PTFE-free self-lubricating compound

PTFE-free self-lubricating compound

PTFE is a polymer with peculiar characteristics, including a very low friction coefficient. This property can be transferred onto different thermoplastic matrices by dispersing appropriate percentages of PTFE into them though compounding. The tribological behaviour of such formulas stands out for low static and dynamic friction coefficients, even for grades reinforced with glass or carbon fibre.

The elevated performance delivered by the PTFE enables the use of these self-lubricating compounds in technologically advanced applications where wear and friction need to be limited.

The processing of self-lubricating compounds containing PTFE however has a disadvantage linked to the formation of deposits on moulds, and corrosion problems for equipment and the danger of fumes due to the possible thermal deterioration of part of the PTFE. Formulas containing PTFE also have problems caused by fluorine, a halogen whose presence is today subject to increasingly stringent regulatory restrictions due to the risks associated with their release into the environment at the end of their life.

The replacement of PTFE is therefore a highly topical debate and LATI (www.lati.com) has developed a family of self-lubricating grades, Latilub, formulated to ensure high tribological performance without the use of fluoropolymers. Lati chose UHMWPE as a replacement polymer, an ultra-high-molecular-weight polyolefin known for its extreme resistance to abrasion.

The results are encouraging, even in formulas highly reinforced with glass fibre. The UHMWPE, dispersed in amorphous or semi-crystalline matrices, means friction coefficients are comparable to PTFE with similar run-in times.
Even abrasive and adhesive wear has been clearly slowed. From a mechanical standpoint, no significant differences were noted under static load action nor in the presence of impulsive stresses. Lastly, the lower density compared to PTFE permits solutions that are interesting also from an economic point of view.

UHMWPE Latilub are available in reinforced and non-reinforced grades, also with additional self-lubricating systems (for example, silicon oil or aramid fibres) and for thermal performance up to 200 °C. LATI supports Latilub formulas also by facilitating the work of engineers and designers.

Latilub 66-10E G/15 with UHMWPE has obtained Gold Moldflow characterization, enabling the simulation of moulding with the utmost reliability.

Artemide and LATI: the success of Ameluna

Ameluna

“An innovative vision of design where light is able to generate emotion and interaction”.

This phrase perfectly fits Artemide’s presentation of Ameluna, the lamp designed in partnership with Mercedes-Benz Style.

Artemide and Mercedes-Benz are leaders in their respective fields and the development of a synergy between the two could not have been expected to result in anything other than a new icon, destined to become an eternal point of reference in the world of lighting design.

Ameluna — the name is a blend of Artemide and Mercedes with Luna (Italian for moon) — is a lamp designed to reflect and diffuse, in an unusual way, the light produced by a series of LEDs arranged inside it and controlled by a sophisticated and innovative optoelectronic system. The elegant asymmetric dome in PMMA is the most surprising part of this object, although every element of the whole reflects its highly innovative content.

Innovation: Artemide regards innovation as a concept that must embrace respect for ethical and sustainable values, especially when it comes to products designed for people and the environment they live in.

This deeply-held philosophy of design underlies the decision to adopt innovative solutions with a low environmental impact even for the most hidden part of Ameluna, that is to say the large round ring that houses the LEDs and also allows the lamp to be suspended from the ceiling.

To create this important element Artemide chose to use thermally conductive compounds supplied by LATI. The demands of the design are such that the engineering polymer must be able to effectively dissipate the heat produced by the LEDs but also fulfil a structural function, supporting the weight of the entire fixture. To guarantee maximum aesthetic quality, Artemide decided to produce the ring as a single monolithic piece: a challenge within a challenge, given its considerable size and the dimensional stability, in terms of flatness and roundness, that it must guarantee in order to ensure perfect coupling with the dome.

The design phase saw the LATI technicians engaged in an intensive simulation activity and FEM calculation that allowed them to establish the thermal performance of the material, the best configuration for the mould, and the optimal moulding process setup. The material, too, was carefully studied and improved, especially with regard to its rheological properties, in view of the flowability it must possess in order to efficiently fill the mould cavity in spite of the large quantity of non-abrasive ceramic fillers necessarily dispersed in the polymer matrix.

The heart of Ameluna is made from LATICONTHER 62 CEG/500-V0HF1, a PA6-based product that contains isotropic, thermally conductive ceramic fillers, and is self-extinguishing yet free of environmentally harmful additives such as halogens red phosphorous. The formulation of the material helps to ensure not only excellent thermal and mechanical performance levels, but also low dimensional shrinkage and excellent surface smoothness and varnishability.

