Mould Makers Information

Lower cost polymer combats plasma effectively

2007-03-07T02:26:00.001-08:00

To replace Vespel electrical insulators in plasma cutting torches, a manufacturer chose lower cost PEEK polymer that offered the same electrical insulating and high temperature properties.

When Esab Welding and Cutting Products of Florence, South Carolina, USA, wanted to replace the Vespel electrical insulators in their plasma cutting torches, they chose Victrex PEEK polymer. The polymer offers the same electrical insulating and high temperature properties as Vespel but is less expensive and easier to machine. Plasma cutting torches are used to cut and fabricate metal parts.

They utilize electricity to create an arc between the electrode (torch body) and the work piece.

'The arc is forced through a nozzle with a small hole in it along with a flow of gas, such as air, and this results in the air becoming very, very hot, up to tens of thousands of degrees,' explains Stan Severance, Staff Engineer at Esab.

'As a result, this high temperature effluent of gas along with the arc can cut through metal.' Located in the head of the torch, the PEEK polymer insulator electrically insulates two different potentials inside the torch from each other.

Explains Severance, 'A torch typically has two electrical potentials.

One is associated with the electrode and the other is associated with the nozzle.

In order to start the torch, an arc is struck between the electrode and the nozzle which is called a pilot arc.

Once the pilot arc makes contact with the work piece, the arc transfers to the work piece.

It is necessary to separate the electrode potential from the nozzle potential.

This means having one or more insulators inside the torch body to insulate the two potentials from one another.' Because the insulators are exposed to the high voltage electrical discharge used to start the torch, they must be able to withstand very high temperatures.

Explains Severance, 'To get the arc started, you can have very high voltages - up to 10,000V - at high frequency, plus temperatures can be very high especially in air-cooled torches.' Before switching to PEEK polymer, Severance said 'We looked at a variety of different materials.

Vespel is very expensive and it has a very complicated manufacturing process.

We wanted a material that would be substantially less expensive but still have all the properties needed to meet the requirements of the application.

In addition to good electrical insulative properties and good high temperature properties, we wanted machinability, heat aging and creep resistance.

PEEK polymer fulfills all these requirements.' With operations in a large number of countries, Esab is the world's largest producer of welding and cutting consumables and equipment.

Industrial cleaners adopt polymer helical gears

2007-03-07T02:25:00.003-08:00

When a leading manufacturer of industrial cleaning equipment, wanted a material for the helical gear wheels in its spray heads, it chose a polymer because of its superior chemical resistance.

When Toftejorg A/S of Denmark, a leading manufacturer of industrial cleaning equipment, wanted a material for the helical gear wheels in their equipment's spray heads, they chose Victrex PEEK polymer because of its superior chemical resistance and high mechanical strength. According to Andrew Ragan, Victrex Global Leader polymer was chosen because of its resistance to virtually all organic and inorganic solvents, and because it delivers the required high mechanical fatigue strength over a wide range of temperatures and pressures.' The cleaning equipment is used in a variety of demanding environments including cargo ship containers for transporting crude oil, chemicals or solid bulk products. The containers are cleaned after the cargo has been unloaded to prevent contamination of the new cargo.

Depending on the applied pressure and nozzle system used, the equipment can completely clean a tank within a few minutes.

The gear wheels are manufactured in a custom mold specially designed for co-injecting an unfilled PEEK polymer resin onto a pre-heated metal insert.

Using the polymer gives the wheels the ability to resist high mechanical loads and provide long-term resistance to both cleaning agents and aggressive residual media in the storage tanks.

And, because unfilled PEEK polymer complies with FDA regulations for repeated food contact, Toftejorg can also market its products to the food and beverage industry.

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

For more information on the properties and performance advantages of Victrex PEEK polymer, please call (800) Victrex or visit the Victrex website.

The PEEK trademark - for many years Victrex has been using the PEEK trademark to refer to its brand of Polyaryletherketone.

Victrex is the sole manufacturer and supplier of the PEEK brand polymer worldwide.

PEEK is a trademark of Victrex.

Latest guide includes nano-filler technology

2007-03-07T02:25:00.001-08:00

Particulate fillers in polymers continue to play a very important role and a book provides a guide to the fundamentals and has a chapter covering the latest developments in nano-filler technology.

The use of particulate fillers in polymers has a long history, and they continue to play a very important role today. The aim of Rapra's new Handbook, Particulate-filled Polymer Composites, Second Edition, is to provide a guide to the fundamentals of the use of particulate fillers, which is accessible to people from the many different industries and disciplines who have an interest in the subject. In the relatively short time since the publication of the first edition in 1995, much has changed and all the chapters have been updated and revised, and a completely new chapter covering the latest developments in nano-filler technology is included.

Particulate-filled Polymer Composites begins by considering the selection and use of particulate fillers, including factors such as cost, purity, particle size and shape, and density.

This is followed by discussion of the different types of particulate filler, the characterisation of filler surfaces and their modification.

The current practices for preparing particulate filled polymers are described, as are characterisation of the compounds and the relationship between compounding route and material properties.

The use of particulate fillers in specific classes of polymers (elastomers, thermoplastics, and thermosets) is described.

Effects of other additives, the properties of the filler, and the performance, processing and application of the filled polymer are considered.

The author, Roger Rothon, is now an independent consultant, specialising in the production, surface modification and application of particulate fillers for polymer composites.

He previously worked for ICI for over 25 years, where he was responsible for several new product developments, including new types of coupling agents for silica and calcium carbonates and novel conductive and magnetic fillers.

After leaving ICI, he was Technical Manager for Flamemag International, where he led the development of a new process for the production of magnesium hydroxide flame retardant fillers.

In 1996 he was made a visiting Professor at the Manchester Metropolitan University, where he is now involved in research on filler surface modifiers.

Mould-in films cut automotive production costs

2007-03-07T02:24:00.001-08:00

Hardcoated in-mould decoration films simplify the production process by reducing the number of manufacturing stages and streamlining part production.

Autotype International has launched a new family of hardcoated films designed to meet the growing plastic component demands of the automotive industry, while helping to reduce both costs and lead times. The new Autoflex In-Mould Decoration (IMD) films simplify the production process by reducing the number of manufacturing stages and streamlining part production. The hardcoated films are reverse printed, formed and cut to shape before being back injection moulded.

Developed for shallow, medium and deep-draw IMD applications, Autotype's new films provide the perfect solution whereby intricate graphics can be reproduced on 3D components, such as HVACs, PRNDLs and other automotive interior parts.

The four films that make up the range have been individually designed to provide a variety of options, enabling end users to specify the film that best meets the demands of different applications.

The range includes Autoflex EBG, which is ideal for cost-effective embossing and shallow-form applications; Autoflex AutoForm, best suited for gently-formed parts where micro-cracking must be avoided; and the innovative Autoflex HiForm and robust Autoflex XtraForm films.

HiForm features an ingenious self-healing coating that repairs itself when scratched and is ideal for parts that require a medium depth of form with simplicity of processing, whilst Autoflex XtraForm is designed for deep form applications where maximum draw and extra hardness are required.

The Autoflex IMD range delivers all the design and cost advantages associated with other forms of IMD technology, but also offers a number of additional benefits, including high levels of abrasion resistance for component parts likely to be exposed to excessive wear and tear, and the ability to be used for backlit components or where complex or photographic quality graphics are required.

Perhaps as importantly, as Richard Townsend, Product Manager at Autotype, explains, 'Unlike first surface In-Mould Decoration or the use of uncoated films, Autoflex IMD is an extremely economical technology, offering low unit costs due to savings both in tooling costs and reductions in the number of moulding, assembly and finishing processes and materials required.'

PBT plastics mouldings need no annealing

2007-03-07T02:22:00.000-08:00

PBT plastics allows a user to mould an airflow sensor body in one piece without annealing - saving two production steps, when compared to alternative materials.

Hitachi Automotive Systems Europe has selected a reinforced Arnite polybutylene terephthalate (PBT) blend from DSM Engineering Plastics for injection moulded mass airflow sensor body destined for Audi engines. Arnite TV4 261 30% glass reinforced grade PBT provides a combination of properties important to the application, including excellent flow, long term dimensional stability, stiffness and strength over a wide temperature range and chemical resistance. Production requires only moulding - no annealing is required to relieve internal stresses that could lead to warpage.

'Throughput is excellent with this design,' said Andrew Bridge, procurement and design manager for Hitachi.

'The ability to mould the unit in one piece without annealing saves us two production steps compared to less sophisticated, two-piece approaches with alternative materials.' The Hitachi body serves both to mount the mass airflow sensor system precisely and to shape air flow using a moulded-in grid.

To control the turbulent airflow, the grid induces a laminar flow that helps ensure accurate feedback about engine air intake temperature to the engine control unit.

Mass airflow sensor data help engine control systems maintain an optimum air-fuel balance.

The grid's thin-wall elements and intricate geometry benefit from Arnite's flow properties, minimising moulded-in stresses and strains that later might contribute to warpage or unpredictable dimensional change, causing the sensor to misread airflow.

The design process for the component was a collaboration involving Hitachi, moulder and toolmaker WH Smith and Sons, materials and processing expert DSM Engineering Plastics and design and mold flow specialist DSM/DADC (Design and Development Centre).

* About Hitachi Europe - Hitachi Europe Limited is a wholly owned subsidiary of Hitachi Limited, Japan.

Headquartered in Maidenhead, UK, it has operations in 15 countries and employs 470 people across Europe, the Middle East and Africa.

As a 'Best Solutions Partner' Hitachi Europe tailors its services and solutions to meet the specific needs of its customers.

Hitachi Europe comprises eleven key business areas: power and industrial systems; rail; industrial components and equipment; information systems; high performance computing; digital media; display products; air-conditioning and refrigeration systems; procurement and sourcing; corporate technology group (research and development) and the Hitachi Design Centre.

Hitachi Automotive Systems Europe is headquartered in Horwich, Bolton UK.

* About DSM Engineering Plastics - DSM Engineering Plastics is a business group forming part of DSM's Performance Materials cluster.

DSM Engineering Plastics is a global supplier of Stanyl PA46 and Akulon 6 and 66 polyamides, Arnitel TPE-E, Arnite PBT and PET polyesters, Xantar polycarbonate, Yparex extrudable adhesive resins, and Stamylan UH Ultra High Molecular Weight PE.

These materials are used in technical components for electrical appliances, electronic equipment and cars, in barrier packaging films as well as in many mechanical and extrusion applications.

Showing the way for low-energy polymer processing

2007-02-27T22:05:00.004-08:00

The newly reconstituted Faraday Plastics has produced a 'technology road map' for low-energy polymer processing industry into measuring and bettering its energy-use performance.

The newly reconstituted Faraday Plastics, the UK's plastics research and development centre, has produced a 'technology road map' (TRM) for low-energy polymer processing that aims to catalyse tbe plastics and rubber industry into measuring its energy-use performance and changing it for the better. Among the recommendations of the TRM report 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.' The Technology Road Map technique - used in this case by Faraday Plastics to create a future scenarios for lower energy technologies - is a high level business tool - developed in industry, management and also politics - to support planning and to help programmes such as national foresight schemes.

In its most basic form, it is a time-based futures chart that includes commercial, legislative and environmental perspectives.

Ideally, the TRM tools allow the user to more completely visualise the evolution of markets and technologies - the linkages and the consequences of certain factors and inputs.

The new Faraday Plastics business plan was agreed in Spring of this year, ensuring further DTI funding for the next three years.

The newly constituted Faraday Plastics gives companies in the UK plastics sector an opportunity to be able to continue to attract plastics technology development funding and access Faraday Plastics initiatives.

Faraday Plastics has also selected a number of priority areas for the next three years: These are energy; recycling and sustainability; nano and smart materials; healthcare and automotive applications.

Faraday Plastics has a new, independent and high profile chairman in Professor Tony Ledwith, former chairman of the EPSRC.

Lord Sainsbury, Government Minister for Science and Innovation recently described Faraday Plastics as having added 'coherence to the disparate and fragmented activities that are taking place in this sector.

It has helped stimulate new products and processes, new patents, and new start-up companies,' said Sainsbury.

The new Technology Road Map on Low-Energy Polymer Processing is available free of charge on application to Faraday Plastics.

Polymer satisfies high temperature conveyor needs

2007-02-27T22:05:00.003-08:00

When designing conveyor belt chains for high-speed beverage and food processing lines, a company chose a polymer for its high temperature and superior chemical resistance properties.

When Tokyo-based Yamakyu Chain Company was designing conveyor belt chains for high-speed beverage and food processing lines, they chose Victrex PEEK polymer for its high temperature and superior chemical resistance properties. According to Andrew Ragan, Victrex Global Leader polymer slat band chains are proving an ideal fit for the food processing industry where high heat resistance and superior chemical resistance are an essential requirement. Traditionally, this industry has used intermesh, low friction transfer plates made from acetal.

But acetal's operating temperature limit of 176degF (80degC) prohibits its use in high-temperature environments.

Chains made with PEEK polymer, on the other hand, can withstand exposure to temperatures as high as 482degF (250degC).' In addition, the PEEK polymer chains offer superior long-term resistance against detergents such as chlorine and hydrogen peroxide as well as antistatic properties.

Stainless steel has typically been the material of choice for chains requiring high heat resistance.

However, stainless steel chains need lubrication to ensure smooth operation and this creates adhesion problems and product contamination.

'PEEK polymer is naturally lubricious,' says Ragan.

'The chains can run at a rate of 11ft/sec (200m/min) without lubrication.' In addition, the chains are a third of the weight of stainless steel chains.

This allows for motor downsizing that saves power and reduces operating noise.' Yamakyu is a leading manufacturer of slat band chains for conveyors.

The company focuses on offering customers a total solution from chain selection to the design and manufacture of a complete conveyor system to meet individual requirements.

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

Plastics track plates may be largest yet

2007-02-27T22:05:00.001-08:00

The largest plastics track plates yet produced by the industry are intended for the newest sub sea tractor to install interconnecting array cables used to gather power from offshore windmills.

Quadrant Engineering Plastics Products (formerly Erta and Polypenco) recently produced the largest plastics track plates in the industry for the newest sub sea tractor developed by Soil Machine Dynamics. The machine runs on a D6 chain. The sub sea tractor is used to install the interconnecting array cables used to gather the power from offshore wind turbines.

Despite weighing almost 60 tonnes (132,000 lb) when fully loaded, the Nylatrack track plates are able to support and propel the vehicle on the weakest soils typical at wind farm sites.

Nylatrack track plates are cast from a specially modified nylon and can be fitted on various kinds of machines operating on all types of surface.

On paved roads, they cause no damage, and on soft ground, even marsh, they do not sink.

Compared with steel plates, Nylatrack track plates are highly resistant to wear and corrosion, and light in weight - up to 80% lighter, saving as much as 2500kg per machine.

Because of the flexibility of track plates, vibrations are absorbed and the noise of the undercarriage is muffled.

The bending force is absorbed so that broken chains are no longer a problem.

Standard track plates vary in width, weight and chain pitch for machines of up to 30 tonnes weight.

For machines up to 90 tonnes, special plates can be designed.

Different types are available for optimum traction or low surface pressure.

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

Quadrant EPP also produces custom nylon castings and finished parts and is the sole manufacturer of Extreme Materials with a unique combination of properties: vastly improved wear resistance, better dimensional stability over a wider temperature range, greater strength at higher temperatures and new levels of static dissipation.

Nano-composites development 'roadmap' formulated

2007-02-27T22:04:00.003-08:00

Faraday Plastics and Hybridnet held a successful Technology Road Map meeting on the 'Commercialisation of Polymer/Ceramic Hybrids and Nano-Composites'.

Faraday Plastics and Hybridnet (an EPSRC funded network) held a successful Technology Road Map meeting on the Commercialisation of Polymer/Ceramic Hybrids and Nano-Composites. A group of twenty five met at Sheffield Hallam University to map out the future for the sector. Representatives were included from Faraday Plastics, Hybridnet, Sheffield Hallam University, Nottingham Trent University, Surrey University, Brunel University, PowdermatriX, Qinetiq, Linpac, DSTL, Imreys, JCB, Zotefoams, and Faraday ADVANCE.

Major areas of technology and research in polymer nanotechnology were highlighted.

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

In a recent statement Lord Sainsbury, Government Minister for Science and Technology noted that 'Nanotechnology promises huge benefits for the environment and our health and wealth.

Today's investment will help UK companies 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.

I want to make sure the UK wins a share of this prize with a prosperous, world-class nanotechnology sector in the UK.' Notes from the Faraday Plastics/Hybridnet October 23 TRM material on polymer/ceramic nanocomposites will now be developed into a final document that will be presented at the next Hybridnet meeting to the TRM attendees and other interested bodies on 7th January 2004.

The meeting will be held at Oxford University, Materials Science Park at Begbroke, Oxfordshire and will be organized by Faraday ADVANCE.

More durable plastics to be developed for vehicles

2007-02-27T22:04:00.001-08:00

Superior hardcoating/scratch-resistant materials and processes will be developed in the UK's Foresight Vehicle research project.

Danielson has reinforced its reputation for breaking new technological ground by playing a central role in a partnership research project that is key to the UK's national automotive R and D programme, Foresight Vehicle. The aim of the project, known as PABS2K, is to develop superior hardcoating/scratch-resistant materials and processes that will meet increasingly stringent environmental requirements and growing expectations for safety, cost, performance and desirability. Danielson, one of five industrial partners involved in the project, will contribute manpower, equipment and materials to ensure background work, sample preparation and testing are completed successfully.

In return, Danielson will be the first European supplier of specialised man/machine interfaces, nameplates, labels and metal-fabricated parts to gain access to the project's findings and resulting technologies.

The three-year project has two main focal points; the continued development of Vitresyn hardcoats - a TWI trademark-registered product - and the establishment of transparent nanocomposites through improved stiffness and increased abrasion resistance.

In particular, Danielson will be involved in the evaluation of improvements to resistance against abrasion and adhesion testing.

Ben Phelan, Head of Automotive Division at Danielson, said the project would benefit a wide range of industries.

'This ground-breaking project will ensure the development of formulae, testing procedures and, ultimately, production processes that can be applied to a number of products, including badges and kickplates.

Danielson's involvement in PABS2K secures our reputation of actively supporting new production techniques and introducing the very latest technologies.' The Polymeric Automotive Body System (PABS) project relies on the development of dual-injection moulding techniques to create tough, adaptable components that comply with Foresight Vehicle's aim of stimulating technologies fit for the vehicles of the future.

Part funded by the Department of Trade and Industry, the programme's key objective is to make a significant impact on the use of energy and the emission of pollutants.

Alan Taylor, Principal Project Leader at TWI, said that along with other project partners, Danielson's involvement was critical to the success of PABS2K.

'Getting a company like Danielson on board was important because of their experience in automotive trims and membrane panels.

We've developed a close working relationship with Danielson and their input has been invaluable.'

Polymer research and test house adds on 3D systems

2007-02-23T03:40:00.000-08:00

Europe's leading polymer research and test house, has invested in software and three new work stations to ensure the company's leadership in plastics product design and testing.

Rapra Technology, Europe's leading polymer research and test house, has recently invested in new software and three new work stations, as well as additional consultant resources, in order to ensure the company's continuing leadership in the business of plastics product design and testing. Rapra now offers 3D design analysis and services through the IDEAS 3D design, through to SigmaSoft true 3D flow analysis and MSC Patran and Marc, together with finite element analysis (FEA). 'All of these are fine products and services on their own,' says Andi Clements,' business development manager for the technology, 'but taken together by the user, they are far greater than the sum of their parts.

We are even working with the software suppliers for complementary support using the other software that we have, but adding our own specialist materials knowledge'.

Leading OEMs are all numbered in the range of Rapra clients that are increasingly using the CAD services to establish fault free, long-term plastics product design and launch, as well as improving those elements of design and production that are already underway.

Over œ100,000 of consultancy business has already been sold in relation to the new CAD resources.

These Rapra services are also in demand from designers and suppliers of plastics materials; anxious to ensure that their materials perform as stated from the time they are moulded throughout their service life.

The demands and expectations of plastics materials and components are also becoming increasingly stringent - from Tier 1 and 2 suppliers to all industries where product and component performance is an essential part of business.

Clements says of the new technology that, 'exporting the fibre orientation or residual stress pattern from true 3D flow into FEA means that we can run realistic loading on a realistic moulded part.

Running FEA on an already pre-stressed part also gives a much more realistic description of what the part will experience in reality.

Effectively this gives us the ability to inform our customers on how to make really informed value-engineering decisions using real data.' Rapra Technology Chief Executive Andrew Ward notes that recent business expansions have been greatly enabled by the new structure of the company.

'At the time of the Management Buy Out in July 2002 we promised investment in the fundamentals.

We are delighted to be delivering on that promise now.' Ward adds that 'Rapra's research, technical and analytic strengths underpin all that we do.

Helping companies to address their product design and development issues is one of our key stated business growth areas.

Benchmarks to be set for plastics manufacture

2007-02-23T03:39:00.000-08:00

The plastics compounding group at the British Plastics Federation is undertaking industrial analytical work by creating a number of benchmarks for its manufacturing performance.

The plastics compounding group at the British Plastics Federation is undertaking some leading-edge industrial analytical work by creating a number of benchmarks for its manufacturing performance. Five leading companies from the sector are taking part in the current exercise which is being led and facilitated by PICME, the Process Industries Centre for Manufacturing Excellence. The five UK compounders from the BPF compounders group taking part are Albis, Distrupol, Hellyar, Asahi and JPG Perrite.

