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POLYMER MATERIALS

High flow backed up with higher stiffness: Two new XtremeFlow Bayblend grades (T65 XF and T85 XF) from Bayer MaterialScience have 10 - 15 per cent better flow properties than their standard equivalent grades. They also have improved low temperature impact strength and stress cracking resistance.
     And supporting the extra flow is an increased stiffness, which extends the ability to fill thinner walls with the necessary additional mechanical integrity. Stand 6 A75.

Flame retardance without halogens: New halogen-free FR grades of DSM's Xantar C have been introduced for use in applications such as TV housings - where their surface appearance, high flow/impact behaviour and high stiffness enable wall thicknesses to be reduced - and battery boxes. Stand 6 B11.

Ecovio polyester/PLA now foamable for XPS sheet replacement: BASF's Ecoflex is a copolyester which, while being derived from petrochemical sources, is innately biodegradable. It has been blended with other biopolymers, including NatureWorks' polylactic acid, to make Ecovio, and with other starch-based products to make mulching and packaging film, such as in BIOP Biopolymer Technologies' Biopar.
     Now BASF has increased the PLA content in a new 'burger box' product containing more than 75 per cent PLA. The new Ecovio L Foam is aimed at the XPS (extruded polystyrene foam) market and can be processed on standard XPS equipment without modification to make sheet for thermoforming into packaging. Stand 5 B21.

Higher fill levels cut compound cost: Tyrin EXT 1000 from Dow Chemical accepts higher levels of filler and oil than traditional CM grades, resulting in lower overall compound costs for automotive hoses and ducts, industrial hoses, wire and cable jacketing, and other technical rubber goods.
     The material can be crosslinked using any of the three cure systems typically used for chlorinated polyethylene - peroxide, thiadiazole derivative and radiation. In addition, says Dow, new cure technology offers improvements over traditional thiadiazole cure technology making thiadiazole-cured Tyrin CM an alternative to sulphur-cured elastomers such as polychloroprene or chlorosulphonated polyethylene. Stand 8A K47.

Higher shear strength for LGF compounds: New long glass fibre reinforced compounds with improved properties will be introduced by TechnoCompound on stand 6 B44.
     The new TechnoFiber materials have a new formulation which has improved adhesion between the glass fibres and the polymer matrix and so increased shear strength.

Electronic focus for new Zenite 5000 grades: Two grades with specific properties for use in electronic components are being added by DuPont. Zenite ZE55201 is an ultra-low-warp LCP to maintain flatness in components such as connectors, chip-card holders and large parts in appliances such as oven parts. The ultra-low warp performance of this new grade has been achieved by reducing anisotropic shrinkage - more than 50 per cent reduction of shrinkage in its cross-flow direction.
     Zenite ZE55801 is a palladium-doped, glass-reinforced grade of LCP that enables selective chrome-plating of connectors for moulded interconnect devices if used with a standard grade of Zenite in a twin-shot moulding process. The new grade has close to 10 per cent lower density compared to competitive products, resulting in lower part costs, plus good elongation and weld line strength, says DuPont. Stand 6 D27.

Rhodia nylons focus on improved performance without sacrificing properties: Four improved performance ranges of nylon 6 and 66 have been introduced by Rhodia over the past year or so and can be seen together on stand 6 E24.
     A high flow PA66 will be introduced as High Fluidity Polyamide. Rhodia says it will enable moulders to improve productivity and to reduce cycle time, while maintaining the temperature, chemical and mechanical advantages of polyamide 66. The materials provide for a high level of stiffness and retention of mechanical properties at high continuous use temperatures, particularly in applications for which high levels of mineral or glass fibre reinforcement are required without compromising either productivity or surface appearance.
     Technyl SI (Super Impact) is a series of nylon 6 compounds balancing impact resistance with stiffness and intended to provide better mechanical properties in high abuse environments. A major application focus is power tool housings, for which Rhodia says the material gives the necessary impact performance while its higher stiffness brings better structural characteristics and improves screw retention, eliminating the need for inserts.
     Technyl XT is a nylon 6 series tailored for extrusion and blow moulding which Rhodia says matches standard PA6 in mechanical, thermal and chemical properties but gives better impact resistance. It process around 20 degC lower than standard PA6 which reduces energy consumption and translates into shorter cooling cycles and higher production runs. Applications so far include corrugated pipe and bag-in-can to fuel tanks for motorcycles and power tools.
     The fourth new series is a range of PA6 and 66 grades optimised for use with the MuCell micro-cellular foam process. These Xcell materials bring enhanced processability and good property retention when used in the MuCell process, while maintaining good surface appearance. Trials have shown that Technyl XCell permits a density saving of at least 10 per cent in the MuCell process while retaining its rigidity, heat deflection temperature and notched impact performance.

