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Invista introduces thermoplastic resin that acts like a thermoset

By: Clare Goldsberry Invista’s Chemical Intermediates Division (Houston, TX) recently introduced a new thermoplastic material that acts more like a thermoset resin. business partnership Image courtesy Stuart Miles/freedigitalphotos.net. The new nylon-1,6 resin (formaldehyde-hexanedinitrile copolymer) has spectral features and thermal behavior aspects similar to features historically known in resins such as UF, melamine, Bakelite and others, according to Senior Research Advisor William J. Tenn. A high density of amide residues in the polymer makes it significantly more hydrophilic than other nylons; it can be used in combination with other thermoset and thermoplastic materials to modify properties such as water and hydrocarbon absorbance. Nylon 1,6 can provide a more rapid cure response than other polyamides in epoxy applications. It is being evaluated as a fortifier for use in UF-, PF- and melamine-based formulations, and as a composite material in combination with other thermosets and thermoplastic materials. Invista is currently offering partnership opportunities to accelerate development and aid in bringing the product to market. The company is interested in discussing opportunities for partnering that could take many forms including co-development, licensing and consulting. If you're interested in exploring some opportunities, send an e-mail to William Tenn , Intermediates R&D. https://www.plasticstoday.com/materials/invista-introduces-thermoplastic-resin-acts-thermoset/59773997956630

Ms. Kang 2017-05-15

Metallocene polypropylene resin eliminates weld lines in interior plastic parts

By: Stephen Moore in Automotive and Mobility ▲ Welnex/GF delivers weldless injection-molded parts. Weld line elimination and excellent surface appearance are key properties achievable with a new grade of glass fiber-reinforced thermoplastic polyolefin (TPO) based on metallocene catalyst and process technology developed by Japan Polypropylene (JPP, Tokyo). The primary target application of Welnex/GF is automotive interior components. Welnex/GF delivers weldless injection-molded parts. As opposed to conventional talc-filled polypropylene (PP) grades employed in interior applications, weld lines are almost invisible with the new grade, which crystallizes relatively slowly like a random copolymer grade, resulting in better integration of the two flow fronts. According to a JPP spokesperson, while the cycle time might consequently be roughly 10% slower, advantages such as no need for coating and a softer feel despite the 10–30% glass fiber reinforcement content have already convinced some end user to adopt the material. Further advantages of Welnex/GF include excellent mold pattern duplication, i.e., higher gloss for mirror surfaces and lower gloss for grained surfaces. And remarkably, according to JPP, glass fibers are invisible in grained surfaces. The grade is also said to exhibit outstanding color vividness (good pigment dispersion), anti-stress whitening, and less shrinkage and warp, meaning larger parts can be molded. A Welnex/GF 20% glass fiber-reinforced grade exhibits an MFR of 30, flexural modulus of 2730 MPa, Charpy impact strength at 23°C of 30 kJ/m 2, and shrinkage in the flow direction of 1.2x10 -3. JPP has also reported developmental progress in its Waymax metallocene-catalyzed high melt strength PP material. Using double-sided vacuum forming machinery commonly used to process polystyrene foam sheet, 4.2-mm thick extruded foamed sheet (10-fold expansion ratio) is now possible. JPP is also touting Waymax as a film modifier for air-cooled blown film processed using its Wintec metallocene random copolymer PP resin. Addition of 10% of Waymax grade MX3 to the core Wintec layer achieves better bubble stability, and hence higher productivity, with no sacrifice in haze, which is maintained at a level of 2.6%. https://www.plasticstoday.com/automotive-and-mobility/metallocene-polypropylene-resin-eliminates-weld-lines-interior-plastic-parts/159853120856622

