Short glass fiber reinforced plastics (SGFRP) offer superior mechanical properties compared to polymers, while still also enabling almost unlimited geometric variations of components at large-scale production. PA6-GF30 represents one of the most used SGFRP for series components, but the impact of injection molding process parameters on the fatigue properties is still insufficiently investigated. In this study, various injection molding parameter configurations were investigated on PA6-GF30. To take the significant frequency dependency into account, tension–tension fatigue tests were performed using multiple amplitude tests, considering surface temperature-adjusted frequency to limit self-heating. The frequency adjustment leads to shorter testing durations as well as up to 20% higher lifetime under fatigue loading. A higher melt temperature and volume flow rate during injection molding lead to an increase of 16% regarding fatigue life. In situ X-ray microtomography analysis revealed that this result was attributed to a stronger fiber alignment with larger fiber lengths in the flow direction. Using digital volume correlation, differences of up to 100% in local strain values at the same stress level for different injection molding process parameters were identified. The results prove that the injection molding parameters have a high influence on the fatigue properties and thus offer a large optimization potential, e.g., with regard to the component design.

Electrochromic (EC) windows on glass for thermal and glare protection in buildings, often referred to as smart (dimmable) windows, are commercially available, along with rearview mirrors or windows in aircraft cabins. Plastic-based applications, such as ski goggles, visors and car windows, that require lightweight, three-dimensional (3D) geometry and high-throughput manufacturing are still under development. To produce such EC devices (ECDs), a flexible EC film could be integrated into a back injection molding process, where the films are processed into compact 3D geometries in a single automized step at a low processing time. Polycarbonate (PC) as a substrate is a lightweight and robust alternative to glass due to its outstanding optical and mechanical properties. In this study, an EC film on a PC substrate was fabricated and characterized for the first time. To achieve a highly transmissive and colorless bright state, poly(3,4-ethylenedioxythiophene) polystyrene sulfonate (PEDOT:PSS) was used as the working electrode, while titanium dioxide (TiO₂) was used as the counter electrode material. They were deposited onto ITO-coated PC films using dip- and slot-die coating, respectively. The electrodes were optically and electrochemically characterized. An ECD with a polyurethane containing gel electrolyte was investigated with regard to optical properties, switching speed and cycling behavior. The ECD exhibits a color-neutral and highly transmissive bright state with a visible light transmittance of 74% and a bluish-colored state of 64%, a fast switching speed (7 s/4 s for bleaching/coloring) and a moderately stable cycling behavior over 500 cycles with a decrease in transmittance change from 10%to 7%.

For the application in flexible electrochromic devices (ECDs) on plastic substrates, a new polyurethane-based gel electrolyte was manufactured. In this context, the curing behavior and the influence of the proportion of solvent and salt on the ion conductivity as well as the optical and mechanical properties were investigated. Furthermore, the stoichiometric ratio of the polyurethane matrix was varied to influence the ion conductivity. As an isocyanate component, the aliphatic difunctional polyisocyanate prepolymer, synthesized by Hexamethylen-1,6-diisocyanat (HDI), was chosen since the resulting polyurethane is considered to be particularly lightfast, color-stable and temperature-resistant and therefore frequently used for paints and coatings. As polyol a trifunctional polyetherpolyol was selected to form a wide-meshed crosslinked matrix to achieve a mechanically stable but flexible electrolyte, that enables the processing and bending of film-based ECDs. The additives amount and the matrix stoichiometric ratio affected the curing behavior and curability. The salt content had almost no influence on the measured properties in the chosen experimental space. Solvent content had a great influence on ion conductivity and mechanical properties. An understoichiometric ratio of the polyurethane matrix (0.85) increases the ion conductivity and the mechanical flexibility, but also the optical properties in a negative manner. The best specific ion conductivity with 10⁻⁵ S/cm was reached with an understoichiometric ratio of 0.85 and a high solvent content (30 wt%). Concluding, due to its high flexibility and transmittance, color neutrality and sufficient ion conductivity, the application of the researched electroyte in ECDs might be suitable. A demonstrator ECD was successfully manufactured and conducted.

The influence of thermomechanical stress on the conductivity of indium tin oxide (ITO)-coated polycarbonate (PC) films was investigated. PC is the industry’s standard material for window panes. ITO coatings on polyethylene terephthalate (PET) films are the main commercially available option; as such, most investigations refer to this combination. The investigations in this study aim to investigate the critical crack initiation strain at different temperatures and crack initiation temperatures for two different coating thicknesses and for a commercially available PET/ITO film for validation purposes. Additionally, the cyclic load was investigated. The results show the comparatively sensitive behavior of the PC/ITO films, with a crack initiation strain at room temperature of 0.3–0.4% and critical temperatures of 58 °C and 83 °C, with high variation depending on the film’s thickness. Under thermomechanical loading, the crack initiation strain decreases with increasing temperatures.

The multicomponent injection molding of liquid silicone rubbers (LSR) with thermoplastics, such as polybutylene terephthalate (PBT) or polyamide (PA), is a state-of-the-art technique and is used in the manufacturing process for many components in the automotive industry and in the field of sanitary engineering. Standard thermoplastics, such as acrylonitrile butadiene styrene (ABS), cannot be bonded with silicone rubbers in injection molding because of their low heat deflection temperature. In this study, we investigated ABS grades approved for medical applications to show how dynamic mold heating and various pretreatment methods for thermoplastic surfaces can be used to produce ABS-LSR test specimens. In addition, such components’ sterilization effect on the adhesive bond will be shown.

The increasing demand for renewable raw materials and lightweight composites leads to an increasing request for natural fiber composites (NFC) in series production. In order to be able to use NFC competitively, they must also be processable with hot runner systems in injection molding series production. For this reason, the influences of two hot runner systems on the structural and mechanical properties of Polypropylene with 20 wt.% regenerated cellulose fibers (RCF) were investigated. Therefore, the material was processed into test specimens using two different hot runner systems (open and valve gate) and six different process settings. The tensile tests carried out showed very good strength for both hot runner systems, which were max. 20% below the reference specimen processed with a cold runner and, however, significantly influenced by the different parameter settings. Fiber length measurements with the dynamic image analysis showed approx. 20% lower median values of GF and 5% lower of RCF through the processing with both hot runner systems compared to the reference, although the influence of the parameter settings was small. The X-ray microtomography performed on the open hot runner samples showed the influences of the parameter settings on the fiber orientation. In summary, it was shown that RCF composites can be processed with different hot runner systems in a wide process window. Nevertheless, the specimens of the setting with the lowest applied thermal load showed the best mechanical properties for both hot runner systems. It was furthermore shown that the resulting mechanical properties of the composites are not only due to one structural property (fiber length, orientation, or thermally induced changes in fiber properties) but are based on a combination of several material- and process-related properties.