Saturday, December 23, 2006

High-speed composite moulding evaluated

A high-speed moulding technology that allows an instantaneous heating of the mold surface only is being evaluated for use with composite materials and reducing moulding costs.

Azdel, a 50/50 joint venture of GE Advanced Materials and PPG Industries, based in Lynchburg, Virginia, USA. has announced that it is currently evaluating the potential advantages of the Cage System, an innovative, high-speed composite moulding technology developed by the RocTool Company of France, for use with its own Azdel composite materials. According to Ken Forden, president Azdel: 'We are working in conjunction with RocTool to investigate the use of the Cage System for the production of composites with a class A surface finish.' The Cage System allows an instantaneous heating of the mould surface only, the rest of the mould remains cold.

The technique to achieve this involves passing an electrical current over the surface of the mold by means of inductors that are placed around it to form a cage.

The mold cavity surface is heated within seconds, and it is possible to use high temperatures - up to about 400 deg C - and to precisely manage temperature thresholds, even using spot heating.

This high level of localised control helps enable a considerable reduction in production cycle times and potentially therefore a reduction in the cost of manufacturing composite parts making it an excellent candidate for medium-run and mass production applications.

Furthermore, the Cage System process offers a truly generic solution that can be adapted to all types of composites, as the heating power is applied at the mould surface only.

With the heating by Joule effect principally taking place within the material itself, the mould can be rapidly cooled using a simple system of circulating water.

Moreover, the technology is compatible with standard compression-molding machines and requires only the addition of an induction generator and cooling unit.

However, a process-specific mould, with integrated induction heating and water-cooling system is necessary.

The potential advantages of molding composites using the Cage System are: * Reduced cycle time.

* Higher production rates.

* Potential for class A surface finish composite sheet.

* Possibility for heating threshold control and in-mold cooling of the material.

* Lower energy consumption.

Advantages that might open the way for composites to enter many applications from which they have previously been excluded on the basis of too high cost or too low aesthetic value in the finished part.

Azdel composites are produced and distributed by Azdel.

Azdel composite customers are provided with support in design, testing, moulding and prototyping to achieve excellent performance and weight reduction in automotive applications.

GE's Automotive Application Development Center in Southfield, Mich.

USA, and the European Design Center in Bergen op Zoom, The Netherlands, can help to provide the world's leading automotive manufacturers and tier suppliers with extensive technical support.

Expert staffs can assist with concept generation, complete pre-production consultancy, application and performance prediction, processing simulation, feasibility and cost studies, advanced processing capabilities, system solutions, and innovative automotive expertise.

Moreover, in the United States, GE Advanced Materials in collaboration with Fitch, leaders in industrial design, and GE Polymer Design Associates in Europe, can assist customers with a range of design and engineering services, or with helping to find an optimal solution to a specific task.

This support covers a wide range of automotive disciplines - styling, engineering design, CAD, finite element analysis, model and prototyping, tooling, testing and project management.

* About Azdel - Azdel is a joint venture of GE Advanced Materials and PPG Industries.

The Azdel business was established in 1972 by PPG, and the 50/50 joint venture was set up with GE in 1986.

Azdel is a global leader in the manufacture and supply of high-performance composite materials serving a wide variety of markets and industries including automotive, transportation interiors, large truck, materials handling, heating, ventilation and air conditioning (HVAC), and building and construction.

Impact-resistant resins reduce cycle times

Latest impact-resistant resins provide significantly improved flow performance compared to standard grades and may offer automotive OEMs cycle time improvements up to 10%.

Demonstrating another example of its commitment to provide technically advanced material solutions to automotive customers across the globe, GE Advanced Materials, Automotive has introduced a reinvigorated Instrument Panel (IP) program, featuring several new high performance acrylonitrile-butadiene-styrene (ABS) and polycarbonate (PC) grades, as well as an expanded range of world-class technical resources and support. GE shifted its IP programme into high gear with the launch of a new series of Xtreme Cycoloy PC/ABS resin blends, representing the latest materials breakthrough in GE's continuing development of its Cycoloy resin family. This selection of impact-resistant resins delivers best-in-class thermal aging and hydrolytic stability, as well as excellent low odor and emissions.

The Xtreme Cycoloy resins also provide significantly improved flow performance compared to standard grades, which may offer automotive OEMs the potential for improving cycle times by as much as 10%.

Reduced wall thicknesses of up to 10% may also be achievable, therefore offering the possibility of lower-cost components.

Additional momentum to GE's upgraded IP program comes from its introduction of Lexan EXL 1414H resin, a new polycarbonate-siloxane (PC-Si) copolymer grade that offers automotive designers and OEMs new synergies between integrated airbag and IP design, which may help to enhance consumer safety.

The low temperature ductility of the new resin, down to -40 deg C, allows robust airbag deployment with no material fragmentation, potentially increasing consumer safety vs similar PCs or lower performing resins currently on the market.

Also key to airbag and IP designers is GE's recent innovation of a new integrated seamless airbag door design, and its dedicated Airbag Testing facility located in Pittsfield, Massachusetts, USA, for helping customers with application development.