The happy ending to the Ameluna story is a lifetime of safe and reliable performance!

PPA and carbon for fuel lines

PPA and carbon for fuel lines

The automotive industry is certainly among those in which high performance thermoplastic compounds have seen an exponential increase in interest and applications over the last few years. The reasons are many: From the ever-pressing need to contain weights and costs to the widespread use of electronics in the control of the vehicle and its utilities, from hybrid solutions involving the management of electric and thermal loads to temperature increase in the underhood environment. LATI’s special compounds are the natural answer to all these needs embodied in the evolution of the concept of car and transport.

So PPS, PSU, PPA, and PEEK are used near the engine for their thermal properties, self-extinguishing materials where important electric currents are to be handled, electrically conductive and shielding compounds for the protection of onboard electronics and computers, thermally conductive grades for cooling of LED optical solutions, and structural materials wherever robustness and strength of metal are required.
Fuel transport is a particularly critical field within the complex propulsion system for obvious safety and reliability reasons.

Any part operating with fuel streams must withstand continuous contact with hydrocarbons without embrittlement or loss of strength. Accumulation of electrostatic charges is also to be avoided due to the risk of malfunction or fire.

For these reasons, SAROPLAST, an Italian company specializing in the molding of high performance resins, has chosen the LARAMID K/30 compound for the manufacture of fittings used on diesel fuel transport lines. The reasons for this choice are the excellent chemical resistance of the PPA matrix to oils, solvents, greases and hydrocarbons, as well as the electrical and mechanical properties offered by 30% carbon fiber contained in the compound.

Carbon, in fact, allows to have electrically conductive technopolymers, so perfectly suitable for electrostatic discharge to ground. At the same time, fibers also increase the structural strength and dimensional stability of the molded part, which are parameters required to safely handle the pressure and fuel flow to the engine.

As is customary in underhood applications, operating temperature, too, requires to be safely managed. In this case, LARAMID K/30 ensures maximum performance beyond the required 130° C.
The range of LATI solutions based on aromatic polyamides includes not only carbon fiber reinforced products, but also purely structural grades with up to 60% glass fiber, self-extinguishing, self-lubricating and thermally conductive products.

LED COB and thermally conductive compounds

LED COB and thermally conductive compounds

The rapid evolution of LED lighting systems has led to the development of increasingly powerful and efficient devices, suitable for replacing conventional sources even in the most challenging applications, such as, e.g., lights for public and industrial use. The main players of this sector are the COB LEDs (Chip On Board) LEDs in which numerous light diodes are joined together and mounted on the substrate to form a single large source. The advantages of the COB LED solutions are many, such as the reduction of necessary components for the lowest number of welded joints, the absence of lenses, and the higher light density. It is clear that the management of the heat generated by such a structured system is of vital importance for the duration of the product. The use of aluminum heat sinks is a solution considered to be mandatory even at maximum junction temperatures close to 150° C.

Electromagnetica, a company based in Romania and a leader in the production of electrical and electronic equipment, has decided to buck the trend focusing on thermally conductive plastic compounds to develop a new industrial projector built with COB LED light sources.

This challenge required a robust scientific approach, based on numerous rigorous simulations and experiments aimed especially at evaluating the cooling as well as the quality of the emitted light.
The result is the CASTOR 2M light, an industrial projector that houses two COB modules for a total power close to 70 W. The unit must be reliable up to an ambient temperature of 45° C and under natural convection, i.e. without forced air. Despite the high electrical efficiency, the system generates a large amount of heat to be dispersed.
Is it possible to use a technopolymer heat sink with such a scenario? The answer is affirmative, provided that the geometry of the radiating elements and the interface between the PCB substrate and the thermoplastic compound are correctly configured.

The material chosen by Electromagnetica is LATICONTHER 62 GR/70, a product that LATI has developed to disperse 70% of selected graphite in the PA6 polymer matrix. The thermal performance of this compound has been carefully measured. The average thermal conductivity was close to the effective 10 W/mK even at high ambient temperatures and regardless of the orientation of the graphitic flakes. These values are well above the benchmarks of other LATI and competitor compounds.

The correct design of the heat sink has proved to be fundamental due to the large amount of heat to be disposed of and the thermal limits of the thermoplastic matrix. So the thickness of the heat sink base as well as the shape and spacing of the fins have been optimized.
The meticulous study of the thermal phenomena at the base of the cooling efficiency is also fundamental, to which the radiation contributes in a similar way to the convection.