A structured approach to industrial benchmarking will be offered in a group setting in order that the companies can learn form each other's experiences and methods.

The PICME benchmarking suite of tools - especially developed for the process industries - will be used.

Each company will initially collect data on their business and operations metrics.

The data will then be processed and feedback to each participant individually and supported by a written report and on site visit.

As part of the exercise a group report will be generated which will show the performance of the group on key operational and business metrics.

This will also be presented to participating firms.

The first batch of company feedback is expected in the next 6-8 weeks.

PICME is no stranger to plastics compounding, having undertaken manufacturing assessments, benchmarking and masterclasses at a number of important UK sites, including names such as Doeflex, Vita and Stakehill.

For the past two years PICME has also sponsored the compounding section of the Plastics Industry Awards.

PICME consultant Steve Williamson notes that group benchmarking can be a difficult process - but the eventual gains for the industry can be enormous.

'The benefits of collaborating in this way come out in the opportunities to learn about best performance and practice - even from other related sectors,' says Williamson.

Good customer service or safety practices, for example, are often readily transferable from other sectors.

Adaptation skills, however, are often needed, and this is where the PICME/BPF sponsoring forum can make all the difference and provide invaluable assistance.' Peter Davis, Director General of the British Plastics Federation is delighted that the compounding sector of the plastics industry is engaged with this element of PICME's work.

He encourages others - especially in plastics processing, and in injection moulding - to do more in terms of their manufacturing improvement and world-class competitiveness.

'We have long been a supporter of PICME and its manufacturing mission and are pleased to be using the organisation's skills in this way.

My hope is that more and more UK plastics processing companies will raise their manufacturing performance through use of PICME's services, tools and techniques,' he adds.

In addition to plastics compounding PICME has also recently facilitated group benchmarking exercises for the batch chemicals, aerosols, and coatings sectors and is also about to start work with the BPF's pipes group in a similar fashion.

Compact dehumidifying dryers have molecular sieves

2007-02-23T03:37:00.002-08:00

Compact dehumidifying dryers with molecular sieves can be installed on the machine or on trolleys and free up much more floor space for the plastics processor.

Sandretto UK has launched a new range of compact dehumidifying dryers, manufactured by Dal Maschio in Italy. The new range is immediately available to UK customers. 'The new designs free up much more floor space for the plastics processor,' comments Chris Whitlam of Sandretto UK.

'The equipment is made in stainless steel and a good deal of attention has been paid to making sure that the design aesthetics lead the field.' The Sandretto UK dehumidifier drying systems with molecular sieves represent the most advanced solution in the continuous cycle dehumidification of all hydroscopic material.

Only a very low percentage of moisture is left before the polymer processing takes place.

The series is comprised of models which can be installed on the machine or on trolleys, realising real dehumidifying plants with one or more hoppers.

The different produced models have an air capacity from 30 to 600m3/h.

Meanwhile Sandretto UK's hot air dryers have been designed for the treatment of non hygroscopic thermoplastic granules.

The temperature is electronically controlled.

Particular technical and structural features guarantee quality production processes and make for large amounts of energy conservation.

The range is composed of various models with air capacity from 30 to 250m3/h and the dryers can be installed on the machine, beside the machine and in sets for centralised installations.

Smallest capacity dryer processes polymers

2007-02-23T03:37:00.001-08:00

Compressed air dryer - the smallest in a range - typically processes polymers at a rate of 1-3 kilos an hour and has capacity of a throughput at up to 10 kilos an hour.

Vienna based Wittmann has introduced the compressed air dryer, the DryMax 15, to its award-winning range of materials dryers. UK sales have already been achieved for Wittmann's newest and smallest capacity dryer, which typically processes polymers at a rate of 1-3 kilos an hour and has capacity of a throughput at up to 10 kilos an hour. Wittmann UK's most recent sale of the DryMax 15 in the UK has been to an insert-moulder producing very small parts at near micro moulded tolerances.

The rate of material per hour needed was 1.4 kilos - ideally suited to the DryMax 15 which is fixed to the customer's injection moulding machine.

'Very often,' says Ed Holmes of Wittmann UK, 'most dryers are overly big for the purpose required.

This customer wanted a more appropriate capacity and the DryMax 15 was the ideal solution.' The Drymax 15 and its elder brother the DryMax 30 are designed for use on moulding machines of between 25 and 150 tonne locking force.

Meanwhile lighting specialist Fotolec has recently invested in a new materials drying and handling systems supplied by Wittmann UK.

The award-winning Wittmann Compact 100 polymer drying unit was chosen to make sure that the Fotolec polymers reach the coating process in optimum condition.

The new Wittmann dryer is playing its part in the production cycle by drying the stored polymer to the optimum temperatures.

Even a small amount of moisture can jeopardise the processing conditions, and these need to be within strict tolerances for successful manufacture.

The Wittmann Compact 100 is consequently fitted with valve technology that will prevent over drying - and overpaying for energy used.

After drying the resins are then delivered to the Fotolec production line via Wittmann's S18 single phase hopper loader.

Wittmann UK made sure to optimise Fotolec's processing by trialing its materials on a standard machine off-site - and then, once satisfied, supplying the company with the Compact 100 for full production.

Pre-processed polyethylene gives better properties

2007-02-23T03:36:00.003-08:00

Pre-processed polyethylene resins provide improved properties - including superior mechanical properties, reusability and recyclabilitiy without using chemical cross linking agents.

Ion Beam Applications, together with its subsidiary IBA Advanced Applications, has introduced a new family of pre-processed polyethylene resins. Called Raprex, these new resins are formulated to provide improved physical properties without the use of chemical cross linking agents. They offer superior mechanical properties, enhanced design flexibility, reusability, recyclabilitiy and reduced cost.

According to Raprex product manager George Forczek, 'Prior to the introduction of these new resins, the preferred way to improve the physical properties of formed polymer products was to utilize chemicals which imparted a high degree of cross linking.

The problem with chemical cross linking, however, is that it ultimately limits the processability and recyclability of the resin in the conversion process.

In other words, parts in final form are not recyclable.' With Raprex resins, however, there is no need for chemical additives.

The cross linking affect is achieved prior to forming the finished parts through radiation processing of the base PE resin.

'Because the cross linking effect takes place primarily in the amorphous region of the polymer, the result is an inhomogeneous cross link distribution in the polymer,' explains Forczek.

'This results in parts that are higher in mechanical properties than their unmodified versions, plus they also are fully recyclable.' Pre-processing of the base PE resin is achieved through a controlled ionizing radiation process as well as other proprietary processes.

'It works equally well with high density, low density and linear low density polyethylene resins,' adds Forczek.

Raprex resins are available in three grades for a wide variety of applications.

Extrusion grade Raprex 100 is used for pipe, tubing, containers, and profiles; injection molding grade Raprex 200 is used for tote bins, pump housings, industrial clamps, and luggage handles; film grade Raprex 300 is used for steel pipe sleeves, greenhouse film, and timber pole sleeves.

Additional applications include bubble packaging and bag applications.

IBA Advanced Applications specializes in the application of radiation processing technologies to industrial products and materials for the purpose of improving product performance and reducing costs.

Its parent company, IBA (Ion Beam Applications), headquartered in Belgium, is an acknowledged world leader in three primary business segments: Technology Services and Equipment, Sterilization and Ionization Services, and Radioisotope Production and Distribution.

Natural flax fibre reinforces plastics car panels

2007-02-23T03:36:00.001-08:00

Flax fibres are being re-discovered by French automotive manufacturers and used as fibre reinforcement for moulded interior plastics panels used in cars.

While textile flax produced in France is exported all over the world for the production of high-quality linen clothes and sheets, these natural fibres are now being re-discovered by French manufacturers and put to unexpected and exciting uses. Increasingly, flax is being used by automotive equipment manufacturers as a source of raw material that is environmentally friendly and less dangerous - in the event of a vehicle crashing - when used for interior panels in cars. Hemp fibres are also employed in industry to provide rigidity for plastics and in buildings as a natural insulator.

Near Yvetot, in Normandy (in North-Western France), newly-formed company Techni-Lin processes flax fibre into interior panels for car doors.

Automotive equipment manufacturers are very interested in natural fibres to make their cars environmentally friendlier and easier to recycle.

In Chemille, in the Maine-et-Loire region (in Western France), Effireal manufactures hemp wool from hemp fibres produced by farmers in the Aube region of Eastern France.

The fibres are prepared and cleaned by the Chanvriere de l'Aube co-operative company.

More and more home owners are looking for natural materials to insulate their properties and are starting to value and appreciate this new use for hemp.

Flax-polypropylene - a winning combination Textile flax is a plant widely cultivated in Northern France for the manufacture of yarn and textiles which are exported all over the world.

But not all the fibres in flax are of the same quality.

'We were looking for a new market, different from that of woven textiles or paper making, to exploit the lower quality fibre,' explains R‚mi Dubost, a farmer in Seine-Maritime and the president of flax-hackling co-operative Centrale Liniere Cauchoise.

(The word 'hackling' comes from 'hackle', referring here to the steel comb used for dressing flax.) 'We came up with the idea of introducing flax fibre into composites.' The heads of the co-operative from Yvetot had met by chance some automotive equipment manufacturers who quickly became interested in their approach, and this is how Techni-Lin came to life in 1995, in the form of a subsidiary set up by the co-operative.

'We took two years to develop our product fully,' explains Francois Asselin, manager at Techni-Lin.

'It is a composite material made from a mixture of 50% polypropylene [PP] fibre and 50% flax fibre.

The ratio of the mixture can also be 60%-40% or 70%-30%'.

This new material is manufactured in Techni-Lin's factory.

Flax units fitted in 2,000 vehicles a day - from 1996, demand gradually increased and, in July 2000, the company installed a new production line and its own thermo-pressing machine.

Today, it provides the interior door panels for the Opel Corsa and the Citroen C5 as well as the rear parcel shelf for the Renault Twingo.

In 2002, Techni-Lin processed no less than 800 metric tonnes of flax fibre and provided the interior door panels for an impressive total of 2,000 vehicles per day.

'Flax is appreciated because it is a very strong natural fibre, which prevents the panel from breaking in the event of an accident,' points out Fran‡ois Asselin.

'It also has the advantage of reducing the weight of the finished product by 20% while yielding cost benefits.' To enter this market, Techni-Lin had to meet the very rigid requirements of the automotive industry with regard to quality assurance.

Indeed, in a few months, the start-up became an approved supplier to the automotive industry (EAQF), was ISO 9002-certified, and also obtained AQP (Product Quality Assurance) quality certification.

For Francois Asselin, there is no doubt that the market can only grow.

'In Europe, there is a wealth of interest in composites made from natural fibres,' he says.

'Other industries are also interested in this type of product.

For example, a designer has just produced his first table from one of our composites.' Hemp - a natural insulator also used for making lightweight concrete Industrial hemp is also grown in France, but traditionally for the paper industry.

(It should be pointed out that industrial hemp, as distinct from Indian hemp, contains, according to French regulations, less than 0.2% THC, the psychotropic substance present in Indian hemp.) The search for more natural products in all sectors of activity was taken up by hemp producers and especially by the Chanvriere de l'Aube co-operative - a group of slightly more than 300 hemp farmers in Eastern France, who process the production from 6,000 hectares of hemp.

'We were looking for markets for our products and we investigated the possibility of manufacturing hemp-wool as an insulator for homes, as an alternative to glass-wool or rock-wool,' explains Yves B‚trencourt, the co-operative's sales manager.

'We met companies interested in this use of hemp, such as Effireal and Natilin (in Western France) and Buitex (near Lyons).

Trials quickly showed that hemp-wool exhibited the same insulating properties as glass-wool.

It even has the advantage, compared with glass-wool or rock-wool, of regulating interior humidity, which brings additional comfort in the home.' Hemp-wool does, however, have a disadvantage, in that it is quite expensive, at EUR 8 to EUR 15 per m2, or 2.5 to 4 times as much as glass-wool.

'This product appeals to those who are concerned about the environment and who are committed to using natural products in the construction of their homes,' notes Pierre Barth‚lemy of Effireal.

'Many others are interested in the idea of using natural fibres but are reluctant to pay the extra.

For hemp-wool to be used by everyone, we would need a certain amount of assistance from the government, such as tax incentives, like those for solar energy.' Fibres from ChanvriŠre de l'Aube are also used for making insulating panels and lightweight concrete.

Indeed, the co-operative is in the process of developing breeze-blocks containing hemp, and intends to file for a patent shortly.

'Today, the building sector makes up 15% of our market, but I am sure that it will represent much more in the future,' predicts Yves B‚trencourt.

'The market is still in its infancy.' Hemp reinforces superior organic plastics Hemp, like flax, is also used in the interior trim for cars.

'In this market, natural fibres have great appeal for manufacturers since they weigh only half as much as glass fibre, for which they are a substitute, and are half its price,' says the spokesperson for ChanvriŠre de l'Aube.

Similarly, the co-operative has recently turned its attention to rigid plastics.

To enter this market, it formed, with Eurochanvre (a subsidiary of cereal growers' co-operative Interval, in the Haute-Saone region), a company called Agro Fibres Technologies Plasturgie (or AFT Plasturgie).

'We are still at the research and development stage with it, but the first plastics reinforced with hemp fibre have already been tested and the first products should be available [commercially] shortly,' says AFT manager Gerard Mougin.

'The plastics manufacturing market is vast, and ranges from computer cases through to household electrical products, and includes plastic furnishings, vehicle dashboards, food crates, and moulded packaging - the possibilities are endless.' The big advantage of natural fibres, compared with glass fibre, lies in the fact that organic plastics are less abrasive, easier to mould and cut and, above all, easier to recycle than artificial (or conventional) plastics.

Fibres at work - in the Techni-Lin factory, the natural flax fibre, bleached or coloured, is mixed with polypropylene fibre.

The mixture is homogenised and stretched into a fine layer of non-woven fibres, and several dozen fibre layers interlocked by needles constitute the mat.

The mat is several millimetres thick and weighs, depending on the products, between 150 and 3000g/m2.

It is cut up and then usually sent in this form to the equipment manufacturers, who then thermo-press the finished product.

For certain models, Techni-Lin itself takes care of the compression stage of the process.

In its factory, ChanvriŠre de l'Aube separates the hemp fibres from the central stem of the plant and the seeds.

The fibres are sent to Effireal, for instance, which then takes over.

'We work the fibres to obtain a product to our requirements,' says Pierre Barthelemy at Effireal.

'We apply to them a fire-retardant treatment, then mix them with some polyester.

The fibre sheet is then heated in an oven, which causes the polyester to fuse and link the hemp fibres together.' Effireal markets the hemp-wool in the same way as glass-wool is sold, in rolls that are 10cm, 8cm, or 6cm thick.

Report underlines thermoplastic polymer innovation

2007-02-23T03:33:00.000-08:00

In a market teeming with participants and products, thermoplastic polymer manufacturers have taken to product innovation in a big way to tap new markets and find fresh sources of revenue.

In a market teeming with participants and products, thermoplastic polymer manufacturers have taken to product innovation in a big way to tap new markets and find fresh sources of revenue. Innovative biodegradable polymers (BDPs) made of renewable raw materials and special grades of reinforced compounds are making their way into the manufacturing processes for environmentally-friendly electronic notebook housing and packaging of silicon chips, and enterprising BDP manufacturers are moving out of the confines of food packaging, agricultural film and other small-scale applications to the electronics market. These innovations and market expansions are likely to see them grow at a double-digit growth rate to generate more than $525 million by 2009.

New grades of liquid crystal polymers (LCPs) are also finding uses in the electronics market such as for production of lens holders for optical pick up parts in CD-ROM and DVD drives, creating additional streams of revenue for the $249.3 million market.

Manufacturers of cyclic olefin copolymers (COC) are exploring fresh possibilities by developing improved impact- and heat-resistant products for light-guide plates in LCDs and automobile headlamp parts.

This market is expected to grow at a compound annual growth rate of 3.8 per cent to finish at $59.8 million in 2009.

The $116-million polyketone (PK) market is set to witness a boom with 249 new applications being commercialised in six months by 31 March 2003 and another 1,380 projects in the pipeline.

Injection moulding is the new buzzword in the market, although film extrusion and blow moulding uses are not lagging far.

The electrical and electronics vertical has opened up exciting possibilities for PK in the manufacture of critical materials designed to transport and protect microchips and electronics.

There is also a surge in demand from energy-related applications and medical devices.

By establishing production units in new geographical markets - especially Asia - market participants are hoping to increase sales as well as capitalise on the lower labour costs.

Major multinational companies are seeking a presence in all three major world regions (Asia Pacific, North America and Europe) to expand their global marketing reach.

While established participants are making strong gains, entrants are being compelled to strike up licensing agreements with recognised suppliers to gain a toehold in these developing polymer markets.

This method is preferable to the costlier options of acquisition or development of a new business.

Brian Balmer, Industry Analyst from Frost and Sullivan, points out, 'Selecting the right company to partner with as an entrant is important to not only boost sales of products but also drive awareness.

It also helps to own an excellent and growing repertoire of versatile products.

Partnerships and alliances have helped relax the stranglehold of a few multinationals on the industry and made it easier for the smaller companies to compete.' Entry of more participants is likely to lead to greater price competition, stimulating further application development.

By constantly introducing new polymers or compounds/composite materials, the developing thermoplastic polymer market is set to thwart competition from traditional materials manufacturers.

Originality in product design and features and the superiority of performance are expected to help polymer companies distinguish themselves from competitors.

For instance, the COC market has developed disposable insulin pens that enable diabetics to deliver their own medication safely and quickly.

Such 'smart' devices not only raise the bar on innovations in drug delivery systems but are also vital product differentiating factors.

The numerous advantages of the innovative polymers over competing products notwithstanding, high costs are restricting mass uptake.

To make inroads into mass market applications, companies will have to slash prices considerably, especially since the costs of commodity plastics have fallen drastically.

'Various challenges including high costs and a crowded marketplace limit the wider acceptance of innovative polymers in large-scale applications,' notes Balmer.

'Producers are remedying the situation by continuously improving the property profile of their products, leading to greater market growth.' Title: Innovations in the Engineering Plastics Market Code: B256.

Review compares rubber and TPEs

2007-02-15T01:03:00.003-08:00

A review covering thermoplastic elastomers that have the elastic behaviour of rubber and the processability of thermoplastics, includes comparisons between the two material types.

Thermoplastic elastomers (TPEs) have the elastic behaviour of rubber and the processability of thermoplastics. The Freedonia Group has forecast that demand will expand by 6.4% per year to around 2.15 million tons in 2006. There is potential for these new, exciting materials to expand into the much larger thermoset rubber markets.

This latest Rapra Review Report, Developments in Thermoplastic Elastomers, includes comparisons between the two material types.

The review covers the structure, chemistry, performance and application of TPEs for the most recent 8 year history since the previous Rapra Review Report by J.A.

Brydson was published.

There are three major types of TPE: block copolymers, rubber/plastic blends and dynamically vulcanised rubber/plastic alloys known as thermoplastic vulcanisates.

The chemistry of these materials and how their unique properties are achieved are discussed in this review.

There are many developments taking place in this field.

These are discussed in the review.

Specialist grades are being introduced for specific applications and with unique properties, such as softness or processability.

New types of styrene block copolymers have improved high temperature ageing, fluid resistance, elastic recovery and set.

New block copolyester TPEs have better blow moulding processability, softness and high dynamic flexing fatigue performance.

One of the advantages of TPEs over thermoset rubbers is that they can be processed by standard plastics processing methods.

This review considers rheology, injection moulding, extrusion, blow moulding, thermoforming and other secondary processes.

There are a variety of factors to consider when designing with TPEs, which are discussed here.

One particular advantage is in combining components of a product as TPEs can be co-injected or used in overmoulding, reducing assembly steps.

Developments in thermoplastic elastomers will be of interest to producers of TPEs, designers and manufacturers.

The review is accompanied by around 400 abstracts from papers and books in the Rapra Polymer Library database, to facilitate further reading on this subject.

A subject index and a company index are included.

The author of the review, Ken Kear, has worked as a Senior Applications Specialist with Advanced Elastomer Systems.

He has over 20 years of extensive experience in developing and working with thermoplastic elastomers.

He is a member of the Society of Plastic Engineers (SPE).

Twin screw compounder acquired for development

2007-02-15T01:03:00.001-08:00

A leading polymer research and test house has ordered a new twin screw compounder from Rondol Technology in order to enhance its capabilities in thermoplastics compounding development.

Rapra Technology, Europe's leading polymer research and test house, has ordered a new twin screw compounder from Rondol Technology in order to enhance its capabilities in compounding and compound development. The new 21mm twin screw machine will initially be used in work to establish new nanofilled thermoplastic compound technology. Possible applications are set to include flame retarded products; biodegradable materials, and barrier membrane materials.

The Rondol compounder will also be available for compound development and client consultancy.

Business manager for Polymer Processing at Rapra Technology, Emyr Peregrine explains that 'our new Rondol machine offers an ideal combination of flexibility, output and power input.

We are very fortunate to have such supplier expertise close by - in Stone, Staffordshire - and are now looking forward to expanding our operations in the nanofiller compounding area.' A number of Rapra partner companies are already set to participate in the new nanofiller compounding work and Rapra welcomes interest from other companies.

Rapra Technology has been investing across the board; in analytical, testing and design equipment, as well as laboratory sized processing machinery.