'Designers of modern automotive interiors must strike a delicate balance between functional and safe designs on the one hand, and stylish and consumer-enticing aesthetics on the other,' said Robert Nelson, market director for Interiors and Structures at GE Advanced Materials, Automotive.

'GE can help with enhanced performance and better looks for instrument panels, new innovations in integrated airbag door designs, or all of the above'.

'Designers can expect to find an array of solutions and support from GE's innovative IP program and the advanced new resins we are now offering.' In addition to the new IP programme's impressive array of innovative materials and value-added customer support, automotive OEMs will find that GE Advanced Materials offers several other world-class resources, including: * One of the broadest product portfolios of colors and effects for interior trim and component applications in the form of its Visualfx resin family.

* Top-end support for performing structural CAE and process simulation to help customers reduce risk and speed up development cycles.

* An array of offerings from GE's LNP specialty compounds portfolio to address emerging needs such as electronic shielding, noise reduction, and wear resistance.

GE Advanced Materials, Automotive distributes all its new and existing IP grades globally, and offers a wide range of resources to support automotive application development worldwide.

* About GE Advanced Materials - GE Advanced Materials is a world leader in providing high -technology material solutions.

Headquartered in Pittsfield, Massachusetts, its businesses include Plastics, Silicones, Quartz, Automotive, Specialty Film and Sheet, Polymershapes, and Sealants and Adhesives.

GE (NYSE:GE) is a diversified technology, media, and financial services company dedicated to creating products that make life better.

From aircraft engines and power generation to financial services, medical imaging, television programming, and plastics, GE operates in more than 100 countries and employs more than 300,000 people worldwide.

Friday, December 22, 2006

Thermoplastics resins benefit auto-makers

Since the late 1960s, advanced materials have helped the automotive industry build best-selling vehicles offering world-class performance, style, safety, reduced costs, weight, and emissions.

Since the late 1960s, ground-breaking technologies from GE Advanced Materials have helped the automotive industry build best-selling vehicles offering world-class performance, style, safety, reduced costs, weight, and emissions. These GE technologies have also contributed to significant fuel savings for the consumer. Through science, GE has helped automotive manufacturers build lighter and more fuel-conserving vehicles.

GE is creating innovative, ecologically optimized solutions to support the global automotive industry's work to address a range of adverse impacts on the environment and to reduce the global consumption of energy.

By offering high-performance thermoplastics resins and compounds as lightweight alternatives to metals and glass, GE is assisting the industry in its drive to build/produce cars that use less fuel and have lower emissions than previous car generations.

Reducing Vehicle Weight and Fuel Consumption with GE's High-Performance Engineering Resins Plastics play a major role in today's vehicles.

Plastics can be found today in bumpers, fuel tanks, body panels, battery housings, instrument panels, wire, lighting, electronics, and many other automotive applications.

Plastics can help reduce fuel use and emissions; according to the American Plastics Council, (APC) a vehicle's gas mileage increases by five percent for every 10 percent taken from its weight.

According to the APC, plastics in some vehicles have contributed to reducing weight by up to 700 lb.

Industry sources claim that 257 pounds, (116 kilograms) of the total weight of an average vehicle is comprised of plastics.

Likewise, in a study published by the Association of Plastics Manufacturers in Europe, a car with 7.5% of its total weight consisting of plastics, and driven over 93,000 miles (150,000km) during its service life would use approximately 264 US gallons (1000 liters) less fuel than a car using traditional metal and/or glass components (based on a 15 year service life).

This would be a total savings of $1,250 per vehicle (based on an average price of $1.25 per liter), a common price for fuel in Europe.

An estimated total of 4 billion lb (1.8 billion kg) of plastics was used on automobiles worldwide in 1999, increasing to 5.1 billion lb (2.3 billion kg) by 2009.

Today GE sells a significant amount of its engineering thermoplastics resins into the automotive industry in over 19 vehicle brands produced by OEMs worldwide and to well over 80% of the industry.

According to the Department of Trade and Industry (DTI) in the UK, in 1999 the global automotive industry produced 46.7 million passenger cars.

By 2002 the industry was forecast to produce nearly 50 million cars and around 9 million MPVs and SUVs, and by 2005 over 52.7 million cars.

Based on these statistics, advanced materials used in today's automobiles can help save consumers nearly $4.9 billion per year in fuel.

GE is aggressively investing in the expansion of its advanced materials portfolio to provide an even wider range of solutions for automotive manufacturers.

GE's continued investment will help reduce emissions to the environment, and further increase weight-out opportunities for the industry without compromising performance and safety.

Some of GE's key applications include: * GE glazing systems, which can lighten the automotive load by up to 50% by replacing glass with glazing solutions, which also offer greater parts integration, excellent aesthetics, styling and weathering performance, and reduce tooling costs.

* Fenders and tailgates incorporating NORYL GTX resin instead of steel could be made 40% lighter, and provide a combined added value of styling freedom and high impact resistance.

* Under-the-hood components, such as electronic throttle bodies, can weigh up to 50 percent less when constructed from GE's heat-resistant ULTEM resin grades.

* GE's brand of LNP* specialty compounds offer lightweight alternatives to metal, as well as a diversity of customized performance qualities for specialized applications.

