Other Markets Case Studies
Sewage Tunnel Liner
Leak resistance. Chemical resistance. Abrasive resistance. Nowhere are these properties more critical than in sewage tunnel liner.
Add to that the challenge of producing a liner on the spot, as the tunnel is being bored. Utilizing a material that would form a high-strength bond with structural concrete, and meeting tight tolerance specifications.
Telene, our RIM molding process and our engineers met all of these challenges with an on-site solution. Our unique liner design included an integrated rubber seal to eliminate leakage.
The consistency of our casting process and finish quality of the Telene material fully eliminated the need for a send pass required by traditional in-situ lining methods. It also eliminated HSE issues and allowed for tunneling speed to be increased.
So water and sewer districts can now look forward to a more rapid completion of major sewer projects, with greater confidence in their integrity and durability, thanks to Telene.
Individual Wastewater Treatment Plant
One of the early and most successful products constructed of Telene is this individual wastewater treatment plant. Over the past 20 years, 800,000 systems have been installed and are currently operational in Japan utilizing this product.
As you would expect with wastewater treatment, the first requirement is watertight construction. In addition, the unit had to be capable of withstanding harsh chemicals over a long period of time. And while it is not apparent from the exterior, the internal design has integrate highly complex equipment.
Because this unit is installed on-site in hard-to reach places, it has to be manufactured and shipped in two parts, be lightweight and easy to assemble with perfect surface mating.
Telene has proven to be ideal polymer for this product. Rapid RIM production with fast flow and low pressures results in cycle times of less than 6 minutes per half shell. It is light enough for easy storage, transportation and installation, while meeting all expectations for durability and integrity for decades of use.
Industrial Strength Waste Container
The design and materials would have to withstand exposure to outside elements. They had to have built-in resistance to dirt, liquids, acids and all forms of waste materials. The large scale would a long flow pattern, in order to achieve a one-piece molding. The 3-D walls would have to be thin enough to keep the weight down for ease of lifting, yet have enough structural rigidity to withstand the abuse of automated refuse handlers.
When you look at the design parameters, it’s no wonder dumpsters have traditionally been made out of steel. Until now.
This waste container made exclusively of Telene makes utilizes the latest innovations in 3-D design, with built-in ribs and specially reinforced attachment points for hardware, including the hinges for the top and casters for the bottom. A short cycle time, together with a limited number of postmolding assembly steps reduces labor costs and increases product quality.
It is the largest plastic injected waste container in the world, capable of holding 3200 liters (113 cubic feet) of trash. Others see a trash container. We see proof that Telene can bring exciting innovations even to the most mundane of products.
If you’ve ever heard a fan rattling and making excessive noise, you understand why the manufacturer of this industrial fan shroud wanted to find a better alternative to steel. The design parameters called for an expected life in excess of 16,0000 hours, with strong resistance to high temperatures and the ability to withstand the abrasion of particles being hurled toward the opening. Most important, the substance had to be flexible enough to absorb the inherent vibration of the rotating blades and motor.
The challenge for Telene designers was made even more interesting by the fact that only external dimensions were known. We had to develop our own load and vibration models, then develop a prototype from the production material that could withstand a 7500-hour field test.
Using Telene 1800, our designers created a prototype for the fan shroud in less than 8 weeks, machined it to the required thicknesses, then validated the design.
A formidable challenge, met on time and within the budget that resulted in a viable commercial product that is a quiet sensation in the air handling industry.
Mypower Wind Mill
Harnessing new forms of energy such as wind power is an exciting challenge. We always feel good when our products help companies create a more sustainable environment and reduce the dependence on natural resources.
Our designers leapt at chance to create blades for a small-scale consumer windmill out of Telene. Its unique characteristics of light weight (able to pick up the slightest breeze), structural integrity (for attachment at the center post) and flexability made it an excellent alternative to traditional composite materials.
Of course, the fan blade also had to be able to withstand hurricane force winds. Our designers came up with an innovative overmolding process that had never been used before in industrial applications, incorporating a metallic structural sub-assembly at its core and surrounding it in the mold with Telene.
Finite Element Analysis confirmed that the combination of a metal “skeleton” inside a skin of Telene would provide the maximum deflection. It was proven to have superior resistance to UV degradation, thermal distortion and cold-weather cracking, to the degree that the OEM offers a full 5 year warranty on the product including the blades.
All this was accomplished in less than 5 months from design to development and mold setup.
That’s what happens when you harness the energy of Telene’s innovative chemists and industrial designers.