Overall some œ400,000 in capital purchasing was released for spending at Rapra's Shawbury HQ earlier in the summer of 2003, much of this in the analytical services area.

The investment was the biggest ever made by the consultancy over the course of its 80-year history.

The new capabilities will strengthen Rapra Technology's position at the forefront of independent polymer analysis in Europe.

Rapra Technology Chief Executive Andrew Ward notes that recent investments have been enabled by the new structure of the company.

'At the time of the Management Buy Out in July 2002 we promised investment in the fundamentals.

Polymers and composites expand applications range

2007-02-15T01:01:00.000-08:00

Innovative polymers and composites, such as long glass-fibre reinforced thermoplastics, are dramatically broadening the range of applications and commercial production of thermoplastics.

Innovative polymers and composites are dramatically broadening the range of applications and commercial production of thermoplastics. Made from both well-established and novel polymers, materials such as long glass-fibre reinforced thermoplastics, wood-plastic composites (WPC) and nanocomposites are experiencing high growth despite being relatively developmental markets. Nanocomposites are forecast to be the highest growth market, but from a rather small base.

WPCs, on the other hand, are a profit-generating market in North America although their penetration in the Europe is just beginning.

Brian Balmer, Industry Analyst from Frost and Sullivan explains, 'The high cost and lack of a mass market has restrained the uptake of these materials thus far, but the WPC market is set to take hold in Europe and Asia as a growing number of extruders emulate the U.S.

and adopt WPC in construction applications.' Since Europe lacks a decking market, WPC technology uptake will take place in a different manner in comparison with the United States.

Focus will be on specialised applications and intricate products such as window profiles, skirting boards and some furniture applications.

Thermoplastic composites are expected to replace metals and thermosets in numerous applications as they offer remarkable advantages over these traditional materials.

Durable, light, environmentally-friendly and chemically stable, composites also offer a myriad of possibilities in terms of optimising materials to suit applications.

This adds further to their attractiveness.

LFT is one of the fastest growing plastics industry sectors and automotive applications account for over 95 per cent of the worldwide demand.

In Europe, an annual growth rate of 10-12 percent was observed during the period 1999-2002.

'The automotive industry is the main driver for the European long fibre reinforced thermoplastic (LFT) market, which has been expanding faster than other LFT markets,' notes Balmer.

'New applications include under body panels, front-end modules, and door panels.' Acceptance of nanocomposites has been relatively slow despite the initial promise of 'a dream material for the 21st century.' Nevertheless, the market is expected to pick up rapidly in the near future.

While carbon nanofibres and nanotubes are currently under development, nanoclays are already finding applications in high barrier resins for food packaging and in some automotive applications.

'Ongoing R and D efforts, growing demand for conductive compounds, miniaturisation of electronics parts, improvements in processing machinery and the development of new applications will open more avenues for these materials,' adds Balmer.

Continuous product improvement and innovation hold the key to the further development of innovative composites.

As globalisation and consolidation increase, developing new markets, both in terms of new end users and geographic expansion, is crucial.

Lowering cost bases, speeding up innovation, and building expertise will help LFT suppliers to attract/retain automotive end users.

Companies also need to enhance their customer services, and technical support.

In the WPC market, participants are increasing marketing budgets to raise awareness and adhering to building industry standards to expand revenues.

Licensing, formation of strategic partnerships, and acquisition can help new companies build market share.

In the meantime, nanocomposites suppliers are focussing on developing new products through the compounding process.

Efforts are on to toughened nylon nanocomposites for injection moulding and high-viscosity nanocomposites for blow moulding.

Engineering plastics improve semiconductors

2007-02-15T01:00:00.000-08:00

Many semiconductor manufacturers have recently raised concerns over the availability or extremely long lead times for engineering plastics, but a reeadily available material offers better performance.

Victrex continues to make strategic investments in its supply chain, technical and market support, which enable it to offer readily available high performance materials to customers anywhere in the world. These investments are particularly appealing to semiconductor fabs who are currently facing issues over the availability of other engineering plastics. This positions Victrex and the Victrex PEEK family of products as ideal solutions for end users seeking stable supplies of high quality, high performance materials.

Many fabs have recently raised concerns over the availability or extremely long lead times for engineering plastics (such as certain PPS grades) for use in CMP (chemical mechanical planarization) retaining rings.

Victrex PEEK offers proven superior performance in these applications.

Victrex currently supplies Victrex PEEK polymer to a range of wafer fabrication facilities across the world, including facilities in Europe, China, Japan, Korea and Taiwan, through a network of fabricators.

'We've been using Victrex PEEK polymer for the rings for a number of years and our customers are very pleased with the results,' said Bill Kalenian, engineering project manager at Strasbaugh.

'Victrex PEEK polymer is widely acknowledged as one of the premier high-performance thermoplastic materials for CMP rings because of its unique range of properties including inherent purity, strength, chemical resistance, and wear resistance.

Because Victrex PEEK polymer can be machined to extremely tight tolerances and is compatible with process components such as slurries, it has proven ideal for CMP rings, affording more wafer passes during fabrication - resulting in lower downtime and lower cost per wafer.' Strasbaugh purchases the Victrex PEEK polymer blanks from CDI Seals in Humble, Texas, USA.

* test results Revealed - 'One of the key drivers in this area is developing better, longer-wearing CMP rings to match the advancing performance of other critical CMP equipment consumables that complement the CMP head,' said John Walling, Victrex Americas semiconductor manager.

'Materials used in CMP rings in the past have included PPS, but wear tests reveal that CMP rings made from Victrex PEEK polymer have a useful lifetime of up to 2.5 times when compared to PPS.

At Victrex, we are strongly aware of the need for compatible long-life parts and are continuing to develop our materials in line with these technology advances.' Walling continued: 'In the semiconductor sector and in particular CMP retaining rings, our high performance polyaryletherketone material is often the difference between process success and failure.' He said: 'We have customers in the United States and Asia that have switched from PPS to Victrex PEEK polymer because of our application expertise and the product high performance.

Victrex PEEK polymer-based CMP rings enable more wafer passes during fabrication, resulting in lower downtime, and lower cost per wafer.' * Victrex's supply chain strategy - 'The importance of the security of supply in the semiconductor sector cannot be underestimated,' said Blair Souder, commercial director at Victrex.

'It's essential that semiconductor fabs have the material they need when they need it.

Wafer fabs are 24x7 facilities that need a constant supply of high quality, batch-consistent materials.

If a material is unavailable, the cost of delays is immeasurable.

It's not only that the wafer is delayed, but the subsequent effect in the consumer market as the end-product release date is pushed back is often critical.' Assurance of supply and investing ahead of demand has always been part of Victrex's business strategy.

The company is self-sufficient in the manufacture and supply of both Victrex PEEK polymer and its key monomers.

Victrex has made significant investments in two key components of its supply chain.

First, Victrex has backward integrated its raw material supply chain to better control quality and availability for its polymerization facilities.

This was achieved primarily by acquiring, and subsequently upgrading, these facilities.

Second, the company has continually added capacity ahead of demand to ensure a continual supply to customers.

The most recent investment is another Victrex PEEK polymer plant, currently under construction, which will bring the company's total capacity to more than 4,200 tons.

These investments allow Victrex to better control supply, costs, and quality, and ensure availability to customers.

MS screener provides equal feed distribution

2007-02-15T00:59:00.000-08:00

Rotex Europe has announced the installation of the first MS Screener in Europe.

Rotex Europe has announced the installation of the first MS Screener in Europe. Sold and installed in The Netherlands to a very important company (which prefers to keep its anonymity) in the Agro Processing field, the MS Screener is the perfect solution to all screening requirements at high temperatures and large volumes. The MS Screener provides unsurpassed screening performance when exact separations and high efficiencies are required, and maximises product recoveries at material temperatures up to 200andordm; C.

Specifically designed to screen fine products at high capacity, the MS Screener provides excellent screening performance due to equal feed distribution to all screen decks, uniform bed-depth across the entire screen surface and a reduction in screen blinding, due to the use of durable declogging balls.

The stacked, multiple-deck, tray access design allows for individual screen access without the need to remove all decks.

A patented Lift- Rail system enables easy installation and removal of the screen frame.

Access and maintenance are simple with single decks being able to be changed in ten minutes - with all 12 decks changed in just two hours.

The screen deck is sloped to an angle of six degrees, which maximises screen efficiency and meets demanding product specifications.

An easily accessible external drive cartridge allows continuous operation at temperatures up to 200C and is designed for 200,000 hours of service.

The MS Screener utilises a support shaft suspension system with industrial U- joint bearings and no maintenance, low torsion centre springs.

An optional floor-mounted suspension stand is available for installations without overhead support.

Abrasion-resistant steel construction and 'rockbox' landing areas allow for repeated impact on high-wear surfaces.

The MS Screener incorporates a new silicone seal system that press fits into place without adhesives.

The seal is universal throughout the machine providing exceptional sealing between screen decks on fine separations.

A unique sleeveless brush system on the discharge doors eliminates traditional connecting sleeves for quicker screen deck access.

Integral vent connections enable enhanced dust control on dustier materials.

This newly designed product demonstrates that the food industry remains a key market sector for ROTEX EUROPE, in addition to mineral, chemical and plastic applications.

Rapid prototyping service for membrane switches

2007-02-08T22:52:00.001-08:00

Danielson has launched a new rapid prototyping service for use with all membrane switch and keyboard projects.

Danielson, one of Europe's leading developers and manufacturers of membrane keyboards, touch screens and electroluminescent lamps, has launched a new rapid prototyping service for use with all membrane switch and keyboard projects. Intended to help customers reduce product design and development times still further, the new service forms the latest part of an ongoing programme of investment in the company's UK production facilities. Ben Phelan, Marketing Manager for Danielson, explains that, 'Although we have always been able to produce keyboard prototypes relatively quickly, the new membrane prototyping service means that, for many projects, we will be able to produce working samples for customers within days; this is significantly better than the average for this part of the electronics industry, which is typically weeks rather than days'.

He adds, 'Perhaps as importantly, the ability to produce flat and embossed overlays and composite keyboard assemblies, and to incorporate complex, digitally printed half tone graphics, quickly and efficiently means that we can help customers design and, where appropriate, redesign products from concept stages through to final high and low volume production.

As a result, we believe that we will be able to improve the functionality, performance and reliability of the finished products, without adversely affecting the overall cost'.

This significant reduction in turn-round times has been achieved through the use of the latest computer aided production technology, combined with streamlined and carefully monitored production control processes.

For example, Danielson has extensive CAD resources, automatic 200W large area laser cutting systems, multiple high speed screen print lines and in-house embossing facilities; additionally, as part of a larger European group, the company has access to additional production operations in Sweden, Holland and Hungary.

Copolymer opaque resins are injection mouldable

2007-02-08T22:51:00.002-08:00

Weatherable copolymer resin line includes two new opaque grades specifically designed for injection molding and provide provide outstanding impact strength, good stiffness at light weight.

GE Advanced Materials, a division of General Electric Company has expanded its Lexan SLX weatherable copolymer resin line with two new opaque grades specifically designed for injection molding. The new materials - Lexan SLX EXRL0124 and Lexan SLX EXRL0125 resins - were developed to address environmental issues and costs associated with painting plastic parts in applications that require long-term retention of color and gloss in demanding outdoor use. Polycarbonate (PC) provides outstanding impact strength, good stiffness at light weight, the ability to maintain mechanicals over a broad temperature range, high gloss, excellent tintability and paintability, option for water-clear transparency, and excellent moldability.

In challenging outdoor applications, however, scientists have traditionally needed to use UV additives to help stabilize the polymer, and tints, pigments, or paint to mask color shift.

Hardcoat technology has been employed to improve scratch and chemical resistance, and alloying and blending has been used to expand the chemical resistance for uncoated PC components.

Lexan SLX resin effectively improves the weatherability of polycarbonate.

The new material is a copolymer technology that has been derived from polyester carbonates and resorcinol arylates.

When exposed to UV light, the new copolymer undergoes a photo-fries rearrangement and produces a new structure that is inherently a UV screener, essentially making the resin self-protecting.

The Lexan SLX resin technology was initially deployed by GE Advanced Materials in a high-gloss film for use with in-mold decorated parts for the automotive industry.

Comprised of a clear cap layer over a colored layer (flat or metallic), the film maintains dimensional stability over a broad temperature range and can be back-molded onto a variety of substrates to create a Class A surface.

This technology provides excellent weathering, outstanding chemical and scratch resistance, plus excellent gloss and depth of image (DOI), which are all necessary to meet the automotive industry's demanding aesthetic requirements.

Lexan SLX film is now available from GE Advanced Materials in multiple gauges.

In June 2003, GE introduced the first, injection-molding grades of this copolymer, which are transparent and, in laboratory testing, demonstrate excellent weathering (seven+ years), high light transmission (>83%), and low haze (<1%), with performance and processing much like standard polycarbonate materials.

Depending on weathering conditions, the new materials offer five-to-10 times better gloss, color, and light transmission retention than standard UV-stabilized polycarbonate.

After a slight initial color shift, the transparent grades of Lexan SLX resin offer a longer lifetime of UV stability and clarity vs.

traditional UV-stabilized polycarbonate.

This makes the transparent grades of Lexan SLX resin an ideal candidate for lighting applications, including covers, refractors, and lenses.

With today's announcement, GE Advanced Materials has expanded the Lexan SLX resin technology still further with two new opaque grades that are high gloss and can be pre-colored in a range of hues for paint-replacement in injection-molded parts.

Unlike many self-colored, weatherable polymers and alloys, the new Lexan resin grades offer higher chemical, thermal, scratch, and weathering resistance.

Post-weathered ductility is high, while most other physical, mechanical, processing, and shrinkage properties are very similar to standard PC grades.

The new Lexan SLX materials are being positioned for use in components for sporting goods, automobiles, recreational vehicles, agricultural equipment, and telecommunications enclosures.

'When exposed to UV light over time,' says Kurt Schuering, global Lexan product manager, GE Advanced Materials, 'traditional weatherable polymers can lose gloss, where this exceptionally tough copolymer technology can withstand the rigors of long-term outdoor use virtually unscathed.

Key to this is the product's unique ability to actually become a UV absorber, potentially extending the service life of the part by protecting both surface appearance and physical properties.

Due to their outstanding performance, gloss retention, and color stability, these new grades potentially hold the answer to the many challenges that outdoor equipment manufacturers in several areas have had to deal with for a long time,' Schuering said.

Some of the first commercial applications for the new opaque grades of Lexan SLX resin include industrial backhoe fenders and the housing for a wireless infrastructure product from NexGen City.

In both cases, the material was selected after testing revealed it met customer requirements for chemical resistance, weatherability, thermal stability (-40 to 77degC), impact resistance, processability, and knit-line/flow characteristics.

In the case of the backhoe fenders, Lexan SLX resin offered better design flexibility, weatherability, and ductility than painted dicylopentadiene (DCPD).

For the NexGen City communications housing, the material replaces painted steel at lower weight and better design flexibility.

No other thermoplastic tested by the customer passed the long-term impact and gloss retention requirements.

According to Dave Meitzen, NexGen City, chief operating engineer, 'We're very pleased to be using GE's Lexan SLX resin for NexGen City's wireless infrastructure product, which we are currently deploying in a 60-square-mile area around Garland, Texas.

Once complete, this system will serve as the wireless backbone for the city's first-responder - fire, EMT, and police - emergency personnel.

This is a proven, leading-edge technology and a huge homeland security application for us, and Lexan SLX resin helped play a major role in its development,' Meitzen said.

Thermoformable composite replaces steel in bonnet

2007-02-08T22:51:00.001-08:00

A major UK automotive molder will be replacing the steel with a low-pressure thermoformable composite in the bonnet/hood of a high-powered sports vehicle.

As the result of a joint development, GE Advanced Materials' Azdel Superlite composite will be used by BI Composites, a major UK automotive molder, to replace the steel in the bonnet/hood of a high-powered sports vehicle to be launched by a leading international carmaker in early 2004. The bonnet development was driven by the need to provide a cost-effective material solution that could be applied to low-volume production, niche segment vehicles. Key application criteria included recyclability, impact strength, low weight combined with high stiffness, the ability to bond with steel, extremely low coefficient of thermal expansion (CTE), and the ability to obtain a Class A finish with strong paint adhesion.

BI Composites tested a range of high-temperature engineering thermoplastics before selecting Azdel Superlite composite as the material that offered the optimum balance of properties and met the cost-reduction target.

While initial series production using Azdel Superlite composite indicated a premium over that for a steel bonnet skin, the tooling cost for a steel skin solution could only be justified by amortization over high-volume production.

In contrast, tooling for Azdel Superlite composite is a substantially lower investment because of the material's low-pressure formability.

With a EUR 70,000 (approx.

$88,000 USD) tool, meeting a production level of 15,000 units per year, and the process being developed to achieve 150,000 units from a single tool, unit cost represents a 50 percent savings over low-volume steel production and a 75 percent savings over comparable thermoset composites.

This illustrates the competitiveness of Azdel Superlite composite and the low-pressure forming process for vehicle production volumes of between 500 to 50,000 units, whereas steel shows savings after 100,000 units.

'This development also achieved a very considerable weight savings,' says Mike Birrell, business development director for BI Composites.

'With an optimized skin thickness of two millimeters, Azdel Superlite composite gave greater stiffness than the steel it replaced at 50 percent lower weight.

As part of our benchmarking process we also produced a bonnet skin in a carbon fiber/epoxy composite, however, it weighed as much as steel in this application.' The performance of Azdel Superlite composite bonnets was independently measured.

In high-speed, offset front-impact tests, the bonnets exhibited less damage than that sustained by similar steel panels tested under the same procedure.

Moreover, the bonnets' adhesive bonding remained intact throughout impact testing.

As well as delivering high impact strength, the continuous unidirectional glass fiber reinforcement of Azdel Superlite composite, and its thermal stability, enable a Class A paint finish.

The material's surface is flame treated and prepared with a standard polypropylene primer before painting with a finishing coat.

'With Azdel Superlite composite, we are offering the outstanding combination of light weight, high impact strength, and thermal stability properties,' says Gordon King, commercial director of Azdel, Europe.

'We expect Azdel Superlite composite to benefit OEMs in the automotive industry for specific applications - from interior to bonnet - where, previously, composites would not have been considered.' GE Advanced Materials' Azdel Superlite composite is a low-pressure, thermoformable composite developed specifically for automotive applications.

composite is based on short, chopped-fiber reinforcement, with a glass content of 42 to 55 percent and a weight of 600 to 2,000 grams per square meter.

The material can be compression molded in less than one minute at very low pressures of 0.5 to 5 bars.

This ratio of fibers to polymers, as well as the base weight of the web, can be customized for different interior and exterior automotive applications.

Characterized by light weight, a high stiffness-to-weight ratio, good dimensional stability, and high impact resistance over a wide temperature range, Azdel Superlite composite allows engineers to design high-performance components that can replace steel, meet aesthetic demands, and contribute to vehicle weight reduction.

Azdel Superlite composite's good polypropylene/fiber bond enables it to be recycled into other engineering applications at the end of its first-life use.

BI Composites, a leading producer of molded components for executive and luxury cars, is a business of the UK-based BI Group Plc, an international group of specialist engineering companies.

The company has annual worldwide sales of approximately ?

200 million (approx.

$364 million USD) and employs more than 2,000 people in 14 countries.

Azdel Superlite composite is produced and distributed by Azdel, a joint venture of GE Advanced Materials and PPG.

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

Low-pressure, thermoformable composite cuts weight

2007-02-08T22:50:00.000-08:00

Low-pressure, thermoformable composite of a polypropylene resin matrix and chopped-fibre reinforcement reduces weight and enhances performance in automotive interiors.

Already achieving successes in automotive interior programs, which include headliner, sunshade, and parcel shelf applications in the U.S., Australia, and China, Azdel Superlite composite is now being trialed by automotive OEMs in Europe. Azdel Superlite composite is a low-pressure, thermoformable composite of a polypropylene resin matrix and chopped-fiber reinforcement. Developed specifically for automotive interior applications, the material offers light weight, a high stiffness-to-weight ratio, good dimensional stability, and high impact resistance over a wide temperature range.

This combination of properties enables engineers to design components for vehicle weight reduction without compromising part performance or aesthetics.

As well as achieving weight savings of up to 50 percent in some components, Azdel Superlite composite also delivers production advantages.

In headliners - the first application in which Azdel Superlite composite was used - this versatile sheet can be molded directly in one step together with surface textile and special functional layers, thereby eliminating the several production steps required with traditional materials.

Because of the product's high stiffness-to-weight ratio, headliners can be constructed with ultra-thin profiles, down to three millimeters thick, half the thickness of conventional systems.

'The combination of wide versatility and performance properties can make Azdel Superlite composite an excellent material for pre-assembled modular headliners,' says Gordon King, commercial director, Azdel, Europe.

'It allows the entire system to be mounted to a vehicle as a single assembly.

Its light weight and low-pressure formability, often using existing tooling, means that Azdel Superlite composite has the potential to reduce system costs by up to 20 percent.' To meet growing OEM demand for Azdel Superlite composite, Azdel,is expanding its U.S.-based global supply facility in Lynchburg, Va.

The introduction of a third Azdel Superlite composite line will add 7,000 tons to the company's current annual capacity, totaling more than 25,000 tons when it comes on-stream this quarter.

According to James Forden, president, Azdel: 'This investment reflects the strong interest in Azdel Superlite composite by the automotive industry and the global translatability of the application programs it's supporting.