* Automotive electronics typically wired with cross-linked polyethylene (PE) can be made 21 percent lighter by using flexible NORYL* CRX resin instead.

* GE also offers a range of other lightweight alternatives to metal for wiper systems, machined brackets, transmission components, fuel systems, valve covers, thermostat housings, compressor housings, and die-cast or machined parts.

Other Consumer Benefits GE's resins and compounds can also help consumers extend the useful life of vehicles with components that are more resistant to corrosion, heat, and impact.

GE is investing in new resin and composite technologies that are intended to allow more interior space and passenger comfort, increased color retention and higher gloss, and that provide greater design freedom.

Improved design capability, based on GE's materials, could enable automotive designers to create colorful and easily replaceable body panels and components.

One possible result: automobiles could also be sold with the option of 'two cars within one', with accessories that totally change the look and feel of the car and that could represent greater efficiency, performance, and style combined in one package.

'GE is working hard to contribute to the development of vehicles that support our customers' efforts to reduce fuel emissions as required by more stringent environmental regulations, and to help shape an automotive industry that uses the planet's natural resources more wisely,' said Greg Adams, vice president, GE Advanced Materials, Automotive.

'GE is a leader in advanced material solutions that can help meet design challenges for vehicle performance, safety, and style.' About GE Advanced Materials GE Advanced Materials is a world leader in providing materials solutions through engineering thermoplastics, silicon-based products and technology platforms, and fused quartz and ceramics.

Among its businesses are: * Plastics - which is a global plastics materials supplier and distributor, serving customers in a variety of industries including aerospace, appliances, automotive, building and construction, data storage and optical media, medical, electrical and electronics devices, telecommunications, computers and peripheral devices, outdoor vehicles and devices, and packaging.

* Silicones - which includes GE Toshiba Silicones in the Pacific region and GE Bayer Silicones in Europe, offering silanes, specialty silicones, urethane additives, adhesives, sealants, resins, and elastomers for a variety of industries such as personal care, automotive, tire and rubber, construction, healthcare, electronics, household and institutional, agriculture, textiles, appliances, bedding and furnishings, foam control, and consumer.

* Quartz - which provides high-purity quartz and advanced ceramic materials for the semiconductor, telecommunications, lighting, electronics, personal care, water purification, and various other industries.

Practical guide to polythene published

Practical Guide to Polyethylene provides information about every aspect of polyethylene production including polyethylene, properties and in-service performance, and processing.

Polyethylene is probably the most commonly used polymer in everyday life. It is the polymer that is used to make grocery bags, shampoo bottles, children's toys, and even bullet-proof vests. Rapra's new Practical Guide to Polyethylene provides information about every aspect of polyethylene production and use in a reader-friendly form.

It discusses the advantages and disadvantages of working with polyethylene, offering practical comment on the available types of polyethylene, properties and in-service performance, and processing.

The Practical Guide begins with general background to the polyethylene family, with price, production and market share information.

It describes the basic types of polyethylene and reviews the types of additives used in.

Polyethylenes offer a wide range of properties due to differences in structure and molecular weight, and the Practical Guide gives the low down on the properties, including, amongst others, rheological, mechanical, chemical, thermal, and electrical properties.

Design of a polymeric product for a certain application is a complex task, and this is particularly true for polyethylene with its variety of forms and available processing methods.

This Practical Guide describes the processing issues and conditions for the wide range of techniques used for polyethylene, and also considers post-processing and assembly issues.

It offers guidance on product design and development issues, including materials selection.

The Practical Guide to Polyethylene is an indispensable resource for everyone working with this material.

Written by Cornelia Vasile, a senior researcher at the Romanian Academy, 'P Poni' Institute of Macromolecular Chemistry, and Dr Mihaela Pascu, an associate professor in the Physics Department of the 'Gr T Popa' Medicine and Pharmacy University of Iasi, Romania.

Thursday, December 21, 2006

Polymers mould into thin-walled parts

Engineered to replace thermosets, ceramics and metals a family of high flow polymers is mould thin-walled, intricate components and highly-filled compounds without sacrificing ease of processing.

Victrex USA has introduced the VICTREX 90 family of high flow Victrex PEEK products designed for injection molding thin-walled, intricate components and highly-filled compounds without sacrificing ease of processing. These new products are engineered to replace thermosets, ceramics and metals in electronic consumer, surface-mount technology and micro-fluid handling applications. VICTREX 90-based products have a lower molecular weight than other Victrex PEEK polymers and offer equivalent mechanical, thermal, chemical, and electrical properties.

They are available unfilled (powder or pellets) or reinforced with glass or carbon fibers.

Fiber loadings up to 60 wt% are possible without sacrificing ease of processing, surface finish or cycle time.

The higher filler loadings produce substantial improvements in modulus, toughness, and coefficient of thermal expansion.

VICTREX 90-based products enable engineers to design components previously only possible with lower performing, lower viscosity polymers like LCP, PPS, and epoxy thermosets.

The spiral flow at 2mm (0.08in) depth is more than double that of standard flow VICTREX 450-based products.