Thermal conductivity of alloys normally used to manufacture heat sinks is close to 150 W/mK, thus far from the 237 W/mK of pure aluminum. This difference helps to reduce distance between metals and LATICONTHER. Higher heat capacity of plastics provides another valuable advantage, that is reduction of thermal load to be transferred thanks to increased heat storage capabilities of the sink itself.
Advantages provided by LATICONTHER include extremely low moulding shrinkage and related excellent dimensional stability, required for flawless assembling, and reduced weight thanks to its density, close to one half that of aluminum.

The light is able to provide a minimum luminous flux of 8000 lm without the junction exceeding 80° C. The excellent appearance of the product is also ensured by the quality of the surface finish of the heat sink in LATICONTHER and by the cataphoresis coating directly carried out on the technopolymer. The IP65 classification completes the technical framework of the CASTOR 2M.

For any further information please contact LATI Technical Assistance.

Lati & Dräger for road safety

Lati & Dräger for road safety

Dräger is a leading multinational company in the field of technology dedicated to the medical and safety field. The company’s motto, “technology for life”, also translates into the range of equipment designed to increase road safety.

The family of Dräger drug and alcohol detection devices for roadside testing by law enforcement today also includes additional solutions designed to allow the driver to personally test his or her driving ability.

Interlock 5000 and 7000 devices, which can be installed on any vehicle and equipped with GPS/GPRS communication modules, instantly detect the alcohol content in the breath exhaled by the driver, preventing the engine from being started in the case of positive test.

These devices require, of course, maximum operating precision, so as to prevent the vehicle from being blocked or, worse, used due to wrong measurements. In addition, the electrochemical sensor of the breathalyzer should be quickly ready for use and feature low power consumption of the electronics even at very low ambient temperatures.

To achieve these results, Dräger successfully used LATI Spa (www.lati.com) thermally conductive compounds of the LATICONTHER family based on 70% graphite reinforced PP and PA6. These technopolymers were chosen by Dräger engineers for the manufacture of the molded mouthpiece and sensor heaters due to their combined high electrical and excellent thermal conductivity greater than 20 W/mK, so one hundred times that of conventional plastics.

The injection molding of these pieces is made possible by the rheological properties of the compounds, formulated so as to ensure the filling of complex cavities despite the presence of a high percentage of conductive charge. Mechanical strength and heat resistance typical of automotive applications (from -30° C to + 85° C) are additional properties of selected compounds.

The special composition of PP-based LATICONTHER compounds also allows the use in contact with food and therefore with the driver’s mouth.

The performance of LATI compounds also allowed to obtain for the breathalyzers of the Interlock family both the E1 mark and the EN 50436-2 certification, the European standard for the use of blocking devices based on alcohol concentration for preventive purposes.

For any further information pls. contact LATI Spa technical service – www.lati.com.

Replacement of thermosets in the electromechanical industry

Replacement of thermosets in the electromechanical industry

Thermosetting materials have played a leading role in the history of applications related to transport, management and use of electricity. Since the time of the first synthetic resins, products such as bakelite and melamine resins, to which epoxy resins and polyester were subsequently added, have been widely used as insulation and safety materials. Modern markets, however, require simpler, safer and more flexible solutions during the converting process, which also offer recycling opportunities in the post-industrial stage and possibly also in the post-consumer one – that is at the end of the product’s life cycle.

For this reason, the attention of designers and technicians in the electrical and electronic sector gradually shifted towards the most advanced thermoplastic compounds able to provide advantages typical of thermosetting materials, especially in terms of dimensional stability and strength, as well as ease of use and low environmental impact.

Telergon, a leading Spanish company operating in the electromechanical sector and specializing in the manufacture of manual and motorized switches and changeover switches, has chosen a thermoplastic material for the production of changeover switches and bypasses of the latest generation.

The housings of the most recent devices, in fact, have been manufactured with LATER 4 G/30-V0HF1, a LATI self-extinguishing and structural PBT-based compound.
This choice has considerable strengths, such as, first, the base resin, a polyester that, unlike conventional polyamides, is completely anhygroscopic, thus ensuring dimensional stability, strength and dielectric strength even in very humid environments such as the Equatorial and Asian ones.

The material also features high self-extinguishing properties, UL-certified for low thicknesses without the use of halogen and red phosphorus as required by the most stringent market requirements in terms of respect for the environment and human health. As regards safety during operation, reliability is ensured by extraordinary electrical performance, with tracking resistance greater than 600 V and a high dielectric strength even in extremely humid environments.

