WO2024208414A1 - Electrical plug connector with improved co2 footprint - Google Patents

Abstract

The present invention relates to an electrical plug connector having one or more plastics components, wherein at least one of the plastics components comprises a sustainable polymer. The use of sustainable polymers in one or more plastics components of an electrical plug connector permits the production of sustainable electrical plug connectors that feature an improved CO₂ footprint.

Description

Electrical connector with improved CO2 footprint

Description

The present invention relates to an electrical connector with one or more plastic components, wherein at least one of the plastic components comprises a sustainable polymer. The use of sustainable polymers in one or more plastic components of an electrical connector allows the production of sustainable electrical connectors that are characterized by an improved CO2 footprint.

State of the art

Electrical connectors usually have one or more plastic components. These include, for example, insulating bodies, locking mechanisms, protective covers, cable glands and housings. Modular connectors enable the combination of a large number of individual connector modules, which are usually combined in a housing via a holding frame. The individual connector modules, but also the housing and the holding frame can be designed as plastic components.

Over the last few years, sustainability and in particular the carbon dioxide balance have become the focus of attention in the production of electrical connectors. One of the European Union's declared goals is to reduce harmful greenhouse gases by 55% by 2030 compared to 1990, and to achieve climate neutrality by 2050. For every (industrial) product, the so-called carbon footprint (CFP) can be determined as a measure of its carbon footprint. The CFP of a product is usually determined as part of a life cycle assessment according to ISO 14040/140044 (in the version valid on the date of registration).

Petroleum-based polymers are usually used to manufacture plastic components for electrical connectors and connector modules. These include polymers such as acrylonitrile-butadiene-styrene copolymers (ABS), polyamide (PA) or polycarbonate (PC). This is a major disadvantage from an environmental point of view, as these products are burned at the end of their life cycle, using a high level of energy and releasing environmentally harmful greenhouse gases.

It is known that sustainable raw materials can be used to reduce the carbon footprint of an industrial product. For example, US2016/0237353 A1 describes flame-retardant block copolymers that are made from renewable raw materials such as polylactide. The block copolymers described can be used in various industrial products. Electrical connectors are subject to very strict requirements, particularly with regard to low flammability. The block copolymers described in US2016/0237353 A1 achieve reduced flammability by polymerizing a phosphorus-containing polymer. Corresponding block copolymers are characterized by a high synthesis effort, which means that cost-effective production of electrical connectors is not possible.

In view of the above, there is therefore a need to provide electrical connectors that are characterized by an improved carbon footprint and that meet industrial requirements with regard to flammability and at the same time can be produced cost-effectively.

task

It is therefore the object of the present invention to provide an electrical connector with an improved CC balance. The electrical connector according to the invention should have at least comparable, preferably improved, performance properties in relation to its mechanical and electrical properties. Furthermore, the connector according to the invention should have reduced flammability and be able to be manufactured cost-effectively.

The problem is solved by an electrical connector with one or more plastic components, wherein at least one plastic component comprises one or more sustainable polymers.

A second subject matter of the present invention is also a plastic component for an electrical connector containing one or more sustainable polymers.

A third object of the present invention is also the use of a sustainable polymer in at least one plastic component of an electrical connector to reduce the CO2 footprint of the electrical connector.

For a better understanding of the invention, the following explanations of the terminology used herein are considered useful.

For the purposes of the invention: - “Sustainable polymer” is a collective term for all polymers that are based on natural or recycled raw materials and are not a direct product of exclusively petrochemical production. In particular, the term sustainable polymers includes natural oil-based and/or bio-based polymers, but also polymers that are processed through a recycling process in such a way that they can be used directly as a plastic or as a reactant to produce a polymer. In contrast, the term “synthetic polymer” describes a polymer that is derived from petroleum or petroleum reactants.