New nylon 6 grades improve film and injection moulding: A high productivity grade of Akulon nylon 6 has been introduced by DSM for packaging film.
     Akulon PA6 is established for food packaging, offering thermoformability, printability, transparency and heat resistance. In particular it creates an oxygen barrier, aroma and flavour barrier, mechanical protection, and puncture resistance.
     The new Akulon XP has a broader processing window leading to more flexibility and more uniform thickness distribution in cast film, more melt strength and better parison stability leading to optimised LDPE/LLDPE ratio in multi-layer films without sacrificing mechanical properties. It brings more shear thinning than with standard PA6 making possible higher coating speeds, and DSM says it is 'absolutely gel free'.
     Today, more than three quarters of PA6 film is being used for food packaging applications such as meat, cheese, fish, sausage skins and coffee packs. Non-food applications include medical and pharmaceutical films, protective packaging (bubble film), agricultural film and industrial films.
     There are also new high flow injection moulding grades of Akulon. Akulon Ultraflow is said to yield around 25 per cent cycle time reduction and give a good surface appearances, especially for highly reinforced grades. Grades available include glass-filled, glass/mineral-filled and flame retardant glass and mineral-filled.
     A new flame retardant injection moulding grade of Akulon Ultraflow - K-FKMV5 - for power distribution applications such as miniature circuit breakers is said to give 15 per cent lower injection moulding cycle times, better dielectrical surface properties compared to standard halogen free FR mineral grades and similar stiffness as halogen-containing FR mineral grades. Stand 6 B11.

PA46 competes with LCP for electronic connectors and pushes heat resistance: DSM has improved on its high flow Stanyl PA46 with what it is calling Stanyl Super Flow. This has been formulated to compete with high flow LCP which DSM says it outperforms in a number of ways: no micro cracking, better weld line strength, high toughness for pin retention and retention of strength after lead-free soldering. Because rejects during assembly and after lead-free soldering are reduced, system costs are lowered for the connector manufacturer. There is also high productivity from the short injection moulding cycle times.
     Further innovation in Stanyl likely on Stand 6 B11 is the result of the new Diablo project which aims to overcome the problem with long term exposure to elevated temperatures when a nylon's surface blackens, roughens, and becomes liable to crack propagation. DSM has had the new material on test for 2,000 hours at 230 degC during which it has long passed the point at which standard grades fail.

New PPA keeps corrosion at bay: Reduced corrosion in electrical applications is claimed for a new grade of Zytel HTN PPA - polyphthalamide - from DuPont (stand 6 D27). Standard polyamides contain stabilisers that can escape from the polymer matrix, corroding contacts and electrical circuits, says DuPont. New technology available through the latest range of Zytel HTN (non-V0) polymers helps prevent this corrosion.

High-heat and crash-resistant nylons for automotive parts: New nylons for automotive use will be introduced by BASF (stand 5 B21).
     Ultramid TOP3000, is a 10 per cent mineral-filled partly aromatic polyamide which is intended for body components able to withstand on-line painting and drying at just above 200 degC. BASF says that Ultramid TOP3000 has achieved Class A quality in various coating lines under different conditions and coating concepts. It can be powder-coated without a primer.
     The nature of the mineral filler is undisclosed, as is the nature of the nano-particles which form part of the compound's make-up and aid flow.
     Ultramid TOP 3000 has been developed to improve on 'the often employed polymer blends based on PPE/PA66' with a lower coefficient of thermal expansion and dimensional stability at elevated service temperatures.
     The new nylon also has improved hydrolytic stability. BASF says it absorbs and releases water 'considerably more slowly' than other nylons and retains stiffness when moist.
     The other new nylons are grades which BASF has analysed with its Integrative Simulation process to predict their performance in the event of a crash. BASF says that plastic parts likely to be subjected to stress in a crash can only be designed efficiently when the material is sufficiently rigid but still absorbs a lot of energy and its behaviour in a crash can be precisely described by means of CAE software.
     The new CR range consists of four Ultramid grades tuned for high energy absorption and two grades that are optimised for dynamic loads. The materials for high energy absorption include three Ultramid B grades (PA 6) having different levels of rigidity. The three black-coloured products are reinforced with 30, 35 and 40 per cent glass fibres and BASF says high-speed tensile tests show that these materials exhibit distinctly more advantageous behaviour for crash applications than conventional grades. One of these, Ultramid A3WG7 CR1, also exhibits high energy absorption and combines impact resistance with the resistance to heat and chemicals typical of PA 66. This gives it a relatively high temperature reserve for short-term thermal loads (greater than 200 degC) as can occur in a cataphoretic dip painting oven. This is important for structural components that are installed in the vehicle at an early stage of production and pass through the complete CDP process, such as inserts which stiffen the bodywork of the vehicle and affect failure in a crash.
     The two grades intended for high dynamic loads are PA 66 reinforced with 35 and 50 per cent glass fibres and are seen as alternatives to metal. They possess high strength and rigidity and can be used at high temperatures.
     The service support provided to customers for these products includes the complete description of the material for crash simulations. Apart from the dependence on strain rates this includes consideration of the orientation of the glass fibres and of fracture behaviour. The material models can be implemented in all crash simulation programs commonly available on the market such as LS-Dyna, PamCrash and Radioss.

