New Polyolefins at K 2007.

While the majority of new materials at K fall into the engineering thermoplastic category, several interesting polyolefins will also make their debut.

Novel PP resins

A reportedly unique PP resin designed to produce caps for bottled water and sports and energy drinks will be launched by Borealis. Grade RE450MO, based on the company's Borstar technology, is said to preserve the taste of the liquid contents of the bottle while providing design possibilities not previously available from PE or PP cap resins. For example, it boasts good flow, low stress-whitening, and good hinge performance.

It contains no additives that could taint the taste or odor of the bottled product, contains ultra-low levels of VOCs, and matches the excellent taste and odor properties of standard HDPE grades used for beverage caps.

Borealis will also introduce what is calls a "pioneering" detergent-resistant, glass-reinforced PP for appliances. Grade GB266WG can be used for the interior of washing machines and dishwashers. Its detergent resistance reportedly makes it an effective alternative to steel for dishwasher frames and other structural parts.

Borealis attributes its performance to a novel stabilization system that also enhances the lifetime of important structural components. It is said to resist the aging effects of light, oxygen, and wear-and-tear, such as scratching, discoloration, or gloss reduction. It also boasts high stiffness and low CLTE, which is said to ensure watertight connection between components. GB266WG is also said to decrease thermal and acoustic transmission, minimizing the need for separate insulation materials.

Dow Europe plans to launch about 20 new and enhanced grades of PP at K 2007 that initially will be aimed at the European market. They represent the "first wave" of new offerings from the Dow Horizon Project, an effort to expand the PP performance envelope by exploiting the latest Unipol high-activity catalyst. Among the new grades are a 100-MFR random copolymer for thin-wall injection molding that boasts outstanding taste and odor performance. Another is a 42-MFR random copolymer for injection molding food-contact articles.

New olefin elastomers

Dow will also showcase its new family of Infuse Olefin Block Copolymers (OBCs), first unveiled at NPE 2006. They have been lauded as a breakthrough in olefinic TPEs due to their unique block structure, consisting of linear MDPE hard blocks and Engage-type ethylene-octene soft segments. Infuse is said to allow for novel combinations of end-use properties and processability at a "cost in use" competitive with materials such as TPVs, TPUs, and styrenic block-copolymer (SBC) TPEs.

Infuse OBCs have potential uses in a broad spectrum of applications, including flexible molded goods, extruded hoses and tubes, elastic fibers and films, foams, coated fabrics, adhesives, and tapes. Dow announced two months ago that Infuse OBCs had met all U.S. FDA and EU regulations for food contact applications. They also appear to look promising for auto interior applications, both as neat resins and as impact modifiers.

HDPE for coaxial cable

Borealis will showcase what it terms a "cutting-edge," fully compounded HDPE for the gas-injected cellular insulation of small to medium-size coaxial cables. Borcell HEl106 is said to allow cost-effective production of cables with greater or more reliable data transmission at higher frequencies. This reportedly allows network providers to minimize signal loss, raise performance, and use more bandwidth to offer a greater range of services over the same cable.

Borealis says, its new insulation material is produced under strictly monitored compounding conditions using electrically clean raw materials. It is said to give consistent foaming performance during extrusion, providing up to 80% expansion. The compound also contains a uniformly dispersed nucleating agent said to give a wide processing window and the lowest possible dielectric loss, even at high frequencies of 3000 MHz. Insulation made with this compound boasts uniform cell structure and surface smoothness, making the material more difficult to crush. By strengthening the finished cable, this compound is said to allow manufacturers to achieve longer production runs by winding bigger rolls without potential cable damage.

PE tie layers for pipe

Dow will introduce two new additions to its line of Amplify functionalized polyolefin adhesive tie-layer resins, which are specially formulated for HDPE pipe. GR 380 is designed to bond layers of polar barrier materials such as EVOH, PET, or epoxy to layers of non-polar polyethylene in making multi-layer hot- or cold-water pipes. GR 380 is formulated to complement the performance of Dowlex PE-RT (an HDPE with raised temperature rating). Another new product, GR 388, is specially formulated for in-floor heating systems.

Scratch-resistant TPO 

Borealis also will showcase its new talc-filled TPO for injection molded auto interior components. It was chosen by DaimlerChrysler for all visible trim in the interior of the 2008 Mercedes C-Class. Daplen EE188HP reportedly provides excellent scratch resistance and low gloss. Its high dimensional stability and wide processing window are said to provide consistent surface quality. The material's balance of toughness and stiffness is said to help parts meet industry crash-test requirements.