VICTREX 90-based products enable the reliable molding of sections thinner than 0.2mm (0.008in).

According to Andrew Ragan, Product Manager, Victrex USA, 'We have had very positive response from connector manufacturers having difficulties with highly filled, high flow PPS and LCP products.' A promising new area for VICTREX 90-based products is the lead-free soldering processes (260 deg C (500 deg F)) used in the electronics industry.

Explains Ragan, 'Traditional polymeric materials such as PBT, Nylon and PPS fail because they distort or melt under lead-free solder conditions'.

' In contrast, high temperature resistant Victrex PEEK readily meets the demands of the most rigorous lead-free solder processes'.

' Moreover, the polymer's high flow characteristics are ideally suited for the complex shapes required by the electronics industry to make devices smaller and more lightweight.' Victrex USA, a division of Victrex, is the sole manufacturer and supplier of PEEK?

High performance thermoplastics protects wiring

French engineers have chosen a high performance thermoplastics for all of the components for a lightweight composite backshell to protect the Airbus A380's wiring.

When engineers at the Electrical Interconnect Division of French-based Zodiac AeroSafety Systems wanted to develop a lightweight composite backshell for the Airbus A380, it chose Victrex PEEK, a high performance thermoplastics, for all of the components. The backshells are used to protect the plane's wiring and must be able to withstand temperatures ranging from -55 deg C (-67 deg F) to +175 deg C (+347 deg F). According to Andrew Ragan, Product Manager, Victrex USA, 'Engineers at Electrical Interconnect are continuously implementing new concepts with a strong emphasis on metal to plastics conversion in order to lower component cost, decrease weight, increase design flexibility, and improve system performance'.

'Using Victrex PEEK enables them to meet these goals'.

' It combines high stiffness with a density around two times lower than aluminum and offers a huge weight reduction potential compared to the existing metal solutions, especially at the scale of a plane which contains hundreds of such backshells.' The backshells are designed with bulkhead fittings and connector adaptors.

They are suitable for conduit technology by screwing the conduit onto the rear of the backshell or for overbraiding technology by adding an elastomer compensator.

To withstand the continuous service temperature requirements and to be in compliance with the Airbus specifications, a reinforced grade of Victrex PEEK was selected.

'Several other materials were considered including PPS and PEI,' says Ragan.

'However, neither was selected for mechanical or chemical resistance reasons.' The full range of adaptors and nuts are injection molded and fitted with an external conductive layer as well as an internal abrasion resistant coating.

Victrex PEEK offers a wide range of benefits including high temperature resistance up to 260 deg C (500 deg F), excellent mechanical properties even with impact and dynamic loads, corrosion and chemical resistance to fluids such as Skydrol, inherently flame retardant without halogens and a very low level of smoke and toxic gases in fire situations.

The Electrical Interconnect Division of the AeroSafety Systems Segment of the Zodiac Group specializes in manufacturing electrical interconnect systems for military and aerospace applications.

Most of the Division's products are manufactured by Aerazur and Plastiremo in France and Amfuel in the USA.

Victrex USA, a division of Victrex, is the sole manufacturer and supplier of PEEK polymer worldwide.

Wednesday, December 20, 2006

Liquid silicone rubber is injection mouldable

A liquid silicone rubber grade that combines improved oil and fuel resistance, self-lubricating performance, and excellent processing properties can be liquid injection moulded.
With the commercial launch of FSL 7586/40 TP3854, GE Advanced Materials is introducing a new liquid silicone rubber (LSR) grade that combines improved oil and fuel resistance, self-lubricating performance, and excellent processing properties. This fast-curing silicone elastomer may be used for gasketing and sealing applications, such as those found in under-the-hood automotive applications. GE's innovative formulation of its new FSL 7586/40 TP3854 grade incorporates tailored fluorine structures that enable it to help deliver processing performance similar to non-fluorinated LSRs, but with greatly enhanced chemical resistance.
The properties of this material may make it suitable for use in applications that require occasional contact with automotive fuels or long-term contact with most automotive oils like connector gaskets and parts in air-intake systems.
'FSL 7586/40 TP3854 LSR offers low compression set and low swelling, helping it to provide excellent long-term sealing,' said Heinz Mueller, industry manager Automotive Elastomers, GE Advanced Materials.
'Also, its much lower volume swell makes this liquid silicone rubber product a versatile alternative to conventional, non-fluorinated grades.' This new grade can be used in liquid injection-molding processes.
The material enables high-performance elastomeric parts with self-lubricating properties.
Its ability to self-lubricate derives from a fluid that exudes from the cured rubber over an extended period, ranging from a few hours to one day.
The practical effect is that FSL 7586/40 TP3854 offers reduced insertion forces for complicated parts.
Available as a translucent two-component silicone rubber, FSL 7586/40 TP3854 also offers colorability for color-coded parts.
Its high temperature stability translates into durable physical properties, potentially allowing extended performance in seals and gaskets.
In addition, this new grade offers low temperature flexibility - down to -50 deg C - ensuring excellent sealing, even at the lower limit of automotive requirements.
* About GE Advanced Materials - GE Advanced Materials is a world leader in providing high-technology material solutions.
Headquartered in Pittsfield, Massachusetts, USA, its businesses include plastics, silicones, quartz, automotive, specialty film and sheet, polymershapes, and sealants and adhesives.