Pipe and cable grades for higher product performance: The latest BorSafe HE3490-LS-H from Borealis for pressure pipes has 'exceptional' resistance to slow crack growth, which can be caused by surface scratches or notches created prior or during installation, or by external point-loads on the pipes, such as rocks. This phenomenon can cause long-term weakness in pipes allowing water to escape. The material was tested by passing it for 18,000 hours in the Notch Pipe Test, 100 times more than required by the European standards for PE drinking water pipe systems. Additionally, Borealis says it exceeds by a considerable margin the specified German requirements defined as Full Notch Creep Testing.
     Also new on stand 6 C58 will be a high density grade for coaxial cable manufacture. Borcell HE1106 is a fully compounded HDPE for the gas injected cellular insulation of small to medium coaxial cables. The insulation solution is produced under strictly monitored compounding conditions using electrically clean raw materials. Borealis says it gives consistent foaming performance during extrusion providing an expansion degree of up to 80 per cent and a constant standard of quality for the manufacturer.
     Borcell HE1106 also contains a uniformly dispersed nucleating agent, which optimises processing by giving a wide processing window and also optimises the cable performance in offering what Borealis says is the lowest possible dielectric loss compared to other available alternatives even at high frequencies of 3,000 MHz.
     The uniform cell structure and surface smoothness achieved with HE1106 insulation also makes the material more difficult to crush. By strengthening the finished cable, manufacturers can achieve longer production runs as bigger rolls can be produced without the potential of cable damage.

New polypropylenes tailored for purpose from engineering to packaging: Polyolefins major Borealis likes to stress that it is not in the commodity materials business, but makes 'high volume plastics'. Two new materials on stand 6 C58 demonstrate the role of polypropylene as an engineering material for two particular high volume applications: complete car interiors and as a steel replacement in white goods. The company will also be showing how, in a traditional 'commodity materials' application - bottle caps - its polypropylene brings additional application benefits.
     The car interior material is Daplen EE188HP, a polypropylene-based thermoplastic olefin compound. It has been used for all the injection moulded interior trim items in the Mercedes C-Class, replacing the need to use several polymer types. More than 40 injection tools are used.
     Daplen EE188HP is a talc-filled compound with a particularly high scratch resistance (MAR nail scratch test) and low gloss with a balance of impact resistance and stiffness which Borealis says helps parts to achieve industry crash test requirements. Also important for interior use are its low odour, emission and fogging characteristics.
     Daplen EE188HP is used for the dashboard, centre console, pillars, and cladding for tailgates, seats and door sides of the C-Class, providing the same gloss, scratch resistance and colour effect for all visible components in the interior.
     The material is supplied ready-coloured in five Daimler Chrysler-specified colours enabling easy colour matching between injection moulded trims and PUR skins within the interior.
     The new white goods material is a glass-reinforced PP, grade GB266WG, which is detergent resistant for use inside washing machines and dishwashers. It has what Borealis describes as a 'novel stabilisation system' that prevents the ageing effects of light, oxygen and usage-induced wear and tear, such as loss of strength, stiffness or flexibility, discoloration, scratching or loss of gloss.
     Borealis says that traditionally, different PP materials have been needed to survive the corrosive effects of the different types of detergents in dishwashers and washing machines. By eliminating this requirement, GB266WG enables manufacturers to reduce their inventory materials through the use of the same PP for both appliances.
     As an alternative to steel GB266WG offers easier handling and transport of components and finished appliances. The amount of energy required when using the appliances is also reduced, and it decreases thermal and acoustic transmission, minimising the need for separate insulation materials and further lowering production costs for appliance manufacturers. GB266WG is also characterised by high stiffness and low heat extension which ensures a watertight connection between components such as a PP dishwasher frame and connecting steel parts.
     Also designed specifically for purpose is the new RE450MO polypropylene for bottle caps. This material is based on Borealis' Borstar technology which allows the tailoring of molecules to combine good mechanical properties with good processability. The material does not contain additives that could taint the natural taste or odour of the bottled product. Until recently, the organoleptic properties of polyethylene have made it the only option for unlined caps used for taste sensitive drinks such as water, says Borealis. RE450MO contains ultra-low levels of volatile organic compound and the company says that tests have shown that it is able to match the taste and odour properties of standard PE grades commonly used for beverage caps.
     To this is added the design potential of polypropylene. It enables a 'living hinge' with low stress whitening and vivid colours that cannot be achieved in polyethylene. Alternatively it offers high transparency.

