What's new at the show in materials.

The major thrust in new materials at K is engineering thermoplastics for automotive, appliance, medical, and electrical/electronic parts. There are plenty of new nylons, acetals, PBTs, and LCPs. There's also news in TPEs, including crosslinkable TPUs with properties closer to thermoset rubber. Also look for a brand-new, high-heat amorphous polyphenylsulfone line. There will also be some news in PP and PE materials, and even in thermoset LSR.

Renewable bioplastics

A major thrust in R&D at DuPont is toward polymers made from chemical building blocks obtained from renewable resources--i.e., from biological/agricultural sources rather than fossil hydrocarbons. Its first success in this area is production of propanediol (PDO) starting with fermentation of cornstarch. A 100-million-lb/yr joint-venture plant was opened in June. This "Bio-PDO" has been used to make Sorona PTT polyester, which was first commercialized for textile and carpet fibers. DuPont is now testing PTT as an engineering thermoplastic and expects to enter this market area commercially late this year or early in 2008.

Another Bio-PDO introduction, expected later this year, is in Cerenol polyols used to make automotive paints and new grades of DuPont's Hytrel co-polyester TPE. These Hytrel RS grades will contain rubbery soft blocks made from Cerenol polyols.

Nano- and other composites

DuPont will also highlight its ongoing developments in two other "hot" areas of plastics innovation--nano- and long-fiber composites. DuPont has been experimenting with a proprietary nanoclay having a 10:1 aspect ratio. Just 1.5% by weight of this additive in PET reduces creep by the same amount as 30% to 45% fiberglass. DuPont is also looking at organic nano-fillers, such as highly branched, star-shaped polymers. These materials are incompatible with other thermoplastics and can add reinforcement while dramatically improving flow relative to other nano-fillers.

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In the long-fiber area, DuPont is in advanced development of "engineered fabric composites" involving woven glass or carbon fibers embedded in a thermoplastic matrix. Their strength/weight ratio is said to be competitive with aluminum and steel, and DuPont hopes their economics will be suitable for broad industrial markets, not just aerospace, marine, or sports applications.

Aluminum hybrid debuts

Lanxess Corp. will show off the first automotive front end made of a plastic/aluminum hybrid structure. Until now, steel has been the metal component in hybrid front ends. The nylon/ aluminum hybrid for the Audi TT is 15% lighter than the steel alternative. The structure consists of Lanxess' 30% glass-filled Durethan BKV 30 nylon 6 molded around three sheets of aluminum. Besides lowering fuel consumption, the aluminum hybrid improves the vehicle's driving characteristics because of less weight in front of the front axle. Lanxess foresees other potential applications for the aluminum hybrid in B-cross members, roof frames, and instrument-panel reinforcements.

DuPont is exploring another type of plastic/metal hybrid, which it plans to announce by showtime. This involves "nano-metal" plating on plastics (such as its Zytel HTN PPA) to provide mechanical reinforcement. Today's chrome plating on plastics produces a porous, discontinuous surface that adds only aesthetic properties, not strength. DuPont has proprietary technology for achieving a continuous coating by electroplating with a "pulsating" electrical charge that repeatedly starts and stops formation of metal deposits. This results in much smaller metal particles than in conventional electroplating. The resulting "nano-metal" coating is said to be quite strong.

In addition, DuPont has developed selective nano-plating technology, by which conductive particles that promote plating adhesion "float" to the surface of the injected melt in a mold cavity--but only in specific locations as determined by differences in mold temperature.

News in nylons

Lanxess will introduce a highly filled nylon for external car door handles. Durethan DP BKV 60 H2.0 EF is a 60% glass-filled nylon 6 with high flexural strength and tensile modulus. Surface quality and flow characteristics are said to be comparable to those of standard 30% glass-filled nylon 6. The material has low moisture absorption and high dimensional stability. It can be coated and electroplated.

A new super-high-impact nylon 6 will be unveiled by Rhodia Engineering Plastics. Technyl SI is a new range of nylons that balance exceptional impact resistance with good stiffness. Target applications include machine components, power tools, and sporting goods. In power tools, the material's stiffness improves structural characteristics and screw retention, eliminating the need for inserts and simplifying assembly.

Rhodia also has a new family of modified nylons for extrusion and blow molding. Technyl XT is claimed to have unique rheology that boosts its processability without sacrificing performance. The product family includes Technyl C 502XT, Technyl C 507XT (heat stabilized), Technyl C 52XT (UL 94V2 version), and Technyl C 536XT (for blow molding). Applications range from corrugated pipe and bag-in-can packaging to fuel tanks for motorcycles and power tools.

Also new is a high-flow nylon 6 series that delivers outstanding surface finish, high stiffness, and high heat resistance.

