A range of hybrid solutions combine metals and engineering plastics to be used in high-load bearing (semi-) closed structures, either with rib or hollow, are targeted at automotive usage.

Rhodia Engineering Plastics has developed a range of hybrid solutions that combine metals and engineering plastics to be used in high-load bearing (semi-) structural components. These closed structures, either with rib or hollow, are targeted especially at automotive applications, where they bring benefits such as potential parts integration, depth, weight and size reduction, cost savings, enhanced energy absorption, and added-value appearance. While existing open rib designs, where thin metallic sections are moulded over with thermoplastic ribs, provide a good strength-to-cost ratio, their effective mechanical strength and stiffness is highly dependent on the direction of the applied load.

This typically results in complex mold requirements, which must be met by means of sophisticated hot runner technology and/or the use of very low-viscosity resins.

Furthermore, the open rib approach cannot be used for applications that need to be safely protected from dirt and water penetration.

In contrast, Rhodia's closed rib and related hollow designs have a more balanced profile of high stiffness and strength regardless of the load direction, that is in both tensile stress and in compression areas.

In addition, the hollow sections may be used to integrate other functions.

Rhodia has been investigating three different closed hybrid technologies - Metal Over Molding (MOM), Plastic and Metal Assembling (PMA), and Metal and Gas or Water Assisted injection molding (MGAIM or MWAIM) - each providing a number of distinct advantages depending on the specific application requirements.

In each case, Rhodia's Technyl Star polyamide technology helps to enable the fluidity and processability for these closed hybrid technology alternatives to succeed.

Metal over molding (MOM) - in MOM, one or more metal inserts are directly molded over with an engineering thermoplastic resin.

The final reinforcing design is then created in a second step by one or several plastic covers assembled on the existing metal-plastic structure.

The resulting hollow section(s) within the structure can serve to integrate cables, flow channels or fluid containers, As one potential application example, a structure of this type would eliminate the need for a separate cooling water expansion tank in automotive front-ends.

While MOM components will be somewhat heavier than open rib designs, this is counterbalanced by their superior load-bearing, energy absorption and integration capabilities.

MOM is one solution to improve energy absorption, or to redesign classical parts -- reducing their size while keeping the same energy absorption.

The time and cost for the additional injection mold and the jointing process is counterbalanced by reduced mold complexity, lower injection pressures, and reduced mold wear.

Plastics and metal assembling (PMA) - PMA also involves two process steps, by combining a rigid, ribbed injection molded plastic part with a metal section by means of clips, rivets and/or ultrasonic welding.

Again, this requires additional capital expenditure, but the space within the final product provides significant potential for cost and weight savings, and functional part consolidation.

The mechanical strength compares well with that of open rib structures at lower overall costs.

Metal and gas or water assisted injection molding (MGAIM or MWAIM) - in MGAIM or MWAIN, the complete hybrid component is manufactured in a single integrated process, by over-moulding a metal part and then coring the plastic material by use of the gas or water assisted technique.

The result is a very stiff and lightweight, energy absorbing structure with outstanding surface appearance (no sink marks).

The cored-out sections lend themselves to functional integration.

Gas and water assisted injection molding involve some additional cost, but are state-of-the-art, and the mold technology is even simpler yet.

In particular, the freedom of design offered by MGAIM and MWAIN clearly exceeds that of any deep-drawing metal, leading the way to a number of high-end applications replacing expensive aluminium or pure steel components while also minimizing the number of jointing and assembly steps.

Potential automotive applications - Rhodia sees a wide range of automotive applications for these three technologies, from structural front ends and instrument panel carriers to highly integrated door modules as well as seat shells and an array of smaller applications, such as brake pedals.

As far as front ends are concerned, MOM, MGAIM, MWAIM can be of help for car manufacturers in their pedestrian protection concern.

In fact, the stiffness of such potential solutions is so improved that it provides the opportunity to redesign the part and reduce its size, creating thus a free space between the engine hood and the upper beam of the front end.

This hollow space can then be optimized to smoothen the impact on pedestrian upper-leg.

Application development expertise - Rhodia supports its customers worldwide through eight technical application development centers with comprehensive material advice, process optimization for injection molding, as well as component testing.

Component testing alternatives span from thermal aging in (hot) air and liquid media to fatigue and resonance trials used to determine/review the long-term and reliable function performance of parts at typical operating conditions under vibration.

Facilities for pulse pressure, leakage and highly dynamic burst pressure tests are available for components with media-carrying sealed hollow sections or integrated channels.

To optimize part geometry and the injection molding process, Rhodia offers computer-assisted simulations of static and dynamic loads as well as mold flow analyses.

The results of these examinations provide valuable input for part and mold design, particularly regarding gating style and gate location(s).

Benefits include shorter cycle times as well as high strength, high dimensional stability and dimensional accuracy of mouldings in series production.

Rhodia Engineering Plastics, headquartered in Lyon, France, is the world wide specialist in polyamide engineering thermoplastic materials.

The company has a sales network that spans the world, with manufacturing plants and technical development centres in Europe, North America, South America and Asia.

Rhodia is one of the world's leading manufacturers of specialty chemicals.

Providing a wide range of innovative products and services to the consumer care, food, industrial care, pharmaceuticals, agrochemicals, automotive, electronics and fibers markets, Rhodia offers its customers tailor-made solutions based on the cross-fertilization of technologies, people and expertise.

Rhodia subscribes to the principles of Sustainable Development communicating its commitments and performance openly with stakeholders.

