Materials.

New materials were plentiful at NPE, ranging from brand-new LLDPE film resins with extra toughness and tear strength to a host of new engineering resins with special properties such as high heat resistance, weatherability, laser-markability, electrical conductivity, or flame retardance. A crowd of new polypropylenes offers increased clarity and melt strength and faster molding cycles. There were also several new TPEs and even one new thermoset compound.

FAST-CYCLE PP COPOLYMERS

Montell Polyolefins, Wilmington, Del., introduced new "high- productivity" PP copolymers with 8 to 65 MFR that are said to allow up to 35% shorter injection molding cycles with minimal compromise of stiffness or toughness. Other claimed advantages are low warpage and easy molding of large parts such as the storage bin shown opposite.

HIGH-CLARITY PP

Montell also introduced new random copolymers that offer clarity plus low-temperature impact strength (down to -40 F) similar to an impact copolymer. They are aimed at housewares intended for freezer use.

Amoco Polymers, Alpharetta, Ga., added three new grades to its Acclear family of high-rarity PP. All are random copolymers with a gloss rating of 102 and haze of 11%. They reportedly meet FDA requirements. Acclear 8249X (2 MFI) is for extrusion, thermoforming, and blow molding. Acclear 8940X (53 MFI) contains antistat and is designed for fast-cycle injection molding of audio/video cassettes and deli containers. Acclear 8649X (23 MFI) is aimed at stretch-blow molded bottles and other rigid containers.

MORE SPECIALTY PP & TPOs

Chisso America; Chicago, plans to introduce metallocene PP from Japan. Chisso will also market here its Expan high-melt-strength PP for large thermoformed and blow molded parts like luggage bins. Unlike other high-melt-strength PPs, Expan is said to exhibit little change in melt flow, melt strength, or heat sag when reprocessed.

Chisso will also soon introduce here its Newcon family of reactor TPOs that are said to have significantly improved clarity in injection molded articles and in calendered and BOPP films. They also boast reduced mold shrinkage, increased toughness, and much lower stress whitening. Products range from 0.2 to 35 MFI and from 58,000 to 116,000 psi flexural modulus.

TOUGH LLDPE FILM RESINS

Two families of hexene copolymer LLDPE film resins based on proprietary catalyst technology were launched by Eastman Chemical Co., Kingsport, Tenn. Eastman has added about 100 million lb/yr of capacity at Longview, Texas, to produce these resins using BP gas-phase technology.

Eastman's new Mxsten film resins reportedly have extra-low density (0.9050.914 g/cc), MFIs from 0.5 to 3.2, and unusually high dart impact and tear strengths. Also claimed are low heat-seal initiation temperatures, high seal strengths, and low gel levels. Meat and poultry wrap, hygienic products, and stretch film are targets.

New Tenite Hifor resins, with densities of 0.917 to 0.918 and MFIs of 0.6 to 2.3, are said to offer very high dart impact and tear strengths, as well as very few gels. Heavy-duty shipping sacks, industrial films, food packaging, and stretch films are potential uses.

HIGH-HEAT GLASS-FILLED PP

Automotive electrical parts currently made from PBT are the target for new Amilon 30% and 40% glass-filled PP from Amoco Polymers. The resins reportedly have higher heat resistance (up to 125 C) and hot/humid aging resistance than other glass-filled PPs. Also, Amilon boasts higher elongation and impact strength than even neat PP resin, the company claims. Amilon is based on Amoco's high-crystallinity Accpro homopolymer plus modifiers and special coupling agents. Prices are around $1.40-1.50/lb.

HIGHER-FLOW IR-PS

A high-flow, ignition-resistant HIPS from Dow Plastics, Midland, Mich., is due to debut this month for use in tv cabinets. At 10.5 MFR, Styron XUS 70036.01 has higher flow than existing Styron 6077 IR-PS (7.4 MFR) and a slightly lower Vicat softening temperature of 208 F.

GLOSSIER STYRENICS

Dow Plastics also has added a higher-gloss extrusion grade, AIM 4950, to its line of enhanced HIPS.

