New Products

HIGH-PERFORMANCE SHORT-FIBER PP RIVALS LONG-FIBER GRADES

Borealis has developed a family of Xmod polypropylene compounds that have the potential to replace long-glass-fiber grades in automotive applications. The grades, which contain fibers slightly longer than those in standard reinforced compounds, run in conventional injection machines.

Compounds made via pultrusion need an ultra-high-flow pp (up to 150 g/10 min at 23°C and 2.16 MPa) for fiber wet-out, which requires low molecular weight. The polymer used in the Xmod grades has a much lower melt flow index and thus higher mechanical properties.

Günther Aumayr, market development leader at Borealis’ engineering applications unit in Linz, Austria, did not disclose the polymer’s mfi, but the compound’s mfi is 2 g/10 min. A long-fiber pp compound with similar flow would need a polymer with a 15 mfi, he claims.

Granules have fibers around 1 mm, compared with 0.7 to 0.75 mm in regular short-fiber grades and 10 to 25 mm in long-fiber grades. He says they are more cost-effective than pultruded long-fiber pp grades. Easier and better coupling of the fiber and matrix yields similar properties. Xmod compounds have lower emissions, lower fogging, and lower odor values than long-fiber pp.

Xmod G30, with 30% glass, has much higher tensile and impact properties than a 30% short-fiber grade up to 140°C. Tensile strength is 115 to 120 MPa, and total penetration energy is 10 J. Weldline strength in short-fiber grades (including Xmod) is over twice that of long-fiber pp.

The grade is already used for a pedal carrier. Now, Borealis is launching a 35%-reinforced grade for vibration-welded or hot-plate-welded air-intake manifolds for small engines (1.6 L). There could be a commercial application by year end.

There is a 20%-reinforced grade for instrument-panel carriers and technical front ends. Aumayr says front-end carriers could be made more cost-effectively with Xmod than lf-pp. Further potential applications include fan supports and shrouds, drive-belt covers, blower wheel covers, bases for air filters, battery supports, engine covers, and cooling-system parts. Borealis A/S, Lyngby Hovedgade 96, DK-2800 Lyngby, Denmark www.borealisgroup.com

MOLDFLOW RELEASES LATEST SIMULATION SOFTWARE

Version 4.1 of Moldflow Plastics Insight (MPI), coming only a few months after version 4.0, is said to contain hundreds of user-driven enhancements. Version 4.0 already included significant advancements in three-dimensional simulation, as well as a new application programming interface that allows users to automate a variety of common tasks, customize their user interface, implement standardized corporate protocols and best practices, and interface with a variety of third-party software. There were also enhanced modeling and meshing tools, as well as new “material intelligence tools” that allow users to quickly identify the material most suitable for their design.

MPI 4.1 has a further improved Flow3D option that includes the prediction of fiber orientation and the resultant mechanical properties and part warpage. Other new features include the capability to simulate Synventive Molding Solutions’ Dynamic Feed system, which provides pressure-related control of individual tips in hot-runner systems, and Trexel’s MuCell process for microcellular foamed parts. Moldflow Corp., 430 Boston Post Rd., Wayland, MA 01778 www.moldflow.com

SOFTWARE ENSURES MEDICAL COMPLIANCE

American MSI’s Celltrack Pro is a production-logging system that enables medical-device makers to comply with the U.S. FDA’s stringent 21 CFR Part 11 regulations. It can reduce a company’s financial exposure by limiting recalls to production batches with specific fail criteria, and contribute to improved product quality through increased visibility of production and employee activities. It records, maintains, archives, retrieves, and transmits manufacturing data, including batch detail and downstream processing, and equipment settings and changes. The supplier says that unlike programs derived from resource planning or production-monitoring applications, Celltrack Pro was designed to answer 21 CFR Part 11 requirements, but it can be used for other markets. American MSI Corp., 5245 Maureen Lane, Moorpark, CA 93021 www.americanmsi.com

RESINS/COMPOUNDS BLOW-MOLDING HDPE HAS STACKING STRENGTH

Providing up to a 25% improvement in cycle times on standard blow molding equipment than its predecessor, GM8260 high-density polyethylene is intended for processing of 20-L containers. Its melt flow rate is 12 g/10 min. It allows better thickness control than the previous grade, GM8255. With a 30% higher flexural modulus, containers have higher top-load resistance. Ipiranga Petroquimica SA, BR386 Rod. Talai/Canoas km 419, III Pòlo Patroquimico, Lote 04, BR-Triunfo RS95853-000, Brazil www.ipq.com.br

FR-SEBS COMPOUNDS ARE HALOGEN-FREE

HQ/FR series of high-performance, flame-retardant sebs compounds have neutral color and are easy to color. They are rated UL94 V0 and can be used in electronic/electrical components, vehicle, ship and aircraft interiors, and injection molded construction applications such as cable distributors and switchboxes. Three grades have Shore A hardnesses from 40 to 75. Kraiburg TPE GmbH, Teplitzer Str., D-84478 Waldkraiburg, Germany www.kraiburg-tpe.com