Quadrant Engineering Plastic Products announces that it will increase its prices for cast and extruded PA and POM stock shapes.

Quadrant Engineering Plastic Products announced that it will increase its prices for cast and extruded PA and POM stock shapes. An increase of 2% on the prices as published in the 'Quadrant European Market Price List' will become effective for shipments on and after June 1, 2004. These measures are being taken in response to the continuous decrease in margins as a result of increased raw material prices (Caprolactam, PA, POM) and the increased costs of labour, energy and transportation.

Quadrant EPP continues to work hard to improve productivity and reduce costs, nevertheless these efforts are inadequate to overcome the current cost pressures.

Quadrant Engineering Plastic Products is the world leader in the manufacture of engineering plastics in stock shapes (rod, plate, tube) for machining.

Quadrant EPP also produces custom nylon castings and finished components.

Quadrant EPP`s General and Advanced Engineering Plastics portfolio includes the broadest range of standard and custom shapes for machining and is available through its worldwide operations, technical support centres and authorized distributors.

Now in its seventh successful year, papers are called for the Thermoplastic Elastomers Conference that concentrates on new developments and opportunities for thermoplastic elastomers.

The thermoplastic elastomers conference is now in its seventh successful year. TPE 2004 is to be held in Brussels, Belgium between September 15 and 16, 2004. This international conference concentrates on new developments and opportunities for thermoplastic elastomers.

The use of thermoplastic elastomers has developed rapidly not just as a replacement for vulcanised rubber but also for other new and innovative applications.

Developments are being driven forward by factors such as recycling legislations in cars and electronic goods, and continued growth of 'soft touch' applications.

Important recent technical developments include improved properties such as greater thermal, oxidative and weathering stability, softer grades of premium TPEs, improved properties like resilience, oil resistance, flammability, smoke emission, fogging, adhesion and transparency, foamable grades and improved co-processibility.

Papers are now being called for inclusion in this conference.

Topics for discussion include material innovations, TPVs, TPUs, design and processing issues, automotive applications and case studies.

For more details on presenting a paper, contact the Conference department.

Presenting authors are entitled to free registration on both days of the conference.

Authors are requested to send details of presentations no later than June 14, 2004.

Corporate Sponsorship opportunities are available with this popular conference.

Companies can sponsor individual events such as dinners and receptions or can sponsor individual items such as pens and notepads.

This will be of use to those selling machinery, materials or services to the TPE market and indeed all those involved with this flourishing industry.

A wallet service is also available where companies can arrange to have a brochure enclosed in every delegate conference bag at a cost of EUR 750.

To find out more about sponsorship deals contact the Conference department.

Places at TPE 2004 retail at EUR 950 before August 6 and EUR 1150 thereafter (Plus VAT).

Discounts are available for companies who register three or more delegates.

Global research center has been established to pioneer the development of innovative technologies and applications for organosilane and silicon-containing chemicals.

Dow Corning Corporation has established a new global research center to pioneer the development of innovative technologies and applications for organosilane and silicon-containing chemicals. The Surface and Interface Solutions Center (SISC), located in Belgium, Europe, is dedicated to designing innovative composites or molecules; processes; surface; interface and interphase technologies. It will serve the global needs of customers in multiple markets, including plastics, rubber, adhesives, sealants, coatings, textiles and electronics.

'The SISC will enable our customers to establish a competitive advantage by providing next-generation solutions and the best technical and business approaches to their challenges,' said Thierry Materne, Dow Corning global technology and business development manager, Silanes Products.

'The solution may be something that helps a customer achieve improved performance or productivity, or it could be the result of working with a customer to develop a tailor-made approach based on the interface between silanes and other materials.' The center, unique among Silanes manufacturers, is staffed by scientists and engineers linked to Dow Corning's global network of technology experts and to external sources of expertise.

They will focus on plastic and rubber applications and on material science for filler reinforcement, crosslinking and adhesion across a large cross section of products and industries.

'The center combines our technology expertise with our market knowledge to discover new opportunities that will meet the new and emerging needs of our customers,' said Mark Maxwell, Dow Corning strategic marketing director, Silanes Products.

'We have made significant investments to support the silanes market in recent years, including adding manufacturing capacity and developing new technologies to support the Green Tire market.

This investment will enable us to further grow our silanes product line and identify new opportunities for performance-enhancing solutions.' The SISC is located within the Dow Corning Business and Technology Center at Seneffe, Belgium, which has world-class resources for research and development and for collaboration with customers and external partners.

'A European facility enables us to provide global support for customers, complementing our existing facilities for silanes in Midland, Michigan, USA, and Chiba, Japan,' said Maxwell.

'Our goal is to be recognized as the global leader in surface and interface sciences and applications for silicon-containing chemicals.

We can accomplish that by using the SISC to contribute significantly to our customers' major technical and business achievements, and set new standards for the silanes industry.' said Materne.

Silanes Solutions.

Distinctly Dow Corning - as the pioneer of organosilane technology, Dow Corning has been improving customers' products and profitability for more than 50 years.

With a full range of silanes product, formulation and application solutions, and rededicated global reach, reliable supply and world-class manufacturing operations, Dow Corning can meet virtually any company's silicone needs through its total solution offering and technology leadership.

Latest Film Insert Moulding developments will help to drive down production costs through effective component integration, while introducing greater opportunity for product customisation.