BASF will unveil an online-paintable nylon for auto exterior body panels. Ultramid TOP 3000 is an impact-modified, mineral-filled nylon with a considerably lower CLTE than competing resins like Noryl GTX PPO/nylon from GE. The partially aromatic nylon can be used in coating processes at temperatures above 200 C.

BASF also introduced this year the Ultramid CR line of nylons tailored for high energy absorption and dynamic loads in automotive uses. These "crash-worthy" grades are based on nylon 6 and 66 and contain 30% to 50% glass fiber.

New nylon developments from DuPont include corrosion-free Zytel HTN PPAs for electrical circuits and connectors in high-temperature automotive environments. Also new is Zytel HTN FR52G30NH, a halogen-free, 30% glass-filled PPA with UL 94V-0 flame resistance at 0.8 mm and UL CTI [greater than] 500V. It is for connectors, heavy-duty circuit breakers, and contactors.

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Conductive acetal 

Ticona will show its new Hostaform EC140XF, a carbon black-filled acetal that provides electrical conductivity in automotive components. It meets the requirements of SAE J1645 for fuel systems. Siemens VDO uses the new grade to dissipate static charges in the fuel-supply unit of the Ford Transit. Ticona is also working on other formulations that will incorporate new conductive nano-fillers.

DuPont will be talking about its planned introduction in mid- to late 2008 of a new generation of engineering thermoplastic compounds with significantly enhanced thermal conductivity for applications in microelectronics, motor housings, laptop computers, and displays. In the last three years, DuPont has been able to raise the level of thermal conductivity from 3 W/mK up to 40 W/mK by using carbon fibers plus metal particles. Though the cost is moderate, the high filler levels make the compounds hard to mold, and they are also electrically conductive.

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Electrically insulative compounds have been formulated up to about 33 W/mK using boron nitride (BN) BN-coated graphite, and copper particles coated with BN and glass plus coupling agents. These formulations are both expensive and also hard to mold. As a result, the first generation of new commercial entries is expected to have thermal conductivities of 10 to 15 W/ mK balanced with moldability and acceptable cost.

More engineering resins

BASF will launch two acetal copolymers for medical applications. Ultraform $2320 003 PRO and W2320 003 PRO have high load-bearing capacity, and good sliding friction resistance. Applications include valves, metering systems, springs, slides, and gears.

In polyesters, BASF's Ultradur high-flow PBT line has been expanded to include thermally conductive, flame-retardant, and low-warp grades. Ultradur B4300 M12 has thermal conductivity of 1 W/mK.

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DuPont will introduce Thermx TE 4004, a new PCT polyester for pencil-coil auto-ignition systems. These parts are getting smaller while delivering higher energy. That requires a material that flows easily in thin walls and has high dielectric strength at elevated temperatures, as well as excellent adhesion to epoxy encapsulants. Also new is Rynite RE 19041 PET, a halogen-free compound with UL94V-0 flame resistance at 0.8 mm and UL CTI greater than 500V.

In polycarbonate, Bayer MaterialScience will be showing off the PC automotive roof module--said to be the industry's largest--for the new "Smart Fortwo" from DaimlerChrysler's Smart subsidiary. The 13-f[t.sup.2] roof is made by injection-compression molding on a swivel-platen press. It weighs 40% less than glass.

New all-polymeric wear-resistant compounds from RTP Co. are said to provide comparable or better performance than PTFE-based low-wear compounds, as well as lower density and better impact resistance, especially in polycarbonate. The "eco-friendly," non-fluorinated compounds have a low loading of a polymeric additive in polycarbonate, nylon, and other engineering resins.

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In high-performance polymers, BASF will introduce two new Ultrason polyethersulfone (PESU) grades for automotive headlights. Ultrason E2010 MR black HM is a black product that reduces heat build-up by providing better permeability to heat radiation. The key is a new pigment system that absorbs visible light but allows infrared to pass through. The other grade, Ultrason E2010 MR HP, is a blend with 10% to 20% better flow than straight PESU. It also offers impact strength comparable to higher-molecular-weight PESU and reduced swelling during processing. BASF has made quantities available for sampling.

And just at press time, BASF announced the launch of a new polyphenylsulfone (PPSU) line as an addition to the Ultrason family. The first grade is Ultrason P 3010, said to combine the high melting point of Ultrason E PESU with the low water absorption of Ultrason S polysulfone. Other advantages are high chemical resistance to strong cleansers and disinfectants and better resistance to steam sterilization than other amorphous resins in its class, withstanding up to 2000 hot-steam cycles without damage. Especially interesting is its Charpy notched impct resistance 10 times greater than other amorphous high-temperature resins, which tend to be notch sensitive.