‘HEAVY’ PP COMPOUND IS FOR PERFUME CAPS

A polypropylene compound with density twice that of the base polymer (2 g/cm3) is used for a perfume bottlecap developed by Seidel GmbH, Marburg, Germany. Supplier RTP says because the perfume is not a premium product, low-cost packaging was essential, although the cap material still needed to be impact-resistant, elastic enough to form a seal, and colorable. The grade, from RTP’s 100 Series, has as flex modulus of 3300 MPa and tensile elongation over 10%. Unnotched Izod impact strength is 25.2 J/m2. RTP Co., P.O. Box 5439, 580 E. Front St., Winona, MN 55987 www.rtpcompany.com

COMPOUNDS OFFER ALTERNATIVE TO FILLED EPR INSULATIONS

Dow Wire & Cable Compounds has developed a flexible insulation compound, HFDB-8202, combining the superior electrical properties and long-life performance of tr-xlpe and flexible performance similar to ethylene propylene rubber (epr). The product offers excellent electrical properties, low dissipation factor and lower density, and meets all cable requirements. An alternative to filled epr insulations, HFDB-8202 will run on existing equipment at full tr-xlpe line rates, which offers additional cost and manufacturing advantages. Better handling, good strippability performance with the HFDA-0792 insulation shield compound, and low-shrink characteristics are featured. Dow Chemical Co., 400 W. Sam Houston Pkwy. S., Houston, TX 77042 www.dow.com

ADDITIVES

GRADES FOR PVC IMPROVE PIPE PERFORMANCE

Crompton has introduced two vinyl additives for pvc pipe and window profiles. One product, the Mark 2910 self-lubricating stabilizer, eliminates the need to use paraffin wax as a lubricant. Mark 2910 imparts better gloss and and improves plateout. It is a pumpable liquid formulation that simplifies addition through metering. Crompton also introduced the Mark 2289 heat stabilizer for window profiles that is well-suited for environments with intense sun exposure. The stabilizer gives added protection against uv radiation and heat, and prevents yellowing and chalking. Crompton Corp., Customer Service, Vinyl Additives, 471 Highway 3142, Taft, LA 70057 www.cromptoncorp.com

ADHESIVES

‘SILENT’ ADHESIVE COATS PRINTABLE PLASTICS, FILMS

Transilwrap is offering a proprietary coating for printable plastics and films that acts as a silent adhesive. The coating gives plastics an ultra-low tack-adhesion capability without any apparent tack to the feel of the plastic. The plastic feels smooth to the touch and adheres to most smooth indoor surfaces, making it ideal for signage, point-of-purchase, and numerous graphic-communications or specialty applications. Transilwrap can be applied to most clear and colored plastics and films, including synthetics, polypropylene, and flexible vinyl. It is applied in roll form, prior to sheeting for offset and screen printing, or prior to slitting for flexographic and narrow web applications. Transilwrap Co. Inc., 9201 W. Belmont Ave., Franklin Park, IL 60131 www.transilwrap.com

FINISHING SCREENPRINTING INKS ARE FOR CONTAINERS

Ruco USA, a division of Comdec, has introduced Super High Opacity White and Black UV screenprinting inks for plastics containers. The Ruco 985-UV Series inks are suitable for pe, pp, pvc, pet, and other types of containers. The formulations provide superior opacity with none of the curing problems associated with dense opaque uv inks, according to the supplier. Free samples are available. Comdec Inc., 25 Hale St., Newburyport, MA 01950 www.rucousa.com

SEMIFINISHED GOODS SHEET COLORS OFFER EDGE EFFECTS FOR DISPLAYS

Atoglas unveiled five colors for the Plexiglas MC Edge-Color acrylic sheet series. The new sheet colors produce stunning edge effects for visual display and point-of-purchase applications. The five colors are 3215 Blue, 3216 Red, 3217 Red, 3218 Orange, and 3219 Orange. These are in addition to the Plexiglas MC 3030 Green edge color, designed to look like glass, and Plexiglas MC 3120 Blue edge color. Atoglas can also supply all these edge colors as Plexiglas Clear-Edge Frosted acrylic sheet, which consists of a middle clear acrylic layer sandwiched between thin top and bottom frosted surface layers. The acrylic sheet series comes in thicknesses of 0.118, 0.177, 0.236, and 0.345 in. Atofina Chemicals Inc., 2000 Market St., Philadelphia, PA 19103 www.atofinachemicals.com

INJECTION MOLDING HYBRID MACHINE HAS SPEED, HIGH ACCURACY

The em Series of hybrid machines from MHI Injection Molding Machinery, to be introduced at NPE, can yield reduced cycle times and increased accuracy. Combining both electric and hydraulic features, the em Series performs high-speed mold opening and closing at rates up to 1.3 times faster than MHI’s conventional models. Core actuation times are shorter due to an ample supply of hydraulic oil for the cores. Efficiency is further improved with the use of peakless pressure control, which eliminates high-pressure spikes at the end of fill during high-speed injection. The utilization of a UB screw and uniform low-temperature plasticizing performance results in reduced cooling time. MHI Injection Molding Machinery Inc., 1250 Greenbriar Dr., Suite B, Addison, IL 60101 www.mhiinj.com