The latest developments by Autotype, the leading UK manufacturer of hardcoated formable films and texture lacquers for Film insert moulding (FIM) also known as In-Mould Decoration (IMD), enable product designers and developers to make significant improvements to both the aesthetic and functional characteristics of plastic components. Perhaps as importantly, the latest developments will help to drive down production costs through effective component integration, while introducing greater opportunity for product customisation. Film Insert Moulding is a relatively new production method whereby product designers and manufacturers can considerably reduce the number of stages and processes required to produce component parts for equipment such as mobile phones, PDAs, car dashboard and instrument mouldings and control panels of home appliances.

Typically, for a product such as the cover for a personal stereo, FIM can reduce the number of component parts from eleven to just one and the number of process steps from twelve to eight or less.

The latest films from Autotype have been developed specifically to meet the demands of the four key process stages in FIM: screen printing, thermoforming, cutting and injection moulding.

Autoflex IMD films can be shallow or deep drawn, have a hardcoat surface finish to provide product durability and are optically clear.

In addition, they are compatible with the latest IMD screen printing inks and are available with polycarbonate, polyester or PMMA substrate bases.

Richard Townsend, Product Manager for FIM Products, explains that, 'Our latest Autoflex IMD materials, combined with new developments in screen inks, offer product designers an exciting range of options.

For example, using silver or metallic inks and Autotype Aquatex surface texturing lacquers they can create brushed aluminium and metallic effects for mobile phones at minimal unit cost.

Perhaps as importantly, as these effects are produced at the screen print stage, it is possible to customise small numbers of components within a large overall production run'.

Two polyamide grades for water injection moulding are the result of three years' R and D to find an optimal balance between water injection processing and glycol resistance in an application context.

Rhodia Engineering Plastics introduces two new Technyl polyamide grades specifically designed for water injected cooling pipes : Technyl A 338Wit1 V30 blk 36N and Technyl A 338Wit2 V30 blk 36N. This major product introduction follows three years of dedicated research and process development work, including the development of Rhodia's own WIT mold, water injectors and injection unit. The challenge of the Rhodia WIT development team was to find an optimal balance between water injection processability and glycol resistance in an application context where specific material properties are required to fit to the technology, while cooling circuit specifications are increasing.

In terms of glycol resistance, these 2 new grades equal or even outperform the actual Technyl GIT product A 218Z1 V30 blk 34N used in mass production for numerous cooling pipes.

For example, following a life test (1000h at 130C in a mix of water and long life coolant), the tensile strength at break of Technyl A 338Wit1 V30 is as good as the GIT grade, when this level is increased by 15% with Technyl A 338Wit2 V30.

Other retained properties such as impact resistance are improved about 80% with a Technyl A 338Wit1 V30 and doubled with Technyl A 338Wit2 V30, when compared to the GIT material.

However, the primary benefit of Technyl Wit1 and Wit2 grades is their ability to create high quality inner surfaces, thanks to even glass fibre coverage by the polymer, along with a constant wall thickness free of water inclusion.

In cooling pipe applications, the end benefits include greatly reduced pressure loss in the cooling circuit, along with reduced water pump size, and a reduced risk of cooling fluid pollution by glass fibres during engine life time.

Prototypes of cooling pipes, designed with critical angles and varied sections to approximate real shapes, have been produced internally by Rhodia Engineering Plastics engineers with Technyl Wit1 and Wit2, using side-cavity moulds (other molding techniques such as pushback, water flow or pre-filling can be also used).

They show a high consistency in the process, with great precision, each shot giving identical part quality and performance, while adding the benefit of reduced shrinkage, reduced warpage and reduced cooling time compared to standard injection molding or Gas Injection Technology.

To validate performance over part life (test 1000h at 130degC under 2,4 bars rel constant overpressure), pipes tested in Rhodia automotive validation labs showed no breakage, along with consistent full wall thickness (no erosion), and no exposure of glass fiber through the polymer barrier.

In addition, Rhodia Engineering Plastics has developed a specific expertise in CAE calculation methods to simulate the WIT process, allowing development engineers to utilize precise engineering data in order to make appropriate decisions when designing a part and a manufacturing tool.

Rhodia Engineering Plastics' unique know-how in the WIT process, injector design, computer simulation, added to available tools and devices for prototype tests, has already led to promising partnerships with customers and equipment manufacturers for industrial developments with new Technyl Wit1 and Wit2 grades.

With the introduction of these two new grades, Rhodia Engineering Plastics has completed its portfolio of Technyl PA66 GF30 glycol resistant grades, and is now in the unique position of being able to supply high performance materials optimized for every technology available to produce cooling pipes (standard injection molding, blow molding, gas injection technology and now water injection technology).

Apart from these two new specific glycol resistant grades dedicated to WIT, a number of Technyl Star grades have already reached the market for use in WIT produced parts, such as design parts as door handles and roof-rails, or semi-structural parts such as front-ends and pedals.

Rhodia Engineering Plastics, headquartered in Lyon, France, is the world wide specialist in polyamide engineering thermoplastic materials.

The company has a sales network that spans the world, with manufacturing plants and technical development centres in Europe, North America, South America and Asia.

Rhodia is one of the world's leading manufacturers of specialty chemicals.

Providing a wide range of innovative products and services to the consumer care, food, industrial care, pharmaceuticals, agrochemicals, automotive, electronics and fibers markets, Rhodia offers its customers tailor-made solutions based on the cross-fertilization of technologies, people and expertise.