BASF Corp. Plastic Materials, Mt. Olive, N.J., has a new ASA, Luran S KR 2859, that reportedly features higher gloss and stain and scuff resistance. Aimed at profile and sheet coextrusion, it has a gloss of 90 and is being used in running boards for vans and body panels of electric golf carts.

CONDUCTIVE COMPOUNDS FOR PAINTABILITY

Electrostatic spray-paintability similar to metal is claimed for new compounds from RTP Co., Winona, Minn. The fully colorable products contain a non-carbon conductive additive. The compounds - based on PP, ABS, PC, nylons 6 and 12, acetal, PBT, TPEs, and TPU - are priced competitively with grades based on stainless-steel or carbon-fiber.

TOUGH NEW NYLONS

New Grilamid TR 90 amorphous nylon 12 from EMS-American Grilon Inc., Sumter, S.C., has 20% higher impact resistance than existing Grilamid TR55 and is transparent in all wall thicknesses. Light transmission is 95% and refractive index is 1.51.

EMS is also developing a high-temperature grade of its Grivory partially aromatic nylon for under-hood uses. It will have an HDT of 570-600 F when it is introduced next year.

New 30%-glass Durethan KU 2-2140/30 nylon 6 from Bayer Corp.'s Polymers Div. in Pittsburgh has higher viscosity for improved vibration welding performance. It can handle long-term under-hood temperatures of 284 F and short-term exposure up to 338 F.

New Ultramid nylon 6 grades for exterior painted and unpainted auto parts were introduced by BASF. Ultramid B3GM35 natural and black 564 are easy-flow grades said to provide a resin-rich surface with better appearance and paint adhesion than other reinforced nylons. B3GM35 UV black 23220 is for unpainted exterior parts.

Several new utility grades of black nylon 6 and 66 were introduced by TP Composites, Aston, Pa. These are also available in lubricated, heat-stabilized, and toughened versions.

M.A. Hanna Engineered Materials, Norcross, Ga., has expanded its Texapol flame-retardant nylon 6 and 66 line to include a number of non-halogenated grades.

For nylon applications that are a bit over-engineered, new nylon/PP alloys from Adell Plastics, Inc., Baltimore, have lower density and cost 20-25% less than straight nylon. Neat ZS-10 grade has a specific gravity of 1.03 and HDT of 120 F at 264 psi. Grade ZR-17 with 33% glass has a specific gravity of 1.29, HDT of 324 F, flex modulus of 1,250,000 psi, and tensile strength of 22,000 psi.

GLASS-FILLED ACETAL

New glass-coupled acetal homopolymers from DuPont Engineering Polymers are said to offer better properties than comparable reinforced copolymers. New Delrin 525GR (25% glass) reportedly has 50% higher impact strength, 30% greater tensile strength, and 10% higher stiffness than competitive reinforced copolymer. Flex modulus is 1,160,000 psi, notched Izod is 1.9 ft-lb/in., and tensile strength is 21,900 psi. Also new is Delrin GR510GR with 10% glass.

HIGH-HEAT PPA 

New flame-retardant AFA-4000 and AFA-6000 series of 33% and 45% glass-reinforced Amodel PPA were developed by Amoco Polymers for electronic connectors. Of the two, AFA-4000 has higher HDT (563 F vs. 531 F at 264 psi), while AFA-6000 has a wider processing window and can be hot-runner molded. Both are rated UL 94V-0 at 1/32 in. and are suitable for infrared and vapor-phase soldering. They can run in hot-water tools at 150 F. Prices are $3.24-3.49/lb tl.

Amoco also has two new Amodel HPA grades that reportedly meet USCAR specs for heat/humidity resistance in Class III and Class IV automotive wire-harness connectors. They are modified with a polyolefin to reduce density and cost (around $2.50/lb).

NEW PBT GRADES

New mineral/glass-filled Valox 771 from GE Plastics, Pittsfield, Mass., is aimed at electrical switches and circuit breakers. It has a comparative tracking index of over 600 v and can be used in wall thicknesses down to 0.050 in.

GE's new Valox 337 impact-modified, unfilled PBT blend for under-hood applications is said to have more consistent viscosity. It also has a high flexural modulus for good snap-fit assembly properties.