This step-increase in capacity will help further ensure product supply, as well as confirm our ongoing commitment to serve this sector.' With its low-weight advantages, ultra-thin profile, and high stiffness-to-weight ratio, Azdel Superlite composite can be formed with varying thickness and stiffness.

Moreover, it allows manufacturers to use slightly modified existing tooling, helping to prevent creasing during the installation process.

Furthermore, with better moisture resistance and lower emissions than traditional materials, Azdel Superlite composite can be an ideal candidate for interior applications.

The composite was recently chosen by Lear Corp.

for the automotive interior integration program for the Ford GT performance vehicle.

Azdel Superlite composite was specified for the headliner, bulkhead cover, door panels, pillar trims, center console, and instrument panel.

The material met all key criteria and demonstrated its cost efficiency in high-end, low-volume models.

It also helped save an estimated 30 percent more weight per vehicle than conventional injection-molded substrates.

Currently in limited production, the Ford GT performance vehicle is scheduled to go into regular production in spring 2004.

In Europe, modular headliners, rear parcel shelves, door trim panels, underbody shields, and instrument panels made from Azdel Superlite composite are currently under development in cooperation with tier 1 automotive suppliers.

These include a novel instrument panel concept featuring a new NIS seamless airbag system that exploits the high integration opportunities offered by the product (which avoids adding extra parts or materials to the passenger airbag area).

The high load-bearing strength-to-stiffness ratio of Azdel Superlite composite is also opening the way for its integration into new rear parcel shelf concepts now being explored by the industry.

The GE Advanced Materials' Automotive Application Development Center in Southfield, Mich., U.S., and its European Design Center in Bergen op Zoom, The Netherlands, provide the world's leading automotive manufacturers and tier suppliers with extensive technical support.

Expert staff 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, GE Advanced Materials' affiliates, Polymer Solutions in the United States and GE Polymer Design Associates in Europe, can assist customers with a complete set of design and engineering services, or with finding an optimal solution to a specific task.

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

Azdel Superlite composite is produced and distributed by Azdel, a joint venture of GE Advanced Materials and PPG Industries.

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

Azdel Superlite composite customers are provided with support in design, testing, molding, and prototyping to achieve excellent performance and weight reduction in automotive applications (www.azdel.com).

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.

Headquartered in Pittsfield, Mass., GE Advanced Materials is the combined entity of GE's former Plastics, Silicones, and Quartz businesses.

Its offerings include: • Silanes, specialty silicones, urethane additives, adhesives, sealants, caulks, resins, and elastomers for a variety of vertical markets such as personal care, automotive, tire and rubber, construction, healthcare, electronics, household and institutional, agriculture, textiles, appliances, bedding and furnishings, and foam control, as well as the consumer 'do-it-yourself' market

Reinforced polyamide chosen for good weldability

2007-02-08T22:46:00.000-08:00

Good welding characteristics, low warpage and excellent flow characteristics were decisive factors in choosing reinforced polyamide for diesel engine oil separators.

System supplier Bosch Waiblingen Kunststofftechnik, in collaboration with Rhodia Engineering Plastics' Application Development Centre Automotive in Freiburg, has developed housings and other elements manufactured using Technyl reinforced polyamide for two new oil separator concepts for diesel engines. DaimlerChrysler is currently considering using the stand-alone solution of this oil separator with three hose connections for its A-Class diesel models. Series production for other diesel applications, using a cassette version fitted to the aluminium rocker cover, will start in the near future.

The material which will be used for both models is Technyl A 218 MT15 V25, a heat stabilised, glass and mineral reinforced polyamide 66.

It has been selected because it meets the stringent demands placed on its mechanical properties, durability and processing.

In the environmentally-friendly closed crankcase ventilation system, when the engine is running, the blow-by gas finds its way from the combustion chambers into the crankcase.

It then flows through the oil separator.

The gas is an aggressive combination of air, fuel remnants such as water vapour, soot and other combustion by-products, as well as oil mist and oil droplets.

The separator splits out almost all the oil and other fluid particles which are reintroduced into the oil system, while the remaining gas is fed back into the air intake.

The oil separator housing, the coil for the centrifugal oil separator for the larger drops and the support for the fleece which absorbs the fine oil mist, are all made from Technyl A 218 MT15 V25.

The support for the pressure control valve membrane is made of fluorine silicon-coated polyamide.

'We believe that this new type of oil separator will open up a wide range of new market opportunities.

The concept is a real step forward and we feel confident it will be the forerunner of a whole new generation of oil separators', said Eric Noyrez, Director Automotive Business, Rhodia Engineering Plastics.

The combination of glass and mineral particles in this Technyl grade precisely provides the demanding mix of properties required in this application, as well as meeting the demand of high production efficiency.

The hostile environment in which the oil separators are used means that they need to have outstanding rigidity and dimensional stability, high creep resistance and be able to withstand temperatures from -35degC to 130degC.

They also have to resist ageing when exposed to an aggressive mixture of lubricating oil, fuel, water and acids, and external factors such as road salt.

Good welding characteristics, low warpage (which simplifies machine tool construction) and Technyl's excellent flow characteristics were decisive factors in Bosch's decision to use the material.

According to Axel Zschau, Leader Application Development Centre Automotive at Rhodia Engineering Plastics, 'This new development is a result of a high level of co-operation between our two companies.

The challenge was to find a way to combine different oil separation systems in the small space available.

We managed to achieve the maximum system efficiency we were both looking for.

This project is one example of the way in which we work with our customers to help them to develop solutions that, as in this case, are often revolutionary.' Rhodia Engineering Plastics assisted Bosch during the material selection and its optimisation of the manufacturing process.

Rhodia offers its customers a wide range of support services during the commercialisation of their projects, such as flow simulation and finite element simulations, as well as a variety of laboratory tests like ageing, burst pressure and leakage tests.

Rhodia Engineering Plastics, headquartered in Lyon, France, is the worldwide 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 speciality chemicals.

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

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

Website gives faster access to technical support

2007-01-30T23:29:00.001-08:00

Rhodia Engineering Plastics recently launched a new web site built in strict accordance with customer needs (www.rhodia-ep.com) to provide faster access to professional technical support.

Demonstrating its role as a global leader in the polyamide world, Rhodia Engineering Plastics recently launched a new web site built in strict accordance with customer needs (www.rhodia-ep.com) to provide faster access to business information and faster access to professional technical support for the entire product portfolio of Rhodia Engineering Plastics. The web site is really a comfortable and efficient working tool thanks to its new design, ease of navigation and categorized information to enhance searches. Categories of Information: * Material Selector: By a simple click, the material selector gives access to markets, brand, polymer type, processing, charge or product name selection and a web page with a first level of product information is visible.

Technical Datasheets and Safety Datasheets are presented and downloadable after registering on the web site.

* Material Selector Advanced: The advanced part of the material selector allows selecting products using multiple values/ranges that the material type must fulfil.

A link is then proposed to save datasheets of interest in 'my library'*.

* About us: This section provides complete information about the worldwide Rhodia Engineering Plastics organization, including sales and distribution channels.

* Markets: The market pages present major segments and applications where Rhodia Engineering Plastics' products have been used successfully.

* Products: The new Rhodia Engineering Plastics web site is providing all needed technical data about Rhodia brands Technyl, Technyl Star, Technyl Alloy.

* Innovation: New products, new applications and new technologies are demonstrated and illustrated to keep customers informed about new possibilities on a regular basis.

* Customer Technical Services: Rhodia provides information and expertise on technical areas such as Computer Aided Engineering; Parts Testing - Processing guides are also available and updated on a regular basis.

This service is enhanced by the possibility to download brochures.

* Sustainable Development: Information about Rhodia's commitments to Sustainable Development including Rhodia Engineering Plastics' health, safety and environmental policies and recycling engagement.

* News: A quick access to the latest press releases concerning Rhodia Engineering Plastics and Rhodia Group has been created.

This section also presents events (conferences and meetings) where Rhodia is demonstrating and exhibiting engineering plastic products.

* E-services - *'SSOL' is the Rhodia e-business platform.

SSOL enables a customer to place and follow orders online, in a totally secured environment, 24 hours a day, 7 days a week! * 'My Library' offers the possibility to store in one place direct links to technical documents of choice.

* 'Contact Center' provides ease in presenting questions directly to the best support resource according to specific location and market of interest.

'Rhodia-ep.com is an effective platform and the most advanced e-tool available today for engineering plastic consumers.

This web site is another example of Rhodia's dedication to providing the best of services to engineering plastics professionals throughout the world' said Dr Pierre Luzeau, Director for Europe.

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.

Polyamide grades oust expensive foams and layering

2007-01-30T23:26:00.000-08:00

Latest two polyamide grades offer more than 4dB improvement versus other engineering plastics such as glass reinforced PP or PA, removing expensive acoustic components such as foams or heavy layers.

Rhodia Engineering Plastics introduces new polyamide materials which offer significantly improved acoustic performance Rhodia Engineering Plastics 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 Star S 218dB1 M50 and Technyl Star 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 Star S 218dB1 M50 and Technyl Star 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.

Obturators, engine covering systems, distribution covers, bonnet louvers or air pipes in automotive, but also various housings in electrical appliances or sound insulators in buildings are applications currently being re-conceived with this innovative solution.

Technical validation on timing belt cover * Acoustic Insulation measured on parts (Timing belt cover).

* Global acoustic insulation performance.

* Current Solution - (PA.6 MD20GF10 + PUR Foam).

* Rhodia Solution (Technyl Star S218 dB1 M50) Values in green --x-- 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.

European polyamide product costs go up

2007-01-25T05:12:00.001-08:00

Rhodia Polyamide announced price increases of EUR 130 per metric ton for PA 66 base resins and Technyl polyamide 6 and 66 compounds will be increased by EUR 200 per metric ton - in Europe.

Rhodia Polyamide announced price increases of EUR 130 per metric ton for PA 66 base resins in Europe. At the same time, prices of Rhodia's Technyl polyamide 6 and 66 compounds will be increased by EUR 200 per metric ton in that region. These increases are effective as of March 29th, 2004.

The price increase is required to help respond to the continuously rising cost of energy and raw materials, and to the significant erosion of margins at a time when the global polyamide demand is strengthening worldwide.

Rhodia has worked proactively to improve productivity, reduce manufacturing and operating cost over the past years and will continue to sustain these efforts while operating according to highest industry standards and promoting sustainable development.

However, under the current circumstances, these efforts are inadequate to overcome the cost pressures.

Rhodia Polyamide, headquartered in Lyon, France, is the second largest polyamide producer worldwide.

The company provides a wide range of innovative solutions in four main businesses: polyamide intermediates, engineering plastics, high tenacity yarns and fibers for industrial and textile applications.

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.

Internally lubricated cast nylon does not leach

2007-01-25T05:09:00.000-08:00

Internally lubricated cast nylon provides a continuously lubricated surface ideal for applications where maintenance greasing is difficult or impossible.

Quadrant Engineering Plastic Products (formerly Erta and Polypenco) has developed a new lubricated cast nylon grade suitable for packaging, bottling and food processing applications requiring FDA compliance. This internally lubricated cast nylon provides a continuously lubricated surface ideal for applications where maintenance greasing is difficult or impossible. The internal lubricant does not leach out of the material after machining or service wear and gives a lasting and considerable improvement in the sliding properties.

Furthermore Nylatron LFG offers reduced coefficient of friction, improved wear resistance and better machinability over standard cast nylon grades.

Nylatron LFG has successfully been introduced in the food market used as wear strips in food drying towers where lubrication is impossible and the continuous operation temperature goes up to 100degC.

Other targeted applications are all kind of unlubricated moving parts requiring FDA compliance.

The new material is available from Quadrant in the form of plate, rod and tube in both natural and blue colour.

Quadrant EPP offers a broad range of bearing and wear resistant materials that can handle aggressive thermal, wear and chemical environments.

Its products range from its numerous grades of Ertalon and Nylatron and Ertacetal to ultra-high performance polymers that maintain strength at temperatures over 425degC.

Quadrant EPP offers its Extreme Materials, as well as its standard lines of plastic stock shapes, through its worldwide operations, technical support centres and authorized distributors.

Tough body panel polyamide is electro-paintable

2007-01-21T23:14:00.001-08:00

Polyamide grade that has specifically been designed to address vertical body panel needs is electro-paintable, withstands e-coat temperature up to 200degC and simplifies mould tool design.

Rhodia Engineering Plastics has announced the introduction of Technyl A 238P5 M25 blk 5N polyamide. This new grade has been specifically designed to meet the critical technical requirements for automotive vertical 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 200C 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 200 degC 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 160 degC 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.

Polyamide grades perform better acoustically

2007-01-21T23:13:00.000-08:00

Two polyamide grades have an acoustic performance that is superior to traditional engineering plastics and offer more than 4dB improvement over glass reinforced PP or PA.

Rhodia Engineering Plastics has 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.

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 EUR5.5 billion in 2003 and employs 23,000 people worldwide.

Rhodia is listed on the Paris and New York stock exchanges.

Hybrid metals/plastics parts offer many savings

2007-01-13T23:37:00.001-08:00

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.

Cast and extruded PA and POM shapes prices raised

2007-01-13T23:37:00.000-08:00

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.

Papers called for thermoplastic elastomers event

2007-01-12T23:36:00.000-08:00

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 center to further non-metallics research

2007-01-11T23:36:00.000-08:00

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.

Film insert moulding brings component integration

2007-01-11T23:35:00.000-08:00

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'.

Polyamide grades designed for water injection

2007-01-10T02:40:00.000-08:00

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.

Polyamide withstands electro-coat temperature

2007-01-10T02:39:00.000-08:00

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.

Polyamides developed for rotational moulding

2007-01-09T02:38:00.000-08:00

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 described

2007-01-09T02:37:00.000-08:00

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.

Polyamides improve on foams and heavy layers

2007-01-08T02:39:00.000-08:00

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.

UK polymeric-based research is 'alive and well'

2007-01-08T02:36:00.000-08:00

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 products reviewed

2007-01-07T02:36:00.000-08:00

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.

Website brings polymer R + D, manufacturing news

2007-01-07T02:34:00.000-08:00

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.

Enhanced productivity is plastics processors' goal

2007-01-06T23:38:00.001-08:00

While price still remains a critical purchase determinant, selecting the right equipment to realise enhanced productivity and efficiency has become the focal point for plastics processors.

While price still remains a critical purchase determinant, selecting the right equipment to realise enhanced productivity and efficiency has become the focal point for plastics processors. This priority is being reflected in the growing number of partnerships between plastics fabricators and machinery suppliers. 'Selecting the right plastics processing equipment is important and it is not always easy to choose correctly given the plethora of equipment suppliers by category, the increasing need for decreased energy consumption on top of equipment functionality and performance and the ever present capital investment quick payback requirement,' comments Research Analyst Donald V.

Rosato from Technical Insights, a business unit from Frost and Sullivan.

Collaborations between equipment suppliers and plastics fabricators need, therefore, to be flexible regardless of whether the plastics processing equipment is of a primary, auxiliary, software, or services variety.

For instance, an off-the-shelf robotic handling system cannot be standardised globally but needs to be adapted to suit regional requirements.

Worldwide, plastic manufacturers are aiming at boosting energy efficiency, upgrading standard equipment capability in terms of labour and material savings, adding cross-product differentiation features and speeding up marketing cycles.

'To develop these high velocity manufacturing systems, emerging cutting-edge plastic processing technologies are the foundation,' says Mr Rosato.

'True sustainable lean manufacturing excellence comes, however, with customising company needs to their given manufacturing environment.' The growing need to tailor equipment such as robots to accommodate the plastic fabricators' specific manufacturing environments is gaining particular significance in full manufacturing cells, which are defined by minimal production staff participation and designed for 'lights-out' manufacturing.

As plastics fabricators rationalise operations, primary and auxiliary equipment suppliers are being compelled to change accordingly.

For instance, auxiliary equipment supplier Wittmann is locating manufacturing plants in Hungary and China to supplement its Austrian base facility.

At the same time, the company has expanded from robot specialisation to become a full-service auxiliary equipment supplier.

Three way partnerships among globally leading plastics manufacturers and their primary/secondary equipment suppliers are becoming a common feature.

Many of these partnerships such as that between Nypro, Husky injection molding Systems and Hekuma in the area of high-tech state-of-the-art in-mould labelling have proved to be extremely productive and cost effective and have excelled at maintaining the proprietary nature of finished product development.

Whereas plastic fabricator manufacturers have concentrated on accelerated paybacks since they are always looking ahead to new orders, plastics processors have focused on emerging next-generation technologies.

Stellar technical progress has resulted in hybrid hydraulic and electric powered injection moulding machines that now deliver 15-30 per cent faster cycle times and in smart blown film software that has yielded the world's largest and most advanced 9-layer co-extrusion.

Embedded production and process monitoring system has been introduced in injection moulding equipment to create a 'boundaryless plant'.

An improved technology for hot runner moulding has also emerged, which displays breakthrough gating on angled surfaces.

Plastics Processing-Emerging Technologies and Trends Code: D287.

Background - Technical Insights is an international technology analysis business that produces a variety of technical news alerts, newsletters, and research services.

Frost and Sullivan, an international growth consultancy, has been supporting clients' expansion for more than four decades.

Our market expertise covers a broad spectrum of industries, while our portfolio of advisory competencies includes custom strategic consulting, market intelligence, and management training.

Our mission is to forge partnerships with our clients' management teams to deliver market insights and to create value and drive growth through innovative approaches.

Frost and Sullivan's network of consultants, industry experts, corporate trainers, and support staff spans the globe with offices in every major country.

Website supports film insert moulding technology

2007-01-06T23:38:00.000-08:00

Film Insert Moulding is gaining popularity as a method for decorating and manufacturing three dimensional plastic parts and a specialised website is on-line to support the technology.

Film insert moulding is gaining popularity as a method for decorating and manufacturing three dimensional plastic parts. Manufacturers across a variety of industries are recognising its potential and cost benefits, and are increasingly seeking information on the process and related products. With the launch of a new specialised independent website, there is now one portal to provide it.

Film Insert Moulding (FIM), a type of In Mould Decoration, is defined as '.

the application of pre printed film to a moulding as part of the plastics injection process.' It is beneficial in many applications: telecommunications and electronics, such as mobile phone fascias or touch sensitive keyboard pads; industrial moulded display panels; interior and exterior automotive parts and trims; and general consumer logos or badges.

Filminsertmoulding.com has been created to educate end users on the benefits of the process.

Endorsed by, and featuring products from, several key players in Film Insert Moulding such as Autotype International, Formech, Proell and Battenfeld, the website features knowledge and advice for those who wish to find out more about this versatile and cost effective process.

The site contains information on materials, a news section displaying up to date information and the latest technological development; and illustrations of the FIM process using Flash movies and comprehensive diagrams.

'Design Focus' looks at how FIM can enhance design productivity and 'Machine Focus' contains specifications of relevant industrial hardware.

Finally, the website also includes a list of suppliers of FIM products and services, from powerful industry leaders through to smaller specialist suppliers.

Manufacturers can research the FIM process and equipment, and select a supplier straight away.

This demonstrates how filminsertmoulding.com really does provide every necessity for understanding, researching and purchasing FIM, all at the click of a mouse.

Carbon fiber reinforced compounds are more rigid

2007-01-05T23:37:00.001-08:00

A full line of carbon fiber reinforced compounds that are based on chopped carbon fiber, milled carbon fiber and carbon nanotubes provide more rigidity as well as electrical conductivity.

Premix Thermoplastics, announces the addition of a full line of carbon fiber reinforced compounds to the company's PRE-ELEC product portfolio. Based on chopped carbon fiber, milled carbon fiber and carbon nanotubes, the new compounds provide the increased rigidity of carbon fiber as well as the electrical conductivity. Premix carbon fiber compounds are available with as much as 60% carbon fiber in nylon 6 and 66 and PPS, and at least 40% in others, including PP, ABS, PC, POM and PSUL.

The addition of carbon fibers not only increases the flexural modulus (rigidity) of the compound, but also increases the tensile strength, lowers the shrinkage and increases the electrical conductivity.

Compounds that are based on milled carbon fiber are less prone to warpage while compounds that are based on carbon nanotubes can be electrically conductive with as little as 3% fiber reinforcement.

In addition, carbon nanotubes can also create thermally conductive polymer compounds when used at higher loadings.

Standard color is black.

Compounds that are 10% carbon fiber-based are available in a variety of colors that facilitate the color coding of molded parts.

Pre-Elec compounds include most of the commercially available thermoplastics combined with virtually all of the electrically conductive additives including: carbon black, carbon fiber, nickel coated carbon fiber, stainless steel fiber, graphite flake, nickel coated graphite flake, silver and silver coated additives, metal powders and flakes, inherently dissipative polymers (IDPs) and inherently conductive polymers (ICPs).

Premix Thermoplastics is a subsidiary of Premix Oy, a leading manufacturer of electrically conductive compounds in Europe.

It offers customers innovative, reliable and safe plastics raw material solutions in applications ranging from ESD proof packaging to EMI shielding.

Quadrant Plastic Composites receives AVK-TV award

2007-01-05T23:36:00.000-08:00

Quadrant Plastic Composites (QPC) has been presented with the AVK-TV innovation award for work with GMT and lightweight composites.