Rhodia subscribes to the principles of Sustainable Development communicating its commitments and performance openly with stakeholders.

Rhodia generated net sales of EUR 5.5 billion in 2003 and employs 23,000 people worldwide.

Pure polyamide plastics for on-line painting of automotive vertical body panels is electro-paintable and withstands the electro-coat temperature up to 200C.

Technyl A 238P5 M25 is a new polyamide grade specifically designed to address vertical body panel needs. This material is electro-paintable, withstands the e-coat temperature up to 200C and meets all critical application requirements in impact, surface appearance and processability. Rhodia Engineering Plastics has announced it has developed specific expertise in conductivity technology allowing the creation of new products for exterior body panels.

The first product introduction is a new grade specifically designed to meet the critical technical requirements for automotive vertical body panels - Technyl A 238P5 M25.

This innovative pure polyamide solution designed with a brand new combination of additives offers high thermal and mechanical resistance coupled with a remarkably consistent conductivity that allows on-line painting using the electro-coat process.

This new technology also provides excellent surface aesthetics along with easy processability that makes it perfectly suited for automotive exterior body panels.

The technical characteristics of Technyl A 238P5 M25 meet the requirements for a better performing material at high temperature and, in particular, with respect to the e-coat process temperature increase announced by many car makers for the near future.

Parts made of Technyl A 238P5 M25 such as front fenders can then be assembled prior to the electro-coating bath (on-line process) and successfully pass through the curing oven at a temperature of around 200degC for 30 minutes.

Successful sag test results, up to 220degC, demonstrate the substantial advantage of Technyl polyamide performance versus other thermoplastic competitive materials.

The excellent thermal resistance of Technyl A 238P5 M25 is due to a pure PA66 polymer matrix modified with specific fillers.

Technyl A 238P5 M25 can be painted by using electrostatic painting systems without conductive primers.

Parts made of this new Technyl grade exhibit a high paint transfer efficiency resulting in VOC emissions reduction as well as cost savings.

The paint thickness uniformity observed with large parts results from a low variation in volume and surface conductivity thanks to the specific technology developed by Rhodia, and is an additional benefit of this new product.

Technyl A 238P5 M25 confirms the typical advantages of plastics exterior body panel applications in comparison to metals : * Weight reduction up to 40% vs.

steel.

* Better low speed impact behavior.

* Design flexibility and more opportunity for complex parts design.

* Good chemical resistance.

* No corrosion.

Furthermore, Technyl A 238P5 M25 offers specific advantages vs.

other thermoplastic materials in use for such applications : * Improved heat resistance.

* Better dimensional stability due to a lower CTLE.

* Easy processing on standard injection molding machines.

* Better productivity through the reduction of injection moulding cycle time and lower part reject rate.

* Mold design simplification.

Technyl A 238P5 M25 has been successfully tested on parts such as exterior front panels.

The parts were submitted to the typical automotive standard tests including : * Resistance to e-coat process up to 200degC for 30 minutes and dimensional shrinkage evaluation.

* Electrostatic painting on production line and measurement of the surface aspect.

The parts were submitted to e-coat, painted, and then dried.

at a typical temperature of 140 to 160degC for 20 to 30 minutes.

* Adhesion tests using the most common automotive painting systems.

Parts were submitted to water immersion, thermal shock, jet of hot water at high pressure, etc * Impact test at room temperature and low (-20degC to -30degC) temperature conditions.

Rhodia Engineering Plastics is promoting Technyl A 238P5 M25 for both in-line and on-line painted parts, for example: vertical panels, fuel filler flaps, rocker pillars, front grills, and exterior trim applications.

Rhodia Engineering Plastics can support its' customers in the development of new applications through its' technical application developments centers worldwide.

Appropriate support is available from the concept to the production of body panels including assistance with mould design, CAE, process optimization and testing on components.

In close collaboration with key players in the rotomolding industry plastics materials producer has developed an alternative for large part production in Polyamide.

Rhodia Engineering in close collaboration with key players in the rotomolding industry plastics has developed Technyl RTM, a new alternative for large part production in Polyamide. 'Technyl RTM now allows Rotomolders to benefit from the mechanical, thermal and chemical properties of polyamide 6 and 66 and enter market segments not accessible for them before' said Sylvie Salier, Applications Development Manager at Rhodia Engineering Plastics. Technyl RTM is a line of polyamides specially designed for this growing industry, combining excellent processing qualities, and chemical, thermal and mechanical properties such as tensile strength, impact strength, and stiffness.

For years Rotomolders were forced to leave behind attractive business opportunities where the classic rotomolding materials were not able to offer a good balance of properties and cost.

However, new technologies combined with materials such as Technyl RTM are allowing this industry to tackle market needs in applications not traditionally seen before.

Some of the more attractive applications for parts produced in Polyamide by Rotomolding include : * Tanks for water expansion, hydraulic oil, fuel, solvents.

* Body Parts.

* Construction panels and ducts.

* Housings.

* Acoustic insulation panels.

Technyl RTM grades represent an attractive value offering for the Rotomolding industry because they unlock the possibility to produce large size parts in one of the most widely used Engineering Plastics.

Today, two grades of Rhodia's Technyl RTM are commercially available : * Technyl RTM C207L Natural Polyamide 6 Heat and Light stabilized.

* Technyl RTM C207 Black Polyamide 6 Heat Stabilized.

Further Technyl RTM grades based on PA66 and PA6 are under development.