SBC competes with PET-G for shrink sleeves: A new blend of SBC/PS has been developed by BASF to compete in the shrink sleeve market. Conventional SBC/PS blends have about the same shrinkage level as PVC, but the new Styrolux HS 70 has a greater shrinkage, close to that of the industry standard, PET-G. And it offers economic advantages through its lower density: approximately 30 per cent more film can be produced per kg in comparison with PVC and PET-G. It is also more transparent than previous grades, is stiffer and can be easily printed on, says BASF.
     SBC/PS blends make films with an average final shrinkage of about 50 per cent within a processing window from about 80 to 95 degC. Styrolux HS 70 gives shrinkage values of 70 to 80 per cent for form-fitting sheathing of bottles with complex geometries or large radius differences such as champagne bottles. The material also exhibits a steady increase in the shrinkage as the temperature rises, so offering a wide processing window. HS 70 is delivered ready-to-use: it no longer needs to be mixed with standard polystyrene. Stand 5 B21.

BASF brings back extrusion grade ABS: A few years ago when BASF separated styrenic plastic specialties from styrenic plastic commodities it slimmed its standard ABS range down to just three types that it could make most efficiently at its Antwerp plant. Extrusion companies had to use the high impact grade, although the material had not been developed for this purpose: the additive blend used is designed for injection moulding, and in particular for the manufacture of impact-resistant housings. Even its melt flow index is more aligned to the requirements of injection moulding technology.
     Now BASF is introducing a grade of Terluran - SP-6 (Sheets and Profiles) - based on Terluran HI-10 that is specially tailored for use in extrusion and can still be produced under the cost-efficient conditions at Antwerp, which means that BASF can keep the price 'competitive'.
     The melt flow index of Terluran SP-6 is about 5 cm³/10 min, notched impact strength about 37 kJ/m² due to its high butadiene content and the yellowness index is a low 16.
     BASF says that in tests the typical problems that occur when using an unsuitable grade - the formation of striped sheet surfaces or of flow structures in coextrusion, the occurrence of residues in degassing or high power consumption at the upper screw speeds - were not observed or were considerably reduced with the new material. The surface quality of monoextruded sheets was also greatly improved, and after coextrusion with PMMA no flow structures could be identified. Finally, the new ABS grade performs well in conjunction with TPU: the delamination occasionally occurring in coextrusion with other ABS materials was not observed. Stand 5 B21.

Polyols from plants at DuPont...: DuPont was one of the early proponents of bio-sourced materials with its research into 1,3 propanediol (PDO), the monomer used to produce the polyester poly(trimethylene terephthalate), or PTT.
     Now it has moved into bio-sourced polyols with Cerenol, a family of polyols with wide ranging applications in, initially, elastomers, personal care and functional fluids.
     The liquid polyol is made using Bio-PDO - the feedstock for its Sorona PTT and also in development for its Hytrel polyester elastomer. Compared to existing alternatives such as polytetramethylene ether glycol (PTMEG), DuPont says Cerenol has a significantly lower environmental footprint as determined by an ISO 14000-compliant life cycle analysis, giving 40 per cent savings in non-renewable energy and 42 per cent reduction in greenhouse gas emissions. Stand 6 D27

...and from Elastogran: Elastogran has developed a new polyol from a renewable raw material - castor oil - which it says is a drop-in for conventional polyols. The new Lupranol Balance 50 can be used in flexible foams: until now castor oil has only been used in in rigid polyurethanes. Typical applications would be in furniture and mattresses - which account for more than 80 per cent of the worldwide 3·8 million tonnes of flexible foams - and it is in use in Austria for bedding, with applications just starting in Germany.
     The new product consists of 31 per cent castor oil and a finished mattress contains up to 24 per cent by weight of castor oil.
     The chemistry behind Lupranol Balance 50 hinges on new catalyst technology. Polyetherols are made by the polyaddition of propylene and/or ethylene oxide to higher-functional alcohols such as glycerine. Normally, this polyaddition is carried out under alkaline conditions with potassium hydroxide serving as the catalyst. After polymerisation the polyol has to be neutralized in another step by adding acid.
     Elastogran has developed a double-metal cyanide catalyst which is far more reactive than potassium hydroxide. Just the slightest traces of this catalyst are sufficient to trigger the reaction between castor oil and ethylene or propylene oxide. A further advantage of the new catalyst is its neutrality, which prevents saponification of the oil, and avoids the formation of odorous by-products. Odour problems are what have prevented the development of polyols from renewable raw materials using alkaline catalysts, says Elastogran. Stand 5 B21.

