Electrical plug connector with improved cofootprint

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

[0001] Electrical connector with improved CO2 footprint

[0002] Description

[0003] 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 characterized by a reduced carbon footprint.

[0004] State of the art

[0005] Electrical connectors typically comprise one or more plastic components. These include, for example, insulating bodies, locking mechanisms, protective covers, cable glands, and housings. Modular connectors allow the combination of a multitude of individual connector modules, which are usually combined in a housing via a retaining frame. The individual connector modules, as well as the housing and retaining frame, can be designed as plastic components.

[0006] In recent years, sustainability, and in particular the carbon footprint, has become a focus of attention in the production of electrical connectors. The European Union has set a stated goal of reducing harmful greenhouse gases by 55% by 2030 compared to 1990 levels, and aims for climate neutrality by 2050. The carbon footprint (CFP) of every (industrial) product can be determined as a measure of its carbon footprint. The CFP of a product is typically determined as part of a life cycle assessment according to ISO 14040 / 140044 (in the version valid on the date of application).

[0007] Petroleum-based polymers are typically 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 poses a major environmental disadvantage, as these products are incinerated at the end of their life cycle, requiring high energy input and releasing environmentally harmful greenhouse gases.

[0008] It is well 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 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 incorporating a phosphorus-containing polymer. Such block copolymers are characterized by high synthesis costs, making cost-effective production of electrical connectors impossible.

[0009] In view of the above, there is therefore a need to be able to provide electrical connectors that are characterized by an improved CO2 balance, that meet industrial requirements regarding flammability and at the same time can be manufactured cost-effectively.

[0010] Task

[0011] It is therefore an 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 characteristics with regard 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.

[0012] 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.

[0013] A second subject matter of the present invention is also a plastic component for an electrical connector containing one or more sustainable polymers.

[0014] 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.

[0015] For a better understanding of the invention, the following explanations of the terminology used herein are considered useful.

[0016] For the purposes of the invention, the following definitions apply: - "Sustainable polymer" is a collective term for all polymers 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 recycled in such a way that they can be used directly as a plastic or as a starting material for the production of a polymer. In contrast, the term "synthetic polymer" describes a polymer derived from petroleum or petroleum starting materials.

[0017] - "a", "an", "another" as an article before a chemical compound class, e.g., before the word "polymer," means one or more compounds falling within this chemical compound class, e.g., different polymers. In a preferred embodiment, this article refers to only a single compound;

[0018] - "at least one", "at least one", "at least one" numerically "one or more". In a preferred embodiment, this term means numerically "one", "an", "an";

[0019] - "Contain," "comprise," and "include" indicate that, in addition to the components mentioned, further components may be present. These terms are meant inclusively and therefore also include "consist of." "Consist of" is meant conclusively and means that no further components may be present. In a preferred embodiment, the terms "contain," "comprise," and "include" mean the term "consist of."

[0020] 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 one another.

[0021] An electrical connector within the meaning of the present invention typically comprises one or more components made of plastic (colloquially also referred to as plastic component(s)). The term plastic here refers to a solid body that predominantly comprises a polymeric matrix containing one or more polymers. The proportion of the polymeric matrix in the plastic is preferably at least 70 wt. %, more preferably at least 80 wt. %, more preferably 90 wt. %, even more preferably at least 95 wt. %, even more preferably at least 98 wt. Further constituents 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.

[0022] 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.

[0023] Components of an electrical connector, which are usually made of plastic, include 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 designed modularly, 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 preferable that, on the one hand, the percentage by weight of the sustainable polymer in a plastic component is as high as possible and that as many as possible, preferably all plastic components, comprise one or more sustainable polymers.

[0024] 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.

[0025] In one embodiment of the invention, the electrical connector comprises an insulating body as a plastic component, which comprises at least one sustainable polymer.

[0026] In a further embodiment of the invention, the electrical connector comprises a housing as a plastic component, which comprises at least one sustainable polymer.

[0027] 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.

[0028] 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.

[0029] 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 derived from petroleum or petroleum derivatives.

[0030] As already explained above, the term sustainable polymer refers to all polymers that are based on naturally occurring or recycled raw materials.