Rhodia Engineering Plastics, headquartered in Lyon, France, is the world wide specialist in polyamide engineering thermoplastic materials.

The company has a sales network that spans the world, with manufacturing plants and technical development centres in Europe, North America, South America and Asia.

Rhodia is one of the world's leading manufacturers of specialty chemicals.

Providing a wide range of innovative products and services to the consumer care, food, industrial care, pharmaceuticals, agrochemicals, automotive, electronics and fibers markets, Rhodia offers its customers tailor-made solutions based on the cross-fertilization of technologies, people and expertise.

Rhodia subscribes to the principles of Sustainable Development communicating its commitments and performance openly with stakeholders.

Clay-containing polymeric nanocomposites have now reached a commercially viable stage and are being incorporated in many new applications as described in an 'encyclopaedic compilation'.

Nanocomposites are being described as the ultimate in new materials this decade. They offer potentially outstanding material performance. Clay-containing polymeric nanocomposites have now reached a commercially viable stage and are being incorporated in many new applications.

It is essential that material suppliers, designers and manufacturers understand the potential and the limitations of these new products.

Clay-Containing Polymeric Nanocomposites, published by Rapra, is an encyclopaedic compilation of the material published to date in this exciting new field of polymer science.

This book describes patents, journal and conference articles and the practical experience of the author in developing and working with these new materials.

All of this information is compiled in useful sections by material, processing, properties and applications.

It also includes useful commercial information, such as the names of the companies who are researching and producing nanocomposites.

Clay-containing Polymeric Nanocomposites includes a very useful section on all the different types of nanoparticles currently available and describes the experimental work on incorporating these particles into polymeric matrices.

Clays are at by far the most advanced stages of development, with the advantage of being relatively cheap and abundant materials.

However, they are also very varied in form and chemistry: impurities can lead to degradation of nanocomposites; different types of clay will be less compatible with different types of polymer.

This book describes the work that has been carried out on all of these issues to look for the best clay and compatibilisers for each polymer type.

Most of the research to date has been carried out on thermoplastics with some on thermosets and a limited amount on elastomers.

Toyota and Allied-Signal have worked on polyamides, for example, whilst Dow, Sekisui Chemical and Toyota have all taken out patents relating to polyolefins.

There is extensive data in this text including numerous tables and graphs illustrating property changes, processing attributes, chemical interactions, material types and so forth.

This is a very comprehensive book and represents the forefront of the technology of clay-containing polymeric nanocomposites.

The author, Dr Leszek Utracki is a Senior Research Officer at the National Research Council Canada, Industrial Materials Institute, and past Head of the Industrial Polymers Section at the SPE.

He is the author of over 500 articles, is named on 12 patents and has written or edited 20 books and 38 book chapters.

In 2003, Dr Utracki was awarded the Outstanding Achievement Award from the SPE Thermoplastic Materials and Foam Division in recognition of his work in rheology, thermodynamics, blends and nanocomposites.

Two polyamide grades offer more than 4dB improvement versus other engineering plastics such as glass reinforced PP or PA and so replace foams or heavy layers.

Rhodia Engineering Plastics today announced the launch of two new polyamide grades offering acoustic performance that is superior to traditional engineering plastics. These new grades offer more than 4dB improvement versus other engineering plastics such as glass reinforced PP or PA. Thanks to their intrinsic acoustic insulation improvement, Technyl STARTM S 218dB1 M50 and Technyl STARTM S 218dB2 MV60 allow designers to remove expensive acoustic components such as foams or heavy layers, without affecting the acoustic performance of their systems and even improving it in some cases.

These solutions open then the way for significant cost savings, combined with new design freedom.

As a mono material solution, these two grades offer an easier recycling solution for parts that have to fulfil a noise insulation role than typically used composite solutions.

In automotive under-the-hood applications, Technyl STARTM S 218dB1 M50 and Technyl STARTM S 218dB2 MV60 not only contribute to improved passenger comfort, but also help in compliance with environmental noise and recycling regulations.

Rhodia Engineering Plastics' engineers at the Lyon, France-based Acoustic Center have demonstrated that these grades can optimize the acoustic performance of any kind of application that requires a high level of noise insulation.

Target automotive applications for these new acoustic grades include carburators, engine covering systems, distribution covers, bonnet louvers or air pipes.

Additionally, various housings in electrical appliances, as well as sound insulators in buildings are applications currently being developed with this innovative material solution.

A recent survey of current UK polymer (plastics and rubber) research funded by the Engineering and Physical Sciences Research Council found more than 300 projects identified across UK universities.

Polymeric-based research is alive and well in the UK. The main strategic issues are to do with the 'development' half of the traditional R and D equation. The Faraday Plastics and Polymers Partnership (FPPP) is at the heart of catalysing academe and industry in their own best interests.

A recent survey of current UK polymer (plastics and rubber) research funded by the Engineering and Physical Sciences Research Council (EPSRC) alone found more than 300 projects identified across a broad spectrum of UK universities, from Southampton to Strathclyde.

A host of other local, national and EU driven initiatives are also underway with these universities; certain amount of individual spin-off developments from these institutions are taking place, and an unidentified number of individual academe/industry projects are always in play.

However, it has been well known for some years that the main missing piece of the jigsaw is an absence of overall strategic direction and priority areas for the new materials and processes.

This holds good, not just for polymers, but for a number of other 'rising sun' sectors in the UK such as bio catalysis, aerospace, food processing, mobile communications, photonics genetics, digital imaging, and many technologies.