For outdoor telecommunications housings, GE offers new Valox 364 weatherable PBT blend. This FR grade is said to have improved impact resistance at -40 F.

LOW-DENSITY THERMOSET

A new low-density polyester BMC from Cytec Industries, Inc., Southfield, Mich., produces parts 20% lighter than standard BMCs. Cyglas Lite molding compound offers thermoset properties at a weight comparable to thermoplastics.

MARK IT WITH A LASER

New laser-markable Valox 325ML PBT from GE Plastics offers a high visual contrast and good flow.

Daicel Polymers, Ft. Lee, N.J., introduced laser-markable Cevian LM grades based on ABS and PC/ABS. They come in white, black, and other dark shades and can produce lettering in white, black, and colors.

PCs & BLENDS

New Ashlene 1500 WO BK polycarbonate from Ashley Polymers, Brooklyn, N.Y., is rated UL 94V-0 and contains 5-8% glass for higher flexural modulus (480,000 psi). Ashlene 1105 is a new 5-7% glass-filled PC for molding large structural-foam panels. It has a flex modulus of 340,000 psi and HDT of 255 F at 66 psi.

New high-flow, UL 94V-0 Cevian CR-210 PC/acrylic alloy from Daicel Polymers has an MFR of 18 for thin-wall molding. It reportedly is non-blooming and non-plating.

Daicel's new DR-620 PC/SMA alloy achieves UL 94V-0 without halogenated additives or antimony oxide. It has an MFR of 20 and reportedly combines high impact strength and good uv and thermal stability.

NEW STYRENIC MATERIALS

New Ashlene PB261 WO PPE alloy from Ashley Polymers is rated UL 94V-0 and has a 190 F HDT at 264 psi and notched izod value of 4 ft-lb/in.

Three new transparent ABS grades from Daicel Polymers (T-140, T-150, and T-160) boast a combination of high clarity and low haze. MFRs range from 17 to 21 g/10 min.

Centrex 815 ASA for injection molding was introduced by Bayer. It is said to have higher heat resistance and better outdoor gloss retention than previous grades.

SOFT-TOUCH TPEs

New Tekron 4100 series from Teknor Apex Co.'s Plastics Div., Pawtucket, R.I., are polyolefin/SEBS alloys for blow molding, injection molding, and extrusion. They provide higher flow than earlier Tekron grades and cost 25% less. Nine new alloys range from 50 to 90 Shore A and have tensile strengths from 760 to 1850 psi and elongations from 600 to 800%. MFR range is 4.5 to 13.8 vs. 0.60.8 for previous Tekron grades of comparable hardness. The only trade-off is slightly lower resistance to distortion at elevated temperatures.

Teknor Apex also has a developmental super-soft Tekron grade 96-E0807A-03NT with only 3 Shore A hardness, ultimate elongation of 1100%, and tensile strength of 470 psi. Coextruded or overmolded surface layers are potential uses, as are seals, gaskets, and linings.

A new class of non-hygroscopic TPV elastomers from Teknor Apex eliminates predrying in many cases. The Uniprene 7100 series comprises seven extrusion and injection grades with Shore hardnesses from 55A to 50D. They reportedly exhibit high tensile strength (610-2350 psi) and elongation (330-560%) and up to 50% lower compression set than other TPEs.

An extrusion-grade TPU/ABS blend is new from Bayer for "soft-touch" truck interior uses. Texin DP7-1157 has 92 Shore A hardness.

SPECIALTY COMPOUNDS

Stat-Tech electrically conductive compounds using carbon or metallic fibers are one of four new standard lines of specialty compounds from M.A. Hanna's CTi Div., Corona, Calif. New ThermaTech high-heat compounds based on resins such as PEEK and PES have HDTs above 300 F at 264 psi. LubriTech lubricated compounds and FibreTech glass- or carbon-fiber reinforced compounds are also new.

NEW FLUOROPOLYMERS

New developmental grades of THV melt-processable fluoropolymers are being sampled by Dyneon, St. Paul, Minn. The new grades expand THV's range of static dissipation, flexibility, and heat resistance.

Dyneon also introduced a new melt-processable ETFE: ET6235 has a service temperature range from -150 C to 150 C and high resistance to outdoor weathering.