Quadrant Plastic Composites (QPC), the world market leader in GMT and lightweight composites, has been presented with the innovation award of the Arbeitsgemeinschaft Verst„rkter Kunststoffe - Technische Vereinigung (AVK-TV: Reinforced Plastics Association - Technical Federation) in the Best Application of the Year category. QPC won this award for the underbody shields of the BMW 1 and 3 models, which are manufactured using the new Symalite technology. The AVK-TV Innovation Award is one of the most prestigious engineering awards in Europe in the reinforced plastics field.

Symalite, developed in-house by QPC, is an innovative, intelligent, lightweight reinforced thermoplastic composite material which is compression moulded under application of low moulding forces.

Economical composite moulds enable up to four components to be produced, die-cut and laminated directly with sensitive decorative material without using adhesives, in a single moulding stroke.

Symalite also enables components featuring different thicknesses to be produced: the degree of consolidation is smaller in the flat surface zones and greater in the edge zones and around attachment points, i.e where the greatest forces are at work.

Component manufacturer and systems supplier is Seeber AG and Co.

KG, Mannheim.

Advantages of Symalite: the underbody shields of the BMW 1 and 3 models are light in weight due to their reduced density; weight savings of some 30% were also achieved compared to conventional solutions as a result of using the new SymaLITE material concept, and the fully closed underfloor module makes the use of PVC for anti-corrosion protection unnecessary.

The high rigidity of the material combined with its low weight have enabled the aerodynamics to be improved significantly, thus reducing fuel consumption by 5%.

Acoustics have also been optimised by the semi-consolidated structure, which generates less noise in rain or from stone chips, and - in contrast to fully consolidated structures - absorbs noise.

'We are especially pleased to have won one of the most important European innovation awards with SymaLITE', commented Volker Fritz, CEO of Quadrant Plastic Composites.

'This award underlines the company's innovative thrust and the expertise of its personnel.

In recent years QPC has invested with the future in mind, and we are now earning the benefits.' The AVK-TV presents three innovation awards annually in the categories of: Promoting new industrial solutions; Achievements in environmental protection; Promoting university work in the field of composites and thermosetting moulding compounds.

The specification of requirements in the category 'Application of the Year 2004' was 'a new product ready for the market or a new, efficient manufacturing process.' The product or process advance, the improvement in the cost/benefit ratio and the development of new markets were rated in this context.

'The AVK is proud that Quadrant Plastic Composites from Switzerland has received the award for the best innovation this year, since this company has been an innovative manufacturer for many years and is very well known on the market', stated Dr U.

QPC already received the innovation award for the Most Innovative Use of Plastics presented by the Automotive Division of the Society of Plastics Engineers (SPE) in November 2003 for the underfloor modules of the BMW 5 and 6 models.

Crane performance lifted by non-slip nylon

2007-01-04T23:36:00.000-08:00

The Fassi Group, one of Europe's foremost manufacturers of hydraulic cranes, found its material solution in Nylatron 703 XL plate.

A crane's ability to efficiently and safely position its load requires a virtual absence of vibration during both fine and gross movements of the boom. Lubrication of moving parts helps to achieve this, but more and more, heavy equipment manufacturers are searching for lubrication-free materials that minimize or even eliminate stick-slip influences during operation. The Fassi Group, one of Europe's foremost manufacturers of hydraulic cranes, found its material solution in Nylatron 703 XL plate from Quadrant Engineering Plastic Products (QEPP).

QEPP's nylon material helped to endow Fassi's equipment with very accurate, smooth control over linear boom movements.

Further, it helped to eliminate chatter as sliding parts overcome inertia as they begin to move.

The material's static and dynamic coefficients of friction, which are consistent at virtually every point over its useful range, allowed Fassi's cranes an unprecedented degree of control.

QEPP developed Nylatron 703 XL nylon to meet the increasing demands for precise motion control, safety and elimination of lubrication in the construction industry.

In addition to its low coefficients of friction, the material offers a superb combination of high strength and stiffness as well as high wear-resistance.

Nylatron 703 XL's particular benefit to manufacturers of material handling equipment, however, is its ZERO 'stick-slip' during initial and continuous movements.

Comparative tests performed by an independent research institute established that Nylatron 703 XL has the lowest dynamic and static coefficient of friction of any commercial nylon tested against unpainted services.

Preliminary tests against painted surfaces show identical results.

Fassi's application represents the first commercial use of Nylatron 703 XL parts formed in customized low-pressure casts.

Low Pressure Casting (LPC) processes offer improved economies for plastic parts ranging from a few grams to several kilograms in weight, that carry no wall thickness limitations and that run in series from a few hundred to a several thousands parts per year.

LPC's lower processing temperatures and injection pressures also enable the use of aluminium tools rather than hardened tool steel, further benefiting small volume series and parts produced for evaluation purposes.

Decorative sparkle impregnated into plastics

2007-01-04T23:35:00.000-08:00

An attractive colour finish with a decorative sparkle can be produced from an aluminium impregnation of plastic materials - even in small batches.

An attractive colour finish with a decorative sparkle can be produced from an aluminium impregnation of plastic materials which adds to the presentation of any container for the 'cosmetics' market. Designed and manufactured by Toolcraft Plastics of Swindon in tough PPR, (random co-polypropylene), the thread can be pre-formed into stopper and body, making the complete product 'ready for market' without additional operations. Toolcraft Plastics of Swindon specialise in tooling and manufacture of plastic parts with particular finishes and colours, even in small batches.

Special pre-moulding and mixing techniques guarantee parts with clean finishes and colours with good dispersion.

With experience in plastics of all colours, transparent, opaques, luminescent, even metallics Toolcraft can colour match to existing parts or customer choice, or create a special finish to enhance the product or presentation.

Recyclable plastics make reinforcements

2007-01-03T23:26:00.000-08:00

A 12-month research project undertaken by Pera Innovation has shown that recycled plastic can be successfully used as a reinforcement medium for high pressure engineering applications.

A 12-month research project undertaken by Pera Innovation has shown that recycled plastic can be successfully used as a reinforcement medium for high pressure engineering applications. Pera Innovation, a unique independent research and development organisation, won a grant of GBP 152,420 from The Onyx Environmental Trust through the Landfill Tax Credit Scheme to carry out this innovative research project. Researchers wanted to demonstrate that Polyethylene Terephthalate (PET) fibres and tapes derived from plastic squash bottles and food trays could be treated and reused to manufacture high value reinforced thermoplastic pipes.

The products were also assessed in terms of life cycle analysis to further determine their commercial viability.

A number of prototypes were developed, together with a mechanism for joining the pipes to.

When tested, the prototypes were successful in achieving proof of concept for putting recycled PET from the plastic bottle waste stream into a high added value pipe application, achieving burst pressure exceeding 100bar.

Andy Huang, Researcher for Pera Innovation said: 'Preliminary cost assessments suggest that this pipe will cost less than a third compared with products currently on the market with the same pressure rating.

'Such reinforced thermoplastic pipes could play a major role in the GBP 900m European market for transmission lines used in the oil and gas industries.

By creating this new high value market for low value PET waste, the team has provided a great incentive to recycle and re-use the material.' Margaret Cobbold, General Manager of The Onyx Environmental Trust, said: 'The Trust is delighted to see such encouraging results from this research project.

Pera's innovative approach to identifying commercial opportunities by recycling materials demonstrates environmentally responsible alternatives available to the engineering industry.' Now that the proof of concept has been established, Pera is seeking further industrial sponsorship to develop and demonstrate a full-scale continuous manufacturing facility that will help ensure the technology is adopted and exploited by industry.

With further research, the same technology could be utilised in many other products and market sectors.

Materials driers offer energy savings

2007-01-03T23:25:00.000-08:00

Materials driers offers plastics processing customers a significant key benefi, that of energy saving and fully automatic operation for medium to large throughputs.

Sandretto UK's latest range of materials driers offers plastics processing customers a significant key benefit: energy saving with a market leading performance. Sandretto UK offers two ranges in this area. For small material throughputs a single desiccant system and for medium to large material throughputs two desiccant systems are used.

The DDT model offers: a.High saving of energy.

b.High linear dew-point (up to - 50).

c.Fully automatic operation.

d.Operation without refrigerated water.

e.Operation without compressed air.

In terms of energy saving, the return air from both the process and regeneration is intercepted and recycled, hence reducing the amount of wasted energy.

In more traditional driers the return air is cooled using water and is then reheated again, making for increased running costs.

Any cooling that is required before the air reaches the blower is achieved by a small electric fan.

This procedure eliminates the need for water cooling and gives the DDT dryers a high saving of energy, typically up to 30 - 40% compared with traditional dryers.

Sandretto UK's latest range of drier can link a number of materials hoppers to a single dehumidifier generator unit.

The dehumidifier supplies the air unheated to the hoppers hence eliminating the need to lag pipes.

Each hopper has its own heater and booster blower attached that controls the flow of air through the hopper.

If the hopper is turned off for material change a valve automatically closes off the dehumidified air supply to that hopper.

Chris Whitlam, National Manager for Sandretto Ancillaries and Automation reports that 'our ancillary sales have this year exceeded budget and expectation.

Not only do moulders prefer one-stop-shopping with their injection moulding machinery supplier, they are also ever more cost conscious.

This is good news for our energy saving driers and bodes well for their success into next year.'

Twin drying hopper unit has separate controls

2007-01-02T23:24:00.001-08:00

Series of materials dryers for the plastics processing sector has been expanded in order to include the option of two drying hoppers, each with independent temperature control.

Wittmann UK has expanded its Drymax C30 Series of materials dryers for the plastics processing sector in order to include the option of two drying hoppers, each with independent temperature control. Besides the currently available configurations of the Drymax C30 with one drying hopper, either as a hopper mounted unit or beside-the-press unit, and as a compact dryer mounted on a frame and attached to the drying hopper, the Drymax C30 can now be supplied with two hoppers mounted on a frame with casters. In this configuration the Drymax C30 is available in several combinations of hopper sizes of 20, 30, 50 and 70 litres.

The Drymax C30 dryer generates a dry air capacity of 30m3/h and guarantees throughputs up to 20kg/h depending on the material to be dried.

The dual hopper version of the Drymax C30 offers all the features of the single hopper unit with the added flexibility to dry two materials independently using a single dryer.

The Drymax dryer uses the principals of adsorption and is equipped with two independent desiccant beds for a constant dry air supply.

By means of reverse flow direction between process and regeneration air, the dryer is able to achieve a constant process air temperature and dew point of - 60 deg C, independent of the ambient air condition.

The Drymax microprocessor control has been developed and optimized by Wittmann for drying applications and performs extensive monitoring and temperature control tasks in addition to the automatic and independent adjustment of airflow through the two drying hoppers.

The integrated SmartFlow function controls two motorized flappers to divert the airflow based on the material throughput of each drying hopper.

In conjunction with the embedded material saver function, the set point of the process heaters are lowered as soon as a press stoppage is detected in order to avoid over-drying and thermal degradation of the material residing in the drying hopper.

Should an increase of the material consumption be indicated via a rising temperature differential in the hopper, the microprocessor automatically raises the drying temperature to the original set point and the SmartFlow motor valve increases the air flow according to the material throughput.

By using electrically driven switch-over valves in the dryer and SmartFlow valves no compressed air supply is required for the operation of the Drymax C30 dryer.

Free 'white paper' discusses plastics purging

2007-01-02T23:23:00.000-08:00

Technical brief provides plastics processors vital insights toward meeting goals for Increased purity and productivity and helps identify practical and effective purging technology.

Novachem, a leading provider of safe and effective purging solutions for thermoplastics processors, has announced the availability of a free industry White Paper that tackles head-on various purging issues and dilemmas facing todays plastics processing managers. The 12-page technical brief, entitled 'Toward a Systematic Approach to Evaluation and Resolution of Purging Issues in Thermoplastics Processing', includes an abstract overview and a four-page appendix of useful tools, such as a data collection sheet, a factors checklist, and a cost comparison matrix. Written by Novachem General Manager and industry specialist Frank Van Haste, the document offers approaches to contemporary purging issues, including reducing product contamination and increasing the efficiency of color and/or resin changes.

The report also discusses the impact of these challenges on overall productivity, and provides solutions for increased efficiency.

'An informed and systematic technical approach - the antithesis of the typical - episodic or ad hoc approach - is now required to truly minimize the effects of contamination while maximizing productivity', adds Van Haste.

'As an industry leader, Novachem has made it a priority to provide meaningful resources and unbiased solutions for its many constituents in plastics processing', comments Frank Winner, V.P.

Marketing and Sales, 'and this White Paper is just one of many steps we are actively taking'.

A free, downloadable PDF version is available online at the companys website.

*Title: 'Toward a Systematic Approach to Evaluation and Resolution of Purging Issues in Thermoplastics Processing'.

* Author: Frank Van Haste.

* Abstract - purging issues (which encompass changes in color and/or resin type and the removal of contamination from equipment) historically have received little attention from engineering and production managements.

The pressures to optimize productivity that prevail in the modern industrial environment make this kind of inattention unacceptable.

The present paper describes an unbiased, systematic approach to the evaluation and resolution of these issues that is commensurate with the importance of their impact on productivity and gives examples of the benefits that are derived when such an approach is adopted.

The approach must be planned and implemented in an orderly way, consistent with good manufacturing engineering practices.

* Relevance - it has long been a fact of life in the thermoplastics processing industry that color changes, material changes and the presence of contamination in process equipment - collectively, purging issues - would negatively affect productivity.

This has been accepted in the industry for two reasons: (1) because every facility faced the same problems, there was no differential effect on competitiveness; and (2) in the hierarchy of problems to be solved ranked by expected benefit, these issues were not at or near the top of the list.

Heretofore a variety of ad hoc approaches have been employed to address purging issues on an episodic basis: * Running large amounts of resin, preferably of a low melt-flow character; * Partial or complete disassembly and mechanical cleaning; * Symptomatic application of one or more formulated purging products.

However, this episodic approach neglects underlying causes and fails to address whether the result actually represents a significant improvement.

Therefore, an informed and systematic technical approach is required to truly minimize the negative productivity impact of purging issues.

German automotive OEMs choose common Ethernet

2007-01-01T23:22:00.000-08:00

Four major German automotive companies agreed to back the Industrial Ethernet standard Profnet which has been developed by Profibus International, the organization responsible for the PROFIBUS.

German automotive OEMs choose common Ethernet platform In an announcement made at the SPS/IPC/Drives Fair in Nuremberg on November 24th, four major German automotive companies agreed to back the Industrial Ethernet standard profinet which has been developed by PROFIBUS International, the organization responsible for the PROFIBUS and PROFINET automation technologies. Speaking jointly at a PROFIBUS International press conference, representatives of Audi, BMW, DaimlerChrysler and Volkswagen said that the announcement is intended to encourage supplier companies to introduce PROFINET-based systems quickly so that the requirements of next generation automation systems in automotive manufacturing can be met. The target is to achieve a fixed, uniform protocol that is neutral with regard to manufacturers and users and which has an integrated safety technology.

Standardization of the engineering tools for the communications bus is also required.

The four companies make up AIDA, the Automation Initiative of German Domestic Automobile manufacturers, which took as its starting point the fact that today's automation systems are heterogeneous and are compatible to a restricted extent only.

Also, fieldbus systems tend to have relatively limited bandwidth and can restrict the distribution of automation components.

Today, this requires additional resources and integration and results in increased costs.

AIDA believes that a common Industrial Ethernet platform is the way to overcome these challenges in future automation systems and has selected PROFIBUS International's PROFINET for the task.

Edgar Kuester, Chairman of PROFIBUS International, said: 'This announcement will not only influence the automotive industry in Germany but the rest of the world too.

I also believe that the leadership of the automotive industry will have a significant influence on most other branches of industry.

This exciting moment in the history of automation offers us all the chance to focus on real end user benefits using a vendor-neutral communications solution.

One of the unique advantages of PROFINET is that it enables legacy fieldbus systems like PROFIBUS and INTERBUS to be integrated easily, thus protecting existing automation investments.

Everybody looks to be a winner in this new automation world and I invite once again other major fieldbus organizations to join our mission.' Mike Bryant, Deputy Chairman of PROFIBUS International and Executive Director of the PROFIBUS Trade Organization in North America added: 'This decision by key players in the European automotive market sends out a powerful signal globally.

My assessment at this point in time, based on our experience of the PROFIBUS market 10 years ago and because PROFINET offers a number of key Industrial Ethernet advantages, is that AIDA's lead will be followed by automotive manufacturers worldwide, including I believe in North America.' PROFINET has been developed by PROFIBUS International for distributed automation and component-based automation applications.

PROFINET is also supported by the INTERBUS Club whose members are now developing PROFINET-compatible products.

Together, PROFIBUS and INTERBUS have nearly 20 million fieldbus devices installed, roughly 75% of the world fieldbus market.

At SPS/IPC/Drives PROFIBUS International announced that more than 70 PROFINET products and services are now available from 20+ major vendors in North America, Europe and Japan.

PROFIBUS International believes the number of PROFINET products will rise significantly by hannover fair in April 2005.

PROFINET can simultaneously meet the needs of three automation domains with a single-cable Industrial Ethernet solution.

These are: IT integration, realtime automation and isochronous realtime motion control.

The PROFINET solution is fully compatible with IEEE802.3 standards.

In motion control applications PROFINET can control up to 150 axes in 1mS using the isochronous realtime (IRT) mode while other automation or IT functions are running.

More than 140 engineers are working today in 11 international Working Groups on the development, enhancement and standardization of PROFINET, including key features such as data security and the integration of PROFINET into MES systems.

A machine and personnel safety profile based on the proven PROFIsafe fieldbus solution is under development.

Acetal extruded stockshapes have colours

2007-01-01T23:21:00.000-08:00

In response to increasing market demand for products that enable and enhance colour identity, a range of colours for extruded Acetal stockshapes is available.

Quadrant Engineering Plastics (EPP) has introduced a range of standard colours for extruded Acetal stockshapes. The company launched the selection in response to increasing market demand for products that enable and enhance colour identity. The products deliver all the familiar performance qualities of Quadrant EPP's range of Acetal materials, including an excellent ratio of weight/strength performance, a low coefficient of friction and good abrasion resistance.

The Ertacetal product line is also known for its excellent machinability.

But Quadrant's new line delivers several additional benefits related specifically to colour.

For example: * Companies wish to distinguish themselves and their products from the competition, and colour offers a simple visual approach to brand recognition.

* Standard colours can quickly determine whether a faulty part originated at a company's factories or those of a competitor.

* Ordering materials and parts in standard colours simplifies many customer designs and processes by removing guesswork about colour consistency and accuracy during later product development stages.

* Pre-coloured materials and parts simplify design of colour-coded systems that require multiple parts to be accurately changed out or replaced.

* Colour-coding parts not only helps customers avoid accidental mistakes in assembly processes, it can also improve safety, facilitate product inspections, and save time.

Quadrant now offers customers with a broad selection of Acetal stock shapes in a range of seven standard colours beyond the black and white.

The new colours include red, blue, yellow, green, orange, brown and grey.

Customers can select from these standard colours instead of formulating their own custom colours.

Emerging FSR technologies compared with FKMs

2006-12-31T23:20:00.000-08:00

Independent research report highlights the continuing evolution of fluorosilicone rubber (FSR) technology, and compares new materials with conventional FKM compounds.

Dow Corning has published independent research entitled 'FSRs in Extreme Applications', which highlights the continuing evolution of fluorosilicone rubber (FSR) technology, describing laboratory results comparing the performance of Silastic brand LS 5-2060 and LS-2860 FSR from Dow Corning against conventional FKM compounds. In addition, the research outlines the opportunities these FSR materials represent for more cost-effective, high-performance elastomer applications that require superior chemical, fuel, and oil resistance; good abrasion resistance; and excellent performance at extreme temperatures. FSRs in Extreme Applications alerts designers and OEM engineers of new chemical and compounding advances for fluorosilicone materials that could help usher in higher performance and more cost-effective solutions.

The published research summarizes conclusions derived from laboratory tests sponsored by Dow Corning and conducted in 2003 by Rapra Technology, an independent plastics and rubber testing company located in Shawbury, United Kingdom (www.rapra.net).

'The results of these tests could augur a paradigm shift for FSRs, demonstrating enhanced performance and lower price points,' said Martin Rowlands, Engineered Elastomer Industry, Science and Technology Global Director, Dow Corning.

'These new materials could potentially begin to supplant hydrogenated nitrile rubber (HNBR), carboxylated nitrile rubber (XNBR), urethane, acrylic rubber (ACM), ethylene acrylic rubber (AEM), and FKM materials in extreme applications.' As proof of this new paradigm, Dow Corning's research results details the comparative performance of two FSR compounds tested against three FKM-based compounds.

Some examples of what Rapra Technology's tests demonstrated include: * The tear strength at 200 deg C (392 deg F) of the two FSR compounds tested was significantly higher than the FKM compounds; * The elongation at break for the FSR compounds at 200 deg C was significantly better than any of the FKM compounds evaluated; * The two FSR compounds exhibited tensile strength values at 200 deg C, similar to those of FKM compounds; * FSR compounds generally had a wider operating temperature range compared to FKM compounds, due to their lower glass transition temperatures; and * With better tear strength performance and with similar tensile strength values, FSR elastomers compared favorably with FKM materials for high-temperature applications (up to 200 deg C).

For more than 40 years, FSRs have delivered excellent fuel resistance and performance in both low- and high-temperature conditions.

Dow Corning developed an advanced compounding expertise that offers a new family of high-value, specific compounds.

This innovation has improved FSRs' historically excellent balance of fuel and oil resistance and good mechanical properties over a wide range of temperatures.