A need for a defining vision and strategy for these new niche sectors had become clear and urgent by the turn of this century.

The UK Government's response was to provide some strategy and leadership by creating a number of Faraday Partnerships to match the technology areas.

The Faraday Plastics and Polymers Partnership (FPPP) was accordingly established by the DTI in the Spring of 2000.

The main part of the FPPP mission is stated as 'enabling research to meet the critical technological challenges of the plastics sector.' In practice this means ensuring that the industry and the research community are fully engaged with each other through: - Front-end industrial involvement in defining and shaping research priorities - Continuous access from both sides into Faraday's network of skills and resources FPPP also now provides the framework in UK plastics and rubber for: -Core strategic research in polymers to underpin business opportunities -Effective technology translation (between academe and industry) -Analyses of the technological issues/driving forces that shape the industry -A technically educated, market oriented, skills base.

The Faraday Plastics partnership is led by Rapra Technology, Europe's leading polymer research and testing house.

The supporting Faraday Plastics partners include; Strathclyde University, Warwick Manufacturing Group, Bradford University, MERL, Institute of Materials, British Plastics Federation, and GTMA.

And through a process of experimentation and discussion, Faraday Plastics has identified three technology areas that are key to the UK's future polymeric development These are: Nano and composite materials - research and development of materials in these areas that offer competitive advantage Energy - research and best practice on the best types and volumes of energy needed to process plastics and rubbers.

Recycling and Sustainability - identifying environmental and legislative drivers for materials and products.

Faraday Plastics has also attached two leading market sectors that will be critical to the development of new polymeric materials and products.

These are: Automotive - a sector with a growing use of thermoplastics and Medical/Healthcare - a niche sector with high added-value and growth potential Taking its cue from recent innovations in business and politics, the 'road map' has become a key instrument for FPPP in developing these ideas for the marketplace.

For example, FPPP has recently produced a 'Technology Road Map' (TRM) for low-energy polymer processing that aims to catalyse the plastics and rubber industry into measuring its energy-use performance and changing it for the better.

Among the recommendations of the FPPP TRM are: Industry benchmarking and sectoral targets - a programme of market research is recommended to study how energy-efficient (or not) the polymer processing sector is in its current practices.

Heater insulation - a campaign to promote the use of insulation and to save energy wastage and cost in this area.

Demonstration Unit - establishing a 'show and tell unit' to demonstrate to processors the benefits of energy efficiency Cost of Ownership Model - establishing a financial model for typical paybacks - so as to incentivise the industry to adopt energy saving measures.

Training - to be provided in energy measurement and management.

Faraday Plastics director, Richard Simpson notes that 'this is the beginning - not the end - of a very important debate that needs to happen within the plastics and rubber sector on energy -processing.

Not only does the practice make commercial and competitive sense - but energy efficiency is also desirable on environmental and health and safety grounds.' Simpson adds that 'issues such as the climate change levy have put polymer processors more into the 'front line', and have politicised these issues to some degree.

The good news is that moulders who save their own costs through lower energy bills are also making a positive contribution to the environmental health and credentials of their industry.

I urge all involved in processing to read our TRM report and to help us help the sector in implementing its findings.' Work is also underway between Faraday Plastics and Hybridnet (an EPSRC funded network) in creating a TRM for the Commercialisation of Polymer/Ceramic Hybrids and Nano-Composites.

Representatives from Faraday Plastics, Hybridnet, Sheffield Hallam University, Nottingham Trent University, Surrey University, Brunel University, PowdermatriX, Qinetiq, Linpac, DSTL, Imreys, JCB, Zotefoams, and Faraday ADVANCE have all made inputs into the major areas of technology and research in polymer nanotechnology.

Discussion topics included applications, funding, materials modelling, processing, materials characterisation and industry skills.

The FPPP TRM in this particular area will help UK polymers take advantage of the exciting commercial opportunities offered by scientific advances in nanotechnology.

Some estimates predict a global market in nanotechnology worth over $1 trillion in a decade.

The Technology Road Maps provide the polymer sector with a clear picture of the priority area terrain, now and for the foreseeable future.

But in order to fully explore and exploit that terrain, expert guides are often needed.

A need for polymer-based Technology Translators has arisen and Faraday Plastics has now put a team of eight individuals together - deployed to help to bridge the gap between the academic and business worlds of the UK plastics industry.

Each FP TT individual has a niche expertise in the priorities identified by FP - ie healthcare, energy, automotive, healthcare, recycling and other topics.

The TT visit programme is ongoing and a battery of case studies and project opportunities is now coming to the fore.

However, the lines of resistance to commercial exploitation are more than conceptual and technical.

Even assuming that industry and academe are able to work together on polymer-based research and development projects the constraint of finance rears it head with many companies unable or unwilling to face development for reasons of cost.

FPPP has found that most companies in the sector are unaware of the tax credit opportunities available to them through research and development activity.

FPPP has now held a programme of successful seminars on this subject as part of its mission.

Spokesmen from accountancy firms and from the Inland Revenue have outlined the criteria for tax relief eligibility.

And Faraday Plastics is now sharing the method and content of these seminars with five sister Faradays in the chemical and biotech areas.

Richard Simpson says that 'judging by the feedback received at our seminars to date, this is an area where most plastics processors have not been well advised by their accountants.

Up to 150% of a company's research and development expenditure can be set against profitability and the company's tax burden.' On occasions the UK's plastics processing sector will also have a need of co-ordination and direction in basic areas such as health and safety.