Moulding resin developments shown

Automotive orientated exhibits in Stuttgart included resin for blow-molding applications, a chrome plating grade for exterior and interior door handles and a conductive grade.
'Innovation in New Components Technologies' was the theme of the GE Advanced Materials exhibit at the European Automotive Components Expo (EACE) at the Messe Stuttgart this week. GE took part in the expo with a broad spectrum of raw materials, innovations, and solutions. GE's participation in the European Automotive Components Expo showcased the company's new material innovations for components, delivered through leading technologies and featuring a full range of traditional applications such as mirror housings and spoilers, along with newer applications like roof racks, running boards, and wipers.
The new material technologies being introduced are the latest grade of Noryl BN9003G resin for blow-molding applications (i.e spoilers); new Geloy XTW resin for mirror housings, appliques, trims, and grilles; Xenoy X4000BM resin for running boards and step assists; Cycoloy CP8930 resin, a chrome plating grade for exterior and interior door handles, running boards, wheel covers, grilles, roof racks, and trim components; as well as conductive Noryl GTX resin for tank flaps allowing on-line electrostatic painting.
GE's Visualfx special effects resin also helps automotive components stand out from the crowd with a designers' paradise of over 34 different effects and over 33,000 dynamic color variants, loadings, and derivatives to contrast.
The newest grade of Noryl BN9003G resin can help manufacturers produce blow-molded spoilers with lower system costs by means of maximised efficiency in manufacturing via reduced sanding time.
Thinner wall capability with equal performance along with higher heat performance, tensile and impact strength, and coefficient of thermal expansion (CTE) vs.
high heat acrylonitrile butadiene styrene (ABS) also help manufacturers with reducing their system costs.
This new grade may also provide lower odor and improved chemical resistance to gasoline and diesel fuel that can potentially cause damage to spoiler surfaces.
The spotlight falls next on Geloy XTW resin, which is a key solution for paint elimination and part of the GE ecomagination series of products designed specifically to help customers meet environmental concerns.
Geloy XTW resin offers best-in-class weathering, multiple color capability, high gloss and jetness to help OEMs reduce their dependence on paint solutions.
Hence this GE grade can help OEMs achieve cost savings from the elimination of paint operations.
Visualfx resins add a new dimension to the design of both interior and exterior car components.
Rich colors and special effects come straight from the mold, thereby eliminating the need for more costly painting and coating operations.
Furthermore, unlimited opportunities for product differentiation help manufacturers to attract new customers and conquer niche markets.
The constantly evolving Visualfx resins portfolio, featuring Lexan, Cycoloy, Geloy, Xylex, Xenoy, and Cycolac resins, is regrouped into five families of colors and special effects.
Whether it is metallic, warm yellow, down-to-earth brown, or dynamic red, automotive customers can rely on a consistent, high quality finish that can potentially replace paint applications.
Another new material is high-heat, conductive Noryl GTX resin, which enables on- and in-line painting, while eliminating the need for a conductive primer.
It can also provide improved paint transfer efficiency (reduced volatile organic compounds (VOCs)/sludge), cycle time reduction, and improved quality over comparable materials.
Noryl GTX resin is an excellent choice for tank flaps, providing automotive manufacturers a cost-effective, on-line painting solution vs off-line painting.
It also offers low warpage, dimensional stability, reduced environmental impact, and higher overall quality compared to traditional materials.
Another GE introduction is the chrome-plating grade Cycoloy CP8930, which is poised to respond to new trends: * Continuing growth in grilles and trim applications for trucks and SUVs.
* Greater use of chrome in luxury cars.
* Growth in the use of wheel covers and wheel trim.
* Increasing complexity of plated nameplates.
* Exterior door handles with bigger impact and heat requirements.
* New applications including roof racks and running boards.
Addressing increased performance requirements for heat resistance and stiffer OEM standards, Cycoloy CP8930 resin is providing a strong and durable solution to trendier metallic looks.
Unique, chrome-plated vehicle components made of Cycoloy CP8930 resin, which provide shine and gloss, enable vehicle consumers to differentiate themselves from their peers.
The final offering in the portfolio of top new GE solutions is Xenoy X4000BM resin for blow molded running boards or step assists.
Xenoy X4000BM resin solutions offer superior hang strength and processing windows along with excellent regrind stability/usage.
The Xenoy resin solution was designed to meet critical specifications for Asian OEMs such as significant weight reduction vs steel beams, excellent impact and toughness, and cost savings via improved parts consolidation, in contrast to conventional steel systems utilized today.
The new GE grade can also be utilized in recreational vehicles, a growing market sector for GE.
* Differentiated state-of-the-art components - 'The market for differentiated, state-of-the-art components in Europe is expected to continue growing at an above-average rate over the next few years,' said Venkatakrishnan Umamaheswaran, market director, Components, GE Advanced Materials.
'This is particularly true for newer thermoplastics resins offering premium features with superior performance'.
'GE Advanced Materials is determined to further strengthen our position in this growing segment'.
'We are investing in new technology and state-of-the-art production facilities in Germany, India, and China so that we can participate in the strong growth markets of Asia/Pacific and Eastern Europe.' High quality thermoplastics with high gloss and reduced VOC content - and reduced paint and primer solutions - are becoming increasingly important in Europe and globally.
Comparisons with other materials show that these new systems meet or even exceed today's high quality standards for the production of components.
GE's introduction of paint-elimination solutions reflects the company's commitment to innovative and environmentally compatible products.
* About GE Advanced Materials - GE Advanced Materials is a world leader in providing high-technology material solutions.
Headquartered in Pittsfield, Massachusetts, USA, its businesses include plastics, silicones, quartz, automotive, specialty film and sheet, polymershapes, and sealants and adhesives.
GE (NYSE: GE) is Imagination at Work - a diversified technology, media and financial services company focused on solving some of the world's toughest problems.
With products and services ranging from aircraft engines, power generation, water processing and security technology to medical imaging, business and consumer financing, media content and advanced materials, GE serves customers in more than 100 countries and employs more than 300,000 people worldwide.