Dow Corning's publication also summarizes the company's unique range of services in base formulation technology and compounding expertise.

These value-added services enable Dow Corning to meet specific customer needs while delivering the exact properties their design needs to be competitive.

FSRs in Extreme Applications points out, for example, that formulations based on Silastic LS 5-2040 FSR exhibit good resistance to lubricating oils, while the more consistent properties of the company's Silastic LS 4-9062 fluorosilicone rubber product stem from the fact that it is a blend of FSR and VMQ elastomers.

Heat resistance plastics take over in camping

2006-12-31T23:19:00.000-08:00

When a major manufacturer of camping and outdoor recreation equipment, decided to switch to thermoplastic parts it found a heat-resistant product that did the job.

When the Coleman Company, of Wichita, Kansas, USA, a major manufacturer of camping and outdoor recreation equipment, decided to switch from metal to thermoplastic parts in order to increase performance and reduce the size and weight of their products, they chose Victrex PEEK for the heat-resistant swivel ring on their F1 Power Stove. The F1 Power Stove is a butane/propane cartridge-type portable stove used in camping or mountain climbing. With a high-power burner producing 3,700kcal/h, the highest heating power of all the companys products, it is capable of boiling 1 liter of water in 2 minutes and 30 seconds.

The swivel ring is built into the fitting base of the stoves pan support and is located directly under the burner which produces a 1500 deg C (2732 deg F) to 1600 deg C (2912 deg F) flame.

The part, therefore, needs to withstand temperatures exceeding 200 deg C (392 deg F) that result through heat transfer.

'Prior to switching to Victrex PEEK, Coleman used brass or plated iron to provide the necessary strength and heat resistance,' says Andrew Ragan, Victrex Global Leader—Industrial, 'They switched to Victrex PEEK because it delivers the high-temperature resistance [320 deg C (608 deg F)] and high strength required by the swivel ring.

It also enabled them to limit the main units weight to 146g (5.1oz), achieving a 10% weight reduction over the unit with the previously used brass part.' The lubricity provided by Victrex PEEK is another important factor.

According to Ragan, 'The F1 Power Stove uses a rotating/retractable pan support, which requires that the swivel ring be able to slide, and since Victrex PEEK also exhibits excellent lubricity, it is ideal for the application.' In addition, says Ragan, 'Since the swivel ring has a complex shape, switching from the machining of a metal part to the injection molding of a thermoplastic part has also contributed to reduced manufacturing costs.' Victrex USA, a division of Victrex, is the sole manufacturer and supplier of PEEK polymer worldwide.

thermoformable composite is light weight

2006-12-30T04:23:00.002-08:00

Azdel Rail-Lite composite is a low-pressure, thermoformable, lightweight composite sheet that exhibits excellent flame, smoke, toxicity, and heat-release properties.

GE Advanced Materials has selected Schneller (USA), a leading manufacturer of engineered decorative laminates, to co-develop new grades of Indura GTform decorative laminate for interior rail vehicle applications formed with a AZDEL* Rail-Lite* composite from Azdel, a 50/50 joint venture of General Electric Company and PPG Industries. New Azdel Rail-Lite composite is a low-pressure, thermoformable, lightweight composite sheet that exhibits excellent flame, smoke, toxicity, and heat-release properties. It has been designed to help deliver outstanding, robust performance in combination with reduced weight and enhanced safety for a broad range of interior components for the global rail industry.

Interior rail structures formed with the new high-performance Azdel Rail-Lite composite can now tap the added benefits that Schneller's Indura GTform decorative laminate can help provide.

These include enhanced 3D formability, outstanding durability and in-mold decorating capabilities, and excellent stain, solvent, and graffiti resistance.

Like Azdel Rail-Lite composite, Indura GTform decorative laminate also meets strict regulatory standards for low flame, smoke, and toxicity.

Indura GTform decorative laminate - utilizing a tough, graffiti-resistant fluoropolymer surface layer - lends itself to many of the interior rail applications GE is targeting with AZDEL Rail-Lite composite.

These include window masks, ceiling panels, seat backs, arm rests, tray tables, stow bins, luggage racks, valances, and partitions.

The Schneller laminate can be customized to parts formed with GE's new composite in virtually any color or pattern and offers a high degree of design freedom to improve interior aesthetics for both new and refurbished passenger rail cars.

'Azdel Rail-Lite composite and Indura GTform decorative laminate represents two materials technologies from two global industry leaders that may offer tremendous potential to rail industry OEMs,' said Benny David, global industry manager of Transportation Composites, GE Advanced Materials.

'The potential of this new material for the interior rail sector may now be greatly multiplied by helping to give designers greater flexibility to create new high-performance, aesthetically pleasing components.' Matthew Miklos, general manager for Schneller's Transportation Products Group concurs.

'We have essentially thrown the door open to a wide range of application development possibilities through the greater design options the two materials technologies can help provide.

These complementary materials may offer a potential solution to the interior rail segment that goes beyond other currently available products,' Miklos said.

* 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.

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.

* About Schneller - Schneller is a global leader in the development and production of engineered decorative laminates and non-textile flooring for the transportation and architectural industries.

Schneller provides custom design and color matching, material selection, continuous roll, and sheet production from its ISO-9001 certified production facilities in Kent, Ohio, and Pinellas Park, Fla., with global sales and service support from its Paris, France facility.

Plastics stock materials costs to rise

2006-12-30T04:23:00.001-08:00

Quadrant Engineering Plastics Products (EPP) is set to introduce a price increase of up to twelve per cent depending on the kind of product line or shapes this year.

Quadrant Engineering Plastics Products (EPP) is set to introduce a price increase of up to twelve per cent depending on the kind of product line like: cast, compression-moulded and extruded stock shapes this year. These increases apply to pricing in Europe and will take effect from March 1, 2005. This decision is a direct result of the significant increases which Quadrant EPP has incurred in raw material, energy and transportation costs.

In particular, the escalating cost of Benzene, the main feedstock of most engineering plastics, has been a primary cause of these price increases.

Although Quadrant EPP operates a company wide programme of continuous improvements and regularly implements new measures to improve productivity which help contain costs, the new price increases have been unavoidable given the substantial increases in materials and production related costs.

Quadrant does not foresee any relaxation of this cost situation in the near future.

* Quadrant Engineering Plastic Products (QEPP) is the world's leading manufacturer of engineering plastics in stock shapes (rod, plate, tube) for machining.

Other specialities include custom nylon castings and finished parts.

QEPP's catalogue of General and Advanced Engineering Plastics covers the broadest range (in terms of materials and dimensions) of standard and custom shapes for machining.

Products are available through a worldwide network of branch offices, technical support centres and authorized dealers.

Precision gear unit bearing cages chosen

2006-12-29T02:37:00.001-08:00

German-based Harmonic Drive chose Victrex Peek for the bearing cages of its Harmonic Drive (HD) gear units because of the polymer's superior combination of properties.

German-based Harmonic Drive, a manufacturer of precision gears and drives, chose Victrex Peek for the bearing cages of its Harmonic Drive (HD) gear units because of the polymer's superior combination of properties. HD gears are engineered for highly demanding applications in aerospace and defense. Their extreme light weight and compact design sets them apart from traditional planetary and helical gears.

Depending on the design, HD gears have a transmission ratio of between 30:1 and 320:1 and a torque of 0.5 Nm to 9000 Nm with single-step gearing.

Backlash and maintenance free, they can be used over a wide temperature range and offer high repeatability and torque capacity.

According to Andrew Ragan, Victrex Global Leader Industrial, 'The gear's bearing cages have to withstand operating temperatures of -55C (-67degF) to 150C (302degF) and be non-corroding and lubricant-friendly'.

' Because of the way the gear operates, the bearing cages are not tightly guided, which means that very high sudden impact stress is generated'.

' The cage also suffers constant elliptical deformation during operation.' Victrex peek has a continuous service temperature of 260C (500degF), as well as excellent characteristics at sub-zero temperatures.

It has very good chemical resistance and is compatible with almost all the lubricants and fluids used in the aerospace industry.

In addition, its outstanding sliding friction properties as well as high strength significantly extend the life of the bearings cages.

Low outgassing is an important requirement for space applications'.

' 'Precipitation on the sensitive electronics and optics could have serious consequences,' explains Ragan'.

' 'Victrex peek has very low levels of ionic extractables, which is why it is often used in semiconductor production.' Aerospace applications include actuators for solar panels, antenna orientation systems, opening mechanisms and manipulator arms.

The drives for exploration robots (Lunar Rover, Mars Pathfinder, Odyssey, etc) are also based on HD gears.

HD gears are also used in passenger aircraft as sensors for reporting the position of the landing flaps and in active vibration dampers which reduce structural noise in the rear cabin section.

Films and texture lacquers developed further

2006-12-29T02:36:00.001-08:00

Hardcoated formable films and texture lacquers for the Film Insert Moulding process include Autoflex films and Aquatex formable texturing inks to enhance plastics components.

At this year's Plastics Design and Moulding 2005 exhibition, Autotype International will be promoting its latest range of hardcoated formable films and texture lacquers for the Film insert moulding process (also known as In-Mould Decoration). In particular, Autotype will be previewing its Autoflex films and Aquatex formable texturing inks, which are designed to enable significant improvements to be achieved in both the aesthetic and functional characteristics of plastics components. * The Autoflex range of formable polycarbonate films can be shallow or deep drawn, and incorporates a hardcoat surface to provide a durable, high gloss finish.

The range is available with polycarbonate, polyester or PMMA substrate bases and offers excellent chemical and solvent resistance.

The range is available with a variety of performance capabilities including Autoflex XtraForm, which is ideal for mobile phone applications.

The deep draw characteristics of XtraForm allow the front housing, lens and back housing of a mobile phone case to be integrated in one component part.

* Aquatex FPH is a range of four water based, screen printable and formable texturing inks that are specially designed for Film Insert Moulding applications.

The range includes supermatt, fine and coarse versions plus a gloss modifier.

The four inks, which are suitable for deep profile applications, can be blended together to enable a wide range of surface textures and gloss finishes to be achieved.

In addition, when selectively printed, Aquatex enables the integration of both gloss and textured areas to be incorporated on a single part.

* Film Insert Moulding is an innovative, flexible and cost-effective method of In-Mould Decoration (IMD) that produces high quality profiled or three dimensional plastics parts.

Typical components include fascia panels, lenses, keypads and mouldings for mobile phones and telecommunications equipment, consumer appliances and automotive trim and dashboard panels.

The process can significantly reduce the number of production stages and component parts, cutting both production time and cost, while improving the quality, complexity and durability of finished products.

Reviews pulished on rubber mixing and bonding

2006-12-28T02:35:00.001-08:00

Two Rapra Review Reports focus on key aspects of manufacturing with rubber, includes a thorough overview of how to successfully bond rubber to a given substrate.

Rapra has just published two new Rapra Review Reports focusing on key aspects of manufacturing with rubber. No single adhesive can provide the needed levels of adhesion and environmental resistance to all polymers. Even when bonding a particular elastomer, the adhesive of choice can vary depending upon the compounding of the rubber including the cure system, the environmental application of the bonded assembly, the substrate to which the rubber is going to be bonded, the moulding method and the geometry of the part.

Other factors affecting adhesive selection might include colour, conductivity, and means of application.

Bonding Elastomers: A Review of Adhesives and Processes offers a thorough overview of how to successfully bond rubber to a given substrate in the manufacture of quality rubber engineered components: substrate preparation, selection of adhesive, adhesive preparation, adhesive application, moulding conditions, testing and bond failure analysis, future trends Developments that have taken place in mixing equipment over the last eight or nine years have been significant, with almost all major machinery makers having made innovations of one type or another.

Some developments have been as small as re-profiling rotors of relatively conventional design.

Others have been the introduction of completely new rotor designs, both intermeshing and tangential.

Mixing of Vulcanisable Rubbers and thermoplastic elastomers provides historical background against which the latest developments are set.

The report considers batch and continuous systems, containing details of key developments by equipment manufacturers, with the different concepts discussed in layman's terms.

It also summarises the range of mixing techniques applied in the industry.

The quality of rubber mixing depends not only on the mixer itself, but also on control of the whole mixing process, from raw materials to the moment the compound leaves the mill room for further processing, and this review offers the relevant developments in drive, hopper arrangement, temperature measurement systems and discharge systems.

All Rapra Review Reports are supported by an indexed section containing several hundred key references and abstracts selected from the Rapra Polymer Library database.

Team to advance polycarbonate automotive glazing

2006-12-28T02:35:00.000-08:00

The cooperation of a leading automotive equipment supplier and the leading international polycarbonate glazing specialist heralds a new era in automotive design.

The cooperation of a leading automotive equipment supplier and the leading international polycarbonate glazing specialist heralds a new era in automotive design. Czech Republic based Peguform Bohemia and Exatec, the PC Glazing Technology Joint Venture of Bayer MaterialScience and GE Advanced Materials, announced on March 8, 2005 their cooperation in a major effort to bring advanced Exatec PC Glazing Technology to the automotive market. Peguform Bohemia will build a new polycarbonate glazing facility based on Exatec's comprehensive glazing system technology.

This will make Peguform Bohemia the first company to use Exatec's advanced Glazing technology including Plasma technology to manufacture clear, light weight and impact resistant polycarbonate side and rear car windows as well as panoramic roofs for car manufacturers worldwide.

Exatec's advanced polycarbonate glazing solutions offer car manufacturers clear advantages with respect to design flexibility, functionality and weight, combined with extensive weathering and glass-like abrasion performance.

'The market opportunity for PC glazing is huge,' says Pavel Neuman, Peguform Bohemia's CEO.

'Over the past ten years, Peguform Bohemia has expanded aggressively as a highly specialized automotive supplier with a proven record of successfully adopting new technologies'.

'We see the use of Exatec technology in our new cleverGlass business as a natural extension of this strategy'.

'It is a strategic target of Peguform Bohemia for the years 2005 - 2010 to increase the turnover by 50%'.

'Besides the acquisition of new customers for the standard production this target can be reached by developing new applications'.

'The pre-development department of Peguform Bohemia is currently involved in many programs utilizing PC glazing which due to its properties is able to replace glass'.

'This offers great potential for future growth'.

'The production of the PC glazing systems with Exatec technology in the new cleverGlass business has become one of the most important steps in Peguform Bohemia's growth strategy,' adds Pavel Neuman'.

' 'Polycarbonate is about to become a major alternative to glass in future cars,' predicts Exatec CEO Clemens Kaiser'.

''The introduction of Exatec 900 Glazing Technology will open up entirely new construction and design options for automotive manufacturers which will help to transform the market.' With Peguform Bohemia, Exatec has found the forward thinking and technologically advanced partner needed for such an ambitious and significant development.

Kaiser added: 'With their automotive expertise, skills and economically competitive location, we are confident that Peguform Bohemia is ideally positioned to help establish polycarbonate as the material of choice in automotive windows.' Exatec's products combine an enhanced 10-year weathering layer with a glass-like Plasma topcoat that exhibits superior abrasion properties.

In addition, Exatec provides materials and processes for defroster and antenna functionalities.

Polycarbonate can be molded into almost any shape, accommodating today's most sophisticated automotive design trends and opening opportunities for future developments.

Peguform Bohemia, headquartered in Liberec, Czech Republic, will begin construction of its glazing facility this year.

The new business named cleverGlass will be designed specifically to meet polycarbonate glazing demands, utilizing the latest advanced optical molding technology as well as Exatec's high performance glazing systems.

This highly competitive cleverGlass operation will feature a purpose-built state-of-the-art clean room environment ensuring that automotive manufacturers around the world are supplied with PC glazing which meets the highest quality standards.

About Peguform Bohemia - Peguform Bohemia was founded in 1946.

Currently Peguform Bohemia operates three plants and a tool shop in the Czech Republic.

The plants are located in Liberec and Liban, the construction of the third state-of-the-art manufacturing plant in Nymburk was finished in 2004.

Production is focused mainly on the plastic parts and systems such as painted bumpers, instrument panels, door panels, center consoles and radiator grills.

The tool shop in Liberec produces tools up to the 50 tons of weight.

Company headquarters are located in Liberec as well as the engineering and advanced engineering centers.

Peguform Bohemia supplies a range of global manufacturers including Skoda, Audi, Toyota/PSA (TPCA), GM and Suzuki.

About Exatec - the company was founded in 1998 as 50:50 Joint Venture of Bayer MaterialScience and GE Advanced Materials with the mandate to develop polycarbonate glazing systems for the automotive market.

Headquartered at its state-of-the-art Technology Development Center in Wixom, Michigan, Exatec has developed patented polycarbonate coating systems, which ensure market leading weatherability and glass like abrasion performance.

Exatec operates an engineering design and development office in Bergisch Gladbach, outside Cologne, Germany, to support the European automotive market.

Thermoplastics replace fluoropolymer in valves

2006-12-27T02:34:00.000-08:00

A high-performance thermoplastics, for overmolding the steel core of a cone valve, has replaced a fluoropolymer to withstanding continuous operating temperatures of 120 deg C.

Italy-based Fluorten chose Victrex PEEK, a high-performance thermoplastics, for overmolding the steel core of a cone valve used to process tomato paste. When compared to the fluoropolymer it replaced, Victrex PEEK not only extends the life of the valves, it also results in significant cost savings due to reduced downtime. During processing, the tomato paste is forced through a system of pipes and cone valves to obtain the right quality and consistency.

Because the valves are in contact with the paste, the valve material must be capable of withstanding continuous operating temperatures of 120 deg C (248 deg F) and have good non-stick properties.

It must also exhibit superior surface hardness due to the high processing rates and good adhesion to the steel core.

Victrex PEEK has a glass transition temperature of 143 degC (289 deg F) and can withstand continuous service temperatures close to the melting point of 340 deg C (644 deg F).

'The combination of thermal properties together with low wear properties and excellent adhesion of the polymer during overmolding were the major reasons Fluorten chose Victrex PEEK,' says Christine Karas, General Manager, Americas.

'The fact that Victrex PEEK is FDA approved for contact with foodstuffs and has excellent chemical and hot steam resistance were also a factor.' Victrex USA, a division of Victrex plc, is the sole manufacturer and supplier of PEEK polymer worldwide.

Test metals developed for new materials

2006-12-27T02:33:00.000-08:00

Rapra Technology has helped in developing a range of test methods and results for innovative materials used for packaging absorbents, bio-degradable, microwaveable and ovenable materials.

Rapra Technology, Europe's leading independent plastics and rubber research organisation, has been working with Telford, UK-based Sirane assisted by support from the Wolverhampton, UK-based Polymer Cluster. Sirane manufactures a range of packaging and other products including specialised absorbents, bio-degradable, microwaveable and ovenable materials and protective materials for a number of food and other applications. Rapra's involvement included developing a range of test methods and results for the innovative materials used by Sirane in developing its packaging solutions for clients worldwide.

Richard Walton, Rapra Technology marketing manager says that: 'We are delighted to be once more helping Midlands-based companies succeed - with help from the Polymer Cluster'.

'Our scientific and technology services help free up the creativity and innovation of clients such as Sirane'.

'They can focus on the marketplace and we can help ensure that all their materials and manufacturing are fit for purpose.' Sirane has been in business for just three years, and last year it successfully developed and launched over ten new products for the food packaging and processing industries.

Jointly founded by Simon Balderson and Ian Beardsall, Sirane now employs twenty people, with turnover approaching GBP 1.5million'.

Glass-reinforced PBT deliver enhanced toughness

2006-12-26T03:08:00.002-08:00

Glass-reinforced PBT compounds are alternatives to short-fibre glass-filled PBT, polypropylene (PP) and nylon resins and deliver enhanced toughnessat wide temperature extremes.

GE Advanced Materials, Plastics has introduced two new grades of its glass-reinforced LNP Verton polybutylene-terephthalate (PBT) compound as alternatives to competitive short-fibre glass filled PBT, polypropylene (PP) and nylon resins. LNP Verton WF-7007 compound, with a 35% long glass fibre loading, and LNP VERTON WF-700-10 compound, with a 50% loading, deliver enhanced toughness, strength, and stiffness at wide temperature extremes. These properties, combined with light weight and exceptional UV and corrosion resistance, make the two new compounds excellent candidates for metal replacement in an array of outdoor applications, as well as for a variety of automotive, electrical, and consumer components where exceptional toughness and durability are required.

The use of long glass fibres instead of traditional short fibers enhances the performance and appearance of LNP Verton WF compounds in several important ways.

The low moisture absorption rate of these fibers helps improve the dimensional stability of molded parts, especially in exterior environments.

Long glass fibers further help contribute to excellent impact resistance and flexural modulus and also enhance part appearance by minimizing the migration of fiber ends to the surface of injection-molded parts.

Further, by delivering high performance in demanding applications that exceed the capability of short glass-fiber-reinforced resins, LNP Verton WF compounds can help to reduce costs through part consolidation.

The new LNP Verton WF compounds have been engineered to help meet the growing demand for materials that can replace metal while offering greater design freedom, lower cost, and lighter weight.

Manufacturers looking for new ways to differentiate their products through design or performance, or to reduce costs through part consolidation or simplified assembly and/or finishing, can benefit from the performance characteristics of these new GE products.

LNP Verton WF compounds offer the balance of high-performance properties required for exterior metal-replacement applications such as vehicle windshield wiper arms, side mirror housings, and handles for garage doors.

They are also excellent candidates for a range of other applications including electrical connectors and switches, appliance handles, and electronic motor housings.

