Solvay at K 2013: Launched Bio-based Kalix® HPPA Series for Smart Mobile Devices

Solvay Specialty Polymers has announced a major extension of its Kalix® high-performance polyamide (HPPA) product line, launching a new portfolio of bio-based high-performance polyamides offered for use in smart mobile devices such as smart phones, tablets, laptops, and other smart mobile electronics. The introduction includes the Kalix® HPPA 3000 series, the first bio-based amorphous polyphthalamides (PPAs), and the Kalix® 2000 series, a family of bio-sourced semi-crystalline polyamide grades that provide outstanding impact performance. Solvay unveiled the new materials at K 2013.

The Kalix® 3000 series breaks new ground as the industry's first bio-based amorphous PPA which delivers exceptional processability. The two new grades — Kalix® 3850 and Kalix® 3950 — provide less warp, reduced shrinkage, and low to no flash. This improved processability results in tighter dimensional tolerances and more cost-effective manufacturing due to fewer secondary operations such as deflashing. The two compounded grades consist of 16% renewable content according to the ASTM D6866 test method for determining bio-based carbon content. One of the key raw materials for the Kalix® 3000 series is a renewably sourced material supplied by sister company Solvay Novecare, a specialty supplier of surfactants, polymers, amines, solvents, guar, and phosphorus derivatives.

"The launch of the industry's first bio-based amorphous PPA is a major breakthrough because it extends the performance profile of bio-basedpolyamides," said Tom Wood, senior vice president of crystalline products for Solvay Specialty Polymers. "Our new series is a renewably sourced option that not only meets sustainability needs but also delivers world-class performance and processability."

Under the development work, Solvay utilized the specialized resources of its R&D teams in India, Belgium, China, and the U.S. while also taking advantage of new Solvay raw materials captively available since the Rhodia acquisition in 2012, according to Wood.

Meanwhile, the new Kalix® 2000 series of semi-crystalline materials, based on PA 6, 10, consists of Kalix® 2855 and Kalix® 2955. They provide strong mechanical properties, high impact, exceptional surface finish, and low moisture absorption. These two compounded grades consist of 27% renewable content according to ASTM D6866.

Both the Kalix® 2000 and 3000 series compounds offer manufacturers more sustainable options while providing the exceptional physical attributes and processing capabilities that are required in demanding structural applications such as injection molded chassis, housings, and covers, according to Sebastien Petillon, global market manager electronics for Solvay Specialty Polymers. "Our expanded portfolio of bio-based polyamides is driven by environmentally-conscious manufacturers who are continually striving for more sustainable alternatives," said Petillon. "These manufacturers also seek tailored materials to meet targeted application needs, taking advantage of Solvay Specialty Polymers' wide portfolio."

Both the 2000 and 3000 series contain monomers that come from the sebacic acid chain which is derived from non-food competing and GMO-free castor oil. Overall, in addition to their renewable content, the grades introduced today (between 50-55% glass fibers loading) provide greater strength and stiffness than most competing glass-reinforced materials including high-performance polyamides and lower-performing engineering plastics such as polycarbonate.

The introduction of the Kalix® 2000 and 3000 series represents a major expansion of Solvay's long-time offering of Ixef® polyarylamide (PARA) and Kalix® HPPA grades which have served the mobile electronics market the past 15 years. The new bio-based grades are expected to penetrate a greater share of smart mobile device applications due to their easier processability compared to Ixef® PARA, according to Petillon. Ixef® will continue to be used in niche structural applications where the ultimate combination of strength, stiffness, and surface finish are key requirements. The Kalix® 9000 series, currently one of the leading structural high-performance polyamide-based materials for the smart device industry since its debut in 2009, will also continue to be offered and improved for applications that don't require the bio-based composition and exceptional processing of the Kalix® 2000 and 3000 series.

Both the Kalix® 2000 and 3000 series offer an excellent surface finish. They can be matched to a wide range of colors including the bright and light colors of the smart device industry and can be painted using existing coatings commonly used for portable electronic devices. The new materials are available globally and Solvay intends to primarily manufacture in the region of sale, according to Petillon. The company expects most production to be conducted at its Changshu, China, facility since Asia is the primary manufacturing center for smart mobile devices.

Both Kalix® 2955 and 3950 have been qualified and specified by OEMs for use in smart mobile devices. Solvay is already developing next-generation bio-based products with enhanced flow, better mechanical performance, and higher renewable content for constantly redesigned and innovative smart mobile devices.

Source: Solvay

Putnam Plastics Reports Increased Interest in Integrated Catheter Components Made by Medical Device Co.