Tuesday, December 19, 2006

Autotex film for keyboards in demanding are

The Autotex polyester film from Autotype International is being used by Hoffmann+Krippner to enable the company to produce keypads for industrial and computer equipment in demanding environments.
The Autotex polyester film from Autotype International is being used by Hoffmann+Krippner to enable the company to produce keypads for industrial and computer equipment in demanding environments subject to high levels of dust or humidity. The structured polyester film, Autotex, is 150m thick, and consists of a polyester base and a flexible, chemically bonded UV-cured coating. Developed to withstand continuous use in harsh operating environments, the film offers high levels of resistance against conditions of severe mechanical stress, as well as resistance to most chemical substances and cleaning agents said Autotype.
The surface structure of Autotex is suitable for the touch-sensitive lens-shaped key tips that are formed in the Hoffmann+Krippner keyboards using a patented process called GT Technology.
That enables the manufacture of raised, optically clear tips that are claimed to have excellent mechanical characteristics and provide superior tactile response, making the new keyboards suitable for applications where large volumes of data are being entered.
In recognition of the new keyboards' features and aesthetic qualities Hoffmann+Krippner has just been awarded the coveted 'Red Dot' award from Design-Zentrum NRW, Design Centre, North Rhine Westphalia.

Rapra leads EU research for conductive polymers

Rapra Technology has secured EUR 5 million of EU funding together with a 20 strong European consortium to improve the electrical conductivity of a range of polymer materials.
Rapra Technology, Europe's leading polymer research and test house, has secured EUR 5 million of EU funding together with a 20 strong European consortium to improve the electrical conductivity of a range of polymer materials and demonstrate their application in medical, electrical and automotive end use sectors. The research project is being part financed by the European Commission under the sixth framework programme as an Integrated Project for Small and Medium size enterprises (IPSME scheme - Project number IP 515835-2). A team of companies and research partners from the development consortium - spread across the EU - recently met in Valencia in order to map out the plan of activity for the next four years.
These companies and the EU will commit a total of EUR 9.06 million to the project.
In addition to Rapra, the partners include UK companies, Whitaker Technical Plastics, TBA Electro Conductive Products and Rondol Technology.
Spanish companies Faperin, Intermedic, Molespol, Compaoia Levantina de Reductores and Aimplas are also involved, as is Finnish company Panipol, Labo from Hungary and Dutch companies Promolding and Colorex.
These organisations are supported by researchers from TNO in Holland, VTT in Finland and the Hungarian Academy of Sciences.
The results of the work will be communicated through EU bodies that are members of the consortium such as the European Plastic Converters in Belgium, Mavesz in Hungary, BvM in Holland and the British Plastics Federation in the UK.
The consortium of these companies estimates that a return on funding of some EUR 17.8 million is possible within five years; with the project costs being recovered within a period of about two years.
The main goals of the PolyCond project are: * To develop melt processable inherently conducting polymers (ICPs) with increased electrical conductivity.
* To develop new cost effective processes for the surface modification of carbon nanotubes.
* To develop a cost effective plastic processing method for temperature sensitive conductive composites.
* To develop new cost effective plastic products with embedded EMI shielding and ESD protection.
* To increase SME competitiveness.
The PolyCond project is the latest in an increasing number of Rapra-led successes in large collaborative polymer research projects.
Indeed, this activity is now Rapra's fasting growing business.
Project leader Mark Gaddes notes that: 'From a standing start four years ago we have now contributed some GBP 3.1 million to total group turnover'.
'Our annual income for 2005-2006 is projected at some GBP 2.4million'.
'Our successful projects are often developed on an opportunistic basis but most typically stay close to the stated programmes and guidelines for research and development within the EU and its nation states.' Gaddes says the Rapra activity makes special demands on the skills of Rapra's research and proposal team; a team which has developed a unique blend of research, scientific and other skills in order to win bids and create workable proposals for various funding bodies in Europe and for other investors, including the Rapra Technology Board.
The success of the work is also solidly founded on 'the scientific and technical know-how of Rapra's Analytical and testing laboratories and their ability to deliver'.

