Duroplast is a composite thermosetting resin plastic developed by engineer Wolfgang Barthel in 1953 [2] in the German Democratic Republic. [3] [4] Its production method places it in a similar family as Formica and Bakelite. It is reinforced with fibers (typically waste fabrics from the garment industry) making it a fiber-reinforced plastic similar to fiberglass.
The German Democratic Republic regularly encountered shortages of steel and had little to no iron reserves of their own. As a result, state-owned automobile manufacturer VEB Sachsenring Automobilwerke Zwickau instead used Duroplast to produce the body shell of the Trabant. Production lasted from 1955 until just after German Reunification in 1991. A light, yet strong material, Duroplast is made of recycled material: phenol resins and cotton waste fiber reinforcement. [5] Because it is formed in a press, it is more easily applied to volume car production than fiberglass.
Duroplast is difficult to dispose of responsibly, a similar problem encountered with fiberglass. As discarded Trabants began to fill junkyards after 1991, creative solutions were devised for recycling them. One was developed by a Berlin biotechnology company, which experimented with bacteria to consume the body in twenty days. [6] [7] Urban legends, depicted in the movie Black Cat, White Cat and described in a song by the Serbian band Atheist Rap, described recycling Duroplast by feeding the cars to pigs, sheep and other farm animals.
In the late 1990s, Sachsenring's developed a disposal solution in which the body shells were shredded and used as an aggregate in cement blocks for pavement construction. This was featured in an episode of the program Scientific American Frontiers on the American PBS TV channel. [5]
The use of Duroplast in Trabants and subsequent GDR jokes and mockery in western auto magazines such as Car and Driver gave rise to an urban myth that the Trabant is made of corrugated cardboard. [8]
Trabant is a series of small cars produced from 1957 until 1991 by former East German car manufacturer VEB Sachsenring Automobilwerke Zwickau. Four models were made: the Trabant 500, Trabant 600, Trabant 601, and the Trabant 1.1. The first model, the 500, was a relatively modern car when it was introduced.
Glass fiber is a material consisting of numerous extremely fine fibers of glass.
Fiberglass or fibreglass is a common type of fiber-reinforced plastic using glass fiber. The fibers may be randomly arranged, flattened into a sheet called a chopped strand mat, or woven into glass cloth. The plastic matrix may be a thermoset polymer matrix—most often based on thermosetting polymers such as epoxy, polyester resin, or vinyl ester resin—or a thermoplastic.
In materials science, a thermosetting polymer, often called a thermoset, is a polymer that is obtained by irreversibly hardening ("curing") a soft solid or viscous liquid prepolymer (resin). Curing is induced by heat or suitable radiation and may be promoted by high pressure or mixing with a catalyst. Heat is not necessarily applied externally, and is often generated by the reaction of the resin with a curing agent. Curing results in chemical reactions that create extensive cross-linking between polymer chains to produce an infusible and insoluble polymer network.
Phenol formaldehyde resins (PF) are synthetic polymers obtained by the reaction of phenol or substituted phenol with formaldehyde. Used as the basis for Bakelite, PFs were the first commercial synthetic resins. They have been widely used for the production of molded products including billiard balls, laboratory countertops, and as coatings and adhesives. They were at one time the primary material used for the production of circuit boards but have been largely replaced with epoxy resins and fiberglass cloth, as with fire-resistant FR-4 circuit board materials.
Eastman Chemical Company is an American company primarily involved in the chemical industry. Once a subsidiary of Kodak, today it is an independent global specialty materials company that produces a broad range of advanced materials, chemicals and fibers for everyday purposes. Founded in 1920 and based in Kingsport, Tennessee, the company operates 36 manufacturing sites worldwide and employs approximately 14,000 people.
Horch was a German car manufacturer, which traced its roots to several companies founded in the very late 19th and early 20th century by August Horch.
Micarta is a brand name for composites of linen, canvas, paper, fiberglass, carbon fiber, or other fabric in a thermosetting plastic. It was originally used in electrical and decorative applications. Micarta was developed by George Westinghouse at least as early as 1910 using phenolic resins invented by Leo Baekeland. These resins were used to impregnate paper and cotton fabric which were cured under pressure and high temperature to produce laminates. In later years this manufacturing method included the use of fiberglass fabric, and other resin types were also used. Today Micarta high-pressure industrial laminates are produced with a wide variety of resins and fibers. The term has been used generically for most resin impregnated fiber compounds. Common uses of modern high-pressure laminates include electrical insulators, printed circuit board substrates, and knife handles.