Putnam Plastics Corporation, among the leaders in advanced extrusion for minimally invasive medical devices, reports increased interest in integrated catheter components made by medical device companies. These components leverage continuous manufacturing to combine sub-component processes, eliminate assembly steps and reduce manual labor, thus allowing device companies to reduce overall costs.

"Industry reports in 2009 suggested double digit compound annual growth rates for the interventional cardiology devices. By 2012 some industry reports adjusted this growth rate down into the single digits," said Jim Dandeneau, Putnam Plastics Chief Executive Officer. "However, this more likely reflects competitiveness and cost reduction pressures on devices rather than decreased innovation." Over a ten year period beginning in 2003 there was a steady decline in these patents issued until 2008, where it bottomed out at 168. Since then, there has been a strong increase in catheter patents issued reaching 454 in 2012, representing a 170% increase over the four year period.

"At Putnam Plastics, we have experienced double digit demand in complex catheter shafts since 2008," continued Dandeneau. "Leading device companies are increasingly looking for innovative manufacturing solutions to produce better catheter shafts while reducing total production costs and time to market."

Putnam Plastics' growth of ‘continuous manufacturing technologies' for complex catheter shafts continues to exceed market growth rates. Continuous manufacturing integrates multiple extrusion related processes to produce tubing with different properties on the inside and outside surfaces, and variable stiffness from the proximal to distal ends. These technologies replace costly manual assembly of discrete components for angioplasty, angiography, guiding and other interventional catheters.

Source: Putnam Plastics

BASF Introduces Partly Bio-based Ultramid® S Balance PA 6.10 for Monofilament Applications

BASF is now globally offering Ultramid® S Balance in a version for monofilament applications. The high performance polyamide 6.10, partly based on renewable resources, is available in various viscosities. The bio-based sebacic acid, which is used to produce Ultramid® S Balance, originates from the castor oil plant. In compounded and glass-fiber reinforced versions, BASF has already introduced the material in different commercial applications, e.g. in a design lamp or automotive quick connectors.

"The demand for bio-based raw materials is increasing worldwide", says Hermann Althoff, Senior Vice President of the Global Polyamide and Intermediates Business Unit. “The introduction of Ultramid® S Balance for monofilament applications is another contribution of BASF to support this trend."

Polyamide 6.10 offers unique mechanical properties such as higher dimensional stability and softness compared to polyamide 6 orpolyamide 6.6. Many of the benefits arise from less moisture absorption and higher carbon content. Due to its specific properties, Ultramid® S Balance can be used in various monofilament applications, e.g. filters for paper machine clothing or industrial brushes, as well as textile fibers and different engineering plastic applications.

High performance Ultramid® products for the engineering plastics, film, fiber and monofilament industry:

With more than 60 years of experience, BASF is one of the leading suppliers of high quality polyamide and polyamide intermediates for the engineering plastics, film, fiber and monofilament industry. The line of products include Ultramid® B (polyamide 6), Ultramid® C (polyamide 6/6.6 copolymer) and Ultramid® A (polyamide 6.6). The product offerings are supplemented by technical services for our customers.

BASF operates Ultramid® polymerization plants in Ludwigshafen, Germany; Antwerp, Belgium; Freeport, Texas and São Paulo, Brazil. The production of polyamide for film, textile and carpet fiber as well as for engineering plastics applications is integrated into BASF's global Verbund structure with polyamide intermediates (i.e. adipic acid, anolon, caprolactam), chemical raw materials (i.e. ammonia, cyclohexane, sulfuric acid), energy, by-product recovery, logistics and other services.

Source: BASF

My Article has got published in couple of magazines and websites.Biocomposites in Automotive Applications

http://www.omnexus.com/resources/articles/article.aspx?id=33580

ATK Research on NASA advanced graphite composite booster

ATK has achieved a milestone in its NASA Research Announcement (NRA) Advanced Booster risk-reduction program for the Space Launch System (SLS) by successfully completing filament winding of a pathfinder Advanced Booster composite case.

Ultimately, this Advanced Booster NRA effort will enable NASA and ATK to optimize a case design that will be stronger, yet more affordable than traditional steel cases. In turn, this will provide increased payload performance due to reduced weight inherent in composite materials.

The pathfinder article is a 92-inch-diameter, 27-foot-long composite case. In order to achieve both the affordability and performance required of an Advanced Booster, ATK overcame challenges during case winding operations. ATK leveraged 45 years of composite case winding experience, its experienced workforce, and a modern fiber-placement tooling system to achieve success on its first attempt.