Monday, December 18, 2006

Plastics research resources offered

Leading UK resource and coordinator for polymer-based research, will use Interplas 05 to promote the research and development providing much needed tools, information and resources.
Faraday Plastics, the UK's leading resource and coordinator for polymer-based research, will use Interplas 05 to promote the research and development agenda for companies; providing much needed tools, information and resources for visitors to the show. Richard Simpson, Faraday Plastics director says, 'Our recent research has shown us that the overall level of R and D in UK plastics overall - less than 0.5% of its total turnover - is sadly lagging behind any measure you might care to mention, not least the figure of 1.9% shown by UK industry as whole.' Simpson says that: 'We know that many plastics-based companies want to improve their R and D position but are currently struggling to fund and create the activity that will help take their businesses forward in this area. Faraday Plastics will be at Interplas 05 to help these companies in just this task; providing analysis, contacts, ideas and funding routes that will hopefully keep the spirit of innovation alive.' A key recent success for Faraday Plastics has been the Technology Road Map (TRM) tool - which can be applied to the future of individual companies or to sectors as a whole (such as nano-composites or engineering plastics) or to issues within the sector such as energy consumption or machine utilisation and cost.
Simpson urges all in plastics to visit the exhibition and to check out their R and D plans, modus operandi and needs in strictest confidence with the Faraday experts on the Faraday Plastics stand.
'Every part of the plastics industry, like it or not, cannot stand still - has to innovate.
But most undertake this work alone and without calling on resources such as ourselves.
There may be connections, funding, ideas and resources that we can identify that might make all the difference to the life of an R and D project.'

Formable hard-coated polycarbonate boosts FIM

To maximise the performance of the Film Insert Moulding (FIM) process, a HMI manufacturer is using formable hard-coated polycarbonate film technology.
IGT Industries, a leading UK manufacturer of man-machine interfaces, has invested in the latest Film insert moulding (FIM) technology, also known as In-Mould Decoration (IMD), as part of its ongoing commitment to providing customers with the highest levels of design and manufacturing capabilities. As part of the investment, IGT is using the latest HiForm formable hard-coated polycarbonate film technology from MacDermid Autotype International to maximise the performance of the FIM process. IGT specialises in the design and manufacture of man machine interface systems including highly sophisticated multi-technology sub-assembly through to PCB based keyboards and passive overlays and labels.
Twelve months ago, the company decided to expand into the relatively new production process of Film Insert Moulding for decorating and manufacturing a wide range of profiled or three dimensional plastic components.
One of the key drivers for expanding into the FIM process was that it offers considerable benefits over conventional methods of component manufacture; in particular, it enables the number of process operations and component parts to be significantly reduced, while improving productivity, quality and the functionality and aesthetics of the finished product.
In addition, the process is highly flexible in terms of design and manufacturing options for shallow and deeply drawn profiles.
This enables original and often innovative design constructs to be considered and can be used to produce both short and long production runs without cost penalties.
IGT has invested heavily in the process in terms of expertise, technology and plant, as Vince Light, Technical Director at IGT Industries explains, 'Having investigated the potential for the process, we believe it is a considerable growth market and with this capability we will soon be able to offer our customers the ability for flexible circuits to be moulded into complex shapes without any loss of functionality or cost penalties.' IGT will be screen printing images using MacDermid Autotype's HiForm substrate for medium draw applications.
HiForm incorporates a unique 'self healing' hard coat on a polycarbonate film base.
The self healing coating gives improved scratch resistance, with the surface gradually healing itself over a period of hours to repair light scratches.
In addition, the film is easily formable by thermoforming or pressure forming, has a gloss finish on both sides of the film and is available in thicknesses ranging from 180 to 750 micron.
Forming is carried out by a specialist partner, Hitech Forming.
HiForm has high levels of transparency so it is possible to reduce component costs by integrating housing and windows in one piece of film through a selective screen printing process.
IGT Industries is already targeting a number of its existing markets such as marine, air and rail transport plus telecommunications, industrial and process control, to promote the benefits of the FIM process.
Vince Light explains, 'Working with world leaders in the field of film insert moulding, such as MacDermid Autotype, enables us to meet our objective of becoming one of the leading manufacturers'.
'We offer high levels of competence in this rapidly emerging technology that provide enhanced quality, functionality and aesthetics for a wide range of finished products.'

