Materials.

Materials

Quite a number of interesting new materials surfaced in Disseldorf, all of which are available here now or will be in the near future. These include two major announcements in packaging materials: a novel high-barrier resin competitive with EVOH and PVDC, and new amorphous nylon barrier material that launches a completely new family of resins for GE Plastics. And that's not all, several other new and unusual nylon materials made their debut, as did a new family of liquid-crystal polymers, lots of new engineering resins and alloys for automotive and electrical/electronic parts, improved polyestercarbonates, and brand-new fluoropolymers.

NEW BARRIER RESINS

A new vinyl-alcohol-based, chlorine-free barrier packaging polymer, which will be marketed in the U.S. in 1990, was unveiled by Neste Oy Chemicals of Finland (offices in New Jersey--see box). Known as Optene B, the material is available in medium-, high- and super-barrier grades, comparable in oxygen barrier to nylon 6, PVDC, and EVOH, respectively. Its melt-flow index is adjustable from 1 to 30 g/10 min.

As a barrier material in multilayer thermoformable sheet, blown or cast film, or bottles, Optene B can be used with Neste's proprietary tie-layer resins (Optene A series), which also adhere to PP, PE, nylon and EVOH. A company spokesman said Optene B will be priced similar to EVOH. Pricing and physical properties were not released.

Gelon A100, the first grade in a new family of amorphous nylon resins from GE Plastics, this year will be domestically produced and available to processors in limited, test-sample quantities. As reported last month (p. 14), the new crystal-clear, moderate-barrier resin is designed for monolayer and coextruded bottles, film and sheet packaging. It's said to be especially suited to hot-filled food products and combinations with polycarbonate in multilayer barrier sheets--the latter owing to the two resins' compatibility, which produces clear regrind mixtures.

So far, however, GE will not reveal for publication any specific material properties other than its glass-transition temperature of 260 F. Nor will they reveal pricing. They do say it will be a direct competitor for nylon 6 and 66 resins, which are said to have similar processing characteristics, but they will not compare it to Du Pont's Selar PA amorphous nylon, which is aimed at similar applications, and with which GE has experimented on nylon/polycarbonate barrier packaging.

Mark Bulriss, general manager of crystalline products, told PLASTICS TECHNOLOGY that blow molding will be the main initial application for Gelon A100, and that GE is involved with several domestic processors in proprietary bottle developments that make use of the resin's clarity, heat resistance, barrier properties and impact strength.

MORE NOVEL NYLONS

A new high-heat, high-crystalline nylon 46 known as Stanyl, developed by DSM of the Netherlands, will be compounded in the U.S. this year at a recently purchased compounding facility in Reading, Pa. Anthony G.J. DeVrught, business manager for DSM engineering plastics, told PLASTICS TECHNOLOGY that the Reading plant will compound nine grades of filled and unfilled Stanyl, aimed at injection molded electrical connectors, bearings and gear assemblies, and automotive under-hood components, though not at uses currently served by nylon 6 and 66. DSM, by the way, has broken off negotiations with Allied-Signal for the latter to market Stanyl in the U.S. (see PT, April '88, p. 113).

While declining to reveal price information on the new material, DeVrught said Stanyl can withstand continuous use at 320 F, and short-term exposure to 540 F. He said Stanyl's injection molding processing range is between 572 F and 590 F, with a mold temperature of 248 F for unfilled and 320 F for filled grades. Compared with nylon 66, Stanyl offers up to 30% faster cycle times due to its flow and crystallization properties, and has up to three times better fatigue resistance, according to DeVrught.

Once its U.S. Stanyl operation has been established, DSM will initiate market development and compounding of another new material in Reading: a styrene maleic anhydride (SMA) copolymer known as Stapron S. DeVrught said the material is in the early stages of development, with some field testing now underway by European customers. He declined to give further information on Stapron S.

A new high-temperature, crystalline nylon known as MCX-A will be introduced to North America this year by Mitsui Petrochemical Industries Ltd. Seiji Oshima, manager of specialty polymers for Mitsui Petrochemicals America, N.Y.C., said five grades of MCX-A will be imported from Japan, including a flame-retardant offering. All five grades will be glass reinforced, from 15% to 50%.