Spray or cast skin: the choice is yours: New materials for soft touch interior automotive components will be introduced by Elastogran on stand 5 B21. The new Elastoskin S is suitable for sprayed PU soft-touch surfaces and is related to the existing Elastoskin I materials which are already used in volume production cast skin technology. Elastogran S will be used for the first time in Europe in large-scale production by a premium car manufacturer in 2009.
     The process, also referred to as IMC-PU sprayed skin (IMC: in-mould coating), exhibits a steep reaction profile and good adhesion to the paint, which has to be put into the mould before the spray application of the polyurethane. Adhesion to the semi-rigid foam after the foam backing process is also good since both materials belong to the same family.
     Although aromatic polyurethanes are not lightfast, and therefore have to be painted, they are still seen as lower in cost than aliphatic systems beause of their relatively low painting costs which make a switch from expensive aliphatic to aromatic PU systems economic.
     The finished component properties using sprayed or cast formed skins are very similar. Both can be multi-coloured and both can accept very small radii, enhancing styling freedom. In practice, says Elastogran, the cast Elastoskin I has the advantages of low waste in trimming and short demoulding times. However, the sprayed skin technology uses simpler and therefore cheaper moulds since spraying is done into an open mould while the cast-skin process needs a closed mould and hence two mould halves.
     Design freedom is a greater with the sprayed skin but the cast skin produces constant cross-sections over the entire component which simplifies the later foam-backing operation. There is also no overspray which can account for up to 20 per cent of the total weight of the skin.

Rubber companies stick together: With the emphasis at K on plastics processing, the few suppliers of rubber materials could be lost, so 11 of them have joined forces in 'Rubber Street'. This by-now-traditional showcase is organised by the German Rubber Industry Trade Association and one of Germany's main rubber publications, and hosted by Lanxess - 'the successors to the inventors of synthetic rubber from Leverkusen' adjacent to its stand in Hall 6. The exhibitors in Rubber Street are: Ahauser; GMT; Interep; KKT Frölich; Wilhelm Köpp Zellkautschuk; GW Kraiburg; Lord; Parker ITR; Rohm & Haas; Kraiburg TPE and RET REIFF Elastomer Technik.
     A newcomer this year is Tecno Compounds of Italy, a business unit of Parker ITR which makes rubber compounds for DIN 7863-compliant window and façade seals, cables, drive belts, waste-water gaskets and hydraulic hoses as well as compounds for the automotive industry.

No need to prime for co-extrusion: Self-adhesive solid silicones for extrusion will be introduced by Wacker (stand 6 A10). The new elastomers adhere to a wide variety of substrates at atmospheric pressure which the company says makes them ideal for coextruding with metals, plastics and other silicones.
     The patent pending adhesion technology forms a chemical bond quickly in the heating tunnel so productivity is on a par with standard extrudates. Preparation steps such as priming or flame treatment are unnecessary. This not only lowers energy consumption and manufacturing costs, but also reduces the solvent load.
     Also new from Wacker will be the self-lubricating Elastosil LR 38xx series available in a range of oil contents and Shore hardnesses. The new materials are easier to process than earlier grades, and besides being more resistant to injection moulding, they can also be moulded faster and demoulded more easily. New tear-resistant grades improve puncture resistance.
     For where the 38XX series' mechanical properties are still not enough, Wacker has the new self-lubricating platinum-catalyzed Elastosil R plus 4800 solid silicone which was designed for cable-bushing applications.

Improved heat resistance and flow in new PESUs from BASF: A new polyether sulphone to be shown by BASF is intended for automotive headlamp housings which are usually coloured black with just a small amount of colorant, which BASF says gives a better surface finish. But the black pigments do not easily allow heat transmission.
     This is a particular problem above the bulb. The options are to either raise the thermal conductivity with fillers - risking the surface finish - or to reduce the wall thickness, which can lead to filling and stiffness problems. The BASF answer is a new pigment system which absorbs visible light - so it looks black - but allows heat radiation to pass through. BASF says test results show that in a situation where a conventionally-pigmented PESU is heated with a halogen light bulb and reaches 190 degC, under the same conditions a PESU with the new HM (heat management) pigment only reaches 130 - 150 degC.
     The HM grade of Ultrason has been introduced alongside an even more radically-modified PESU. This has been formulated to improve flow by blending the PESU with another, unspecified, thermoplastic rather than lowering the molecular weight which can improve processing but at the expense of impact strength and stress crack performance. Flow is improved 10 - 20 per cent compared with pure PESU while maintaining temperature resistance and impact strength. Stand 5 B21.