- "a", "an", "another" as an article before a chemical class of compounds, e.g. before the word "polymer", means that one or more compounds falling within this chemical class of compounds, e.g. different polymers, can be meant. In a preferred embodiment, this article means only a single compound;

- "at least one", "at least one", "at least one", numerically "one or more". In a preferred embodiment, this term means numerically "a", "an", "one";

- "contain", "comprise" and "include" mean that in addition to the components mentioned, there may be other components. These terms are meant inclusively and therefore also include "consist of". "Consist of" is meant conclusively and means that no other components may be present. In a preferred embodiment, the terms "contain", "comprise" and "include" mean the term "consist of".

For the purposes of the present invention, the term “electrical connector” also includes modular connectors in which at least two or more individual connector modules are combined with each other.

An electrical connector in the sense of the present invention usually comprises one or more components made of plastic (also colloquially referred to as plastic component(s)). The term plastic here refers to a solid body that predominantly comprises a polymer matrix that contains one or more polymers. The proportion of the polymer matrix in the plastic is preferably at least 70% by weight, more preferably at least 80% by weight, more preferably 90% by weight, even more preferably at least 95% by weight, even more preferably at least 98% by weight. Other components of the plastic can be, for example, organic and/or inorganic fillers that are added to the polymer matrix in order to adjust certain properties of the resulting plastic.

According to the invention, at least one plastic component of the electrical connector contains one or more sustainable polymers. However, it is also possible for two or more plastic components of the electrical connector to comprise one or more sustainable polymers. In a particularly preferred embodiment of the invention, all plastic components of the connector contain one or more sustainable polymers.

Components of an electrical connector, which are usually made of plastic, are one or more insulating bodies, the housing, protective covers, cable glands and/or components of one or more locking mechanisms. If the electrical connector is modular, a holding frame in the form of a plastic component can also be added. The greater the proportion of sustainable polymers in the plastic components of the electrical connector, the lower the CO2 footprint of the corresponding electrical connector. It is therefore preferred that the weight percentage of the sustainable polymer in a plastic component is as high as possible and that as many, preferably all, plastic components as possible contain one or more sustainable polymers.

Preferably, the weight percentage of the sustainable polymer based on the polymer matrix of the plastic component is at least 30 wt.%, preferably at least 40 wt.%, preferably at least 50 wt.%, preferably at least 60 wt.%, preferably at least 70 wt.%, preferably at least 80 wt.%, preferably at least 90 wt.%, preferably at least 95 wt.%. Most preferably, the polymer matrix of a plastic component consists of a sustainable polymer.

In one embodiment of the invention, the electrical connector comprises an insulating body as a plastic component, which comprises at least one sustainable polymer.

In a further embodiment of the invention, the electrical connector comprises a housing as a plastic component, which comprises at least one sustainable polymer.

In a further embodiment of the invention, the electrical connector comprises a protective cover as a plastic component, which comprises at least one sustainable polymer.

In a further embodiment of the invention, the electrical connector comprises a locking mechanism as a plastic component, which comprises at least one sustainable polymer. In a preferred embodiment of the invention, the aforementioned embodiments can be combined with each other in any way with regard to the specification of the plastic component, so that the electrical connector comprises more than one plastic component which contains at least one sustainable polymer.

In the aforementioned embodiments, it is particularly preferred that the polymer matrix consists of one or more sustainable polymers. In other words, this means that no so-called "synthetic polymers" are used for the polymer matrix. The term "synthetic polymer" refers to polymers that are derived from petroleum or petroleum educts.

As already explained above, the term sustainable polymer refers to all polymers that are based on naturally occurring or recycled raw materials.

Naturally occurring raw materials for the production of a sustainable polymer can be derived from renewable raw materials, such as one or more natural oils. Such polymers are also referred to as renewable or bio-based polymers.

The term "natural oil" in the sense of the present invention is defined as a naturally occurring starting material that is not derived from petroleum. This includes in particular oils that come from a plant, including its fruits, shells, nuts and/or seeds. However, animal fats and/or oils or any other oil that is not derived from petroleum can also be used. These naturally occurring materials are environmentally friendly and are also referred to as bio-based starting materials from which bio-based polymers are made. Examples of natural oils from which sustainable polymers can be made include soybean oil, canola oil, sunflower oil, corn oil, linseed oil, poppyseed oil, cottonseed oil, tung oil, palm oil, peanut oil, fish oil, olive oil, safflower oil, rapeseed oil, coconut oil and castor oil.