Ms. Kang 2017-05-15

Thermoset resins set to feature heavily in next-generation drive trains

By: Stephen Moore in Automotive and Mobility, Compounding, Injection MoldingThermoset resins continue to play an important role in metal replacement and lightweighting in motor vehicles. And Japanese firm Sumitomo Bakelite continues to push the application envelope through the development of new phenolic resin matrix-based materials targeting the auto sector. ▲ Motorcycle engine housing molded from phenolic resin compounds saves weight and reduces engine noise. One such development turns to the ancient Japanese art of wet papermaking in a wet-laid nonwoven forming technology that interfaces and aramid or carbon fiber “entangled fiber network” with a phenolic resin molding compound. Sumitomo Bakelite envisages application in gears, where the technology has shown to be capable of reducing noise by 10 dB at a torque of 10 Nm and 1000 rpm (the counter material was an S45C steel gear). Further, gear compounds are typically 50–60% lighter than aluminum die-cast alloy gears. Sumitomo Bakelite has also developed a conductive grade for electromagnetic shielding applications. In other developments, the company has developed a long fiber-reinforced phenolic resin moldable compound that boasts shorter molding cycles compared with CFRP prepregs. Further, Sharpy impact strength is 10-times that if short fiber-reinforced phenolic resin compounds (30 kJ/m 2 versus 3 kJ/m 2) on account of the long fibers (4–6 mm versus 0.1–0.2 mm length). The compound is 34% lighter than aluminum and 77% lighter than medium carbon steel (S45C). ▲ Brake pads can be molded with integral back plates in an insert injection-molding process. Sumitomo Bakelite is also challenging the extremes of dimensional stability for thermoset molding compounds with grades Sumikon PM-5240 and 5245. Tests indicate that the standard deviation in internal diameter of parts molded from these grades is of the order of less than 0.005% while concentricity is in the range of 10–20 microns. Besides the driver train, Sumitomo Chemical believes thermoset resins have a role to play in bringing vehicles to a stop. Case in point: the company is developing an insert injection-molding process for back-injecting brake pads with a phenolic resin back plate. Sumitomo Bakelite has also joined forces with the Fraunhofer Institute for Chemical Technology ICT to joint develop composite materials for innovative functional and structural engine parts. Over the coming years, the two partners will work together to make drive trains lighter, better and more compact, and of course to integrate Sumitomo Bakelite materials into a variety of new applications. One such example is an engine housing for the BMW F650 water-cooled single cylinder (650-cc) motorcycle engine. Current die-cast from aluminum, switching to a phenolic compound would reduce the engine’s overall weight (including the mass of the cylinder) by 14–28%, while thermal efficiency would also be improved and engine noise would be reduced by 5 dB. Engine performance is equivalent to an aluminum engine housing. According to the project leader at Fraunhofer, Lars Fredrik Berg, the technology has further potential: “Besides cylinder housings and engine blocks, fiber composites such as Sumitomo Bakelite’s high-performance composite materials can be used in many other components in the drive train, to reduce weight and improve overall performance.” The materials are also opening up new possibilities in component design: “We are just starting to explore a range of new benefits and options which would not be possible with aluminum,” Berg explains. “Sumitomo Bakelite materials offer significant potential for application in and outside the drive train,” adds Pieter Vanderstraeten, CEO of Vyncolit, the European production company for the composite molding compounds of Sumitomo Bakelite in Belgium. The cooperation with Fraunhofer will accelerate the automotive industry’s adoption of these materials for innovative functional and structural engine parts. Sumitomo Bakelite Co., Ltd. is launching the sbDRIVE initiative to the automotive industry for the full development of lightweight solutions at acceptable cost in the automotive powertrain. It includes concept work, design iterations, composite material development and production techniques, prototyping, and validation testing up to industrialization for large-series production. In all of these fields, an intensive cooperation with Fraunhofer has been agreed. https://www.plasticstoday.com/automotive-and-mobility/thermoset-resins-set-feature-heavily-next-generation-drive-trains/212168276556610

Ms. Kang 2017-05-12

Using plastic to buy plastics

by Frank Esposito Teknor Apex customers now can use their plastic to buy plastics. The materials firm’s newly opened online Color Store allows any plastics processor to use a credit card to buy stock color concentrates in minimum order quantities of 2 pounds.Officials with Teknor in Pawtucket, R.I., said in a news release that the new program will simplify purchasing, particularly for processors with small product runs. The system “makes online shopping as easy for color concentrates as it is for consumer items,” they said. The Color Store enables a processor to purchase bags of 12 standard colors for polyolefins and some nylons using a credit card or PayPal. While colors are shipped in two-pound bags, customers may purchase up to 20 pounds per color at a time. There is no limit to the number of standard colors that can be purchased. All orders are shipped via UPS with freight prepaid and Safety Data Sheet (SDS) included. Overnight delivery is available.“Color suppliers typically have a standard minimum order of 50 pounds,” Teknor Color sales director Jeff Neupauer said. “Why buy 50 pounds of concentrate when 2 pounds will do? The Color Store eliminates need to carry unnecessary inventory.” The 12 concentrates are produced with FDA-compliant ingredients. Colors include Salsa Red, Citrus Orange, Sunflower Yellow, Candy Pink, Jungle Green, Forest Green, Celestial Blue, Denim Blue, Earth Brown, Wolf Gray, Raven Black and Winter White. “Ordering concentrates from the Color Store is easy,” Neupauer added. “Starting with ‘Add to Cart,’ site visitors follow the simple four-step procedure familiar to any online shopper.” Teknor is one of North America’s 30 largest compounders and concentrate makers. The firm also manufactures extruded hose products. Teknor employs more than 2,000 worldwide and has annual sales of more than $600 million. http://www.plasticsnews.com/article/20170407/BLOG07/170409929/using-plastic-to-buy-plastics