New damping technology and additional blow moulding grades from GLS: New vibration- and sound-damping thermoplastic elastomer alloys from GLS Corporation are said to be the first of their kind in providing true material damping by utilising unique chemistries for sound deadening across a frequency range from 10 to 20,000 Hz. The technology also provides a wide range of hardness (20 to 80 Shore A) and specific gravity (0·9 - 1·3). Target markets include tools, footwear, electronics, building materials, personal protection, and acoustic control applications.
     Also new from GLS are Versaflex TPEs for blow moulding. They are based on a new proprietary technology, and are available in transparent and translucent grades, ranging in Shore hardness from 35A to 40D. The materials are particularly flexible and resilient, retaining their shape after prolonged demanding use, says GLS. They are aimed at the medical and consumer products sectors.

Transparent TPE over-moulding compounds: Kraiburg TPE will be unveiling its next-generation transparent over-moulding compounds on stand 6 A49-1. These provide the tactile appeal of a soft-touch finish with a high degree of transparency that allows the base product to be clearly seen through the finish. This feature can be further enhanced with colour or by adding metallic or other special effects. These TPE compounds are based on hydrogenated styrene block copolymers, and, says Kraiburg, offer a previously unattainable level of adhesion to polycarbonate and ABS base materials.

Ultrasoft medical and water swell compounds from Vita: An ultrasoft zero Shore A rated TPE compound will be introduced by VTC TPE Group, the thermoplastic elastomer division of the Vita Compounding Group, on stand 8B D83. This latest addition to the company's Mediprene range has been developed for the medical device market including respiratory and wound care applications and is made at the group's Swedish site, VTC Elastoteknik.
     The new material is an SEBS formulated to avoid the irritation and discomfort which can be caused by traditional, more rigid materials. As Mediprene compounds are latex-free they avoid potential allergy risks. All Mediprene grades are based on materials which have passed ISO 10993-5 cytotoxicity tests and are compliant with USP Class VI. Vita says they show excellent adhesion when co-moulded or co-extruded to PE and PP.
     Also new from VTC will be a water-swellable SEBS which increases in volume when immersed in an aqueous solution with a pH from 7 to 12. When water contact is removed, the material returns to its original volume, a process which can be repeated an unlimited number of times. Two grades are available, achieving a swell of around 350 and 850 per cent after three weeks' immersion.
     The Vitaprene Water Swell product is still under development, but is in use on a small scale in water-stop applications in the construction industry where it is being used to seal concrete.

Polyester elastomer cuts costs in VT films: Two new grades of Arnitel TPE-E polyester elastomer from DSM are intended for use in vapour transmission films for roofing, textiles and plasters and for medical gowns and drapes. DSM says that compared to TPU coatings and films Arnitel has better film processing rheology, reducing waste - 50 per cent less than a competitor's TPE-E grades, according to DSM.
     Arnitel VT 3108 is for both textile and roofing applications. It is optimised for cast film and extrusion coating and E2-UV masterbatch for roofing UV protection. Arnitel VT 3104 for medical applications has a high melting point for sterilisation, and is also optimised for cast film applications.
     DSM says that the level of waterproofing offered by Arnitel monolithic membranes outperforms classic microporous systems like PTFE membranes or polyolefinic membranes in roofing as well as in textile applications. The monolithic film gives high water inlet pressures and acts as a viral and blood barrier in medical applications - and does not need treatment with toxic impregnation chemicals after washing. Stand 6 B11.

High performance for automotive cables: A new halogen-free flame retardant grade of DSM's Arnitel TPE-E has been tested in automotive cables exceeding all ISO 6722 class D requirements and showing very good performance in the LV112 tests. DSM says that Arnitel C has the best high heat ageing properties of all TPE-E with continuous use temperature of 3,000 hrs at 175 degC and is also hydrolysis resistant. In addition, the material halves the cost per length of cable compared to ETFE, has low smoke toxicity, a high degree of recyclability and no plasticisers. Stand 6 B11.

