'Green' is an added attraction in bumper crop of new plastics.

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Among the staggering number of new plastics making their debut at last fall's K Show in Dusseldorf, the buzz wasn't all about faster processing or higher strength or heat or chemical resistance. Resin suppliers appeared to be betting that "biobased" or "renewable" content will rank with these other qualities in determining which materials get chosen for new generations of cars and other consumer and industrial products.

It wasn't all about being "green" at K, however. Nanocomposites drew some attention, as did a number of genuine novelties and "firsts" in polyolefins, engineering thermoplastics, TPEs, and thermoset LSRs. More than 100 new materials are reviewed here, but a number of other new materials were previewed in our September pre-show report. (see Learn More).

FIRST BIOBASED TPEs

Spain's Merquinsa introduced the world's first TPU derived from biological/agricultural sources rather than fossil hydrocarbons. The polyols used to make the Pearl-thane Eco and Pearlbond Eco series TPUs are themselves made from renewable resources including vegetable oils and fatty acids. The company launched the Eco series with a renewable content ranging from 40% to 95% by weight. They are said to offer equivalent, and in some cases better, performance versus traditional TPUs.

Development grades are being sampled and commercialization is expected in the coming months. Three grades for injection molding and extrusion coatings will be available in a full range of hardness. Targeted applications include athletic soles, electronics, and automotive. No process modifications are required and prices will be comparable to traditional TPUs.

Another biobased TPE was introduced by Arkema of France. It's Pebax Rnew is said to be the first commercial "engineering" TPE made with renewable resources. (DuPont plans to launch Hytrel copolyester TPE with renewable content this year.) Pebax Rnew is a polyether-block-amide (PEBA) TPE with 20% to 90% renewable content based on castor oil, which is the basis of Arkema's Rilsan PA11 (nylon 11), used to make Pebax Rnew. Available in a Shore hardness range of 25D to 72D, these products are suitable for electronics, sports, and automotive applications.

Also new from Arkema is Platamid HX 2656 Rnew copolyamide, billed as "the first 100% biobased hotmelt adhesive." Made from vegetable oil feedstock, this product is designed to be extruded into film, webbing, or nonwoven filaments for automotive interior laminates, textile interlining, and other uses.

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Other companies were beating the "bio" drum at K. Responding to interest from the automotive and other industries, BASF is bringing back its nylon 610 after a long absence, under the name Ultramid Balance. It is based about 60% on sebacic acid made from castor oil. Compared with nylon 6, nylon 610 has lower density, better low-temperature toughness, and lower water absorption for higher dimensional stability. Radici Group of Italy also will begin making nylon 610 this year. (Arkema is another producer.)

For biodegradable packaging, BASF also rolled out Ecovio L expandable bead foam, which contains 75% polylactic acid (PLA) blended with BASF's Ecoflex biodegradable polyester (which is derived from petrochemicals). It can be processed on EPS bead machinery. Development with selected partners will take place this year.

Italy's Novamont reports two developments in its Mater-Bi starch-based polymer. First, it has developed a special grade for extrusion coating or laminating onto paper using standard machinery and operating conditions. Second, the company came up with Mater-Bi Nanostarch, a modifier that reportedly allows Mater-Bi to be extruded into thinner and stronger flexible films, even in low-humidity conditions. Clarity is also improved somewhat. The additive is functionalized particles of starch that have not been chemically processed into a thermoplastic, like the MaterBi matrix. Novamont plans to introduce new Mater-Bi grades containing 25% to 40% nano-starch this year.

Toray Industries, Inc. of Japan is working on "nano-alloys" of small amounts of conventional engineering thermoplastics dispersed in nano-scale domains within a PLA biopolymer matrix. In 2005, the company alloyed polycarbonate with PLA to add heat and flame resistance to a laptop housing. Since then, Toray has developed a PLA-alloy cellphone charger and is now working on the casing of the phone itself. Toray uses the name Ecodear for its PLA-based materials.

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'NANO' NEWS AT K

"Nano" was almost as hot a marketing handle as "bio" at the Dusseldorf show. Lehmann & Voss Co. of Germany (which has a joint venture with Techmer PM in the U.S. called Techmer Lehvoss) recently developed a lubricated PEEK compound containing carbon fiber, graphite powder, and proprietary nano-additives. This Luvocom 1105-7373 material reportedly shows dramatically lower friction and wear than a standard tribological compound of PEEK with 10% carbon fiber and 10% PTFE. This effect is especially noticeable as the test temperature increases from 150 to 2.50 C (302 to 482 F). The company says avoiding PTFE improves processing and mechanical strength. Luvocom nano-lubricated compounds are also available in PPS and nylon.

