Envalior launches new Tepex® high-performance composites

• Matrices based on polyetherimide, polyphenylene sulfide, polyamide 4.6 and 4.10 as well as thermoplastic copolyester elastomers
• High temperature-resistant materials for aircraft construction
• Sustainable composites based on bio-based raw materials
• Metal replacement in moving parts
• Product innovation through synergies in Envalior’s Specialty Materials division
• Envalior unveils new composites at Fakuma 2024

Düsseldorf, October 15, 2024– “The new structural materials feature the typical strengths of special and high-performance composites. This opens up attractive new areas of application — for example, in mechanical and equipment engineering, running shoe manufacturing, aircraft construction, or specialized uses in automotive engineering such as structural body components,” explains Dr. Lisa Tölle, materials developer at Envalior subsidiary Bond-Laminates, which produces Tepex®.

Stable at high temperatures, yet flame retardant and low in smoke emissions

Thanks to their matrix polymers, the composites based on PEI and PPS have exceptional mechanical strength and rigidity that are barely impacted even at high temperatures. For example, 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 hardly flammable. Furthermore, in the event of fire, they emit very few toxic substances and smoke that would impair visibility. As a result, Envalior expects these two composite series — as well as their matrices — to meet the latest industrial standards for aircraft and railway vehicle components. These include the EEuropean 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 smoke gases. “Potential applications could therefore include components inside airplanes and railway vehicles such as backrests, seat shells, luggage compartment lids, or table structures,” says Tölle.

PEI is a well-established material in 3D printing. As a result, the new composites based on these thermoplastics can also be easily combined with this additive manufacturing process. Formed semi-finished products of the composites can be printed with functions such as ribs, guides, or mounts, and turned into components. “When working with the small production volumes typical in the aircraft industry, for example, this approach is much more flexible and cost-effective than investing in elaborately designed tools for the overmolding of inserts,” explains Tölle.

Based on castor oil

Other variants of the new composites are based on PA4.10 EcoPaxx® from Envalior. Their carbon footprint is about 50 percent lower than comparable fossil-based polyamide 66 types. Around 70 percent of their matrix consists of raw materials derived resource-efficiently from castor oil, meaning they do not compete with food production. At the same time, their mechanical properties are about 10 to 20 percent better than those of polyamide 6 or 66. Additional strengths of the composites are their high scratch resistance, low water absorption, and good melt flowability. “This makes them suitable for the production of higHighly rigid, high-strength, heat-resistant housings with a decorative, durable surface and a complex internal structure,” Tölle explains.

Wear resistant and low friction, even at high temperatures

The new composites with a matrix made from PA4.6 Stanyl® by Envalior offer 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 friction. This makes them ideal for manufacturing moving parts. “We see major potential for replacing metal in transmission system 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® range are especially intended for use in producing sporting goods, such as components for shoe soles. Their matrices span a wide range of hardness, with Shore hardness from 74D and 55D down to 33D. The advantages of the composites include high thermal stability and largely consistent mechanical properties over a wide temperature range, from -45 to 150 °C, such as high tensile strength and abrasion resistance. Although these new composites have elastomeric properties, they are easy to recycle as thermoplastics. For example, used components can be shredded and processed into recompounds.

The harder, carbon-fiber-reinforced composite types are highly suitable for use in so-called power plates for running shoes, for example. These 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 booth in Hall B4, number 4302.

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

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