More copolyesters from Eastman: A new generation of copolyesters with higher heat resistance will be introduced by Eastman Chemical on stand 5 H04.
     The company will also introduce to Europe its Eastar EB062 copolyester for custom container applications, which Eastman says is the only extrusion blow-moulded material to offer a combination of water-like clarity, toughness and melt strength. It is particularly suited to clear liquid containers with an integrated handle, and will be demonstrated in production on the Bekum stand, 14 C04.

Faster-cycling injection moulding PET: The new TechnoPet product family from TechnoCompound is intended to bring the company into the market for injection-mouldable PET compounds, a market said to be growing at a rate of around 6 per cent per year. These compounds have a fast rate of crystallisation, which shortens cycle times. Stand 6 B44.

FR PBT is well-specified for electrical use: Arnite XG is a new PBT from DSM based on a green flame retardant system which meets new technical and environmental requirements for lamp sockets, e-motors and connectors.
     DSM says that it is the only PBT that meets both GWEPT and GWIT requirements according to electrical standard IEC 60335-1 for appliances and lighting. It uses a low density flame retardant system which lowers cost compared to conventional halogen-free systems. Stand 6 B11.

GF PBT 'first for Class A truck exterior parts': What is described as 'the first serial adoption of a glass-fibre reinforced thermoplastic for the class-A exterior body-panels of a truck' will be shown by DuPont (stand 6 D27).
     The parts, in Crastin PBT, cut unit costs by 45 per cent compared with standard components and reduced weight by 32 per cent - 2·4 kg per vehicle. Truck maker MAN tested a number of glass fibre reinforced thermoplastics over a five year period, including those which are typically used for the exterior trim such as PA6, PBT/PET, PC/ASA, PBT/ASA and PBT/ABS. The combination of heat resistance, dimensional stability, surface-finish and processing performance swung the choice in favour of Crastin. The material's high flow means that the large body panels - in some cases up to 1·35 metres long - can be produced in a single operation, and with short cycle times, on standard injection-moulding machinery.

PTT adds 'green content' while PCT puts more spark in your pencil: The bio-sourced PTT (polytrimethylene terephthalate) Sorona from DuPont is being researched for connectors, lamp sockets and actuator housings, and is to be used for a component in a car early next year, enabling the car manufacturer to claim 'green content'.
     Another thermoplastic polyester from DuPont which is slightly off the beaten track of PBT and PET is its Thermx PCT - polycyclohexylenedimethylene terephthalate. A new grade - TE4004 - combines heat resistance and high flow for use in pencil-coil vehicle ignition systems. The recent trend in automotive ignition systems is to reduce the diameter of pencil coils to less than 22 mm (from 26 mm in 1997) and for a higher energy to be delivered by each of the pencil coils (from currently 35 - 45 mJ up to 65 - 70 mJ in the future).
     Materials for this application need to have high flow to fill thin walls, higher dielectric strength at elevated temperatures to deliver higher power and extremely good adhesion to epoxy to eliminate the potential for electrical failures due to thermomechanical stress. DuPont says Thermx TE4004 meets these criteria, but it will also be introducing another grade by the end of the year which offers enhanced flow characteristics without compromising other critical properties. Stand 6 D27.

Nano-additives improve flow for PBT: The use of new nano-additives has enabled more grades to be added to BASF's Ultradur High Speed flow-enhanced PBT series, giving high-flow options for all its PBT grades. Depending on the glass fibre content, Ultradur High Speed flows at least twice as far as comparable standard grades to bring the acknowledged advantages of high flow - such as reduced cooling and therefore cycle time, the ability to fill fine filigree moulds, lower processing energy consumption, lower injection pressure, and the ability to fill more cavities per shot.
     Among the new grades boosting the Ultradur High Speed series to 15 products, there are new thermally conductive and flame-retardant materials. The thermally conductive Ultradur B4300 M12 High Speed has a thermal conductivity of 1 W/mK, and is suitable for replacing metal in housing covers, such as for control devices, and in the sockets of light fixtures.
     All of the flame-retardant Ultradur products made by BASF are now also available as High Speed variants. There are halogenated and halogen-free options. One grade, Ultradur B4300 G3 High Speed, is BASF's first product reinforced with 15 per cent glass fibre with high flow that is suitable for the manufacture of plugs, multi-point connectors or housing parts.
     The nano-additives used to improve flow also improve pigment dispersion, so intense colours can be achieved with less pigment. They also improve the adhesion of PBT to metals by almost 50 per cent and to TPU soft components to almost twice the previous level. Stand 5 B21.