[0031] Naturally occurring raw materials for the production of a sustainable polymer can be derived from renewable resources, such as one or more natural oils. Such polymers are also referred to as renewable or bio-based polymers.

[0032] The term "natural oil" in the context of the present invention is defined as a naturally occurring starting material that is not derived from petroleum. This includes, in particular, oils derived from a plant, including its fruits, shells, nuts, and / or seeds. However, animal fats and / or oils or any other non-petroleum-derived oil 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 produced. Examples of natural oils from which sustainable polymers can be produced 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.

[0033] 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.

[0034] It is preferred that the sustainable polymer is a thermoplastic.

[0035] In a particularly preferred embodiment of the invention, the bio-based polymer comprises at least one thermoplastic polyester 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.

[0036] Polylactides (PLA), also known as polylactic acid, are bio-based and biodegradable / compostable polyesters produced from lactic acid and exist in two stereochemical forms or as a mixture thereof. The monomeric lactic acid and the dimer (lactide) can be sustainably obtained through fermentation for the purposes of the present invention.

[0037] 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, bacterially synthesized polyesters made from saturated and unsaturated hydroxyalkanoic acids. They exist either as homopolymers or as copolymers of various hydroxyalkanoic acids. Polyhydroxyalkanoates are thermoplastic, biodegradable, biocompatible, and nontoxic.

[0038] Sustainable polyhydroxyalkanoates are available, for example, under the trade name lamNature from MAIP or under the product series PHACT from CJ Bio.

[0039] It is also possible for the bio-based polymer, alone or in combination with the aforementioned bio-based polymers, to comprise at least one polyamide from sustainable sources. Castor oil, for example, can be used as a sustainable starting material for the production of sustainable polyamides. Polyamide 11 (PA11), polyamide 510 (PA510), and polyamide 1010 (PA1010) are particularly preferred.

[0040] 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.

[0041] It is also possible to use a recycled polymer as a sustainable polymer, either alone or in combination with the aforementioned bio-based polymers. The term "recycled polymer" in the context of the present invention refers to a polymer based on raw materials produced by recycling consumer goods or industrial (waste) products – such as clothing or fishing nets. The use of recycled polymers offers the advantage of avoiding environmentally harmful incineration processes for waste recycling, which can also have a positive effect on the carbon footprint.

[0042] 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, through the recycling of clothing. For the purposes of the invention, it is preferred that polyamide be used as the recycled polymer, with PA6 or PA66 being particularly preferred. Recycled polyamides are available, for example, under the trade names Akulon from DMS or Agimid from Arkema.

[0043] In a preferred embodiment of the invention, the sustainable polymer comprises both at least one bio-based polymer and at least one recycled polymer.

[0044] 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 within the meaning of the present invention is also capable of reducing 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.

[0045] In addition to the described polymer matrix, the plastic used to manufacture the plastic component can contain further additives that positively influence the production and / or properties of the plastic. These can be, for example, but not exclusively, 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, wherein the filler comprises glass fibers, thereby improving both the mechanical and thermal properties. 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.%, more preferably in a range from 10 wt.% to 25 wt.%

[0046] In a further embodiment of the invention, the plastic further comprises halogen-free flame retardants, which comprise, for example, nitrogen and / or phosphorus compounds.

[0047] The plastic components for the electrical connector are typically manufactured using injection molding. Injection molding offers the advantage of simple and cost-effective production.

[0048] The present invention further relates to 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 equally. If the electrical connector is a modular connector, a holding frame can also be present as a plastic component. The present invention further relates to 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.

[0049] 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 further preferred that the proportion of the sustainable polymer(s) in the polymer matrix is ​​as large as possible. Therefore, the weight percentage of the sustainable polymer based on the polymer matrix of the plastic component is preferably 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. The polymer matrix of a plastic component is most preferably made of a sustainable polymer, as this allows for the greatest possible reduction in the CO2 footprint of the electrical connector.

[0050] With regard to the use according to the invention, all the above statements apply equally, as far as applicable.

Claims

Electrical connector with improved CO2 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.

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