ROTARY INDEXING TABLES FOR INSERT MOLDING

SAS Automation has introduced rotary indexing tables that allow precision transferring of inserts from the operator to the robotic end-of-arm tooling (eoat) for insert molding applications. Typically, the eoat will have docking pins so it can precisely dock on the rotary indexing tables to pick up the inserts and dock in the mold to place the inserts. The insert nests on the rotary indexing table are 3-D contours of the inserts to ensure proper orientation of the insert and to simplify proper placement of the inserts by the operator. Standard features include, among others, aluminum extruded framework with guarding, rotary indexer, safety light curtains, insert verification sensors, and rotary electrical connector. SAS Automation Ltd., 1200 S. Patton St., Xenia, OH 45385 www.sasgripper.com

HOT-HALVES, NOZZLE ARE ANNOUNCED

Heatlock expanded its hot-runner line with hot-halves, which are ideal for companies seeking to bolt on a system without the burden of manufacturing plates and integrating and wiring the system. Hot-halves are designed and manufactured to customer specifications or any international standard, and are supplied fully assembled, wired, and electrically-tested. The product comes standard with guide pins for alignment, clamp slots, lift holes, “A”-plate mounting holes, pry slots, and an electrical box with connectors to suit customer requirements. Heatlock also launched a new nozzle offering excellent heat distribution, allowing for easy start-ups and a wide processing window. With a flow channel of up to 6 mm, the nozzle is suitable for commodity resins and shot weights up to 350 g. It is available in a hot-tip configuration. Heatlock AB, Box 236, S532-23, Skara, Switzerland www.heatlock.com

‘MOLD WITH MEMORY’ REDUCES ADJUSTMENT TIME

A microprocessor-based device from Fast Heat that stores information for part processing functions as the brain of a hot-runner tool, eliminating trial-and-error in starting up the mold on a different injection press. The Mold IQ device stores mold-setup and hot-runner-system information that can be retrieved and displayed on Fast Heat’s Pulse hot-runner temperature controller. Fast Heat can install the microprocessor-based system in the mold box of an existing tool or provide a special box incorporating the system. Mold IQ solves problems that often arise when a molder shelves a tool between runs or ships it to another location. Information is stored in the molding machine and the hot-runner temperature controller. Fast Heat Inc., 776 Oaklawn Ave., Elmhurst, IL 60126 www.fastheat.com

AUXILIARIES

MIXER REMOVES MOISTURE FROM RESINS

Technical Machine Products has launched a proprietary vacuum mixer that removes moisture from resins while in the mixing cycle. Combining heat and the TMP vacuum system, the VMX mixer is ideal for use with both hygroscopic and non-hygroscopic resins. During the batch mixing cycle, the system removes moisture, entrapped air, and volatiles in the compounds. VMX mixers are available in 5-L lab models and 35-, 55-, 75-, 110-, and 200-L production models. Technical Machine Products, 5500 Walworth Ave., Cleveland, OH 44102 www.techmach.com

DESICCANT DRYERS ARE ENERGY-EFFICIENT

D Series desiccant dehumidifying drying systems offer simplified controls and easy maintenance, and are energy-efficient. They have been engineered for throughputs of 15 to 2500 lb/h and materials that require high temperatures, such as pet. The D Series dryers were designed to require minimal maintenance. The layout of the air-switching components reduces wear and provides a better seal between the twin-tower desiccant beds. Process Control Corp., 6875 Mimms Dr., Atlanta, GA 30340 www.process-control.com

GRAVIMETRIC BLENDERS ARE ACCURATE, RELIABLE

Foremost Machine Builders has added the CLWB-II series of continuous-loss blenders. The units are designed for low-cost, reliability, and accuracy. Incorporating a modular design, the series is available in three standard configurations with up to six components each. The 1000-lb/h model comes with weigh hoppers with 0.2- to 0.6-ft3 capacity. The 2500-lb/h model is available with weigh hoppers with 0.2- to 2-ft3 capacity. The 6000-lb/h model comes with weigh hoppers with 0.2- to 6-ft3 capacity. Foremost Machine Builders Inc., 23 Spielman Rd., Fairfield, NJ 07004 www.foremostmachine.com

HOPPER SIMPLIFIES MATERIAL FLOW

Conair’s Miniature Handy Hopper is a machine-mounted hopper that makes it easy for operators to verify material flow, and which can be quickly removed for material changes. The hopper consists of a clear-pc material cone, mounted on a sturdy frame that bolts to the molding machine or extruder. It accommodates about 0.3 ft3 of material delivered via an automatic loader or manually. A lid closes firmly on the top of the material cone and supports Conair’s new TLM Tube Loader or traditional DB8 and DL8 loaders. Conair, One Conair Dr., Pittsburgh, PA 15202 www.conairnet.com MP