Process-focused TPUs from Bayer: New grades of TPU formulated for rotational sintering, hose extrusion and blow moulding will be introduced by Bayer MaterialScience on stand 6 A75.
     Rotational sintering is used widely for making decorative skins for car dashboards and door panels. Desmopan DP 3790AP is an aromatic TPU which is plasticiser- and halogen-free and remains flexible at low temperatures so doesn't become brittle in the cold, which is crucial to the safe functioning of the airbag.
     In addition to its use in conventional rotational sintering, the new material has been adopted by Intier Automotive Interiors for a new in-mould coating slush process which makes it possible to manufacture ready-coated decorative skins in a single step. The process involves coating and heating the cavity of the moulded skin tool and then connecting it to a box with the TPU powder. As this unit is rotated, some of the powder gels on the coating to form a skin. After cooling and removal of the powder box, the coated skin can be removed.
     Compared with polyurethane spray technology and conventional slush moulding, the process has the advantage that multi-coloured decorative skins are easier and more cost-effective to produce by simply laminating them in the tool. There is also no need for a separate coating unit. The Desmopan DP 3790AP not only adheres well to the decorative coating but also to the polyurethane foam used to backfill the skin.
     The new hose material is Desmopan DP 1350 D which was formulated specifically for the production of hoses, solidifying very quickly to produce hoses with high dimensional stability. The ester-based TPU is transparent, or can easily be coloured. It has a hardness of 50 Shore D and withstands bursting pressures of more than 25 bar, depending on the diameter of the hose. The material is also wear resistant and resistant to oils and a broad range of other chemicals. Applications include fuel and lubricant hoses, pressure control systems and pipelines for transporting chemicals.
     There are also ether-based DP 1350 D grades of various hardnesses for applications needing resistance to hydrolysis and microbes, and low-temperature flexibility.
     The third new process-specific TPUs from Bayer are intended for blow moulded bellows. Bayer says TPU currently on the market for this process have the disadvantage that, after a machine has been stopped, restarting production is very involved, time-consuming and cost-intensive. The machine needs to be washed, purged and then gradually restarted. In some cases, acceptable component quality is achieved only after several hours.
     With Desmopan DP 1485A and DP 1490A, based on aromatic polyesters, the injection blow moulding machine can stand for long periods after the screw has been run empty and production can be restarted without any problems, says Bayer.

TPU gives different touch sensations on the same component: Alongside its new spray-skin aromatic polyurethanes Elastogran will be introducing an aliphatic Elastollan HPM-TPU thermoplastic polyurethane (HPM: hard-phase modified) which can produce a combination of colour fastness and softness which Elastogran says is new for the TPUs. Low Shore hardnesses (<80A) could only previously be achieved with the use of additives, but the hard-phase modification in the molecular structure of the TPUs makes it possible to dispense completely with plasticisers without adversely affecting processing properties. The aliphatic base of the material ensures the colour fastness of the surfaces of components and costly off-line painting is no longer needed, so reducing component costs.
     Processing is by two-component injection moulding in which a thermoplastic support material has Elastollan HPM-TPU injected over it to produce the soft-touch component. The high flow of the TPU melt allows thin wall thicknesses and gives accurate reproduction of detail. One of the first volume applications in the interior of a car is the door-closing handle in the BMW 3 Coupe. This has a leather grain effect on the upper side and a velvety fine structure on the inside, giving different touch sensations. BMW has cleared Elastollan HPM-TPU for almost its entire range of models. Stand 5 B21.

Wood-reinforced injection moulding materials: Kareline (stand 7 B20-3) will present what it claims to be the widest range of bio-composites on the market. These materials are based on PP, PE, ABS, PS, POM and PLA thermoplastics with a natural fibre content ranging from 20 to 55 per cent by weight. The fibres are wood-based cellulose fibres manufactured from environmentally certified raw material. Kareline composite granulates can be injection moulded with conventional machines and moulds.

PVC/wood composite in foamed grades as well: A wood-composite PVC compound has been added to the Doeflex-Vitapol range. Doeflex-Vitapol is the PVC division of the Vita Compounding Group, showing on stand 8B D83.
     The new Timbercel is the result of a two year research project to combine PVC with wood sourced from sustainable forests. The composite reflects the natural appearance of wood, while retaining the properties of PVC, including flame retardancy, reduced water absorption and durability.
     It is supplied in granule or powder form, usually in a natural base colour but it is also available in other colours. Timbercel is available in both standard, foamed extrusion and moulding grades and has been formulated to run on conventional single and twin-screw PVC extruders. The PVC component is calcium/zinc stabilised.
     Like wood, profiles made from Timbercel can be fixed using nails, screws or glue and can also be painted, stained or varnished. The material has applications in building and construction including door frames, skirting, cornicing, furniture trim or anywhere where a satin, wood-like finish is required. The high wood content means that profiles used for exterior applications will exhibit the same silvering effect displayed by natural wood.

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