Faraday Plastics, HSE and the Society of Plastics Engineers (SPE) have recently organised the thermoforming part of the UK industry in adopting a new agreement covering 'Provisions of safe guards to prevent gravity fall of raised machine parts on thermoforming machines'.

Following concerns that the thermoforming industry had a poor record in this area, the partners drew together the machinery manufacturers and processors and developed an approach that is regarded by the HSE as a considerable step in the right direction.

As a result: - 90% of the industry has now been made aware of the health and safety issues - 25% of all UK processors have attended a relevant meeting - All save one of the identified machinery manufacturers have attended a meeting - Free advice of safe working practices has been disseminated - Over 80 companies have heard the message For most companies or academics in UK polymers today, the easiest and quickest way to look for an industrial or academic partner is to get involved with the Faraday Plastics affiliate scheme.

Richard Simpson believes that for innovative plastics-based businesses, the affiliate scheme is the best single way to boost polymer-based R and D.

'The affiliate scheme is the basic point of entry for participating businesses.

For a very minimal outlay, companies can get connected to the best plastics-based research in their fields; save time and money in searching for solutions; and also get access to the best researchers, partners and technologies available.' Linpac Automotive is a good example of a plastics processing company based in a key and growing area.

Keith Weedon, Manager, Design and Development, Linpac Automotive says that 'becoming a Faraday Plastics affiliate gives us an added innovative edge - a factor increasingly required from a business such as ours.' On the plastics materials side, Dr Rowena Sellens, Global RT and E Director at Lucite International, owner of the world-renowned Perspex and Lucite brands says that 'timely and focussed research and development is critical to maintaining Lucite's leadership in the marketplace.

Faraday Plastics gives us a handy one stop shop for all the relevant UK R and D expertise.' And Nic Hunt, Global Business Director for packaging major, Amcor Flexibles, says that 'Faraday Plastics gives us direct access to the leading university research programmes.

It also provides a forum from which to benchmark other sectors on innovation management.' On the academic side, Faraday Plastics, the UK's plastics research and development centre, has recently welcomed two of the UK's leading academics to its affiliate community.

Dame Prof Julia Higgins, Chemical Engineering, Imperial College, also Chair of the EPSRC, and Prof Tom McLeish, Director of the Polymer Interdisciplinary Research Centre (IRC) at Leeds have recently become Faraday plastics affiliates.

Richard Simpson sees their membership as a clear recognition of the role to be played by Faraday Plastics in bringing the academic knowledge base to the attention of the industrial community.

He urges other leading UK academics to apply to join the affiliate scheme, which is currently free of charge.

The Faraday Plastics benefits for academe include: - Collaboration with companies to form research teams - Support in the preparation of research bids - Help in identifying funding sources - Opportunities to exploit research outputs.

Testing of plastics and rubber materials and products is involving Rapra Technology's laboratories in more product design and development as reviewed here by Richard Walton.

Testing of plastics and rubber materials and products at Rapra Technology's Shawbury and Billingham laboratories has always highlighted where the leading edge lies for a number of user sectors such as healthcare, automotive, food, chemicals and others. Rapra Technology's Richard Walton provides an update on what Rapra's industrial clients are most looking for in taking their new product ideas to market. As Rapra - formerly the Rubber and Plastics Research Association - Technology becomes increasingly involved in new product design and development, there is an accompanying need for new product testing: New clients are encouraged to talk about the background and context to their work so that Rapra can provide what's needed, not only in terms of designing and engineer new testing rigs and fittings to establish a standard, but also to deliver the scientific and polymeric input and, increasingly, supply the legislative and commercial background needed for the marketplace.

A good proportion of Rapra's current activity involves helping manufacturing companies to develop and maintain product standards programmes of their own, rationalising the process, maintaining and rewriting their existing specifications.

About half of Rapra's testing work in rubber and plastics involves UKAS accreditation.

Across the board, the past twelve months have seen growth in the following areas: * The outsourcing of healthcare testing services is seeing more growth, fuelled partly by our new venture in Ireland but also from a continuing policy in pharmaceuticals and healthcare companies to reduce head counts and contract out manufacturing and other disciplines.

* Sales for tyre testing significantly increased through 2003 due to EU legislation for retread tyres to be approved by the Department of Transport and equivalent overseas national governing bodies.

The prospect of a growing business here remains high, as there is an on-going requirement for conformity of production.

The number of Rapra Technology's overseas clients has also significantly increased in the last 2 years.

* Floor testing sales continue to increase as companies have a duty of care under Regulation 12 of the Health, Safety and Welfare Workplace act to ensure that every floor shall be suitable for the purpose for which it is used.

Rapra Technology is undertaking a research project into typical walking behaviour and floor surface wear and tear.

Rapra is also working with the British Standards Institute in a number of tests as applied to a variety of bathmats.

Rapra Technology also manufactures a variety of flooring gauges and plaques in a variety of polymeric materials in order that companies can have a ready reckoner of the tactile and adhesives properties.

* Contamination testing to military standards has increased as companies are obliged to show conformity and testing is being outsourcing due to increase health and safety requirements and the need for independent test results.

* New business has been won in testing water and oil storage tanks.

Rapra is now OFTEC and AIB-Vincotte approved to test tanks according to PR EN 13341.

* The aerospace sector is providing Rapra with an increasing range of new products to test as part of product validation programmes or value engineering/weight reduction activities.

* Biocompostable materials.