Polyester is a category of polymers that contain one or two ester linkages in every repeat unit of their main chain. As a specific material, it most commonly refers to a type called polyethylene terephthalate (PET). Polyesters include naturally occurring chemicals, such as in plants and insects, as well as synthetics such as polybutyrate. Natural polyesters and a few synthetic ones are biodegradable, but most synthetic polyesters are not. Synthetic polyesters are used extensively in clothing.
Industrieverband Fahrzeugbau, usually abbreviated as IFA, was a conglomerate and a union of companies for vehicle construction in the former East Germany.
The Glasspar G2 is a sports car first manufactured by Bill Tritt in 1949. It was the first production all-fiberglass sports car body built by an American fiberglass manufacturer. A few were built as complete cars but most were offered as a body, or body/chassis kit.
The AWZ P70 "Zwickau" is a small family car which was produced in East Germany by VEB Automobilwerke Zwickau (AWZ) between 1955 and 1959.
Pultrusion is a continuous process for manufacture of fibre-reinforced plastics with constant cross-section. The term is a portmanteau word, combining "pull" and "extrusion". As opposed to extrusion, which pushes the material, pultrusion pulls the material.
Building insulation materials are the building materials that form the thermal envelope of a building or otherwise reduce heat transfer.
Carbon fiber-reinforced polymers, carbon-fibre-reinforced polymers, carbon-fiber-reinforced plastics, carbon-fiber reinforced-thermoplastic, also known as carbon fiber, carbon composite, or just carbon, are extremely strong and light fiber-reinforced plastics that contain carbon fibers. CFRPs can be expensive to produce, but are commonly used wherever high strength-to-weight ratio and stiffness (rigidity) are required, such as aerospace, superstructures of ships, automotive, civil engineering, sports equipment, and an increasing number of consumer and technical applications.
Plastics are a wide range of synthetic or semi-synthetic materials that use polymers as a main ingredient. Their plasticity makes it possible for plastics to be molded, extruded or pressed into solid objects of various shapes. This adaptability, plus a wide range of other properties, such as being lightweight, durable, flexible, and inexpensive to produce, has led to their widespread use. Plastics typically are made through human industrial systems. Most modern plastics are derived from fossil fuel-based chemicals like natural gas or petroleum; however, recent industrial methods use variants made from renewable materials, such as corn or cotton derivatives.
In materials science, advanced composite materials (ACMs) are materials that are generally characterized by unusually high strength fibres with unusually high stiffness, or modulus of elasticity characteristics, compared to other materials, while bound together by weaker matrices. These are termed "advanced composite materials" in comparison to the composite materials commonly in use such as reinforced concrete, or even concrete itself. The high strength fibers are also low density while occupying a large fraction of the volume.
The Trabant 1.1 is the fourth and final series production model of the East German Trabant series, made by VEB Sachsenring Automobilwerke Zwickau. Unlike its predecessors, which have a two-stroke engine, the Trabant 1.1 has a four-stroke engine. In total, 39,474 units of the Trabant 1.1 were made from May 1990 to 30 April 1991. This makes the 1.1 the rarest Trabant model.
The Trabant P 50, also known as the Trabant 500, is the first series production model of the East German Trabant series, produced by VEB Sachsenring Automobilwerke Zwickau from 1957 until 1962. In total, 131,495 units were built. In 1962, VEB Sachsenring switched production from the P 50 to the short-lived intermediate model Trabant 600, which combined the exterior styling of the Trabant P 50 with the technical design of the next generation Trabant model, the Trabant 601.
The Trabant 600, also known as the Trabant P 60, is the second series production model of the East German Trabant series, produced by VEB Sachsenring Automobilwerke Zwickau from 1962 until 1965. In total, 106,117 units were built. The Trabant 600 was a short-lived intermediate model that combined the exterior styling of the Trabant P 50 with the technical design of the next generation Trabant model, the Trabant 601. For a short period of time, the Trabant 600 estate was built alongside the 601 saloon.
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