This picture is completed by mechanical strength and dimensional stability typical of glass fiber reinforced compounds.The range of halogen and red phosphorus free LATI self-extinguishing compounds includes products meeting even the most demanding designers’ requirements thanks to the available formulations based on PA6, PA66, PBT and PPA reinforced with mineral fillers or glass fiber up to 50%.

Per maggior informazioni contattate i tecnici di LATI S.p.A. – www.lati.com

Ergonomics, functionality and safety with Acti 9 by Schneider Electric

Ergonomics, functionality and safety with Acti 9 by Schneider Electric

Innovating by optimizing interactions between man, machines and the environment. This principle has always been inspiring the engineers of Schneider Electric, a leading multinational company in the field of electric energy management. Acti 9, one of the latest Schneider products proposed in the field of modular systems for the final distribution of low voltage, was developed based on this inspiration.

Acti 9 is a system made of multiple devices for the distribution and measurement of the electric current supplied to the end user, and includes protection devices, monitoring and control, metering, communication systems as well as accessories for the installation.

Maximum safety is an absolute imperative when it comes to electric current, and even in the case of Acti 9, attention to ergonomics, flexibility and practicality cannot leave out the reliability of every single element of the project.

Schneider Electric, already partner of LATI for the self-extinguishing compounds used in the production of boxes, supports and housings, has decided to rely on LATI even for the materials to be used in the internal parts of its devices. In particular, the self-lubricating LATILUB 87/28-10T G/20 compound has been selected for the manufacture of the rotary cam actuating the switches of Acti 9, thanks to its excellent mechanical and tribological properties. Formulated from a PC matrix, thanks to the content of PTFE, this grade offers an extremely low friction coefficient resulting in a smooth, fast, pleasant and reliable operation without jamming over time.

Mechanical strength is also due to the structural reinforcement inside the compound, which in this case is made of 20% glass fibers. This is an ideal combination with the self-lubricating properties of PTFE. The amorphous matrix also ensures dimensional stability and compliance with geometric design tolerances, which is an essential requirement for an element required to perform a fundamental function under maximum safety conditions even in harsh environments due to external temperature or humidity.

The range of LATILUB self-lubricating compounds combines many materials developed during the long experience of LATI, and designed to meet the most demanding mechanical, thermal and chemical resistance requirements. However, the attention of Schneider’s designers was driven by an intrinsic advantage offered by LATILUB, namely the availability of self-lubricating elements perfectly able to operate even without external greases and oils, thus not requiring expensive maintenance and preventing the application from the risk of stopping or failure due to wear or dirt build-up between moving parts.

Per maggior informazioni contattate i tecnici di LATI S.p.A. – www.lati.com

LATILUB for safety and protection at work

LATILUB for safety and protection at work

Safety and comfort: two essential requirements of any personal protective equipment. The utmost attention to protection and wearability is definitely the Credo of ENHA, a leading German manufacturer of safety systems for head, face, hearing, and respiratory system.
ENHA GmbH is based and is producing in Nonnweiler, northern part of german Saarland, selling its products with the brand name ROCKMAN.

The lack of ergonomics, comfort and functionality is, in fact, the main reason why operators fail to wear equipment protecting health and safety at the workplace. To ensure the best functionality of helmet face shields, ENHA has designed a lifting mechanism entirely made of polymer, which combines maximum lightness, absence of jamming and smooth sliding even under a small force.

The material selected for the production of the lever actuating the opening of the face shield is LATILUB 66-10T Y/15, a sophisticated PA66-based self-lubricating compound. The special formulation of this material allows the reduction of the friction coefficient between two parts in relative motion due to the PTFE contribution to lubrication, thus making face shield lifting simple and easy.

The mechanism reliability over time is instead due to the aramid fiber powder dispersed in the polymer matrix. In fact, this additive allows to limit to a minimum the adhesive and abrasive wear, even the third body one, resulting from dust and impurities inevitably present in the workplace.

LATILUB 66-01M is another LATI self-lubricating compound based on PA66 and molybdenum disulfide included by ENHA in the same project for the manufacture of other parts of the lifting system requiring wear limitation. Of course, selected polymers should also meet other basic requirements, first of all mechanical strength of the entire item and dimensional stability of individual parts.

Self-lubricating materials are chosen to ensure continuous and reliable operation of elements such as sliding systems, shoes, gears, linkages, bushings, etc., because they allow the transmission of motion without external lubricants.

