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Research & Development Plastics: Design Plastics: Technology Advances

Cut purging compound usage by up to half in high-temp. applications

Cut purging compound usage by up to half in high-temp. applications

The Dynapurge Division of Shuman Plastics announced at NPE that it had recently conducted trials with one of its clients using its new Dyna-Purge E2, an integrated polymer system designed to purge high-temperature engineering resins.

Fam-Lee Products, Inc., an injection molder of medical components in Loveland, Colorado, ran trials on three different parts comparing the new formula with a purging compound used previously. The results in all three trials were a significant reduction in downtime and the use of up to 50% less purging compound. In the first trial, Fam-Lee sampled E2 with a tube connector, changing from black to clear polycarbonate. The company consistently used up to 33% less purging material. Similar results were experienced in the second trial with lever devices, with the resin changing from black to gold polycarbonate. Again, the savings in purging compound were 33%. Lastly, Fam-Lee sampled the new formula changing resins from purple to blue or white high-temperature polycarbonate in the production of a non-invasive medical component. This time, the company used nearly 50% less purging material with E2.

Dynapurge Division of Shuman Plastics (Buffalo, NY);

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DuPont continues to drive its renewably sourced polymers business

At the DuPont booth, the emphasis was on the company’s renewably sourced polymers. Parts on display included the Generation Chair by Knoll Furniture, with the chair back injection molded in Hytrel RS.

Also shown was an air-conditioning louvre molded with Sorona (CHECK SPELLING) renewably sourced PEE. Parts made with Sorona have an excellent surface finish.

E. I. du Pont Canada Company, Performance Polymers (Mississauga, Ont.);; 800-387-2122


BASF nylons drive automotive lightweighing

One of the highlights at the BASF booth was a wheel rim for Daimler’s prototype Smart Car, injection molded with Ultramid nylon 6/6, filled with long (12 mm) glass fiber. The new plastic wheel rim is 30% lighter than cast aluminum, and helps extend the driveability range of the Smart Car. The part was designed using BASF’s proprietary Ultrasim software, which integrates flow and structural analysis.

Another example of automotive part light-weighting on display was a developmental seat back by Faurecia, a French-based Tier One supplier. These are molded in a two-shot process, with short-glass fiber-filled Utramid nylon overmolded over a continuous fiberglass insert. The seat backs are 25 mm (1 inch) thinner than conventional steel or magnesium back, so there’s more leg room in the car interior. Plus, the new process replaces a number of parts versus the traditional metal design.

BASF Canada (Mississauga, Ont.);; 866-485-2273


New high-performance PC materials

SABIC Innovative Plastics has added to its flagship portfolio of high-performance Lexan polycarbonate (PC) materials: Lexan CFR (clear flame retardant) copolymer and three new Lexan LUX resin grades.

Lexan CFR copolymer addresses rising consumer electronics and appliance manufacturer demand for a clear, sustainable flame retardant (FR) material, and the new Lexan LUX resins offer an excellent solution for light emitting diode (LED) applications such as light guides and lenses. These new Lexan PC materials demonstrate SABIC’s ongoing investment in world-class technologies, technical expertise and portfolio breadth. They also underscore how the company continues to increase PC performance to meet customers’ environmental, high-performance, aesthetic and regulatory requirements. In fact, SABIC’s portfolio of customer-relevant PC materials is the broadest in the global plastics industry.

Consumer electronics and appliances continue to shrink in size and thickness, calling for new materials that can provide excellent FR performance at ever-thinner gauges. For example, covers for notebook computers are typically 1.5 mm, and tablet covers are even thinner at 0.8-1.2 mm. Lexan CFR advanced copolymer fills an unmet market need by giving consumer electronics and appliance manufacturers a clear material with superior flame resistance at very thin gauges compared to competitive products, enabling customers to create the next generation of thinner, lighter-weight products.