According to David Cooper, LNP Verton product manager, GE Advanced Materials, Plastics, 'In today's competitive manufacturing environment, the right materials can provide a crucial strategic advantage in terms of cost reduction, greater design freedom, and shorter time-to-market'.

'GE Advanced Materials' wide array of innovative products, like our new LNP Verton grades, offer manufacturers a fresh approach to traditional compounds and greater process optimization that can help them compete more effectively worldwide.' * 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.

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.

High performance materials designed for aircraft

2006-12-26T03:08:00.001-08:00

High-performance engineering resin and sheet materials that have been designed to help enable development of next-generation aircraft interior components.

GE Advanced Materials showcased its latest product innovations for the aircraft interiors industry at the 'Aircraft Interiors Expo'. With the theme 'Imagination at Work', the company featured high-performance engineering resin and sheet materials that have been designed to help enable development of next-generation aircraft interior components. Beyond interiors, GE also offers an impressive portfolio of plastics, silicones, quartz, and ceramic products that deliver critical properties in aircraft applications ranging from windshields, structural components, door and engine gaskets, seals for passenger window assemblies, and brake systems to weather stripping, fuel cell coatings, and lighting and wiring components.

The increasing use of GE's plastics, silicone, quartz, and ceramic materials in the aircraft industry is being driven largely by the products' ability to help the industry meet its key challenges of weight reduction; resistance to impact, chemicals, and heat; flame retardancy; outstanding smoke and toxicity properties; and overall high-performance.

Supported by the exceptional depth and breadth of its renowned global research and development organization, GE is able to offer highly specialised materials that have been engineered with the specific combinations of properties required by different interior, exterior, mechanical, and systems components.

'GE provides a superior array of advanced materials solutions to the aircraft interiors industry and almost everywhere else on the plane,' said Melanie Cook, GE Advanced Materials' global marketing director, Transportation and Outdoor Vehicle Programs.

'By addressing the critical challenges of weight reduction, safety, and performance under high-stress conditions, as well as offering the latest materials innovations, GE can provide targeted products that help give our customers a competitive edge.' * GE's thermoplastics resin and sheet products - GE's Ultem and Lexan resin-based materials are finding ever-expanding use in aircraft interiors.

Ultem 9075 and 9076 amorphous thermoplastics polyetherimide (PEI) resins, in particular, offer excellent properties, including inherent flame resistance with low smoke emission, high strength, and broad chemical resistance.

These high-performance materials are already widely used in interior applications, such as personal service units, retractable video displays, window trim, and air valve panels.

They are available in custom colours.

At the Aircraft Interiors Expo, GE displayed several applications featuring Ultem 9075 resin.

These include a two-person passenger service unit and a two-person gasper air valve panel from the Airbus 340 aircraft, an air nozzle assembly, window trim, and an all-in-one personal service unit panel.

The use of GE's Ultem 9076 resin in aircraft interior extrusions is also being highlighted.

GE's extruded Ultem PEI sheet provides design flexibility, outstanding mechanical properties, and excellent flame, smoke, and toxicity performance.

At the expo, GE is showcasing Ultem 1668A sheet, which can be thermoformed, pressure-formed, twin-sheet formed, or used in flat or cold-formed applications.

In aircraft interiors, this material is used to mold aircraft window reveals, air ducts, seating and flight deck components, galleys, stow bins, and sidewalls.

Ultem 1668A sheet meets commercial aircraft interior requirements, including FAA smoke and flammability testing and toxicity standards BSS7239 and ABD0031, and has an OSU heat-release rate below 65/65.

This material is paintable and is available from GE in a range of colors.

Boeing selected GE's Ultem 1668A sheet for use in its C17 jetliner.

For this application, the thermoformed Ultem sheet forms the aircraft's entire cockpit.

Boeing chose the material for its flame, smoke, and toxicity performance; light weight; and exceptional impact strength.

Another popular GE material for aircraft interiors is Lexan polycarbonate sheet.

An extremely durable material based on GE's tough, virtually unbreakable Lexan resin, this GE sheet product offers unmatched impact strength, outstanding dimensional stability, excellent aesthetics, and high stiffness for a range of interior applications.

GE's Lexan F6000 sheet, which is being featured at the expo, is very durable yet easily formed into complex shapes using standard thermoforming equipment.

This material also provides high impact resistance and high heat performance, and is available in custom colors.

GE's Lexan F6000 sheet applications that are being shown at the Aircraft Interiors Expo include an airline literature rack, a window track and reveal, an emergency door light fairing, and seat cladding parts.

* GE's silicone adhesives and sealants - the ability to withstand exposure to UV light, ozone, heat and cold, moisture, and severe vibration is essential in many aircraft applications.

* GE's silicone products, with their exceptional resistance to stresses and harsh conditions, have long played a major and growing role in commercial aircraft environments.

GE's silicone adhesives and sealants are used to seal and protect doors, wings, fuel tanks, wing edges, vent ducts, electrical wiring, and black boxes from the elements.

They help seal passenger window assembly units and absorb noise-producing vibration.

They are also used in galleys to seal countertops and maintain cleanliness.

Because these products are inert, silicone sealants are effective for sealing air circulation ducts throughout the entire aircraft cabin.

GE silicone sealants, potting gels, and encapsulants are used in on-board aircraft computers to protect delicate electronic components.

GE silicone products also help seal light lenses inside and outside the plane and help protect hydraulic switches and controls.

Two high strength silicone adhesive sealants, GE RTV157 and RTV159 sealants, are on display at the expo.

These one component, ready-to-use materials cure to tough, resilient silicone rubber on exposure to atmospheric moisture at room temperature.

RTV157 and RTV159 sealants offer excellent weatherability and resistance to degradation from exposure to ozone and chemicals.

* GE's quartz and ceramic materials - GE's quartz and ceramic materials are used in several aircraft applications.

GE boron nitride (BN), for example, is used in powdered metal composites as a friction modifier for aircraft brake pads.

The material helps to maintain sliding friction with reduced noise and vibration.

GE boron nitride also helps to create abradable seals that are applied to engine casings for correcting clearances that are difficult to achieve mechanically.

For applications like this, BN powder is sprayed onto the engine housing to form a seal that is worn in by the blade rotation during service.

High performance quartz tubing from GE Advanced Materials is used in high-intensity lighting applications such as aircraft landing lights.

* An expanding product portfolio - in addition to showcasing its high-performance product portfolio at the Aircraft Interiors Expo, GE Advanced Materials will preview a new material under development for aircraft interiors based on its Azdel thermoplastics composite technology with Ultem resin.

Other recently introduced products and technologies in development are also on display: * Ultem 1668L sheet, an advanced, new material, derived from Ultem 1668A sheet, is targeted specifically at first class and business class seating.

This product retains an excellent low-gloss surface in complex geometric designs, provides over 10 percent weight savings versus polyvinyl chloride (PVC)-based sheet materials, and offers an OSU heat-release rate below 65/65.

* Ultem films - new GE film products, available in gauges from 50 micron to 500 micron.

These films are excellent candidates for a variety of electrical and electronics applications like flexible heaters, cable insulation, and insulation tapes.

When metal plated, GE's Ultem film can be used in parts where EMI shielding is required.

* Ultem fiber - new materials based on Ultem resin that can be spun into fiber by melt spinning, or that can be converted as a solvent-spun hollow fibre or membrane.

Because the threads are amorphous, this product has a significantly higher glass transition temperature (215 C) than traditional semicrystalline-based fibers, such as polyphenylene sulfide (PPS) or polyetheretherketone (PEEK).

GE's Ultem fiber can be an excellent candidate for carpeting and seating fabrics, fire-block layers, and insulation blankets.

* Colors and Coextrusion - new GE developments in colour/processing technologies for the aircraft industry.

Recent developments include eye-catching metalic effects in Lexan F6000 sheet and white/black two-layer co-extruded Lexan F5000 sheet, an excellent candidate for window shade applications.

* 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.

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.

For more information, visit the company's website at www.ge.com.

* About GE Advanced Materials' specialty film and sheet - GE Advanced Materials' Specialty Film and Sheet business is a leading supplier of high-performance engineering film and sheet products to global industry.

Through this business, GE Advanced Materials offers a variety of film materials for display films, graphic films, coated products, electrical and electronics applications, specialty products, and a range of others.

The company's sheet product line includes an array of high-performance structures - from single- and multi-wall sheet, corrugated materials, and coated sheet products to laminates and combinations of each - to serve customers in several key global sectors.

Website details metal dectable plastics

2006-12-25T03:10:00.000-08:00

A vast range of 'Detectamet' metal detectable plastics products plus many other products and services are detailed in a comprehensive and easy-to-use, revamped website.

A vast range of 'Detectamet' metal detectable plastics products plus many other products and services are detailed in a comprehensive and easy-to-use, revamped website. A comprehensive and easy-to-use website has been launched aimed at helping users and specifies to discover a vast range of 'Detectamet' metal detectable plastics products, plus many other products and services found within the food, pharmaceutical, bottling, canning and packaging industries etc E-Components and Chains of Pocklington UK has redeveloped the company's previous website. As well as details of ECC`s innovative products, the site also features full product information.

Details on ECC`s entire range can be accessed quick and easily and is supported by an excellent sales/ technical support team.

Electric plastics have controlled resistance

2006-12-25T03:06:00.000-08:00

Electrically conductive thermoplastics compounds with 'controlled resistance' levels allow users to specify the electrical resistivity range required for a particular application.

Premix Thermoplastics announces the development of a new line of electrically conductive thermoplastics compounds with 'controlled resistance' levels. Called Pre-Elec CR, these new compounds allow users to specify the electrical resistivity range (either volume or surface) required for a particular application. Pre-Elec CR products are fully compounded and can be molded without concern for 'hot spots'.

For many applications, these new compounds offer a cost-effective alternative to the more costly inherently dissipative polymers (IDPs) for providing static dissipation.

Most compounds on the market follow the Electronics Industries Association's (EIA) 541 Standard for resistivity yet many applications require much tighter specifications.

Premix Pre-Elec CR compounds can be tailored to the applications requirements i.e when volume resistance is important, volume resistivity is specified, and when surface resistance is important, surface resistivity is specified.

PRE-ELEC compounds have carefully controlled conductive additive levels manufactured with precision compounding techniques, which means they can be electrically controlled to give the proper resistivity value for the application.

While the most common volume resistance range is 1 x 10e6 to 1 x 10e9 ohm-cm, Premix can manufacture virtually any resistivity range from <1 ohm-cm to 1 x 10e11 ohm-cm in most polymers using carbon black.

In many lower temperature polymers, the electrical resistivity ranges can be controlled with inherently conductive polymers (ICPs) alloys within 1 x 10e3 to 1 x 10e11 ohm/square, and with inherently dissipative polymers (IDPs) alloys from 1 x 10e6 to 1 x 10e12 ohm/square.

Premix Thermoplastics is a subsidiary of Premix Oy, a leading manufacturer of electrically conductive compounds in Europe.

Premix compounds provide EMI/RFI shielding, electrically conductive, static dissipative and antistatic properties for a broad range of applications.

Automotive body panel plastics are competitive

2006-12-24T03:06:00.000-08:00

Two thermoplastics products may signal advanced materials for automotive engineers who require weight reduction, improved moldability, and impact protection for large body panels.

Two new revolutionary thermoplastics technology platforms in the works at GE Advanced Materials introduce a new chapter in the company's tradition of enabling automotive exterior body panels that offer a balance of lightweight performance, reliable properties against impact, and competitive cost. High Modulus Ductile (HMD) and High Performance ThermoPlastic Composites (HPPC) may signal two advanced materials solutions for automotive engineers who require weight reduction, design flexibility, improved moldability, and impact protection for large body panels. These technologies were developed to help respond to the growing demand from consumers to produce more stylish automobiles with greater interior space, higher speed, and optimized performance.

For decades, GE's expansive portfolio of high-performance resins has provided the foundation for the industry to address conflicting demands in a single application.

GE's commercial launch for its HMD and HPPC materials platforms carries on this tradition, and represents the latest step in the evolution of higher gloss, sexier silhouettes, and safer, lightweight cars.

'Our role as a leading supplier of automotive thermoplastics has always been linked closely to our mission to be a world-class innovator of materials technologies,' said Mutsuo Aoki, market director, Body Panels and Glazing, GE Advanced Materials.

'As the commercial release approaches for HMD and HPPC technologies, GE looks forward to expanding its scope of solutions for this fiercely demanding industry.' GE's HMD technology offers the potential for new and improved design flexibilities, parts reduction and enhanced integration for body panel applications.

The new HMD grades were developed to help address technology and design limitations imposed by material flow restrictions, and to improve upon the coefficient of thermal expansion (CTE) seen from conventional materials used in current automotive body panels.

GE's HPPC also offers an excellent CTE performance, indicating that it will likely behave like aluminum and steel.

It is an excellent candidate for horizontal body panel applications, where it could deliver up to a 50% weight reduction compared to metals.

For the end consumer, this could represent a greater fuel efficiency, and higher performance in addition to excellent impact protection.

HPPC also offers a Class A finish and superb moldability for unique designs and modern curves.

HPPC's ability to be molded with low-pressure aluminum tools indicates that, compared to metal, the material could provide an excellent balance of cost and performance for horizontal body panel applications.

* 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.

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.

Glass-free composite improves formability

2006-12-24T03:05:00.000-08:00

In response to specific automotive industry needs, a glass-free composite brings the added benefit of improved post-consumer incineration waste management.

A further advance in composite sheet performance from Azdel comes with the introduction of glass-free reinforced Azdel 'VolcaLite' composite which brings the added benefit of improved post-consumer incineration waste management in response to specific automotive industry needs. Azdel VolcaLite composite is produced and distributed by Azdel, a 50/50 joint venture of GE Advanced Materials and PPG Industries established in 1986. A new product technology, Azdel VolcaLite composite is a low pressure, thermoformable thermoplastics composite of polypropylene and long chopped basalt fibre.

An excellent candidate for automotive interior systems such as headliners, Azdel VolcaLite composite offers excellent acoustic absorption properties, low coefficient of thermal expansion (CTE), a high strength-to-weight ratio and excellent ductility.

Together with light weight, good dimensional stability and high impact resistance over a wide temperature range, Azdel VolcaLite may help engineers to design components that may contribute to vehicle weight reduction, while complementing part performance or aesthetics.

As well as potentially making weight savings of up to 50% possible in some components, Azdel VolcaLite composite may also deliver production advantages.

In headliners for example, this versatile composite sheet can be molded directly in one step together with fabric, thereby eliminating the separate production steps required with traditional materials to add functional layers.

Moreover, because of its high strength-to-weight ratio, headliners can be constructed with ultra-thin profiles, down to 3mm thick, less than half the thickness of conventional systems.

This combination of versatile performance properties makes Azdel VolcaLite composite an outstanding material for pre-assembled modular headliners.

It can enable an entire system to be mounted within a vehicle as a single assembly.

Of key importance, its light weight and low pressure formability, often using existing tooling, means that Azdel VolcaLite composite offers the possibility to reduce system cost by as much as 20%.

Furthermore, with its low weight, high stiffness-to-weight and ultra-thin profile (3mm to 5mm), Azdel VolcaLite composite has the potential to extend its value beyond headliners to a range of non-structural interior panels and trims of varying thickness and stiffness.

Better moisture resistance and lower emissions of volatiles and gasses than traditional materials, reinforces the concept of its potential use for interior applications.

Azdel VolcaLite composite has been validated for headliner applications for incineration waste management and is available globally in four constructions and a range of GSM and sizes.

Currently, Azdel VolcaLite composite is under evaluation with a number of Tier 1 automotive suppliers.

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

Further information can be found at: www.azdel.com GE's Automotive Application Development Center in Southfield, Mich.

U.S.A., 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.

High-speed composite moulding evaluated

2006-12-23T03:55:00.002-08:00

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

2006-12-23T03:55:00.001-08:00

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.

Thermoplastics resins benefit auto-makers

2006-12-22T03:10:00.001-08:00

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

2006-12-22T03:10:00.000-08:00

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.

Polymers mould into thin-walled parts

2006-12-21T03:09:00.000-08:00

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

2006-12-21T03:08:00.000-08:00

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.

Liquid silicone rubber is injection mouldable

2006-12-20T22:29:00.000-08:00

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

2006-12-20T22:28:00.000-08:00

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.

Autotex film for keyboards in demanding are

2006-12-19T22:26:00.000-08:00

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

2006-12-19T22:25:00.000-08:00

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'.

Plastics research resources offered

2006-12-18T22:24:00.002-08:00

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

2006-12-18T22:24:00.001-08:00

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.'

High temperature plastics extend into gears

2006-12-17T22:23:00.000-08:00

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

2006-12-17T22:21:00.000-08:00

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.

Network accesses latest materials developments

2006-12-16T01:16:00.001-08:00

By participating in the new KTN network, companies will be able to learn about, and make use of, the very latest global developments in materials technology.

Science and Innovation Minister Lord Sainsbury launched the Materials Knowledge Transfer Network, at the Science Museum last Thursday Jan 19, describing it as a new partnership between businesses, research and technology organisations and universities that would help give UK manufacturing an edge as global markets become ever more competitive. Lord Sainsbury said: 'The Materials Knowledge Transfer Network (KTN) will bring together industry and research expertise, and as a result make the best use of resources and spread best practice'. 'It will provide a one stop shop for unsurpassed materials advice to UK manufacturing and service providers.' The new KTN, said Sainsbury was an organisation aimed at making cutting-edge science available on the factory floor.

The new KTN includes the successful Faraday Plastics partnership - the UK's leading resource and coordinator for polymer-based research.

Richard Simpson, Faraday Plastics director said that: 'We feel energised and motivated by the Government's new initiative in materials.

At our Board Meeting on the eve of the launch we resolved a full commitment to our new materials partners in the network.

It is in fact vital that all of us - in plastics, textiles, ceramics and metals - work creatively and industriously with each other in order to grow the materials sector and the many opportunities in it.' Simpson adds that: 'This renewal of our remit within the new KTN structure is also very exciting news for UK plastics.

We intend to use our increased funding and new network resources to push innovations ever forward into the plastics manufacturing community.' By participating in the new KTN network, companies will be able to learn about, and make use of, the very latest developments in materials technology from around the world.

Businesses will have access to the very best of our scientific and manufacturing facilities to research and apply innovations in the use of materials.

The Department of Trade and Industry will provide more than GBP 11 million for the Materials Knowledge Transfer Network over the next three years.Under the chairmanship of Robert Quarshie of the DTI, the new materials grouping is an important element in the UK Government's aim to consolidate the sector as one of today's key drivers for a successful manufacturing sector.

The GBP 200 billion materials sector is estimated to contribute 15% to the nation's GDP, directly employs 1.5 million people and supports another 4 million jobs.

The Materials Knowledge Transfer Network will also give users access to up-to-date information on materials properties, where to get advice, research and development and other services and provide a forum for sharing information.

The network will have sections dedicated to each class of material, for example, metals, composites, plastics, ceramics, minerals and smart materials.

Simpson points out, however, 'That the KTN is far from an abstract tool.

At Faraday Plastics demand is high for our technology translators and we continue to deploy them throughout the industry to good effect - in matching their ideas to solution suppliers and in helping them Technology Road Map their future; gain access to grants and funds and also recoup tax breaks for company research and development spend.'

Fluoropolymer foams have high 160 deg C limit

2006-12-16T01:15:00.000-08:00

Offering an operational temperature limit of 160 deg C, fluoropolymer foams have exceptional smoke, flame and toxicity properties and chemical and UV resistance.

Zotefoams, the foam technologists, have launched a new range of high temperature closed cell foams; an extension to the successful ZOTEK F family of foams, based on the fluoropolymer Kynar from Arkema. Offering an operational temperature limit of 160 deg C, fluoropolymer foams are have exceptional smoke, flame and toxicity properties and chemical and UV resistance. Designated Zotek F HT, the new foams offer an operational temperature limit of 160 deg C, an improvement of +50 deg C over the current ZOTEK F range.

Four grades are currently available: Zotek F40 HT and Zotek F75 HT both recommended for general use in industrial applications such as chemical engineering, pharmaceutical and medical.

Zotek F38 HT and Zotek F74 HT complete the range and are intended for use in the commercial and military aircraft and aerospace industries.

All Zotek F fluoropolymer foams are characterised by their exceptional smoke, flame and toxicity properties, outstanding chemical and UV resistance and excellent insulation and moisture resistance properties.

The new Zotek F HT grades also offer enhanced chemical and solvent resistance, combined with higher levels of structural rigidity.

Preliminary testing indicates noticeable improvements in terms of tensile strength, elongation, tear strength and compression set.

Zotek F HT foams can be easily converted by using traditional foam fabrication techniques such as sawing, routing, gluing, laminating, welding and die-cutting.

They can also be thermoformed into complex single component structures providing many benefits over multi-layer foam systems, such as weight and cost reduction.

Glass spheres reduce moulding, extrusion costs

2006-12-15T01:14:00.000-08:00

Adding solid glass spheres to resin formulations as resin extenders reduces shrinkage and improves part flatness as well as lowering moulding and extrusion costs.

Potters Industries has just completed a study of the benefits of using engineered glass microsphere particles. According to William Shaker, Market Development manager of Polymer Additives at Potters Industries, 'One of the major benefits of adding solid glass spheres to resin formulations is reduced manufacturing costs'. ' With resin prices soaring, processors are looking to additives as a way to contain rising costs'.