This is a new area of materials testing which Rapra is set to play an increasing role, especially in standards setting.

* Polymer recyclate.

The new plastics recycling industry has a great need to analyse the new products made from recyclate as fit for purpose and Rapra Technology is the test house of choice.

The testing of End of Life Vehicle (ELV) recycled materials in the automotive sector is, for example, a significant part of the materials testing work being carried out at Rapra Billingham.

Following our MBO of July 2002 we have been able to meet these opportunities and demands with a more flexible response to capital investment.

The past year has seen us purchase and also design and build a large number of testers and testing rigs through 2003/04.

These are sited at both the Shawbury and Billingham sites.

The new equipment includes: * Q panel light UV tester.

* Large infra-red testing chamber for climatic testing.

* Large (2 cubic metre) climatic chamber.

* Hot pressure pulsation rigs (primarily for automotive customers).

* Ultrasonic thickness gauge.

* Weighbridge up to 15 tonnes.

* Additional capacity for programmable ovens.

Rapra's Billingham site in the North East, leads the company's testing work in the automotive sector and continues to compete in the demanding automotive business environment with a blend of creative and cost effective engineering skills.

Automotive products tested include everything polymeric from dipsticks to glove boxes, interior and exterior trim, modules, carpets, sunroof materials, tyre formulations, underbonnet component development and testing, tractor air filters, lighting and many other components.

New activities at Billingham this year include: the development, design and build of hot pressure pulsation rigs; the design and build of infra red heating modules for climatic testing on automotives; the testing of racing car tyre materials; the testing of end of life recycling materials; and the vibration transit testing of packaged devices as well the development of high speed tensile testing.

Historically our rubber technology group business has provided the foundation for the growth now experienced in plastics.

Rapra business in the rubber sector continues to grow.

A 50% increase in planned sales is expected during 2004 compared with 2003.

The mix of rubber testing work includes failure investigation and the provision of expert witnesses.

However, a trend to more and more product development activity is discernible as more companies outsource specialist skills.

The processing capability for elastomeric materials has significantly increased at Rapra due to the installation of a LWB Steinl VCE 500/160 combined rubber and TPE injection moulding machine.

Rapra is now able to provide designers in rubber and TPEs a fully integrated package of material selection, compound development, 3D flow simulation, tool design and injection moulding.

Rapra also has a significant business selling reference materials for use in polymer testing.

The current range includes: Rubber sliders - friction reference materials for the TRL Pendulum and BCRA Tortus apparatus; Reference oils - ASTM No.

1 oil, IRM 902 and IRM 903; Rubber Hardness Blocks - Rapra manufacture and supply standard rubber hardness blocks over the range 40 to 90 IRHD/Shore A for use checking the calibration of hardness machines.

New product development in this area has been underway through this year and is expected to yield new business during the next financial year.

On-line reference service has been set up to keep subscribers abreast - at no charge - of the world's emerging discoveries and innovations in polymer science, technology and manufacturing.

Rapra Technology, Europe's leading polymer research and test house, is offering a new service called Polymer Contents. There is no charge for this service, it is custom-created to the needs of individual subscribers and is designed to bring the world of polymers direct to the doorstep of the industry. 'This is a real opportunity for all in the sector to keep abreast - at no charge - of the world's emerging discoveries and innovations in polymer science, technology and manufacturing and, most particularly, an opportunity to monitor special interests within the industry.

To fully understand the scope of this service it is important to realise that Rapra's Polymercontents.com covers literature published by over 150 scientific, technical, economic and trade publishers' says Rien van den Hondel, Rapra Technology's manager of databases.

Every month Rapra abstracts some 400 journals, conference papers and other publications, employing a specialist staff of some 25 abstractors.

In essence, a digest of all this information will now be made available to users at http://www.polymercontents.com After a simple registration, visitors can create 'topic profiles' describing their particular interests via an easy to use menu.

Users may create as many 'topic profiles' as they want.

Each of these will result in a fortnightly e-mail, listing titles and truncated abstracts of recent, specially selected literature.

The content will be sourced from new additions to Rapra Technology's polymerlibrary.com; the largest online Polymer literature database in the world.

Publications covered by this service are journal articles, conference proceedings, trade literature, books, reports and standards.

A list of journals covered by the Polymer Library can also be downloaded.

If - on reading through the fortnightly listings - any particular abstract takes a reader's interest, it is then available to the subscriber to purchase the item via credit card.

A commercial copyright cleared full text copy of the original publication can be delivered to the reader's computer within 24 hours - more typically within a few hours of ordering.

By clicking on the unique accession number next to each title, the price for that document is displayed.

Readers can then place the documents in a shopping basket and after a secure live credit card payment Rapra's Document Delivery service will e-mail you the documents.

Details of all users will be confidential and will not be passed on to any third parties.

Who might use this service?

* Processor looking for new polymers for a specific application.

* Marketing manager interested in market trends.

* Chemist trying to improve properties of polymers.

* Sales manager keeping an eye on products announced by competitors.

* Purchase manager searching for new polymers for a specific application.

* The list of individuals who'll benefit from this free service is virtually endless.

Some subject examples for individual users are: * Uses of thermoplastic elastomers.

* How to work with nano-composites.

* Environmentally friendly blowing agents.

* Properties of certain blends of polymers.

* Chemical resistance of hoses.

* Adhesives for automotive applications.

* Non-destructive testing of composites.

* blow moulding of PET.

* Electric injection moulding machines.