MCX-A AA310, the standard grade, has a melting point of 610 F, heat-distortion temperature of 540 F, specific gravity of 1.30, notched Izod impact strength of 1.5 ft-lb/in., and flexural modulus of 850,000 psi. Oshima said the material has nearly 50% lower water absorption than nylon 66, giving MCX-A enhanced dimensional stability. The material also is highly resistant to fuels, oils and solvents, he said. Applications will be in under-the-hood automotive components, electrical and electronic components, as well as general industrial parts for pumps, valves and engine covers. Pricing was not revealed. (See also PT, Jan. '89, p. 70).

Rhone-Poulenc Chimie of France plans to introduce two new grades--transparent amorphous and opaque semi-crystalline-of a semi-aromatic nylon to the U.S. in 1991. Both grades are designed for injection molding. According to Jean-Pierre Wirotius, director of plastic technology, the unnamed nylon has higher thermal and dimensional stability, better long-term aging and heat resistance, and about half as much water absorption, compared with nylon 66. It also has higher melt viscosity. He added that the new nylon would be priced above competing nylon 66 grades.

The amorphous grade would have an HDT of about 284 F, while the semicrystalline grade would be at 554 F, according to Wirotius. Because of its clarity and high gloss, the amorphous grade will find applications in consumer and sporting goods. The semi-crystalline grade, because of its heat resistance, will target electronic and under-the-hood automotive uses requiring higher heat resistance than is provided by current nylon 66 grades.

NEW LINE OF LCP's

Along with its new nylon, Rhone-Poulenc plans to introduce a family of aromatic polyester liquid-crystal polymers as another new-product foray into the U.S. market in 1991. Wirotius said the company currently is sampling its new Rhodester C.L. LCP's with French processors. The line contains four grades: one unreinforced, 15% and 40% talc-filled, and one with 40% proprietary mineral filler. All four are supplied in either pellet or powder form for injection molding. Major end-use markets will include electrical/electronic, automotive and aerospace.

Rhodester C.L. has a melting point of 572 F, to be used with mold temperatures of 212-320 F. The glass-transition temperature is 219 F and HDT 446-518 F.

Wirotius said that when it becomes available to U.S. customers, he expects Rhodester C.L. to be slightly higher priced than comparable Vectra LCP grades from Hoechst Celanese. This would be mainly due to Hoechst Celanese's greater LCP production capacity. He said Rhone-Poulenc has no plans to produce LCP's outside of France.

Bayer AG, however, told PLASTICS TECHNOLOGY that it has discontinued plans to develop injection moldable LCP's. Bayer (parent of Mobay) previously announced it had planned to unveil four grades at K'89 (PT Oct. '89, p. 33). Plastics Business Group director Kurt Weirauch said Bayer sees a limited near-term market for these resins, already saturated by current producers. He said Bayer may introduce semi-finished LCP products--such as tapes and reinforcements--to the U.S. market in 1990/91.

ABS/PC ALLOYS

Along with Gelon, GE Plastics also introduced three new grades to its Cycoloy family of ABS/PC alloys for injection molding. Two grades, C1000 and C1200, target the automotive market, while the third, C2850, is a halogen-free flame-retardant grade for electrical/electronic applications.

Cycoloy C2850 (rated UL94 V-0) utilizes a proprietary phosphate-based flame-retardant system, which was designed to reduce most of the plate-out problems associated with halogenated ABS/PC alloys. C2850 has an HDT of 185 F, specific gravity of 1.14, flex modulus of 304,500 psi, and notched Izod impact of 8.4 ft-lb/in. Price is $1.65/lb.

Of the two automotive grades, priced around $1.70/lb., C1000 has an HDT of 212 F and same modulus and impact as C2850; while C1200 has an HDT of 248 F, the same modulus, and notched Izod value of 11 ft-lb/in.

MORE AUTOMOTIVE RESINS

Intending it to be a direct competitor for GE's Noryl GTX 910 in North American injection molded automotive fenders, Bayer AG will introduce this year an unreinforced blend of its Apec aromatic polyestercarbonate (PEC) and PBT. The new alloy will begin test-marketing trials in the U.S. during the first half of 1990, according to Bayer's Plastics Business Group director Kurt Weirauch. Compared with Noryl GTX nylon/PPO blend, Weirauch said the PEC/PBT has a two-fold advantage in low-temperature ductile impact performance for painted body panels (to -40 F), a wider processing window (500-554 F), better chemical resistance, and lower moisture absorption. He also said the new blend, designed for existing injection molds, would be "priced competitively" vs. Noryl GTX.