Lexan CFR copolymer complies with the Underwriters Laboratories (UL) 94 V-0 standard down to 1.0 mm and the UL 94 5VA standard at 3.0 mm. This transparent resin provides a non-brominated, non-chlorinated, non-phosphate, non-Teflon® FR that complies with major environmental protocols like Restriction of Hazardous Substances (RoHS), TCO99 International and Eco-Flower, making this product a viable alternative for those seeking sustainable solutions.

SABIC Innovative Plastics (Cobourg, Ont.);; 905-373-3924


Melt additives that impart durable hydrophiliciy

Masterbatch supplier Techmer used NPE to promote its Techsurf hydrophilic melt additive, used as a wetting agent in polyolefin fibers, non-woven fabrics and specialty plastic applications. Unlike a topical treatment, Techsurf is an internal melt additive that continues to migrate to the surface. Benefits include increased absorption capacity, enhanced wettability, and reduced surface resistance of the finished fabric. Techsurf is sold in pellet form. Techmer acquired the technology from BASF in 2010 and renamed the product Techsurf.

Techmer PM, LLC (Clinton, Tenn.);; 865-457-6700


Bioplasticizer with USDA “BioPreferred” certification

PolyOne Corporation has introduced reFlex 100, a fast-acting bio-based plasticizer produced from rapidly renewable plant-based feedstocks developed in collaboration with Archer Daniels Midland Company (ADM). In addition, it’s one of the first bioplasticizers to be awarded recognition by the USDA BioPreferred program, which has granted reFlex 100 a 94% biobased label.

With its fast-acting (high solvating) performance, reFlex 100 can be an alternative to conventional plasticizers such as BBP, DBP, and benzoates, many of which have come under regulatory pressure. Further, with reFlex 100, customers can improve productivity, reduce the amount of plasticizer and stabilizer required, and eliminate defects for greater operational efficiency and profitability.

reFlex 100 can be blended into both traditional phthalate and new non-phthalate systems, providing a formulating tool that helps reduce costs by improving productivity, eliminating defects, and reducing consumption. In addition, customers can leverage the bio-based nature of this product to expand their offerings with differentiated solutions.

To improve productivity, reFlex 100 offers faster setup times and reduced viscosity versus other traditional plasticizers. It helps to eliminate defects through improved air release and thermal stability. Because it is more efficient, reFlex 100 also reduces the amount of plasticizer needed during processing. It acts inherently as a thermal stabilizer as well, which may enable processors to eliminate the need for stabilizers in
their formulas.

PolyOne Distribution Canada Ltd. (Mississauga, Ont.);; 888-394-2662


Antimicrobial masterbatches provide superior processing and long-lasting effectiveness

Americhem Inc. has introduced nShield antimicrobial masterbatches, designed to inhibit the growth of odor-causing bacteria in synthetic fiber and plastic products.

nShield antimicrobial masterbatches are highly effective at low levels against a wide range of microorganisms in a variety of applications, including apparel, filtration, synthetic turf, automotive interiors and other plastic products. The product can be customized in order to suit each manufacturer’s specific requirements, including antimicrobial concentration, use rate and other functionalities.

These masterbatches become an integral part of the fiber or plastic article and render durable antimicrobial properties which restrain bacteria from proliferating and control odor. Because it is engineered into the end product, nShield’s antimicrobial effect is non-migratory resulting in premium durability. nShield antimicrobial agents also resist discoloration and degradation caused by bacteria for long-lasting aesthetic appeal.

An extra value to manufacturers, nShield enhances performance throughout the manufacturing process. It has excellent spinning and processing characteristics for higher yields and lowered pack pressure because of the dispersion quality. nShield also provides higher thermal stability that will not cause decomposition at nylon 6, nylon 6,6 or PET spinning temperatures, allowing for superior processing and optimal manufacturing efficiency.

Americhem Inc. (Cuyahoga Falls, Ohio);; 330- 929-4213


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