Sunday, December 17, 2006

High temperature plastics extend into gears

In spite of metal alloys being the materials of choice for motor and gear applications, high-temperature plastics have established themselves in these areas.
Rise in Large-Scale Application of High Temperature-resistant Plastics in Motors and Gears London, UK - 1st September, 2005 - In spite of metal alloys being the materials of choice for motor and gear applications, high-temperature plastics have established themselves in these areas, especially in, but not confined to, the automotive sector. Automakers are increasingly considering developing fuel reservoirs, ignition modules, air manifolds, fuel connectors, oil screens, pistons, pumps, and valves with plastics that were previously considered incompetent in such high-heat environments. 'Their comparative lightness translates into greater fuel efficiency, a gain brought home by the ongoing spike in gasoline prices,' explains Michael Valenti, who has conducted an indepth Frost and Sullivan research service about this technology.
'As alternatives to the internal combustion engine get closer to commercialisation, lightweight materials will continue to be preferred over metals.' Besides their diversity in temperature ranges, chemical resistance and physical durability, injection moulding and computer-aided design (CAD) enable plastics to be custom-made to suit specific applications.
They also allow faster machining of finished parts and produce less waste, saving both time and money.
Karcoma-Armaturen , of Sindelfingen, Germany, incorporates glass-reinforced victrex PEEK polymers in the oil screens it supplies to trucks, including those from top-of-the-line companies.
In this application, the polymer is moulded in a single step onto a metal fabric, providing Karcoma-Armaturen significant cost and weight savings.
Similarly, one of the toughest applications for plastics in automotive motors is bearings.
Igus, a Germany-based multinational developer of plastic bearings manufactures the IGLIDE series of bearings that can withstand high temperatures and corrosive chemicals.
Even though such high-performance plastics can meet the challenging requirements in engines, they come at a high price.
Hence, the need for reducing the inherent costs of these resources is apparent, and will happen over time with the refinement of processing, reduction of material costs and increase in demand.
Plastics processing is more sensitive to environmental factors such as humidity than metalworking.
However, the benefits offered by these products offset this problem.
Plastic gears are corrosion resistant and reduce noise significantly.
This, as well as their low maintenance costs and longer life, can open up tremendous opportunities in the high temperature plastics market for motors and gears.
Leading plastics makers that are already involved in the development of high-temperature products will continue manufacturing them, particularly for end-user markets that are capable of investing in expensive products such as automotive and marine engines.
Companies that extensively employ chemical engineering capabilities in their research and development divisions will benefit from this opportunity.
Participants also need to mobilise awareness among potential end users about the high heat resistance of these plastics and their chemical and hydrolytic strength.
Such a move will help dispel doubts regarding their performance as well as harness the rising overall demand.
Advances in High Temperature Plastics for Motors and Gears is part of the D923 subscription service and evaluates the latest and upcoming trends in the use of high temperature-resistant plastics in motors and gears.
In addition to discussing the various technology drivers and restraints that govern the market, the study covers research and development efforts at various universities, leading companies and other research institutions across the globe.
Upon receipt of the above information, an overview will be sent to you by e-mail.
Background Technical Insights is an international technology analysis business that produces a variety of technical news alerts, newsletters and research services.
Frost and Sullivan, a global growth consulting company, has been partnering with clients to support the development of innovative strategies for more than 40 years.
The company's industry expertise integrates growth consulting, growth partnership services and corporate management training to identify and develop opportunities.
Frost and Sullivan serves an extensive clientele that includes Global 1000 companies, emerging companies, and the investment community, by providing comprehensive industry coverage that reflects a unique global perspective and combines ongoing analysis of markets, technologies, econometrics, and demographics.

High performance thermoplastics protects wiring

French engineers have chosen a high performance thermoplastics for all of the components for a lightweight composite backshell to protect the Airbus A380's wiring.
When engineers at the Electrical Interconnect Division of French-based Zodiac AeroSafety Systems wanted to develop a lightweight composite backshell for the Airbus A380, it chose Victrex PEEK, a high performance thermoplastics, for all of the components. The backshells are used to protect the plane's wiring and must be able to withstand temperatures ranging from -55 deg C (-67 deg F) to +175 deg C (+347 deg F). According to Andrew Ragan, Product Manager, Victrex USA, 'Engineers at Electrical Interconnect are continuously implementing new concepts with a strong emphasis on metal to plastics conversion in order to lower component cost, decrease weight, increase design flexibility, and improve system performance'.
'Using Victrex PEEK enables them to meet these goals'.
' It combines high stiffness with a density around two times lower than aluminum and offers a huge weight reduction potential compared to the existing metal solutions, especially at the scale of a plane which contains hundreds of such backshells.' The backshells are designed with bulkhead fittings and connector adaptors.
They are suitable for conduit technology by screwing the conduit onto the rear of the backshell or for overbraiding technology by adding an elastomer compensator.
To withstand the continuous service temperature requirements and to be in compliance with the Airbus specifications, a reinforced grade of Victrex PEEK was selected.
'Several other materials were considered including PPS and PEI,' says Ragan.
'However, neither was selected for mechanical or chemical resistance reasons.' The full range of adaptors and nuts are injection molded and fitted with an external conductive layer as well as an internal abrasion resistant coating.
Victrex PEEK offers a wide range of benefits including high temperature resistance up to 260 deg C (500 deg F), excellent mechanical properties even with impact and dynamic loads, corrosion and chemical resistance to fluids such as Skydrol, inherently flame retardant without halogens and a very low level of smoke and toxic gases in fire situations.
The Electrical Interconnect Division of the AeroSafety Systems Segment of the Zodiac Group specializes in manufacturing electrical interconnect systems for military and aerospace applications.
Most of the Division's products are manufactured by Aerazur and Plastiremo in France and Amfuel in the USA.
Victrex USA, a division of Victrex, is the sole manufacturer and supplier of PEEK polymer worldwide.