Ms. Kang 2017-05-12

6 tips for resin selection

by Scott Rishell As a custom plastics molder and contract manufacturer serving the medical, industrial, transportation, energy/environment, computer/business, and consumer markets, Mack Molding’s customers are varied, and so are their needs. To meet these diverse requirements, Mack has vertically integrated services including designing, prototyping, supply chain management, machining, sheet metal fabrication, molding, painting, assembly, testing, and fulfillment. With this diversity of services, it is interesting to note some of the most significant variation in customer requirements comes from the resin selection process. Material properties, processability, and cost all play key roles determining a resin’s suitability for an application. With thousands of grades to choose from, and new ones being developed to fill market niches, customers often turn to a contract manufacturer to help navigate the resin selection process. Here are some considerations when choosing a resin. Mechanical requirements – Parts that have specific strength requirements need to be considered when choosing a resin as different classes have various mechanical properties, including tensile strength, elastic modulus, and heat deflection. Thermoplastic resins offer a variety of strength properties that can often be modified with fillers such as glass or carbon fiber. Chemical compatibility – Many customers are concerned about how chemicals, including cleaning solvents and process reagents, interact with their resin choice. In these cases, we consult published testing data from resin manufacturers that show a material’s performance with each chemical. At times the data may not exist and testing with specific chemicals will be requested. Environmental compatibility – Parts that will be exposed to extreme hot or cold conditions need to be made with resins rated accordingly, making the long-term service temperature and heat deflection temperature critical performance metrics. Other conditions to consider include exposure to UV light and high humidity. Commodity vs. performance – When possible, customer applications are paired with commodity resin grades due to the inherent cost and availability advantages of higher volume raw material production. Some projects call for specific properties – strength, heat resistance – which is where performance resins excel. Though its higher cost makes it most appropriate for low-volume, niche applications. Amorphous vs. semi-crystalline – Amorphous resins can offer wider processing windows and improved dimensional control due to their random molecular structure. They can be transparent and are compatible with many adhesives. Semi-crystalline materials offer improved mechanical and thermal properties but can be more difficult to process. Material shrinkage – The amount a resin shrinks during the molding process can have a huge impact on the ease of building a tool or developing a successful molding process. Try to select resins that have lower shrink rates whenever possible. Once these factors are accounted for the list of suitable resins is typically cut down to a manageable number for consideration. The Mack team uses its knowledge of materials, coupled with supply chain management, to help make the final determination of a grade. Mack Moldingwww.mack.com About the author: Scott Rishell is the technical lead on several programs at Mack, developing part designs for production processes. Prior to his current role, Rishell was a program manager in Mack’s medical business, where he gained unique customer experience insights. He has a bachelor of science in mechanical engineering from the Rochester Institute of Technology. Rishell can be reached at scott.rishell@mack.com. http://www.todaysmedicaldevelopments.com/article/6-tips-for-resin-selection/

Ms. Kang 2017-05-12

Lightweight PP and plastic-metal hybrid solutions on show at Germany’s VDI congress

By: Stephen MooreWith the automotive industry’s continued focus on reducing emissions and increasing fuel efficiency, materials-maker SABIC is presenting a range of solutions at this year’s VDI Plastics in Automotive Engineering Congress in Mannheim, Germany. The solutions cross a range of application segments – from a vehicle’s exterior and glazing to components like instrument panel carriers and structural reinforcements for the body-in-white (BIW). Combined, these solutions can potentially reduce the overall weight of a vehicle by 13 to 15 kg. “Our featured solutions at this year’s VDI Congress bring forward some novel approaches or highlight progress in other technologies,” said Scott Fallon, global leader of SABIC’s automotive business. “I especially like that we’re showcasing answers for the industry that can ease multiple pain points. They not only help OEMs shed weight. They add value in other ways, too.” ▲ Injection-molded foamed instrument panel carrier uses LGFPP in combination with a block copolymer PP grade to achieve lightness and stiffness. A good example of this is plastic-metal hybrid (PMH) structural reinforcements for the vehicle’s BIW. A PMH floor rocker reinforcement, for instance, can help reduce weight by up to 45 percent vs. an all-steel alternative. In this component, NORYL GTX resin (mPPE/PA) from SABIC combines with steel to form a very efficient energy-absorption crash box structure. This saves 1 kg in weight and maintains the required level of crashworthiness. The component is an industry-first use of plastic in a BIW reinforcement without the use of structural adhesives or foams. Use of the NORYL GTX resin allows the part to go through the automaker’s e-coat process with the rest of the BIW. Additional opportunities across the BIW means that a manufacturer could save up to 8 kg of weight with these hybrid solutions vs. all-metal reinforcements. SABIC is also featuring an injection-molded, foamed instrument panel carrier. The part uses the company’s STAMAX long glass fiber polypropylene (LGFPP) resin (60YK270E grade) with a block copolymer SABIC PP resin (612MK10EE grade) in a structural foaming process. In this approach, the manufacturer injects the material into the mold with a foaming agent. Immediately afterwards, the mold is opened a few millimeters, controlling the final density of the part. During the process, the foaming agent produces CO 2 bubbles that create a foamed core. The final produced part is both light and stiff. SABIC’s solution is emission-optimized and meets the VDA278 industry standard. Other potential benefits from this foamed STAMAX resin solution include the need for less material during processing, shorter cycle times, and a better balance of impact and stiffness. Another PP-based solution from SABIC on display is a lightweight, thin-wall front bumper on a recently launched 2017 model. This part uses SABIC PP compound (8650 grade) to optimize the thickness to 2.5 mm, which can save more than 10 percent in weight. Low shrinkage, excellent impact-stiffness balance and potentially reduced cycle times are among the advantages of this approach. SABIC’s material is an open compound, which allows for greater dimensional flexibility for molders. SABIC continues to highlight progress in plastic glazing applications. This time, the featured part is an in-production rear quarter window, the largest in the world in LEXAN polycarbonate (PC) resin (GLX143 grade). A two-shot injection compression molding process combining PC resin with CYCOLOY PC/ABS alloy (XCM830 grade) results in a final part that is up to 40 percent lighter vs. conventional glass. This glazing solution allows for design features not possible in glass, as well. Notably, this window is the first from a new production facility in China devoted to the manufacture of mass-produced LEXAN PC glazing parts. Finally, SABIC is highlighting ongoing development work in the use of unidirectional laminates. The idea is to combine the material supplier’s UDMAX tape with STAMAX LGFPP resin to achieve further weight reduction, while improving mechanical performance. UDMAX tapes are fiber-reinforced thermoplastics, which offer high strength and stiffness, good processability and fatigue resistance. https://www.plasticstoday.com/automotive-and-mobility/lightweight-pp-and-plastic-metal-hybrid-solutions-on-show-germany-s-vdi-congress/160457500956549

Ms. Kang 2017-04-07

BASF·CHINAPLAS showcase solutions for smarter living, co-created with designers, brand owners

