified by BADA AG.  BADA AG is also in a position to test newly developed material systems in accordance with the requirement profile in accordance with UL standards and, if necessary, to list them.
As a user of electronic components Weidmüller will undertake the material qualification on the basis of a benchmark which is intended to show the potential of future material developments.
In addition to technical base polymers, fillers and reinforcing materials, natural fibres will also be included in the assessment. In cooperation with the company ENTEX Rust & Mitschke GmbH investigations are carried out by means of a planetary roller extruder in order to compare the advantages and disadvantages of the process technologies twin screw extruder vs. planetary roller extruder with regard to the incorporation of the innovative flame protection systems.  
The project partners thus represent an efficient project consortium along the entire value chain for the realisation of new flame-retardant polymer composites for applications in the fields of E&E and building materials.

Our thermal oil devices have now a maximum flow temperature of 420°C

Electrically heated thermal oil devices were previously limited to a maximum flow temperature of 400 °C.

With a new product from Fragol, ENTEX already started last year with designing a device that is prepared for a maximum flow temperature of 420 °C. In addition to the suitability of the mechanical components, such as pumps (Fa. Speck), heaters (Fa. Kleinesdar), great attention was paid to the observation and investigation of the thermal stability of the thermal oil.

The joint studies have meanwhile shown that both, the thermal oil and the mechanical components, meet your requirements even in the high temperature ranges.

During the development, ENTEX placed great value on the detailed test runs, to be able to supply the customers with binding and sustainable technology in order to guarantee the highest possible system availability.

ENTEX now has a new generation of thermal oil devices in previously unavailable temperature ranges. - We look forward to advising you!

Again asked...

With regard to the necessity of "hot" premixing of raw materials, the mechanical design and operating principle of the process sections, the effectiveness of the tempering as well as the consumption of drive and thermal energy and some other factors, there are major differences between classical compounding with single and twin-screw extruders and direct extrusion with planetary roller extruders.
In addition to the differences in material feeding, there are also major differences in the mechanical design of the extruder process sections and the input of thermal and mechanical energy into the material to be extruded.
Due to the relatively thick walls between the electrical heating and the melt, in single and twin-screw extruders the thermal control is slow and therefore inaccurate. As a result of the very thin walls between liquid tempering medium and melt a dynamic, very precise temperature control is realized with ENTEX planetary roller extruders and a direct influence on the melt temperature is possible.
There are also major differences between single and twin-screw extruders and planetary roller extruders with regard to the kneading gaps between the kneading elements. Single-screw extruders do not have a kneading gap. While twin-screw extruders have only one kneading gap over the entire length of the process section, depending on the number of planetary spindles, planetary roller extruders have many kneading gaps (two per planetary spindle) in which the compound is mixed, friction stirred and rolled out.
In the process design are also differences with regard to the material feed. In order to ensure that the subsequent extrusion process works correctly, for classical PVC compounding processes it is necessary to heat up and pre-mix different raw materials with the addition of auxiliary agents and to cool them down again in discontinuous intermediate steps. In direct extrusion with the PRE, usually all compounding steps take place without pre-mixing processes directly in the process section of the extruder.
The simplification of the overall process and the elimination of work steps offers great savings potential. In direct extrusion with the PRE better economy and ecology is achieved, among other things by saving heating and cooling energy as well as energy for additional, high-performance drives which are necessary for the pre-mixing of raw materials in classical compounding processes.

For technical questions, please contact our service department or you are welcome to use the following contact form.

One Planetary roller extruder replaces 28 twin screws
with respect to the gaps between the kneading elements!

Enclosed find our PDF with more information.



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