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Two new LCP grades will be highlighted by DuPont. Zenite ZE55201 is an ultra-low-warp LCP designed to maintain flatness in connectors, chipcard holders, and large parts for ovens and other appliances. Zenite ZE55801 is a palladium-doped, 30% glass-filled grade that enables selective electroless chrome plating of connectors for MIDs when used with standard LCP in a two-shot molding process.

Tailored ABS

In styrenics, BASF has a new extrusion grade for sheet and profiles. Terluran SP-6 has a low yellowness index of 16.

Lanxess is introducing Triax KU 2-3050 nylon/ABS alloy as an alternative to PC/ABS in auto interior parts. It has a matte finish that eliminates painting. The company attributes this high-quality surface to the material's high flow. Other properties are good light stability, chemical resistance, and toughness.

BASF will launch Terlux 2812 HD, a transparent MABS for medical applications. It has higher flow than the company's previous clear ABS grade, thus filling multi-cavity molds more easily. A glass-filled version is in development.

Innovative TPEs

GLS Corp. will unveil a slate of proprietary, blow moldable Versaflex TPEs that come in clear and translucent grades and hardnesses from 35 Shore A to 40 Shore D. Barrier applications are among the targeted uses in medical and consumer products.

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GLS will also highlight a new line of vibration- and sound-damping TPE alloys. They are claimed to be an industry first because they use unique chemistries for sound damping across wide frequency ranges (10 Hz to 20 kHz). Hardness range is 20 to 80 Shore A and specific gravities are 0.9 to 1.3. The materials also offer uv protection.

Kraiburg in Germany has come out with a new generation of soft-touch transparent TPEs. They are based on hydrogenated styrenic block copolymers (HSBCs) and reportedly offer a previously unattainable level of adhesion to PC and ABS. When used in overmolding, their clarity allows the base product to show through clearly.

Novel crosslinkable TPU 

Elastogran GmbH in Germany and parent company BASF have developed a cost-saving alternative to rubber/metal composites used for mechanical damping applications. The composite consists of a novel crosslinkable TPU called Elastollan TPU-X in place of the rubber and BASF's new Ultramid CR nylon (see above) in place of metal. Parts can be produced by two-component injection molding. The TPU is made crosslinkable by addition of a liquid curing agent during processing. The new TPU has low compression set and low hardness of 60 Shore A. It withstands temperatures up to 120 C (250 F) long-term and 150 C (300 F) short-term. At the show, Krauss-Maffei will demonstrate a production cell using these materials (see p. 71).

Lubrizol Advanced Materials (formerly Noveon) will launch a non-halogenated Estane FR grade for wire and cable that can meet the European IEC60332-3 cable-tray test. Lubrizol also has a new a series of aliphatic TecoFlex TPUs that are non-yellowing and highly uv resistant. They are aimed at protective films for outdoor weatherable applications.

Novel LSRs

Wacker Silicones will showcase two new and reportedly unusual lines of liquid silicone rubbers for injection molding. Elastosil LR 3800 Series are self-lubricating grades with a complete range of oil contents and Shore hardnesses. They are said to offer much faster cycles and easier demolding than previous products. Also new are tear-resistant Elastosil grades with improved puncture resistance.

NEED TO KNOW MORE?

For more information on these companies and their products, visit www.ptonline.com/suppliers.

BASF Corp., Wyandotte, Mich. [phone] * www.plasticsportal.com

Bayer MaterialScience, Pittsburgh [phone] * www.bayermateriaiscience.com

Borealis Compounds LLC, Port Murray, N.J. [phone] * www.borealisgroup.com

Bow Polypropylene, Houston [phone] * www.dow.com

Bow Specialty Elastomers, Midland, Mich. [phone] * www.dow.com

DuPont Engineering Polymers, Wilmington, Del. [phone] * www.plastics.dupont.com

Elastogran GmbH, Lemforde, Germany [phone] * www.elastogran.de

GLS Corp., McHenry, III. [phone] * www.glscorp.com

Kraiburg TPE Corp., Duluth, 6a. [phone] * www.kraiburg-tpe.com

Lanxess Corp., Pittsburgh [phone] * www.lanxess.com

Lubrizol Advanced Materials Inc., Cleveland [phone] www.lubrizol.com

Rhodia Engineering Plastics, Farmington Hills, Mich. [phone] * www.rhodia-ep.com

RTP Co., Winona, Minn. [phone] * www.rtpcompany.com

ticona, Florence, Ky. [phone] * www.ticona.com

Wacker Chemical Corp., Adrian, Mich.

[phone] * www.wacker.com

Joseph A. Grande & Lilli Manolis Sherman, Senior Editors; Matthew H. Naitove, Editor