Fats and oils can, in fact, collect dirt and dust from the work environment, in addition to requiring ordinary and extraordinary maintenance, which are factors that involve a problematic and expensive management.
For further information please contact the technical service of LATI Spa – www.lati.com.

Structural compounds for S1 safety stirrups – Safe Riding

Structural compounds for S1 safety stirrups - Safe Riding

For a company specializing in the production of compounds for special applications such as LATI, the most sought-after success is to provide answers to those who work in the field of safety and design. This is even more valid if the project adopting LATI’s proposals is meant to protect people’s safety and health.
This is the case of Safety First stirrups of the Safe Riding brand, a special device designed, patented and marketed by the company to ensure maximum safety and comfort for all riding enthusiasts.

The engineering choice behind Safe Riding is based on the great field experience gained by TM Horses, an estate operating in the world of breeding and selection of horses for sporting purposes. By observing the many accidents that affect professionals and simple enthusiasts every year, Safe Riding has decided to design a stirrup allowing not only maximum comfort, but also the unseated rider’s foot to be released, thus preventing it from remaining anchored to the horse during the fall, with consequent great danger.

In fact, the S1 stirrup is designed to completely move 360 degrees outwards, and in all directions, allowing the rider’s foot to be released, thus avoiding to get it caught in the stirrup. The technical trials carried out in the company’s laboratories show that by applying a minimum force of traction on the center of the tip, the stirrups open completely, always releasing the rider.

Being entirely conceived and manufactured in Italy, this project necessarily required technological choices on an equal footing with the challenge. Along with the essential aluminum parts for the most stressed elements during the horseback ride, for the manufacture of all housing and lining parts, LATI’s structural compound LATIGLOSS 66 H2 G/50 was successfully adopted.
Provided with high mechanical strength thanks to the presence of 50% glass fiber by weight, LATIGLOSS was also chosen for its excellent aesthetic performance without defects, which is an essential requirement in an accessory such as the S1 stirrup, where functionality and safety are to be combined with design, elegance and style typical of made in Italy.

The care devoted to both the design and stirrup line necessarily required an impeccable quality of the exposed surfaces, even in the case of reinforced technopolymers. The choice of LATIGLOSS was combined with a material resistant, over time, to aggressive and complex environments such as stables and breeding.

For further information please contact the technical service of LATI Spa – www.lati.com

Perfect gears for professional shears

Perfect gears for professional shears

Lightness and strength are two overriding requirements in many of the industrial sectors where today metal is being replaced with alternative materials.
These features are even more important if the product to be manufactured has to be directly transported and used by the operator, especially if it comes to professional battery powered work tools.

This is the case of electromechanical pruning shears that Campagnola Srl (www.campagnola.it) has developed using thermoplastic materials also for structural elements traditionally made of steel or sintered metals.

Campagnola Srl, a historical company in the production of professional equipment for facilitated harvesting and pruning stands out for the research and development of reliable as well as ergonomic and functional tools, which are essential aspects especially in harsh environments such as agriculture.
With this in mind, a carbon fiber reinforced compound has been successfully used to mold the gear system for the power transmission from the engine to the blade unit of the new pruning shear. The selected material is LATILUB 88/50-20GRT K/10 from LATI S.p.A. .

This grade provides a PEEK matrix in which, in addition to 10% carbon fiber, a PTFE and graphite based self-lubricating system is dispersed. The technopolymer formulated in this way can meet extreme lubrication and temperature resistance requirements. Campagnola has made a choice without compromise, since PEEK ensures, in addition to thermal stability up to 260° C, also excellent dry lubrication, i.e. without oils or fats that may give rise to problems of maintenance and cleaning, especially in a demanding application field such as agriculture.

The appropriate compound conversion, which was entrusted to the experience of SICAM Srl, an Emilia-based company specializing in the molding of technical parts and in the construction of molds for small to medium size objects, allowed to make the most of not only mechanical and tribological properties of this compound, but also of the high dimensional stability of PEEK and graphite, which are basic parameters in the development of gear trains.

SICAM Srl (www.sicam.it) is also involved in the construction of the mold for these gears. This operation is of the utmost importance, especially considering both the necessary observance of dimensional tolerances of the parts and the typical conversion conditions of PEEK in terms of temperature management and fitting on the various parts of the mold. The result is a compact and noiseless gear train without unwanted vibrations, robust and 70% lighter compared to the conventional sintered metal unit.

For further information please contact the technical service of LATI Spa – www.lati.com