ATK has manufactured more than 1,600 commercial solid rocket motors to date, many of which use composite cases and high-energy propellants, for a wide variety of launch vehicles including Delta II and Delta IV, as well as Orbital's Pegasus, Taurus, Minotaur and Antares space launch vehicles. ATK first entered the commercial launch vehicle market in 1987 when it developed its first commercial composite motor, the GEM-40, which is still being used on the Delta II launch vehicle. ATK's commercial product line includes GEM, CASTOR, and Orion solid rocket motors.

The next step in the Advanced Booster NRA program is to continue development of high performance and low-cost propellants that meet the lofty payload and affordability goals of NASA's Space Launch System (SLS). These propellants, many of which are also widely used in ATK commercial solid rocket motors, combined with the achievements made in composite case technology, will provide NASA several options for performance increases for the next generation Advanced Booster.

On the existing SLS boosters ATK's Value Stream Mapping (VSM) process, which is a company-wide business practice, allowed the employees to identify inefficient processes, procedures and requirements to help reach the target condition. Through this process, ATK identified more than 400 changes and improvements, which NASA approved. These changes have reduced assembly time by approximately 46 percent, saving millions of dollars in projected costs for the SLS system.

Source:ATK

BIOTEC at K 2013: Unveiled Biobased BIOPLAST 500 Resin for Film Applications

BIOTEC presented a real breakthrough in biodegradable bioplastic resins fit for film applications during the K 2013.

With a biobased carbon share of more than 50% and intended suitable for film applications, the new BIOPLAST 500 is a real forerunner on the bioplastics market. Biodegradable bags are ready to meet the challenges of European waste disposal regulations that now require more than 40% biobased contents.

The "OK compost HOME" certification also allows bags made of BIOPLAST to comply with waste disposal policies that strongly put the stress on home composting.

Enhanced technical properties

"The challenges to tackle were significant. Process ability and mechanical properties were key factors. And we are extremely proud to announce that BIOPLAST 500 can be extruded down to 18 microns films" says Harald Schmidt CEO of BIOTEC. "Our research team has been working for 3 years in order to deliver such performances, BIOPLAST 500 shows BIOTEC's ability to develop innovative products that can meet market and regulation needs" says Peter Brunk Managing Director of BIOTEC.

Technical data

BIOPLAST 500 is designed for blown film extrusion for the following applications:

• short life packaging
• multi-use bags (e.g. carrier bags, loop-handle bags),
• single-use bags ( biowaste bags, bin liners, etc.)
• agricultural film.

Films made of BIOPLAST 500:

• consist mainly of renewable raw materials
• are home compostable ("OK compost Home" certificate awarded by Vinçotte)
• are biodegradable according to EN 13432
• are recyclable
• are printable by flexographic and offset printing without pretreatment
• have a soft touch
• can be colored with masterbatches
• are sealable (hot, RF, ultra sonic)

Source: BIOTEC GmbH & Co. KG

Toray Industries agrees to acquire Zoltek Companies

The global demand for PAN-based carbon fibers is expected to expand at an annual growth rate of exceeding 15% as an advanced material which contributes not only to energy saving through weight reduction but also to spread of renewable energy as alternative of fuel (oil and coal) energy. On the one hand, regular tow carbon fiber is widely being accepted in the field of high performance / high quality application such as aerospace, but on the other hand, large tow carbon fiber is anticipated to expand its applications, based on its reasonable balance between cost and performance, to wind energy-related which shows rapid demand growth in recent years, and automobile structural parts in future. It is foreseen that demands for regular tow carbon fiber and large tow fiber will grow separately, reflecting each characteristic.

Zoltek entered into large tow carbon fiber business in 1988, and acquired textile acrylic fiber plants in Hungary and Mexico in 1996 and 2007 respectively, and has been promoting development of large tow carbon fiber application and demand. Under its unique marketing strategy distinguished from that of regular tow manufacturers, Zoltek has recently realized outstanding growth in its business along with the demand increase in wind energy-related application, pursuing its ultimate cost competitiveness. 

Toray has showed its presence in the field of advanced applications such as aerospace represented by Boeing 787 and natural gas pressure vessel by concentrating its business resource to high performance / high quality regular tow carbon fiber. Meanwhile, not having large tow carbon fiber as its product line up, Toray has been considering how to address promising growth in commodity industrial field such as wind energy-related application and automobile structural parts application. By acquiring Zoltek, Toray has obtained opportunity for further growth, expanding its business in totally different field from regular tow carbon fiber.

As one of its strategically expanding businesses, Toray has promoted business expansion of carbon fiber composite　materials business by proactively allocating business resources. Through entering into large tow carbon fiber business, Toray aims at further expanding its business and providing solution to global issues including environmental, resource-related and energy issues with this advanced material.

Source:Toray