Much of the R&D in nanocomposites involves carbon nanotubes, which are said to confer superior electrical conductivity at low loadings. Lehmann & Voss has new electrically conductive PEEK compounds containing nanotubes. Premix Oy of Finland (parent of Premix Thermoplastics in the U.S.) also has new Pre-Elec Nano compounds of polycarbonate and carbon nanotubes. They are said to be "clean" (non-sloughing) and to have extremely uniform conductivity--without even micro "hot spots"--in the range of 10 (4) to 10 (9) ohm/sq surface resistivity.

NYLON 4T IS A FIRST

Another novelty in nylons is Ultramid High Speed from BASF. Three years after introducing high-flow PBT, BASF is adopting the same technology to boost the flow of nylon 66 by up to 100% without sacrificing mechanical or thermal properties. This is accomplished by means of a proprietary organic additive that melts during processing but solidifies into nanoparticles when the melt cools.

Three new materials are currently being sampled. Ultramid A3WG8 High Speed and Ultramid A3WG10 High Speed contain 40% and 50% glass respectively, while Ultramid A3WGM53 High Speed is filled with glass and mineral filler. Their improved flow and exceptional heat-aging resistance permit production of large engine components such as cylinder-head covers and intercooler end caps. BASF is also developing similar high-flow nylon 6 grades.

High flow was the theme of other nylon developments. A new high-flow nylon from DSM is claimed to reduce injection molding cycles by 20% for furniture applications. Akulon Ultraflow nylon 6 reportedly also exhibits less warpage, colors more easily, and has better surface appearance in 50% to 60% glass-filled versions.

Rhodia also introduced a line of highly filled nylon 66 grades with high flow. Technyl Star AFX grades offer typical cycletime reductions of 15%, Rhodia says. Superior flow is available in up to 60% reinforced grades. Longer flow, easier cavity filling, and superior surface finish are claimed over traditional nylon 66. In automotive, applications include rear-view mirror supports, gear components, wiper levers, and structural seat components.

Lanxess has also brought out easy-flowing, highly filled nylon 6 and 66 grades. One is Durethan DP BKV 60 EF H.2.0 with 60% glass. Tensile modulus at room temperature is 2.76 million psi, twice that of standard nylon 6 with 30% glass, while providing similar flow.

High heat resistance was the other key theme in nylons. For high-heat underhood applications, DSM introduced the next generation of its Stanyl nylon 46 line. Stanyl Diablo OCD2100 withstands more than 3000 hr of exposure at up to 230 C/446 F with less than 15% reduction in mechanical properties. The new nylon responds to growing use of smaller engines with higher turbo pressures and exhaust gas recirculation (EGR). The result is higher heat exposure for components such as air ducts, intake manifolds, and charge-air cooler end-caps.

Rhodia has another high-heat nylon entry for underhood uses. Technyl HP nylon 66 reportedly has excellent property retention up to 200 C/392 F and can thus replace PPA. It also has high burst strength at high temperature. Technyl HP resists cracking after 1000 hr at 200 C, unlike standard nylon 66 and other high-heat versions. Grades with 35% and 50% glass are available.

New FR nylon 66 grades from Rhodia meet the current WEEE and RollS regulations for electrical/electronics. Technyl A 60G2 V30 contains 30% glass and is rated UL 94V-0 and GWIT 850 C without containing halogen or red phosphorus. It also passes the glow-wire flammability index at 960 C at extremely low thickness, thus satisfying requirements for miniature components.

To meet the glow-wire "no flame" spec (IEC 60335-4) for unfilled grades, Rhodia developed two brominated products, Technyl XA 1318 and Technyl XA 1332, which are rated UL 94V-2 and V-0, respectively. For mini-circuit breakers, Technyl C 52G1 and Technyl C 52 G1 V25 are glass-filled nylon 6 grades that pass the glow-wire 960 C flammability index test at 0.8 mm.

BASF developed new Ultramid Seal-Fit to reduce the risk that electronic components will malfunction due to contact with moisture or oil by ensuring tight overmolding of metal inserts. This new transparent specialty copolyamide has good adhesion to both metals and other nylons and PBT. It is used in a two-step injection molding process. Up to now, thermoplastic housing materials have been limited in their adhesion to metal, exacerbated by differences in thermal expansion, making it difficult to ensure a tight covering without use of silicone adhesives or hot melts or precoating the metal. Now, metal inserts of electronic components are first premolded with the new nylon and then overmolded with conventional plastics.

Arkema's Rilsan Clear G350, launched a year ago, is a clear nylon designed for injection molding into high-end eyewear frames, athletic shoes, and filter housings, and cellphone lenses and housings. It is flexible, tough, and chemical resistant.

In blow moldable nylons, a new grade from Ube Industries is offered as a monolayer solution for small fuel tanks that are now required to meet more stringent fuel permeation requirements. Ube Nylon 1030IU50 is a specially modified nylon 6 that has higher melt viscosity than HDPE and greater impact strength than conventional nylon 6.

Italy's Radici Group has two new nylon 6's for blow molding. Unreinforced Radilon S BMX grades have high chemical resistance for fuel hose applications, while Radilon S BMV has 15% to 20% glass for underhood applications. Both nylons can meet the heat requirements for gasoline and diesel engines.

EMS-Grivory introduced a range of new nylons for metal replacement. Grivory GVX is a PPA with 50% to 70% glass for automotive steering-wheel housings and engine parts. It has an elastic modulus of up to 4.2 million psi and can be injection molded at low pressure.

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In addition, Grivory LFT is a new long-fiber PPA with high energy absorption, creep resistance, and HDT for automotive and industrial applications. Grivory HT3 is a new PPA with high melting point of 295 C/563 F, plus high dimensional stability and low creep. An unreinforced version has high melt strength and excellent barrier properties for extruding fuel tubing.

EMS-Grivory also has a new super-tough nylon 12 with greater stiffness and strength than previous grades. Grilamid SST (Super Stiff & Tough) has good flow and notched impact up to 40 kJ/[m.sup.2]. Its elastic modulus of 2.61 million psi is similar to that of other metal-replacement materials like glass-filled PPS and polysulfone. Market areas include industrial, medical, marine, and sporting goods.

Italy's Lati expanded its range of nylon and PPS compounds for metal replacement in sanitary, heating, and plumbing applications. New Latamid and Latigloss nylon 66 grades contain up to 60% glass and are claimed to have strength comparable to aluminum. Laramid PPA grades with glass or carbon fiber and/or mineral filler are aimed at pump housings, while Larton PPS compounds for valves contain up to 40% glass.

HIGH-PERFORMANCE RESINS

As we reported in September, BASF launched its first polyphenylsulfone (PPSU) under the name Ultrason P 3010. This clear, high-heat, chemical-resistant, inherently flame-retardant, amorphous thermoplastic appears similar in overall properties to Solvay Advanced Polymers' Radel R-5000, though Ultrason P's HDT of 385 F at 264 psi is about 20 [degrees] lower than for Radel R.

A new high-strength, high-temperature blend from Victrex consists of Victrex PEEK plus Extem thermoplastic polyimide from SABIC Innovative Plastics. The Max-Series reportedly provides excellent mechanical performance from 150 C to 275 C (300 to 525 F). Unfilled grades include M1000, which is PEEK-rich, and M2000, which is TPI-rich. Potential markets include oil and gas processing and semiconductors. SABIC is the compounder while Victrex is marketing the materials.

Italy's Lati showed off a new family of carbon-fiber reinforced, ultra-stiff compounds of nylon, PPA, PPS, and PEEK. Depending on the polymer and filler level, the elastic modulus can be as high as 7.25 million psi, compared with 2.2 million psi for typical carbon-fiber compounds. High-load applications in aerospace, automotive, and medical are targeted.

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RTP Co. introduced VLF (very long fiber) PEEK for military radomes. RTP 2299 X 108578 contains 50% long glass and has notched Izod impact of 240 J/m, which is 65% higher than 50% short-glass reinforced PEEK. It maintains a flexural modulus of 19,306 MPa (2.8 million psi) and HDT of 316 C at 1.8 MPa (600 F at 264 psi). RTP sees opportunities in fasteners, oil processing, and compressors.

Lehmann & Voss showed off its new Luvocom XCF compounds of carbon fiber in nylon 66, PPA, PPS, and PEEK. Special fiber type and coupling technology is said to provide properties approaching those of long carbon fibers in a standard 3-mm pellet. Moldability is therefore unaffected. An XCF compound with 30% short carbon fibers is said to achieve properties similar to a 40% loading in a conventional compound (see Table 1).

Solvay Advanced Polymers unveiled its Solviva family of biomaterials for implantable medical devices. The offering includes PEEK, PPSU, polysulfone, and self-reinforced polyphenylene grades for injection and extrusion. The materials are produced in special facilities at Alpharetta, Ga. Solvay is currently developing applications with medical device maker Zimmer Holdings, Warsaw, Ind.

Solvay Solexis launched a new family of MFA fluoropolymers, called Hyflon F, as a replacement for FEP. Hyflon F reportedly offers higher clarity, improved electrical properties, excellent stress-crack resistance, and higher service temperature in automotive applications such as high-temperature-resistant cables. It contains no PFOA, which carries suspected health risks.

Dyneon announced that about half of its fluoropolymer products now are made with a new emulsifier that is not derived from PFOA. Dyneon says product performance will be unaffected by the change.

Zeon Chemicals is developing a new grade of its Zeonex cyclic olefin polymer for Blu-ray high-capacity DVD testing and recording equipment. High-clarity Zeonex 340R is aimed at pickup lenses and prisms.

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MORE ENGINEERING RESINS

Ticona launched five new acetals that provide a range of specialized features. Hostaform Anti-Crobe delivers antibacterial protection at the molecular level. It withstands boiling water and is approved by the FDA for direct food contact.

For auto interiors, a new Hostaform grade provides a metallic look without painting. It reportedly has better stiffness than typically used PC/ABS blends. The new grade is used in door handles for the Honda Civic.

New Hostaform C9021 XAP LS 10/9005 is for laser marking of switches and control knobs for vehicle interiors. And second-generation Hostaform XAP low-odor acetal reportedly offers significantly lower emissions than its predecessor.

Hostaform EC140XF is Ticona's new electrically conductive acetal for auto fuel systems. It is stabilized against today's hotter diesel fuels. Siemens VDO uses it in the Ford Transit.

In polyesters, BASF's Ultradur high-flow PBT line now includes a low-warp version. Ultradur S4090 G4 LS High Speed is a PBT/ASA blend with 20% glass. It is being used in a control device for the Audi A4 and A5 models.

Lanxess's new Pocan DP B 3160 XF is claimed to be the first PBT with 60% glass. It boasts elastic modulus of 2.76 million psi and tensile strength at break of 21,750 psi. Despite the high glass loading, its flow rate is similar to that of 45% glass-filled PBT. Applications include car door hinges, structural components, and end shields for generators.

Lanxess also reports that its Pocan DP BFN 4230 is the first polyester to gain VDE certification according to the IEC/EN 60335-1 spec for electrical/electronic parts. The 30% glass-filled PBT is flame retardant without halogen or antimony. Potential uses include plug connectors and lamp sockets.

Another halogen-free PBT comes from DSM. Arnite XG is designed for connectors in unattended appliances and meets the standard in IEC 60695. It passes GWT 750 C and GWF1850 C, as well as the V-2 needle flame test on assembled parts. Key features include high CTI (600V), good moldability, and lower moisture absorption than nylon 6 and 66.

Bayer MaterialScience launched several new PC/ABS blends for automotive interior and exterior uses. Bayblend DP T88 GF-10 and GF-20 have 30% to 40% higher flow and 25% to 30% greater stiffness than standard glass-filled PC/ABS. Uses include instrument panels and defroster strips.

Meanwhile, two new mineral-filled PC/ ABS grades are potential alternatives to thermoset SMC for auto body parts. Bayblend DP T95 MF has high heat and impact resistance. It is used together with Bayer's Makrolon PC in a large roof module of the Smartfortwo mini car. The other PC/ABS grade, Bayblend DP T90 MF-20, exhibits high flow and low, isotropic CLTE. Potential applications include trunk lids, antenna covers, rear spoilers, tailgates, and rear valance panels.

Ticona introduced a new form of its Celstran long-fiber thermoplastics--continuous, unidirectional prepreg tapes suitable for winding or pressing into formable sheets. The tapes will comprise a range of resins and fibers for producing lightweight structural parts in energy, aircraft, rail, and automotive uses.

Altuglas International, an Arkema subsidiary, is offering new acrylic resins for capstock coextrusion with PVC for building profiles. The company also has new acrylic capstock compounds specifically for thermoformable styrenic sheets used in auto body panels for cars and recreational vehicles. The new grades boast superior chemical resistance and new visual effects such as frosted or matte finish and a range of metallic colors. Altuglas also introduced opaque acrylic resins for injection molding auto exterior trim such as mirror housings and door trim.

NOVEL TPEs DEBUT

There were quite a number of novelties in TP elastomers at the show. One of these was the first crosslinked TPU, developed by BASF's Elastogran subsidiary. By adding a liquid prepolymer mixture to a specially modified Elastollan TPU, reversible chemical crosslinking occurs that confers enhanced compression-set and vibration-damping properties similar to those of thermoset rubber. At the same time, cross-linked TPU (TPU-X) has better resistance to ozone, oils, and greases than rubber.

This Elastollan X-Flex material was molded at the show on a special injection machine from KraussMaffei. It requires better mixing than is possible with a standard injection screw, according to Elastogran officials. KraussMaffei's two-stage Injection Molding Compounder (IMC) uses a twin-screw extruder for plasticating and a plunger injection unit. The prepolymer mix is fed into TPU melt stream at a downstream port in the barrel. Crosslinking occurs in the mold without any extension of the cycle time. The result is a soft (60 Shore A without plasticizer) elastomer that withstands long-term use at up to 120 C/250 F and short-term peaks up to 150 C/300 F.

However, the crosslinking is reversible whenever the polymer is remelted, and the crosslinks reform when the melt cools. So the TPU-X is recyclable and is not apt to cause a problem if there is an interruption in molding. What's more, the material could be customized in the future by changing the TPU base material or the prepolymer mixture or changing the amount of prepolymer added to the melt. Besides injection molding, Elastogran already has a TPU-X application in extruded profiles.

Two entirely new TPEs were shown by Kuraray of Japan. One is a developmental all-acrylic elastomer consisting of alternating hard blocks of PMMA and soft blocks of poly-n-butyl acrylate. This LA Polymer is said to offer high heat resistance, weatherability, excellent transparency, soft flexibility without plasticizer, and good adhesion to polar resins and paint. It can be molded and extruded and formulated in hardnesses from 30A to 60D. Sony reportedly uses it in paintable soft grips for a digital camera. The same paint is used on the TPE grips and ABS camera body.

Kuraray's other development is called Q Polymer. This unidentified composition comes from the Elastomer Development Dept. in Kuraray's Isoprene Chemicals Div. It is being developed primarily in the form of alloys that have densities below 1.0 g/cc, excellent elasticity, softness, and high resistance to abrasion and hot water (but not oils). It reportedly combines the best properties of hydrogenated styrenic TPEs (such as Kuraray's Septon, sold here by Septon Co. of America) and TPUs. Compared with Septon, it has better mechanical properties and scratch and abrasion resistance. Compared with TPU, it has better hydrolysis resistance, lower density, and much better adhesion to polyolefins. Kuraray now has pilot production of a few hundred tons a year and is working with compounders toward full-scale commercial production by 2010.

In other developments, GLS Corp. introduced the first family of TPE compounds based on Dow's new Infuse olefin block copolymers (see Learn More). Target markets for the new Dynalloy OBC injection and blow molding grades are consumer and office products, hardware, food packaging, and medical parts. The compounds are said to have exceptional softness and a wide range of flowability for injection. They bond well to PP. Five standard injection grades include opaque and translucent materials with hardnesses from 5 to 60 Shore A. The 50 Shore A blow molding grade is for soft-touch containers.

Germany's Kraiburg brought out a series of Thermolast K TPEs based on hydrogenated SEBS that are said to show "extraordinary" bonding to PC and ABS. They are also suitable for overmolding PBT, SAN, ASA, PETG, PMMA, and PS. These translucent compounds have Shore hardnesses from 50A to 80A, elongation from 540% to 620%, light transmission of 82% to 91%, and haze of 11% to 13%. Kraiburg also cites "exceptionally high" tear resistance for styrenic TPEs: 45 to 55 N/mm (260 to 317 lb/in.). They also have good UV stability.

Kraiburg's other news was the first SEBS-based TPEs that comply with European regulations for products that contact drinking water. Thermolast K DW grades are for plumbing seals and hoses, shower heads, and decorative fixtures.

Three years ago, at K 2004, a new type of styrenic TPE based on styrene and isobutylene made its debut (see Learn More). Since then, Kaneka of Japan has expanded its Sibstar line to include SIBS and SIB variants and now has introduced Sibstar TPVs comprising silane-crosslinked polyisobutylene (PIB) in SIBS, PP, or HDPE matrices. Sibstar-TPV grades are supplied as masterbatches with high PIB rubber loadings. PP and HDPE grades also contain oil. Sibstar-TPV reportedly has lower compression set at elevated temperatures than Sibstar TPEs and higher gas and moisture barrier than standard TPVs, suggesting applications in cap seals and gaskets. These products have hardnesses of 33A to 42A, densities of 0.91 to 0.93 g/cc, and transparency of 99.7% or higher. Low extractables is another benefit.

The newest "engineering" TPV materials are blow moldable grades of Zeotherm from Zeon Chemicals. This alloy of acrylate rubber in a nylon matrix is aimed at automotive air ducts. These ducts can be all Zeotherm or sequentially coextruded of Zeotherm flexible segments with nylon 6 or 66 stiff segments. The new grades compete with copolyester TPEs and soft nylons.

Meanwhile, Arkema has come out with transparent versions of its PEBA TPEs, called Pebax Clear. Two grades have 59D and 64D hardnesses.

Arkema also has new competition from EMS-Grivory, which has entered the TPE market with its own PEBA line, called Grilflex. New, patented chemistry is said to provide particularly low swelling, high dimensional stability, and--interestingly--good transparency. It's available in a wide range of grades from Shore 35D to 70D, based on nylon 12 or nylon 6 (for higher heat resistance). The nylon 12 types come in standard and flame-retardant grades as well as versions with improved hydrolysis resistance or dimensional stability. They are aimed at corrugated pipe, hoses, films, belts, consumer goods, and industrial components.

Merquinsa introduced a new family of transparent TPUs with a low yellowness index for parts up to 5-mm thick. Fast-cycling Pearlthane Clear 15N85 has a flat modulus curve between -10 C/14 F and 40 C/104 F, as well as good hydrolysis resistance--both useful for sport shoe impact absorbers. Pearlthane Clear 15N60D retains toughness at -20 C/-4 F for winter sport applications.

Also new from Merquinsa are aliphatic TPU extrusion grades with low gel content for calendering and cast and blown film. Pearlthane 92F90 has good weatherability and high-frequency weldability for use in PVC and rubber replacement, while Pearlthane 92F88 features outstanding toughness and transparency for automotive films.

Dow also has a new calendaring-grade Pellethane TPU for belts, sewer liners, fabrics, and nonwovens.

POLYPROPYLENE & TPO 

Polyolefins giant Basell (now LyondellBasell Industries) did not actually exhibit at K but showed off two new packaging materials at molding machinery demonstrations. As we reported last month (see Keeping Up With Materials), one was a metallocene PP for cups, lids, and closures and the other was an HDPE for HIC and personal-care bottles. Both are designed for lightweighting.

Dow Europe introduced four new and upgraded PP resins as part of an initiative to stretch the PP performance envelope obtained from its Unipol PP gas-phase process. Inspire 702 is for injection molding buckets and pails. It reportedly provides fast cycles, a good balance of stiffness and toughness, excellent mold release, long-term antistatic behavior, and food-contact acceptability. Also suitable for food contact is new Inspire 147, a clear grade for high-throughput thermoforming of vending cups, dairy pots, biscuit trays, and blister packs. It reportedly offers improved dimensional stability.

Dow also announced two developmental random copolymers for thin-wall injection molding. DR7023.00 is a 42 MFR with excellent taste and odor properties for food packaging. DR7032.00 is said to be remarkable for combining 100 MFR with excellent taste and odor.

Dow Automotive also made news with its 60% long-glass PP (LGFPP) concentrate for molding structural parts.

Total Petrochemicals of Belgium has a new metallocene PP homopolymer for cast film. MR 2007 (15 MFR) is said to be very clear and glossy with higher dart and puncture resistance than conventional homopolymers. It also offers very low extractables for good organoleptic properties.

Borealis in Austria brought out quite a few new products. It claims a "step change in productivity" of up to 20% faster injection molding of PP tubs and other food containers with its Bormod BJ368MO. This speed is attributed to "exceptional flow" and proprietary nucleation technology for fast setup in the mold, as well as antistatic additives that ensure easy demolding at temperatures up to 90 C (194 F). This high-flow PP reportedly allows molding products as thin as 0.3 mm without sacrificing stacking strength or drop impact resistance--even at -20 C (-4 F). Its shrinkage is also described as being insensitive to colors.

Faster injection molding is also claimed for new BH374MO, a PP grade for pails that boasts an unusually high MFR of 45.

Faster stretch-blow molding of oriented bottles is promised with new Borclear RF926MO, a PP random copolymer containing nucleants and antistats for faster demolding at higher temperatures. Borealis also says it tripled the operating temperature of this resin, which boasts good organoleptics and FDA approval for food contact. Its MFR is 20, HDT is 176 F at 66 psi, and haze is less than 5% at 0.7-mm wall thickness.

Borealis claims a first for packaging films with its Borpact BC918CF, a heterophasic (impact) PP copolymer that offers the high clarity of homopolymers, thanks to Borstar nucleating technology. It is said to offer a unique combination of toughness, stiffness, and heat resistance with high gloss and low haze. This 2-MFR resin has a flex modulus of 203,000 psi and Vicat softening point of 154 C (309 F). It is aimed at blown and cast films for labels, lidding, pouches, and modified-atmosphere packaging (MAP) trays.

Another reportedly unique entry is Borealis' BA110CF heterophasic PP copolymer for blown and cast film, which is said to he suited to all siliconization processes, thus reducing the need for different sealing films in packaging applications such as carrier sheets for self-adhesive tapes and labels. The material is also said to be unusually strong: Tensile strength of 2-mil film is 5800 to 8700 psi MD and 4350 to 7250 psi TD. It is also sterilizeable (150 C/302 F Vicat) for medical uses.

Also new is Borealis' Borclear RB709CF random PP copolymer for high-clarity, unoriented blown film. It contains no slip or antiblock.

Borealis showed off new automotive TPOs in some dramatic applications. For example, the Smart fortwo is the first commercial vehicle to have all-PP (or TPO) body panels. Its hood, front, rear, and side panels are all injection molded from Daplen ED230HP, a 20% mineral-filled TPO that replaces PC/PBT and thereby reduces overall car weight by 15% owing to its lower density (1.05 g/cc). The pigmented panels receive only a clear-coat finish.

Also novel is the first all-plastic, single-module fender on the new BMW X5, called by Borealis "the most complex and highly integrated body application to date." Molded of Daplen EF341AE 30% mineral-filled TPO, the fender can deform up to 80 mm on impact, reducing the potential for injury in low-speed pedestrian impact.

Another unusual application is what Borealis says is the first-ever injection molded truck bumper and front panel. These structural components for Iveco's latest Stralis truck use relatively new Nepol GB303HP (30% long glass in chemically coupled PP). The bumper is covered by a Daplen Class-A TPO fascia.

A novel transparent TPO was introduced by Mitsui Chemicals of Japan. Called Norio, it boasts a unique nanocrystalline structure: Whereas typical TPO shows fairly large crystalline domains within an amorphous matrix, Notio shows no visible domains at similar magnification in an electron microscope. The reason is that Notio has a thread-like 3D network of crystalline segments throughout the amorphous matrix--though it is not crosslinked. As a result, Notio shows a combination of good transparency, elasticity, and heat resistance, as well as softness and very low density (see Table 2). It can be used to make flexible tubing, lenses, and films and can modify PP to add toughness and eliminate stress whitening while maintaining clarity.

POLYETHYLENES

As noted above, Basell introduced a new HDPE for bottles, but most of the PE news at K was in film and pipe. For example, ExxonMobil launched its new Exceed metallocene LLDPE "HTC" (high throughput, high clarity) technology for blown film. The company says that on conventional extrusion equipment, mPE-rich formulations can now achieve very high throughput rates, while optimized machinery can achieve "unprecedented" throughput rates of up to 111.75 lb/hr/in. of die circumference. HTC technology is also said to provide excellent bubble stability plus the toughness, sealing, and optical properties of standard Exceed mLLDPE. During K, extrusion of Exceed HTC packaging film was demonstrated by Reifenhauser and Windmoeller & Hoelscher (the latter at its German technical center).

Dow brought out a new bimodal HDPE for geomembranes and also for steel pipe coating. HDPE 50045E (0.950 g/cc, 0.50 HLMI) has high molecular weight and high melt strength for thick blown films. It contains carbon black for uv stability.

Also new is Dowlex XZ 89438.00 developmental LLDPE (0.930 g/cc, 2.3 MI) for extrusion into fibrillated tape and monofilament used to make artificial turf. It has lower density than Dowlex SC 2108G, already used in such applications, giving it softer touch, 45% higher tear resistance, and greater resiliency (bounce-back).

A third new product is Dow's Amplify GR388, a maleic anhydride-grafted PE designed as an extrudable adhesive to bond Dowlex LLDPE to aluminum for hot and cold water pipes. It is said to combine excellent adhesion with long-term thermal stability and easy processing.

Very large, thick pressure pipe is the target for a new "low-sagging" PE100-type HDPE from Total Petrochemicals. Colored black, it has 0.959 density and 0.2 HLMI.

Also new from Total are three metallocene LLDPEs for cast film. All have hexene comonomer and are described as "second-generation" mPEs that are distinguished from earlier versions by high output rates with low extrusion pressure, low neck-in, excellent drawability, and good gauge control. For highest gloss and transparency, M 3020 has 0.930 density, 2 MI, 1.7% haze, and 89 gloss rating at 45[degrees] (also 8% haze and 64 gloss in blown film). M 3427 has 0.934 density and 2.7 MI plus 2.3% haze and 86 gloss. M 4040 (0.940 g/ cc, 4 MI) has 5.5% haze and 86 gloss.

Borealis introduced a new bimodal HDPE for pressure pipes with "exceptional" resistance to slow crack growth. BorSafe HE3490-LS-H (0.949 g/cc, 0.25 MI) exceeds by more than 100-fold the European standard requirements for slow crack growth in PE water and gas pressure pipe.

TOP OF THE NEWS

* First TPEs from renewable resources.

* First crosslinkable TPU.

* First nylon 4T.

* First clear CPVC.

* First fully fluorinated LSRs.

* Second source of PEBA TPEs.

* Clear TPOs.

* LLDPE raises blown film output.

* PPs speed bottle and container molding.

LEARN MORE ONLINE

Visit www.ptonline,com/articles/200802fa2.html for a link to these related articles:

What's New at the Show in Materials, Sept. '07

Dishwasher Safe: New Clear Copolyester, Jan. '08

New Olefin Block Copolymers Stretch TPE Processability & Cost Performance, Aug, '06

K 2004 Wrap-Up: Materials, Feb. '05

CONTACT SUPPLIERS

For further information about these companies and their products, visit www.ptonline.com/suppliers.

Altuglas International, Philadelphia

[phone] * www.plexiglas.com

Arkema Inc., Philadelphia

[phone] * www.arkema.com

Basell North America Inc. (Now Lyondell-Basell Industries) Wilmington, DE

[phone] * www.basell.com

BASF Corp., Wyandotte, MI

[phone] * www.plasticsportal.com

Bayer Material Science, Pittsburgh

[phone] * www.bayermaterialsciencenafta.com

Borealis AG, Vienna, Austria

[phone] * www.borealisgroup.com

Dow Plastics, Midland, MI

[phone] * www.dowplastics.com

DSM Engineering Plastics, Evansville, IN

[phone] * www.dsmep.com

Dyneon, Oakdale, MN

[phone] * www.dyneon.corn

EMS-Grivory America, Sumter, SC

[phone] * www.emsgrivory.com

ExxonMobil Chemical Co., Houston

[phone] * www.exxonmobilchemical.com

GLS Corp., McHenry, IL

[phone] * www.glscorp.corn

Kaneka Texas Corp., Houston

[phone] * www.kaneka.com

Kraiberg TPE Corp., Duluth, GA

[phone] * www.kraiburg-tpe.com

KraussMaffei Corp., Florence, KY

[phone] * www.kraussmaffei.com

Kuraray America, Inc., NYC 

[phone] * www.kuraray-am.com

Lanxess Corp., Pittsburgh

[phone] * www.lanxess.com

LATI USA Inc., Mt. Pleasant, SC

[phone] * www.lati.com

Merquinsa North America Inc., Seabrook NH

[phone] * www.merquinsa.com

Mitsui Chemicals America, Inc., Rye Brook, NY

[phone] * www.mitsuichemicals.com

Momentive Performance Materials Inc., Wilton, CT

[phone]. * www.momentiveperformancematerials.com

Novamont N.A., Ridgefield, CT

[phone] * www.novamont.com

Premix Thermoplastics Inc., Milton, WI

[phone] * www.premixthermoplastics.com

Radici Plastics USA Inc., Gastonia, NC

[phone] * www.radiciplastics.com

Rhodia Engineering Plastics, Farmington Hills, MI

[phone] * www.rhodia-ep.com

RTP Co., Winona, MN

[phone] * www.rtpcompany.corn

Septon Co. of America, Pasadena, TX

[phone] * www.septon.info

Solvay Advanced Polymers, Alpharetta, GA

[phone] * www.solvayadvancedpolymers.us.com

Solvay Solexis, Thorofare, NJ

[phone]. www.solvaysolexis.com

Ticona, Florence, KY

[phone] * www.ticona.com

Total Petrochemicals USA, Inc., Houston

[phone] * www.totalpetrochemicals.biz

Ube America Inc., NYC

[phone] * www.ube-ind.com.jp

Victrex USA Inc., West Conshohocken, PA

(484) 342--6001 * www.victrex.com

Wacker Chemical Corp., Adrian, MI

[phone] * www.wacker.com

Zeon Chemicals Inc., Louisville, KY

[phone] * www.zeonchemicals.com

By Joseph A. Grande, Senior Editor,

and Matthew H. Naitove, Editor

TABLE 1--Luvocom XCF Carbon-Fiber Compounds
From Lehmann & Voss

                               30% STD.        3046 XCF
PROPERTIES                 CARBON FIBER    CARBON FIBER    DIFFERENCE

NYLON 66
  ELASTIC MODULUS, PSI        3,190,000       3,625,000       +13.6%
  TENSILE STRENGTH, PSI          34,800          44,950       +29.2%
  IMPACT, KJ/[M.sup.2]               50              95       +90.0%
PEEK
  ELASTIC MODULUS, PSI        3,190,000       4,060,000       +27.3%
  TENSILE STRENGTH, PSI          32,625          47,850       +46.7%
  IMPACT, KJ/[M.sup.2]               40              65       +62.5%

TABLE 2--
Notio Clear TPO From Mitsui Chemicals

                                 NOTIO       NOTIO       NOTIO

PROPERTY                       PN-3560     PN-2070     PN-0040
DENSITY, G/CC                    0.866       0.867       0.868
MFR, G/10 MINA                       6           7           4
HAZE, %                              6           7           5
SHORE A HARDNESS                    70          75          86
TENSILE MODULUS, PSI              1740        2320        6090
BRITTLE TEMP., C/F             -28/-18     -28/-18     -28/-18
ULT. TENSILE STRENGTH, PSI        1740        2030        3190
ULTIMATE ELONGATION, %            >800        >800         750
COMPRESSION SET,
  23 C/73 F                         20          20          25
  70 C/158 F                        60          60          75
PERMANENT SET, % (b)                12          12          16

(a) At 230 C/446 F.

(b) For 0.3-mm film after 150% strain.