▶ Extraordinary“TRIO” prototypes include robot hand, revolutionary bicycle tire, and others▶ Interactivevirtual and augmented reality booth concept will enhance visitor experience▶ CHINAPLAS2017: May 16-19 at China Import & Export Fair Complex, Guangzhou Guangzhou,China – February 9, 2017 – At CHINAPLAS 2017, BASF and CHINAPLAS will showcaseextraordinary prototypes for products that improve smarter living atthe “Design x Innovation” event. They include a robot hand, an airless bicycle tire,a unique children’s toy set and a hybrid electronic device – all developedthrough collaboration between topdesigners and brand owners, and facilitated by BASF and using its advancedmaterials. Theseco-creation projects have been named “TRIO” to reflect the cooperation between BASF,designers and brand owners. While BASF provides the material inspiration forthe prototypes, the products are conceptualized by designers and brand owners.BASF, backed by its research and development, technology, engineering, and simulation competences, also helps to optimize and make joint innovations feasiblefor production, while lowering development cost and ensuring fastercommercialization. Theprojects will be unveiled at the Design Forums of the “Design x Innovation” eventheld concurrently at CHINAPLAS 2017. There, BASF will also showcase a range of innovationsfor smarter living, which helps meet regulationsand market trends, such as demand for low volatile organic compound productsand fuel efficiency in transportation, individualization in consumer goods, sustainable infrastructure in construction,as well as the advancement of Industrial Internet-of-things.The innovations to be showcased includethe RN30, a new concept vehicle jointly developed by BASF and Hyundai MotorCompany, which combines key solutions from the chemical industry with purposefulaerodynamic design and specialized high-performance technologies. “Weare proud to unveil the results of our collaboration with designers and brandowners, and demonstrate how our materialsolutions and technical competencies enablebetter design and function for products that contribute to smarter living. By co-creating, we can developproducts that have greater appeal and business potential,” said Andy Postlethwaite, Senior Vice President, PerformanceMaterials Asia Pacific, BASF. The“Design x Innovation” event at CHINAPLAS 2017 will be held at Booth 11.2A41, China Import & Export Fair Complex,Pazhou, Guangzhou, China from May 16-19, 2017. The Design Forums will alsofeature panel discussions with the designers and brand owners from the TRIOco-creation projects. Additionally, interactive virtual and augmented reality boothactivities will enhance visitor experienceand appreciation of how innovative materials enable design and functionality. “Thisprogram marks the third year of collaboration with BASF onour unique Design x Innovation concept,” said Ada Leung, General Manager of Adsale ExhibitionServices Ltd, organizer of CHINAPLAS. “The event has successfully increasedindustry's awareness of the importance of design in product development and thatplastics can make all design achievable. We very much look forward tooffering more interesting content in thenext Design x Innovation jointly with BASF.” Details are available at the “Design x Innovation” official event website http://on.basf.com/Chinaplas2017www.ChinaplasOnline.com/DesignxInnovation

강민정 2017-02-21

Baerlocher additives help stabilize reprocessed resins

▲ Gregory Andersen, business manager for Baerlocher in the United States, and CEO Arne Schulle.January 4, 2017By Jim Johnson Düsseldorf, Germany — Plastics additives company Baerlocher GmbH is pushing into the recycling market with its resin stabilization technology, but realizes it’s going to have to do some educating along the way to gain market share. The Munich-based company said during K 2016 in Düsseldorf that its Baeropol RST brand is an off-shoot of work the company was doing with major resin makers when employees realized the stabilizer also had applications downstream in the recycling market as well.Baerlocher views its RST as a substitute for a long-standing additive that has been the go-to for recycled resins for the last generation, according to the company “So the RST technology can be substituted for phosphites in a typical antioxidant package. And one of the reasons that we’ve taken it into the recycling industry is it also has good antacid properties,” said Gregory Andersen, business manager for Baerlocher in the United States. “There’s very few recycle streams that are 100 percent pure any one polymer. We have done quite a bit of field work,” Anderson said, adding that cross-contamination leads to problems. “One of the difficulties that reprocessors face is the acidic nature that PVC contamination lends to a recycling stream,” he said. “Because RST technology has antacid properties as well as antioxidant properties, it’s very well suited in a recycling stream. “Rather than adding separate antacids in the recycling stream, you can just use RST as a replacement.”The company’s RST approach saves customers about 25 percent when compared to phosphites, but the company touts attributes beyond just that, including soluability, color and melt stabilization before it even brings up pricing. Arne Schulle is CEO of the Baerlocher Group and says the technology launch into the new business space is based on his company’s experience in oleochemistry. “New customers are evaluating these exciting new products every day, and their feedback has been very positive,” he said in a statement.Schulle, in an interview on the K show floor, also provided an update about the company’s continuing growth, including an expansion of operations in Turkey to serve the Middle East and Africa. “We continue to invest in Turkey. So after an initial investment in Turkey and we will further invest into a logistics center,” he said. “This investment is more related to logistics around it, so it’s not in regards to capacity.” The project includes additional warehouse space. http://www.plasticsnews.com/article/20170104/NEWS/170109977/baerlocher-additives-help-stabilize-reprocessed-resins

강민정 2017-01-17