The production of corresponding bio-based or renewable polymers is known to the person skilled in the art and will not be discussed further here.

It is preferred that the sustainable polymer is a thermoplastic.

In a particularly preferred embodiment of the invention, the bio-based polymer comprises at least one thermoplastic polyester which was produced from naturally occurring raw materials. The sustainable polymer is preferably a thermoplastic polyester selected from the group consisting of polylactides (polylactic acids, PLA), polyhydroxyalkanoates (PHA) and mixtures thereof.

Polylactides (PLA), also known as polylactic acid, are bio-based and biodegradable/compostable polyesters that are produced from lactic acid and occur in two stereochemical forms or as a mixture thereof. The monomeric lactic acid and the dimer (lactide) can be sustainably obtained by fermentation in the sense of the present invention.

Sustainable polylactides are available, for example, under the trade name RENEW™ from futerro, such as RENEW™ 201. Other sustainable polylactides are available under the trade name Ingeo from NatureWorks or under the DAN series from Danimer Scientific. Polyhydroxyalkanoates (PHAs) are naturally occurring polyesters made from saturated and unsaturated hydroxyalkanoic acids, synthesized by bacteria. They exist either as homopolymers or as copolymers of various hydroxyalkanoic acids. Polyhydroxyalkanoates are thermoplastic, biodegradable, biocompatible and non-toxic.

Sustainable polyhydroxyalkanoates are available, for example, under the trade name lamNature from MAIP or under the product series PHACT from CJ Bio.

It is also possible for the bio-based polymer to comprise at least one polyamide from sustainable sources, alone or in combination with the aforementioned bio-based polymers. Castor oil, for example, can be used as a sustainable starting material for producing sustainable polyamides. Polyamide 11 (PA11), polyamide 510 (PA510) and polyamide 1010 (PA1010) are particularly preferred.

Sustainable polyamides are available, for example, under the Rilsan product series from Arkema, under the Grilamid product series from EMS Chemie, under the Vestamin Terra product series from Evonik or under the trade name NB Bio PA11 from NaturePlast.

It is also possible that a recycled polymer is used as a sustainable polymer, either alone or in combination with the aforementioned bio-based polymers. The term “recycled polymer” in the sense of the present invention refers to a polymer that is based on starting materials that were produced by recycling consumer goods or industrial (waste) products - such as clothing or fishing nets. The use of recycled polymers offers the advantage that environmentally harmful Incineration processes for waste recycling can be avoided, which can also have a positive effect on the CO2 footprint.

As already stated, polyamide can be used as a bio-based polymer, but it is also possible to use polyamide as a recycled polymer. Recycled polyamide can be obtained, for example, by recycling clothing. For the purposes of the invention, it is preferred that polyamide is used as the recycled polymer, with PA6 or PA66 being particularly preferred. Recycled polyamides are available, for example, under the trade name Akulon from DMS or Agimid from Arkema.

In a preferred embodiment of the invention, the sustainable polymer comprises both at least one bio-based polymer and at least one recycled polymer.

In a further embodiment of the invention, it is also possible for the sustainable polymer to be a hybrid copolymer of a bio-based polymer and a synthetic polymer. This form of sustainable polymer in the sense of the present invention is also able to reduce the CO2 footprint of an electrical connector. An example of a hybrid copolymer in this context is the commercially available product DURABIO from Mitsubishi Chemical.

In addition to the polymer matrix described, the plastic used to manufacture the plastic component can contain other additives that have a positive effect on the production and/or properties of the plastic. These can include, but are not limited to, dispersing additives, flow aids, adhesion promoters, wetting agents, flame retardants, colorants or fillers. In one embodiment of the invention, the plastic comprises at least one filler, the filler comprising glass fibers, thereby improving both the mechanical and thermal properties. The impact resistance is also improved. Depending on requirements, the weight percentage of filler, in particular glass fiber, in the plastic can be varied within a wide range. The weight percentage is preferably in a range from 10 wt.% to 50 wt.%, preferably in a range from 10 wt.% to 25 wt.%

In a further embodiment of the invention, the plastic further comprises halogen-free flame retardants, which comprise, for example, nitrogen and/or phosphorus compounds.