Ten new grades in the Akulon nylon 6 and 66 and Arnite PET and PBT lines for automotive applications such as electrical parts, bumper beams, mirror housings, grills and wheel covers, were introduced by the Akzo Plastics. Here are some initial details, though pricing and physical property data were not available:

Akulon F235-B3H is a black extrusion grade for convoluted tubing. Akulon K-X4328, with 15% glass, is a black injection molding grade for mirror housings. Akulon K-X4076 is an elastomer-modified, 30% mineral-filled injection grade for grilles and wheel trims. Akulon S225 HMO, S-X4494 and S-X4397 are 35-50% mineral-reinforced grades for technical components and external auto parts requiring high dimensional stability and stiffness. Akulon 6 & 66 HGM grades are filled with both mineral and glass fibers for window frames, ignition caps, fuse boxes and light housings.

Arnite AZ2 370 is a mixed-filler PET grade for applications requiring high stiffness and bright surface appearance. Arnite T-X4523 is an unfilled PBT injection grade, while Arnite TX4634 is 30%-glass PBT injection grade.

E&E POLYMERS

Akzo also unveiled 11 new flame-retardant, heat-stabilized injection grades of Akulon and Arnite for electrical/electronic applications. The company did not provide pricing or physical property information.

Akulon K225-KS (in both nylon 6 and 66) is a non-reinforced, halogen-free, UL94 V-0 grade. Akulon K220-HGS6 and S-X4435 are 30% and 35% glass-filled, V-0 grades. Akulon S225-HMV2 is a 10% mineral-filled grade.

Arnite AV2 363 SN and AV4 343 SN are 33% and 20% glass-filled PET's (also V-0). Arnite AV2 353 and AV2 383 are 27% and 43%-glass grades for applications requiring stiffness and high thermal stability. Arnite T-X4487 and T-X4488 are modified PBT grades with 15% and 30% glass for applications requiring a smooth surface appearance.

POLYESTERCARBONATE

Bayer also unveiled its new generation of Apec transparent polyestercarbonate. Compared with the previous generation, the new Apec has higher HDT (464 F vs. 367 F), improved transparency, and better uv stability. Kurt Weirauch said uv yellowing had been a problem in some applications. Production of the new-generation material has begun in West Germany and eventually is expected to be supplemented at Mobay's Baytown, Texas, facility.

FLUOROPOLYMERS

A new specialty family of modified PTFE compression molding powders, known as Hostaflon TFM, was exhibited by Hoechst AG. The new material, which features high chemical resistance and HDT up to 500 F, is an upgraded version of Hoechst's existing Hostaflon TF line.

A Hoechst spokesman, who declined to reveal prices, said the material will be available to U.S. customers this year in two free-flowing grades (TFM 1500 and 1600) and a non-free-flow (TFM 1700) grade. The flow classifications reflect the materials' mean particle sizes: 400-800 microns for TFM 1500 and 1600, and 20-30 [mu] for TFM 1700. The three grades are unfilled suspension-polymer powders.

The material was developed for low-volume, specialty applications, usually for glass replacement in storage or processing of aggressive acids, and corrosion protection of metal parts. The spokesman said the material is especially suited for applications involving high-purity chemicals. Compared with Hostaflon TF, the new Hostaflon TFM features lower deformation under load, higher compressive strength and elongation at break, and better weldability--suiting it to embedding of complex metal parts.

A new fluoropolymer from Du Pont Co., known as Teflon AF, is a high-clarity, amorphous resin designed for coating and molded-part applications, expanding on the properties of Du Pont's existing semi-crystalline Teflon line. Teflon AF has an optical clarity of greater than 95%, with a refractive index of 1.29-1.31 and dielectric constant of 1.89-1.93. The resin has an HDT up to 572 F, tensile modulus of 138,000-312,000 psi, and tensile strength of 3600-3900 psi. Pricing was not released at press time.

Applications include thin-film, solvent-cast coatings and molded, mechanical parts where heat and chemical resistance and optical clarity are key. It can be be extruded, pressed or molded using standard fluoropolymer processing equipment.