'By using Spheriglass solid glass microspheres as resin extenders, they can realise substantial cost savings while gaining enhanced physical properties.' Spheriglass glass spheres are performance modifiers engineered to increase the strength of plastics.

High loadings of glass spheres add significantly to the dimensional stability of the finished product by reducing shrinkage and improving part flatness.

For example,' says Shaker, 'Data show that shrinkage of unfilled or glass fiber filled nylon 66 can be cut by 70-80% when 30% glass spheres are used.

And warpage is reduced 95-97% in the same tests.' High loadings can also increase flexural modulus, abrasion resistance, and surface hardness.

Additional benefits include excellent chemical resistance, increased compound flow, and improved compressive strength.

Used in thermoplastics and thermosetting resin systems, Spheriglass glass microspheres offer processing benefits by increasing the flow during extrusion and injection molding.

Microspheres lower the viscosity of most compounded resin systems, acting as miniature ball bearings to improve flow.

'Because flow is improved, very large and thin walled parts can be molded to dimensions,' explains Shaker.

'The spherical shape also yields better stress distribution.

This is important since localised stress within a molded part often leads to premature failure as well as warpage in the finished part.' In contrast to other additives such as fiber glass which have inherent properties that limit their use in certain applications, Spheriglass non-fibrous glass spheres help engineers confront the problems of maintaining dimensional stability, easing plastic flow and lowering molding pressures.

'The cost of glass spheres is less than half that of glass fibers, making them one of the most economical glass products available,' adds Shaker.

Spheriglass solid glass spheres have a density of 2.5g/cc.

They are very strong, with a crush strength of 30,000 lb/in2.

Moh's hardness is 6.0-6.5.

Glass spheres have very low oil absorption, about 18g oil/100g spheres.

And, because the spheres are nonporous, they do not absorb resin in a polymer system.

They are available in two glass compositions: A-glass (soda-lime glass) and E-glass (borosilicate glass).

Potters Industries, a wholly owned subsidiary of PQ Corporation is the world's leading manufacturer of engineered glass materials serving the highway safety, polymer additive, metal finishing, and conductive particle markets.

PQ Corporation recently acquired by JPMorgan Partners, is a leading producer of silicate, zeolite, and other performance materials serving the detergent, pulp and paper, chemical, petroleum, catalyst, water treatment, construction, and beverage markets.

GE joins with ASC to support automotive industry

2006-12-15T01:13:00.000-08:00

GE - Plastics announced a new collaboration with specialty-vehicle company ASC, - to give car buyers unique and exciting factory-installed options to suit their 'lifestyles'.

At the North American International Auto Show (NAIAS), GE - Plastics announced a new collaboration with specialty-vehicle company ASC Incorporated, showcasing the first results of a joint effort to give car buyers unique and exciting factory-installed options to suit their lifestyles. ASC's patent-pending, bi-directional InfiniVu 'open-air' sliding-roof system, which is incorporated into a prototype minivan dubbed the ASC TriLite, features GE's Lexan* GLX polycarbonate (PC) resin for style, safety, and weight savings. This application marks the first time, worldwide, this GE technology has been showcased in a panoramic automotive roof system - a technology whose advantages include design flexibility to promote creativity and part consolidation; light weight to boost fuel economy; and impact resistance for occupant safety.

The new collaboration between GE and ASC offers ASC additional 'cutting-edge' innovations for its high-image specialty vehicles as well as its more mainstream vehicle systems, such as open-air roof systems.

'As an auto industry first, our InfiniVu bi-directional sliding-roof system called for an exceptional plastics that could meet tough requirements for high performance and design freedom,' said Paul Wilbur, ASC's president and chief executive officer.

'The materials and support from GE are critical factors in the success of this design and others to come, which will give OEMs a new way to differentiate their vehicles and offer consumers new feature choices.' The roof panels, manufactured and coated with Exatec 900vt is made by Exatec, LLC, a GE joint venture company, that gives all occupants of a minivan, SUV, or crossover vehicle the fresh-air enjoyment of a convertible combined with the safety and protection of a hard-panel roof.

For the prototype vehicle, GE's versatile Lexan GLX resin was vacuum-formed; however, in production, the resin would be injection-molded.

The Exatec 900vt coating provides protection against abrasion and scratches, as well as weatherability.

Ideal for large, complex automotive glazing applications such as the ASC panoramic roof system, GE's Lexan GLX resin can provide a number of important advantages to consumers and vehicle engineers and designers: * Lighter weight than glass for improved fuel economy - addressing environmental concerns about fuel consumption, Lexan GLX resin can reduce part weight by about 50% for better fuel economy.

The American Plastics Council reports that for each 10% reduction in the weight of a car or truck, gas mileage increases by 7%.

* Less roof weight to avoid top-heaviness - reducing weight in a typical roof system can help lower the center of gravity.

* Shatter resistance for safety - GE's Lexan resin can offer improved shatter resistance, which may potentially help reduce risk of injury.

* Toughness for intrusion resistance - an exceptionally tough material, Lexan GLX resin helps protect against break-ins.

* Design flexibility - compared with glass and other materials, GE's Lexan GLX resin offers greater freedom to create innovative designs.

Further, the GE material lends itself to part consolidation for cost savings.

* Clarity - the GE material is clear, giving vehicle occupants an unimpeded view of the sky or landscape even when the roof system is closed.

According to Derek Buckmaster, global market director, Body Panels and Glazing, GE - Plastics, Automotive, 'An important focus for GE is helping our customers offer unique designs that broaden the array of choices for consumers.

Collaborating with ASC on this first project and jointly exhibiting our technologies demonstrates the tremendous progress we are making in leveraging plastics to meet consumers' changing lifestyles.

The styling of the panoramic roof system - which is made possible with Lexan GLX glazing - offers consumers a multi dimensional view of the world with no restrictions on enjoyment.

Lightweight components like these roof systems support GE's ecomagination initiative by helping automakers reduce the amount of fuel used - and emissions given off - by cars and trucks.' GE - Plastics is developing a number of next-generation materials that will enhance the style, safety, and weight savings of other automotive components.

* About GE - Plastics -GE - Plastics is a global supplier of plastic resins widely used in automotive, healthcare, consumer electronics, transportation, performance packaging, building and construction, telecommunications, and optical media applications.

The company manufactures and compounds polycarbonate, ABS, SAN, ASA, PPE, PC/ABS, PBT and PEI resins, as well as the LNP* line of high-performance specialty compounds.

GE - Plastics, Specialty Film and Sheet manufactures high-performance Lexan sheet and film products used in thousands of demanding applications worldwide.

In addition, GE - Plastics' dedicated Automotive organization is an experienced, world-wide competitor, offering leading plastics solutions for five key automotive segments: body panels and glazing; under the hood applications; component; structures and interiors; and lighting.

As a Worldwide Partner of the Olympic Games, GE is the exclusive provider of a wide range of innovative products and services that are integral to a successful Games.

* About ASC Incorporated - ASC Incorporated is a full-service specialty-vehicle partner for automotive manufacturers, specializing in vehicle design, body engineering, composite body packages and open-air roof systems.

Compounds conduct, and dissipate static

2006-12-14T01:13:00.000-08:00

A custom compounder of specialty electrically conductive thermoplastics compounds, has introduced a full line of conductive and static dissipative compounds based on copolymer polyacetal.

Premix Thermoplastics, a custom compounder of specialty electrically conductive thermoplastic compounds, has introduced a full line of conductive and static dissipative compounds based on copolymer polyacetal (POM). These compounds offer the excellent chemical resistance, toughness and low coefficient of friction of polyacetal while providing ESD protection. The new compounds are colorable and available with or without fiberglass reinforcement.

* PRE-ELEC 12-000 conductive (<1x10e5 ohm) compounds are based on copolymer polyacetal with carbon black or carbon fiber additives.

They are ideal for applications such as automotive fuel systems, gears and similar components where good toughness, wear and chemical resistance are important.

* PRE-ELEC 12-031 conductive compounds can be colored for color coding if desired without affecting the electrical properties of the compound.

These compounds are useful where the added stiffness of carbon fibers is desirable.

* PRE-ELEC ESD 12-000 static dissipative (1x10e9 to 1x10e11 ohm) compounds are colorable alloys of copolymer polyacetal and inherently dissipative polymers.

They are ideal for applications that require truly static dissipative properties with lower surface resistivity than PRE-ELEC 12-000 conductive products.

They dissipate electrostatic charge at a slower rate than the truly conductive compounds PRE-ELEC 12-000 and PRE-ELEC 12-031.

Using many of the commercially available thermoplastics and virtually all of the electrically conductive additives, inherently dissipative polymers (IDPs), and inherently conductive polymers (ICPs), Premix creates customized solutions to meet customer needs.

Adhesive alternative to PTFE tape

2006-12-14T01:12:00.000-08:00

Victrex has introduced Victrex Peek adhesive tape, a super-tough material providing the best combination of friction and wear properties combined with high temperature resistance.

Victrex has introduced Victrex Peek adhesive tape, a super-tough material providing the best combination of friction and wear properties combined with high temperature resistance, chemical resistance and excellent electrical insulation. It is ideal for use in a broad range of applications including gaskets, aerospace components, high performance labels, solder masking, oil field equipment, semiconductor processing equipment and more. According to John Getz, Victrex Global Commercial Leader Film, 'Victrex Peek tape provides engineers and designers with an excellent alternative to both PTFE (polytetrafluoroethylene) and PI (polyimide) tape.

When compared to PTFE tape, Victrex Peek tape exhibits much higher tensile strength, is a tougher, stronger material with better wear performance in aggressive conditions, and has a lower density.

When compared to PI tape, Victrex Peek tape has lower moisture absorption, better performance in strong alkaline environments, and higher tear strength.' Victrex Peek tape can withstand continuous operating temperatures of up to 220C (428F) and even higher temperatures for short durations.

It resists wear over a wide range of pressure, velocity, temperature and counterfacial roughness.

Hydrolytically stable, Victrex Peek tape maintains its electrical properties over a wide frequency and temperature range, and can withstand over 109 rads of radiation exposure without embrittlement.

In addition, it has excellent chemical resistance to solvents, acids, bases, fuels, and hydrocarbons even at elevated temperatures.

Available in slit rolls, sheets and die-cut pieces in thicknesses of.002' and above, Victrex Peek tape is coated on one or both sides with a variety of adhesive systems including silicone or acrylic.

Adds Getz, 'Victrex Peek tape is able to meet a variety of aerospace, automotive, food/water, medical/pharmaceutical, and military/nuclear approvals and standards.

Resin for automotive glazing solutions

2006-12-13T01:11:00.000-08:00

Italy's Ranger Group has announced that it has chosen GE's Lexan, GLX resin to launch its new premium automotive glazing line with the tradename Organikglass.

Italy's Ranger Group has announced that it has chosen GE's Lexan, GLX resin to launch its new premium automotive glazing line with the tradename Organikglass. GE's Lexan GLX polycarbonate (PC) resin, which provides high impact strength, UV protection, and light weight that are especially valuable in large panoramic roofs, sunroofs, and backlights, will be injection-molded at Ranger's state-of-the-art production facility in Carate Brianza, Italy. Ranger expects to develop new automotive glazing applications that will take advantage of the unique properties of GE's thermoplastic materials vs.

conventional materials.

'Ranger is very excited about developing our new glazing line Organikglass using GE supplied materials.

This will make Ranger the first company to manufacture world-class, light-weight, and impact-resistant PC side and rear car windows and especially panoramic roofs for automotive manufacturers.

Our focus is on growth and innovation,' said Ranger CEO, Matteo Rossini.

'Lexan GLX polycarbonate resin will help us meet changing customer requirements for the latest glazing designs, colors, and shapes, while helping to reduce overall vehicle weight as a glass replacement.' Headquartered in Carate Brianza with several production sites across Europe, Ranger is devoting this new facility to injection mold components such as roof glazing, side and rear windows, and backlights.

With a proven thirty-year experience in the production of molds and complex equipment, its metallurgy and plastic materials know-how is the starting point for each project including this new glazing line.

Ranger Group has doubled its sales, production sites, and staff in three years as a result of this dedication to advanced material technology solutions.

Correspondingly, GE will provide technical guidance to Ranger regarding best practices for the use of its Lexan GLX PC resin in automotive glazing.

Portal covers film insert moulding

2006-12-13T01:10:00.000-08:00

A specialised independent website for Film Insert Moulding (FIM) professionals and end users, now comprises the most recent information for the FIM process including all the latest news.

A specialised independent website for Film insert moulding (FIM) professionals and end users, now comprises the most recent information for the FIM process including all the latest news, product innovations, technological developments and much more. FIM, a type of In Mould Decoration (IMD), provides a means of decorating and manufacturing a wide range of profiled or three dimensional plastics components for use throughout industry. Typically applications include telecommunications and electronics, such as mobile phone fascias or touch sensitive keyboard pads; industrial moulded display panels; interior and exterior automotive parts and trims; and general consumer appliances.

The FIM portal was created to educate end users on the benefits of the process.

With contributions from many of the leading companies in FIM, including MacDermid Autotype, Formech, Proell and Battenfield, the website features knowledge and advice for those who wish to find out more about this versatile and cost effective process.

The site is constantly being updated to keep visitors informed of the most recent developments in the fast developing FIM industry.

All the latest news appears on the site as well as new product information and case studies.

The website comprises all the information needed for understanding, researching and purchasing FIM, at the click of a mouse; including a directory of suppliers of FIM products and services.

Now manufacturers can research the FIM process and equipment, and even select a supplier whenever they need to do so.

GE boosts liquid silicone rubber production

2006-12-12T01:04:00.000-08:00

GE Bayer Silicones plans to invest in additional production capacity for liquid silicone rubber (LSR) at its facility in Leverkusen, Germany to help meet expanding European and global demand.

GE Bayer Silicones plans to invest in additional production capacity for liquid silicone rubber (LSR) at its facility in Leverkusen, Germany to help meet expanding European and global demand. Darrell Hughes, GE's global business manager for Elastomers, said: 'GE's technology for liquid injection moulding of silicone elastomers offers customers significant productivity advantages and new design opportunities. With our innovative LSR technology, we are a global leader in this growing product segment.

Last year we brought our LSR production facility in Thailand on line to support growth in Asia.

With Thailand, we now have the capability to supply locally from the Americas, Europe, and Asia.

In Europe, our teams increased GE's LSR capacity by more than 10 per cent during the last year by applying LEAN and six sigma methodologies.

However, more capacity is needed, so we are expanding the Leverkusen plant to help meet customer demand.

The new equipment will produce standard grades as well as customer-specific LSR materials.

The new investment will support our continuous growth and confirms our long-term commitment to this product line.' Liquid silicone rubber is used to produce high-performance moulded articles for various industries and applications.

Examples are seals and connectors for the automotive industry, baby nipples and pacifiers for the infant care industry, components and seals for the healthcare industry, or insulators and cable accessories for the high voltage industry.

Practical guide covers polyvinyl chloride

2006-12-12T01:03:00.000-08:00

A practical guide to polyvinyl chloride has information for working with PVC and provides background on the resins and additives, their properties and processing characteristics.

Polyvinyl chloride (PVC) has been around since the late part of the 19th century, although it was not produced commercially until the 1920s; it is the second largest consumed plastic material after polyethylene. PVC products can be rigid or flexible, opaque or transparent, coloured, and insulating or conducting. There is not just one PVC but a whole family of products tailor-made to suit the needs of each application.

Rapra's Practical Guide to Polyvinyl Chloride is packed with information for everyone working with PVC.

It provides comprehensive background on the resins and additives, their properties and processing characteristics, as well as discussion of product design and development issues.

PVC is extremely cost effective in comparison to other plastics with a high degree of versatility in end-use and processing possibilities, as the reader will note from this book.

It is durable, easily maintained, and can be produced in a large range of colours.

As a result PVC finds use in an extensive range of applications in virtually all areas of human activity, including medical equipment, construction applications such as flexible roof membranes, pipes and window profiles, toys, automotive parts and electrical cabling.

The PVC industry has also started to tackle some of its end-of-life issues.

There have been, and still are, issues and perceptions over environmental and health acceptance covering vinyl chloride monomer, dioxins, phthalate plasticisers, and lead (and cadmium) based heat stabilisers and these are discussed in depth in this book.

Practical Guide to Polyvinyl Chloride will be of interest to raw materials suppliers and processors or end-users of PVC, as well as anyone with a general interest in this versatile material.

Written by Stuart Patrick who has worked extensively in the PVC and additives business and been involved in both market and technical developments in this competitive field.

Before retirement he was Global R and D Manager with Akzo Nobel/Akcros Chemicals.

He is now utilising his experience as a part-time lecturer at IPTME, Loughborough University and as a co-ordinator for a Research Network established to improve the sustainable use of PVC.

Plastics items shredded on site in seconds

2006-12-11T01:10:00.003-08:00

The mobile shredder provides a cost-effective solution for the recycling of bulky plastics items in seconds that are difficult and uneconomical to recycle due to high transportation costs.

A novel solution from Axion Recycling for recycling bulky plastics on-site - an innovative mobile shredding unit - achieved recognition in the recent Recycling and waste management Awards. A Finalist in the 'Developments in New Technology - Vehicles category', Axion developed the mobile shredding unit with funding by WRAP, the Waste and Resources Action Programme. On-going trials in various industrial and commercial sectors include notable success in recycling car bumpers, redundant fish farm cages and utility piping.

Comments from the judges on the project included - 'brilliant' -, - 'liked it' - and - 'nice, new idea'.

Keith Freegard, Axion Recycling Technical Director received the framed certificate at the awards ceremony and said the company was very pleased to have been selected for the Final, which recognised all their efforts in putting the project (literally) on the road.

Over the next few months, Axion will focus its attention on those market sectors offering big volumes of bulky waste plastics and it welcomes inquiries from potential suppliers.

The mobile shredder provides a cost-effective solution for the recycling of bulky plastic items that are difficult and uneconomical to recycle due to high transportation costs.

By travelling to the locations where there are bulky items to shred, the vehicle reduces transport costs, saves space and diverts material from landfill.

Capable of shredding bulky plastics in seconds, the unit is mounted on a curtain-sided truck and staffed by skilled operators who assist with feedstock preparation and loading.

Shredded material is collected in big bags and taken away for re-processing.

New European Production Location

2006-12-11T01:10:00.001-08:00

New European Production Location and Expanded Capacity to Benefit Customers of GE Plastics' 'xtreme' Lexan Resins.

To provide a European source of supply for its line of 'xtreme' Lexan polycarbonate (PC) resins while boosting overall capacity by approximately 300%, GE Plastics has announced it will expand production of these speciality products beyond the United States. The company will invest 62 million Euro to retrofit its Lexan Resin facility in Bergen op Zoom for the manufacture of Lexan EXL, SLX, DMX, and XHT copolymer resins, giving European customers the advantage of shorter delivery times. Broader availability of these unique materials will help more customers differentiate their applications and achieve new levels of performance, processability, and aesthetics.

'GE's xtreme resins - each with a set of specialised properties - offer customers new ways in which to differentiate their products and even create applications they couldn't produce previously,' said Heiner Markhoff, vice president of GE Plastics Europe.

'We're making a major capital investment to support expected growth of our Lexan resin specials at many of our European customers and worldwide'.

'By adding significant production capacity in The Netherlands, we aim to expedite delivery to European customers so they can accelerate time to market'.

The Lexan xtreme resin line includes the following grades:.

Lexan EXL resins: These grades deliver very high ductility and impact performance in extremely low temperatures (down to -60C).

They also provide improved resistance to heat and humidity.

Flame-retardant grades, based on non-chlorine, non-bromine technology to meet increasingly demanding environmental regulations, are available.

Lexan EXL resins provide improved flow, processing characteristics, and release with opportunities for shorter cycle times, compared to conventional PC resins.

They are available in opaque, transparent, and Visualfx resins with special effects colours.

Applications include mobile phones, electrical enclosures, automotive components, and personal safety equipment.

Lexan SLX resins: Offering outstanding long-term weatherability and UV resistance, these grades are being used in lighting, outdoor vehicles and marine components.

Compared to clear or opaque UV-stabilised PC, Lexan SLX resins demonstrate enhanced retention of clarity, colour, gloss and toughness.

They give customers an alternative to the use of clear UV coatings and paints that can add time and cost.

These resins are available with UL94 HB and V2 listings, and utilise non-chlorine and non-bromine flame-retardant systems for regulatory compliance.

Lexan XHT resins: These materials expand heat resistance capabilities beyond that of standard polycarbonate resins from 165C to 220C Tg, while maintaining many of the desirable properties of polycarbonate.

Typically used in automotive, industrial lighting, and personal protective equipment segments, Lexan XHT resins also offer improved flow and processability compared to other options with equivalent heat resistance, allowing customers to fill larger tools or thinner wall sections.

Current resin grades are available in a range of opaque colours while others in development may be excellent candidates for transparent applications.

Lexan DMX resins: Improved scratch resistance with H pencil hardness, combined with good processing characteristics, offer the potential for improved yields and elimination of painting/coating vs conventional PC.

Lexan DMX resins also provide up to five times better oxygen and moisture barrier performance plus excellent resistance to ammonia, compared to standard PC.

They are available in transparent and Visualfx resins colours, as well as flame-retardant grades with V0 ratings down to 1.5 mm, as well as non-chlorinated, non-brominated flame retardant grades meeting ECO label regulations.

Applications include business equipment, mobile phones, electronic devices, and electrical enclosures.