Victrex to display new solutions at K 2019

September 20, 2019 - United Kingdom

Victrex, a leader in high performance polymer solutions, will display its new solutions under the theme “The Element of Invention” at the upcoming K 2019 show in October. The Victrex Peek and Paek polymer-based portfolio on display will include an innovative food grade, additive manufacturing (AM/3D printing), composite, film, and gear solutions.

Ranging across leading industrial sectors, these products and the know-how of Victrex contribute to solving material limitations in advanced applications, often replacing metals.

“The invention of Peek polymer has clearly had a very positive impact across industries and, in fact, across the globe. We could never have imagined the continuous stream of innovation this high performing versatile polymer would make possible. Visitors to the Victrex K 2019 show booth can look forward to pioneering new grades as well as exciting progress on forms and parts in critical applications where high performance polymers deliver a strong advantage in the development of new markets,” said Jakob Sigurdsson, Victrex CEO, in the run-up to the trade show.

There will be a showcase of new Paek materials, including products developed for use in 3D printing: filament for filament fusion (FF) or fine powder for laser sintering (LS). These new solutions deliver better results with improved mechanical properties in printed parts and easier printing than past attempts to use Peek in AM. To speed the availability of 3D printed Paek parts for customers, Victrex is investing in these new materials optimised for AM and pairing them with new machine technology in order to create integrated solutions. The company is working directly with key industry partners and customers to build an AM Paek eco-system.

Cost-effective polymers, forms and parts for the automotive industry include the tribologically optimised Victrex Peek polymer, thin APTIV films and robust Victrex HPG high precision gears. Together, these contribute to achieve greater CO2 efficiency and improved durability, as well as a potential reduction in total system cost in conventional, hybrid, and electrical powertrains.

With its gears solutions, Victrex is enabling Tier 1/OEM customers to work with one partner, from concept to commercialisation, who supports the development and testing of high-precision Victrex HPG-based gears, as well as the manufacturing of these gears as a component for integration into larger systems (eg within the engine, transmission, pump, actuator, and chassis). Victrex´s gear design and manufacturing facility in Grantsburg, WI, has just received the IATF 16949 certification1), confirming that the systems and capabilities required to meet the needs of Tier1/OEMs are in place.

In electric drives, Peek film-based electrical insulation can help improve thermal management, reliable operation and reduce overall system cost. With the automotive industry transitioning to electric vehicles, the quest for more efficient high-density e-motors and lower cost is still on. Most e-motor manufacturers have opted to use the Permanent Magnet Synchronous Machine (PMSM) in which the design of the insulating system is instrumental. Computer simulation from highly regarded third party specialists on an established 80 kW EV e-motor have shown a potential 5 per cent increase torque output in a same size e-motor, enabled by 40 per cent thinner APTIV slot liner, enabling a 2 per cent increased copper content (slot-fill factor). Additional simulation has indicated that the excellent thermal conductivity of APTIV film results in improved thermal management and a reduction of peak winding temperatures by 2-3°C (36-37°F) versus traditional laminates.

The aircraft industry has forecast that more than 35,000 new aircraft will be required within the next 20 years. Meeting this kind of escalating demand clearly calls for new approaches and new technologies in aerospace engineering.

Victrex AE 250 composites have mechanical, physical and chemical resistance properties typical of members of the polyaryletherketone (Paek) polymer family such as Peek, but with a 40°C (104°F) lower crystalline melting temperature, at only 305°C (581°F). The unique material delivers a combination of cost reduction, light weight, design freedom, strength and production speed in next-generation components.

A breakthrough in the time- and cost-efficient production of complex aircraft parts was recognised with a JEC Innovation Award 2019 earlier this year, for an all-thermoplastic drive-shaft system overmolded with an integral gear that is set to advance the use of thermoplastic composites in aerospace. The OrganoTube and gears of the drive-shaft system are using Victrex AE 250 Paek unidirectional tape (UDT) and Peek polymers in combination with innovative processing technologies. This innovation is expected to open up enormous potential for reduced cycle times and large-scale industrial production.

Also at display will be APTIV films meant for advanced performance in next-generation electronic devices. As 'high tech' continues to advance, the trend is to electronic devices that offer improved performance and reliability in new and lighter form factors, while packed with a range of features. APTIV films from Victrex deliver all benefits of high performance Peek polymer in a thin format and so provide the versatility and high performance required to address customers' complex demands for a variety of devices in this fast-moving market. The benefits of APTIV film include proven mechanical strength; resistance to wear, high temperatures and harsh chemicals; and electrical stability and low moisture absorption. These outstanding attributes mean that APTIV film can be applied in a wide range of products, such as micro speakers, 5G RF antenna substrates, and battery insulation, and also in chip and display manufacturing.

Other special products to be showcased include Victrex CT 200 which are meant for applications at cryogenic temperatures, Victrex Peek injection molded bushing, bearings, and scroll compressors as well as dryer conveyer belts using Peek-based ZYEX fibres.

As the latest member of the Victrex CT Peek polymers, the 200 grade series exhibits improved sealing over a wider range of temperatures, compared to commonly used materials such as PCTFE. It does so at low temperatures on account of its greater ductility, and at high temperatures due to its superior creep resistance. Victrex CT polymers have also been shown to maintain better dimensional stability, with a lower coefficient of thermal expansion than incumbent materials.

Victrex will also bring its dedicated food grade portfolio at the fair. Compared to metals, the Victrex FG family of high-performing Peek thermoplastics offers additional benefits in terms of productivity and performance for OEMs. (SV)