Surface Treatment Four New Developments in the Field of Materials

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ASAHI KASEI EUROPE GmbH

Plasmatreat GmbH

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Trelleborg Sealing Solutions Germany GmbH

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From open-air plasma technology to water-based coating systems as glass substitutes, all the way to EPDM compounds with a reduced carbon footprint: The latest innovations in materials.

Reliable Bonding of Composite Materials

In the aerospace and mobility industries, lightweight composite materials such as carbon-fiber-reinforced plastics (CFRP), thermoplastics, and hybrid structures are increasingly being used to reduce weight and improve efficiency and performance. However, these materials often have low surface energy, which makes it difficult to achieve reliable adhesion with adhesives, coatings, and sealants. Targeted surface pretreatment prior to further processing is therefore essential. Conventional methods such as mechanical grinding or the use of chemical primers often reach their limits when applied to large or geometrically complex components; they are difficult to control and automate, time-consuming, and subject to environmental and occupational safety regulations. Plasmatreat’s Openair Plasma technology operates under atmospheric pressure conditions and enables selective, reproducible surface cleaning and activation using only compressed air and electrical energy. This process removes organic contaminants and specifically increases surface energy without altering the fundamental material properties. A new application in the Openair range is HydroPlasma, in which distilled water is introduced into the plasma jet to effectively and reliably remove organic and inorganic residues without damaging the material surface.

Improving the Recyclability of Interior Components

Traditionally, automotive interior components such as instrument panels, door trim, armrests, and center consoles are manufactured using multiple materials and separate production processes for the surface layer, foam layer, and structural backing layer. Asahi Kasei’s styrene-based thermoplastic elastomer simplifies this approach by allowing both the surface layer and the foam layer to be made from the same material family. Using the core-back injection molding process, the layers can be produced in a single process. A strong chemical bond between the layers eliminates the need for additional bonding. The result is a simplified material structure that reduces manufacturing complexity, minimizes the number of materials used, and improves the recyclability of interior components. In addition, Asahi Kasei is currently developing a novel water-based coating system that enables the use of polycarbonate as a glass substitute for vehicle windshields, rear windows, and side windows. Polycarbonate coated with this technology achieves the abrasion resistance required by ECE R43 as well as the weather resistance necessary for automotive glass. This technology thus opens up new possibilities for further reducing vehicle weight. 

EPDM Compounds with a Reduced Carbon Footprint 

Trelleborg Sealing Solutions has added two new ethylene-propylene-diene monomer (EPDM) compounds to its portfolio; when used as molded parts, these compounds have a CO₂ footprint (Product Carbon Footprint, PCF) that is up to 55 percent lower. The new materials, available in 70 Shore A and 80 Shore A hardness grades, offer processors a more sustainable alternative without having to compromise on technical performance compared to conventional EPDM elastomers. Both are ideal for the manufacture of O-rings, seals, and custom molded parts. The materials are suitable for applications in the automotive industry, process engineering, mechanical engineering, automation, the energy sector, agriculture, and for construction and mining machinery. They provide sealing for applications in engines, doors, pumps, valves, pipe connections, household appliances, pneumatic cylinders, solar modules, ship hatches and doors, as well as a wide range of functions in heating, ventilation, air conditioning, freezing, and refrigeration technology. The new materials were developed in partnership with Arlanxeo, a raw materials supplier with a strong focus on sustainability. In compound form, E7T11 exhibits a 51 percent reduction in carbon footprint and E8T12 a 61 percent reduction compared to conventional materials.

Fire- and heat-resistant up to 760 °C

Where conventional silicone resin and powder coatings reach their limits as heat-protective surface barriers, the CP4000-S2-HT single-component system from the Kager portfolio still performs well. This silicone-glass-ceramic coating is fire-resistant and provides technical surfaces with long-lasting, effective protection at temperatures up to 760 °C (1,400°F). The thermal shock resistance of this coating even extends up to 981 °C ( 1,798°F.). It is therefore generally suitable for the thermal “sealing” of many surfaces, components, and joints that are exposed to intense heat and extreme temperature fluctuations during the value chain or in practical applications. Such a high-temperature coating can significantly increase the service life and availability of a surface while also substantially reducing maintenance costs. The high-temperature-resistant CP4000-S2-HT coating can be applied at normal temperatures (10 °C – 30 °C) (50°F–86°F), has a drying time of about one hour, and cures at room temperature within 24 to 48 hours. If you plan to store the base material for an extended period, you should maintain a temperature range of 4.5 °C to 30 °C (40°F to 86°F) whenever possible.

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