The plastic components for the electrical connector are usually manufactured using the injection molding process. Injection molding offers the advantage that it can be manufactured easily and cost-effectively.

Another subject of the present invention is a plastic component for an electrical connector containing a sustainable polymer. The plastic component according to the invention is preferably an insulating body, a protective cover, a locking mechanism, a cable gland or a housing of an electrical connector. With regard to the plastic component according to the invention, all of the above statements apply to the same extent. If the electrical connector is a modular connector, a holding frame can also be present as a plastic component. Another object of the present invention is also the use of at least one sustainable polymer in at least one plastic component of an electrical connector to reduce the CO2 footprint of the electrical connector.

The plastic component is preferably an insulating body, a protective cover, a locking mechanism, a cable gland and/or a housing of an electrical connector. In the case of a modular connector, the plastic component can also be a holding frame. In order to achieve the greatest possible reduction in the CO2 footprint of the electrical connector, as many, preferably all, plastic components of the electrical connector as possible comprise one or more sustainable polymers. The sustainable polymers can be the same or different depending on the requirements profile of the plastic component. It is also preferred that the proportion of the sustainable polymer(s) in the polymer matrix is as large as possible. The weight percentage of the sustainable polymer based on the polymer matrix of the plastic component is therefore preferably at least 30% by weight, preferably at least 40% by weight, preferably at least 50% by weight, preferably at least 60% by weight, preferably at least 70% by weight, preferably at least 80% by weight, preferably at least 90% by weight, preferably at least 95% by weight. It is particularly preferred that the polymer matrix of a plastic component consists of a sustainable polymer, as this enables the greatest possible reduction in the CO2 footprint of the electrical connector.

With regard to the use according to the invention, all of the above statements apply to the same extent, where applicable.

Claims

Electrical connector with improved carbon footprint claims 1 . Electrical connector with one or more plastic components, characterized in that at least one plastic component comprises one or more sustainable polymers. 2. Electrical connector according to claim 1, characterized in that the plastic component is selected from the group consisting of insulating bodies, housings, locking mechanisms, cable glands and protective covers. 3. Electrical connector according to claim 1 or 2, characterized in that the electrical connector is a modular connector. 4. Electrical connector according to one of the preceding claims, characterized in that the sustainable polymer is a bio-based polymer selected from the group consisting of bio-based polyesters, bio-based polyamides and mixtures thereof. 5. Electrical connector according to claim 4, characterized in that the bio-based polyester comprises polylactide (PLA) and/or polyhydroxyalkanoate. 6. Electrical connector according to one of claims 1 to 3, characterized in that the sustainable polymer is a recycled polymer. 7. Electrical connector according to claim 6, characterized in that the recycled polymer is made from recycled consumer goods or industrial (waste) products. 8. Electrical connector according to one of the preceding claims, characterized in that the sustainable polymer comprises at least one bio-based polymer and at least one recycled polymer. 9. Electrical connector according to one of the preceding claims, characterized in that the plastic component comprises a filler, preferably glass fibers. 10. Electrical connector according to one of the preceding claims, characterized in that the at least one plastic component comprising the sustainable polymer is produced by injection molding. 11. Plastic component for an electrical connector containing one or more sustainable polymers. 12. Plastic component according to claim 11, characterized in that the plastic component is an insulating body, a locking mechanism, a protective cover or a housing of an electrical connector. 13. Plastic component according to one of claims 11 or 12, characterized in that the sustainable polymer is a bio-based polymer selected from the group consisting of bio-based polyesters, bio-based polyamides and mixtures thereof. 14. Use of at least one sustainable polymer in at least one plastic component of an electrical connector to reduce the carbon footprint of the electrical connector. 15. Use according to claim 14, characterized in that the plastic component is an insulating body and/or a housing of an electrical connector.