NPE Materials to take a leading role at NPE

Resin suppliers will flaunt their new and improved wares aimed at better property mixes, lower costs, and improved molding productivity.

What have material suppliers been doing while the industries they serve have been weathering the economic storm? If you guessed research and development, you can go to the head of the class. In addition to entrenching themselves globally, most of the majors have turned to their sizable technical resources in an effort to create materials that meet specific needs at a price point that makes sense.

At NPE, attendees will be able to take a look at their efforts firsthand. For the time being, however, IMM has compiled a summary of what to expect from several of these suppliers. So let’s raise the curtain on the materials that may become the stars of tomorrow.

Bullish on the Future
At GE Plastics, the focus is on new product introductions and the R&D needed to make them happen. According to John Krenicki, who took over the position of president and CEO in January, the company is forging ahead with 1500 application engineers in the field to work with customers early in the design process. “We’re bullish on the future of our business, and we’re investing now to drive development of both applications and industries.”

Parallel to this effort is the introduction of more new products—based on both new molecules and blends—than at any other time in the company’s history. Of particular note are the Extreme resins, new versions of existing products that break outside the bounds of former property limitations.

For example, Lexan EXL polycarbonate promises greater toughness while maintaining clarity, a former trade-off now vanquished. GE added silicone into the PC molecular structure in a copolymerization process. This boosts impact resistance, processability and release properties, and UV weatherability. Also available in opaque versions, the resin’s added low-temperature impact strength and cold-temperature ductility to -40C allow it to withstand prolonged outdoor exposure. Target applications include eyewear, water bottles, medical devices, building and construction products, and lighting.

If you’ve seen the GE advertisement on prime time, you’re also aware of Lexan SLX, formerly called Sollx. The technology promises to replace paint and the $400 million paint line required for automobile exteriors. As previously reported in IMM, SLX meets requirements for high gloss and gloss retention, weatherability (seven to 10 years), and scratch and chemical resistance. The system works much like any inmold decorating operation. SLX film (a multilayer product with color and metallic effects located on separate layers for depth) is thermoformed to the shape of the intended part, trimmed, and then inserted into the mold and backmolded with resin. According to GE, compatibility with various resins can be tailored into the multilayer film.

To give birth to a new industry, the company is moving forward on development of plasma-coated polycarbonate glazing for automotive in conjunction with partner Exatec. Replacing glass in backlights, fixed windows, and sliding windows with PC takes 40 percent of the weight out while allowing greater design freedom via an injection moldable window.

Another offering involves a patented technology used to color polycarbonate resin with fluorescent dyes to add light piping to the edges of CDs and DVDs. The trend toward product differentiation among both content providers such as video game manufacturers and optical media replicators spurred the Edge Glow development.

During a recent press conference at GE Plastics headquarters in Pittsfield, MA, global marketing GM Greg Adams presented a series of megatrend predictions about several of the markets served by the IM industry. “A continuing focus on aesthetic differentiation in business equipment is being driven by increasing consumer awareness,” he explained, “so special effects and colorants will continue to play a strong role here.”

Compound Interest
With specialty compounds on the rise in many market sectors, LNP Engineering Plastics (now a GE Plastics company) is riding the trend with a number of new material launches. First, there are Lubriloy Z and Lubriloy Z ECO FR resins, two internally lubricated alloys based on Noryl PPO resin technology. Benefits come in the form of improved wear performance, low specific gravity, a wide range of potential use temperatures, and improved impact performance over traditional PTFE lubricated materials.

Long-glass-fiber-reinforced Verton composites that combine structural properties, good aesthetics, and colorability will also be introduced.

ReadyServe, a new line of made-to-inventory products based on top-selling compounds, is touted as a means for molders to reduce inventory costs as well as to reduce the time required for developmental programs. These materials are guaranteed to ship within days at no premium to customers.

Halogen-free, red phosphorous-free Starflam flame-retardant PA 6 and PA 66 compounds are newly improved, and can be formulated to comply with tough environmental standards. Other features and benefits include a high relative thermal index and comparative tracking index, excellent glowwire test properties, faster cycle times with no plateout, laser markability, colorability, and a wide range of mechanical properties. These materials are ideal for microcircuit breakers, connectors, contactors, and a host of other electrical and electronic applications.

Casting Call
DuPont Engineering Polymers has turned its attention to design, processing, and material solutions that cut costs, reduce weight, and enhance product performance or appearance. “Especially now, our customers are pressured to get it right the first time, on time, and under budget,” says Jim Weigand, VP of sales and development. “Our challenge is to stimulate new ideas, deliver innovative solutions, create new materials, and to provide technical support to help our customers bring their products to market quickly, cost-effectively, and in a way consumers desire.”

To these ends, DuPont will introduce new functional, aesthetic materials at the show: