Projects implemented
Development of electrically heated components from TPU plates produced by continuous process Akronim: ComfyTPU
Project objective
As a result of the project, a simplified, highly flexible, one-stage heating plate technology from thermoplastic polyurethane (TPU) has been developed, which can be produced using highly automated thermoforming processes from a flat, electrically conductive TPU composite.
The technology obtained is competitive in terms of cost to classic multi-stage processing of thermoplastics, consisting of extrusion and ironing. Thanks to the versatility of the solution, it is not directly targeted at a specific industrial sector.
Project applications include not only specific products made from heating TPU plates with carbon additives, such as seats on trains, stadium chairs or orthopaedic and sports equipment, but also the production process itself. An example is reactive extrusion along with the thermoforming process, which has a number of advantages in terms of process and economic properties compared to classical extrusion and ironing methods.
Application potential
The primary use is the formation of structures from thermoplastic polymers (e.g. TPU, PP, PE, PS) and laminates from thermoplastic polymers reinforced with fibres (the so-called Organo-sheets) or thermosetting polymers reinforced with fibres.
Manufacturers of plastic components that use autoclaves or traditional thermoplastic forming processes are a natural target market.
The rail industry, in particular, for wagon manufacturers and their sub-suppliers, supplying equipment for passenger wagons and locomotives.
The solution can also be used in the medical and rehabilitation industry, where heating TPU plates can be used to manufacture individualised shoe inserts or heated orthoses and prosthes.
The clothing and footwear industry offers customers innovative products with heating elements that can be an alternative to existing heating systems is another potential outlet.
Elements equipped with heating TPU plates can be successfully used in small urban architecture, such as bus stops, railings or underground passages. The production of these components using high-strength plastics can be more cost-effective and contribute to quality improvement, especially when the TPU heating plates are used.
The Polish aviation industry is another interesting outlet for the solution, especially for gliders and motor gliders.
Another potential recipient of the solution is offshore equipment manufacturers, such as offshore wind turbines.
Another sector where TPU heating plates can be used is the construction industry, especially in floor and wall heating systems. This solution can be attractive due to low energy consumption and precise temperature control, entering the concept of smart homes.
The horticultural industry can also use TPU heating plates, which can be used in intelligent gardening systems, providing a positive ground temperature around the plant roots. This is an area which has not yet been sufficiently explored and exploited, which opens up new opportunities for the development of this technology
Project consortium partners
The R & D project was implemented as part of the CORNET activity – 31 in an international consortium with the participation of the Cluster of Innovative Manufacturing Technologies of CNNOMATECH (Poland) acting as coordinator and the Warsaw University of Technology (Poland), Forschungsinstitut für Leder und Kunststoffbahnen (FILK) gGmbH (Germany), Technische Universität Dresden (Germany).