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Real-World Applications
Poor conductivity can lead to undesirable consequences, such as static charge buildup that is capable of creating an electrical spark. As a result, any type of automotive or aerospace components through which fuel flows, such as pumps, filters, tanks or hoses, are ideal candidates for electrically conductive plastic.
Engineers at Robert Bosch recently faced that dilemma when developing a fuel filter housing for use in Audi A4 and A5 sedans. Traditionally, automotive fuel pumps and supply units are made from polyoxymethylene (POM).
But, to comply with the SAE J1645 standard, which addresses electrostatic discharge in fuel systems and components, the Bosch engineers were forced to use a conductive material. So, they turned to Ultraform N2320 C from BASF. The electrically conductive plastic eliminates the risk of electrostatic discharge and sparking as fuel flows through the filter.
“It acquires its excellent conductivity from carbon nanotubes,” says Juergen Demeter, product development engineer at BASF Engineering Plastics Europe. “Thanks to the type of additives and the way they have been incorporated, [the new material has retained traditional POM properties] such as toughness, dimensional stability and elastic resilience. When this material comes into contact with fuel, it is stronger and more creep resistant than conventional POM.”
The fuel filter is currently assembled at a Bosch plant in the Czech Republic, but the supplier is planning to use the new material globally. “Other automotive suppliers have expressed interest in using it, too,” says Demeter, who claims that the material can be “easily processed by laser welding and injection molding.”
Other German automotive suppliers have also been experimenting with conductive polymers. For instance, engineers at Mann+Hummel have developed a fuel filter housing made from Durethan DP BCF 30, a polyamide 6 from Lanxess that is reinforced with carbon fibers. It is a cost-effective alternative to traditional die-cast aluminum.