Plastics Engineering February 2016

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Plastics in Electronics: Lighter & Brighter

• “Wraparound” Electronics • Polymers in Li-Ion Batteries • Molding Polycarbonates • The Word on Plastics Recycling • 3-D Printing & AM: New Options 00 Cover NEW_Layout 1 1/20/16 8:02 AM Page cvr2 01-03 contents NEW LAYOUT_editorial 1/20/16 8:02 AM Page 1

FROM SPE

SPE Member Benefits: What Can They Do For You?

received a call the other day from Teri Chouinard, new Paulson Training, Pennsylvania College of Technology, and membership chair for the SPE Automotive Division. She UL partnerships. told me that she would be attending an upcoming event “SPE is partnering even more now,” I said, “because we forI new members and wanted to review the SPE member realize this really benefits our members.” benefits. SPE and SPI are partnering to offer free membership for I logged into 4spe.org so I could use our homepage to all U.S. students. This allows students to package their SPE help navigate our conversation. We talked about the membership with an SPI electronic membership. This way, launch of THE CHAIN, SPE’s very own community forum, plastics students are networking with professionals before and how members were really finding it a benefit to they even hit the workforce, making for a smoother transi- exchange information on all technology aspects of our tion at the start of their careers. industry. They like being able to ask trusted sources for SPE has also partnered with Credible, an organization help on a technical problem or new innovations. that refinances student loans, which gives SPE members For people seeking more extensive support, they can and their families a simple, free service that can help them find a specialist in various plastics fields on SPE’s save money by comparing their options. Consultant Circle. Or if they’re simply looking for the Teri especially liked it when I told her about SPE selling newest detailed technology information, all SPE members HOP™ (Hands on Plastics™) science education kits now. can access SPE’s Online Technical Library, which contains We talked about how the kits contain everything needed to over 25,000 research and technical papers on materials, introduce K-8 students to the chemistry and characteristics processes, applications, etc., in polymer and plastics tech- of plastics in a classroom setting. I told her about the nology. I told her the library grows each year with over grandfather who purchased a kit because he volunteered 1,000+ new papers! to go into his grandchild’s class and teach. He called me the We spoke about how everyone in this day and age is so day after to tell me the class was a success. He said it was busy, and they have very little time to filter the right infor- quite easy to do because everything he needed, including mation about what’s going on in their specific part of our the experiment instructions and the teaching tips, were in industry. Several members had vocalized that they the kit. received way too many general newsletters and it would We also spoke a bit about the Industry-Academia be a real benefit to them to get only the current industry Collaboration committee, which connects the industry happenings related to their technical area. I told her that’s with the academic-research world for specific projects. how PLASTICS INSIGHT, SPE’s weekly fully customizable Teri’s daughter goes to one of the schools that received an online report of current plastics industry happenings, equipment donation from a manufacturer. She comment- came to be. You can customize the report, so you only ed on how important it is to her daughter’s and other stu- receive the information that’s relevant for you or your dents’ education for companies and universities to work company. together in other areas as well, like project collaboration We talked about SPE’s publications PLASTICS ENGINEER- and mentoring. ING magazine and SPE Technical Journals both having a At the end of the call, I told her that if anyone had any new look and feel. She commented that she noticed the questions or needed any more information on any of these magazine had more content as well. benefits, to contact SPE staff. They would be happy to help! Meanwhile, SPE members receive discounts on all of SPE’s conferences around the world—about 40 events per year—and on other education and training programs Sue Wojnicki through the SPE, such as weekly Webinars, and on our Manager, SPE MarComm

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■ ■ CONTENTS VOLUME 72 NUMBER 2 FEBRUARY 2016

FROM SPE SPE Member Benefits: What Can They Do For You? There’s a lot that can be said about all the new initiatives and 1 changes SPE’s HQ has introduced over the last year or so

RESIN MARKET FOCUS Polyamide Global Dynamics By IHS Chemical 4 A number of factors are creating opportunities for buyers of nylon resins

DESIGN NOTES 8 Additive Manufacturing Faces Challenges as it Grows By Robert Grace 8 But new technologies may open up options for designers for producing 3-D-printed parts better & faster

Plastics in Electronics COVER STORY Plastics Get Flexible for Electronics By Geoff Giordano 14 Integrated circuitry, “wraparound” electronics, and other conductive applications are being made possible using plastics

Plugging Into the Power of Polymers 22 By Jon Evans 14 Lithium-ion and other battery technologies will increasingly be getting more solid support and energy density from polymers

Putting a Charge into Conductive Plastics By Doug Bathauer 26 Demanding electronics require new conductive materials

Innovations in Hybrid Structural Instant Adhesive Technologies By Nicole Lavoie 28 Optimal properties are found in an adhesive that combines cyanoacrylate and epoxy chemistries

About the cover: This reference design uses integrated printed circuitry enabled by DuPont ME series in-mold electronic inks. (Image courtesy of TactoTek and cover designed 22 by SPE MarComm Team; see the original photo and our cover story on p. 14.)

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CONSULTANT’S CORNER Cold Runner Design: Sizing Up Your Runner System By David A. Hoffman 36 Designing runners for multi-cavity injection molds is no straightforward process

Process Innovations Modern Molding for Polycarbonates By Mark Matsco 40 Emerging techniques optimize the appearance and production of PC-based parts 40 ACCE 2015 Highlighted Interesting Shifts in the Composites Industry: Part II 44 By Peggy Malnati More innovations are presented from last year’s SPE event, in this continuation of the review in the November/December issue of Plastics Engineering.

The Word on Plastics Recycling: Momentum By American Chemistry Council 48 Plastics recycling is growing: steadily, broadly, and expansively

INSIDE SPI Less is Less: The Battle to Wrap It Up in Plastic 52 News about the state of the plastics industry from SPI: The Plastics Industry Trade Association 44

DEPARTMENTS Energy-Saving Tip Market Place 50 By Dr. Robin Kent 68 Industry News Editorial Index 54 70 Industry Patents Advertisers Index 60 By Dr. Roger Corneliussen 72 Upcoming Industry 64 Events 48

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RESIN MARKET FOCUS

Polyamide Global Dynamics

s we begin 2016, a number of factors, including low Production Capacity Exceeds Demand crude prices, a strong U.S. dollar, and bearish mar- Requirements ket sentiment in China, are creating opportunities forA buyers of engineering resins to find new leverage points. Global nylon 6 resin capacity will increase over 30% in 2016, Nylon is certainly not immune to these global influences, paced by Northeast Asia, where several new lines are being but underlying demand is strong, particularly in the auto- constructed by several producers. In addition to a new nylon motive segment, and leading producers continue to benefit 6 capacity addition in Western Europe in 2014, new nylon 6 from innovations that create value and increase demand. and nylon 66 capacity is being added in North America, aimed at markets for engineering compounds and film. As a result, global nylon 6 production operating rates are fore- Innovations Drive Market Demand cast to be suppressed for several years until demand absorbs Global nylon consumption is growing almost 3% per year, as that new capacity. new applications—often improving upon conventional met- Global production capacity for nylon 66 is about one-third al designs—are brought to market. This is especially evident the size of nylon 6 capacity. While 40% of nylon 66 capacity in the automotive market, where nylon continues to pro- currently resides in North America, the most significant vide solutions for improved fuel efficiency, safety increases are underway in Northeast Asia, where the capac- performance, styling, and durability. ity is forecast to rise 50% over the 2015/2016 time period. Nylon is most often the polymer of choice for automotive applications requiring heat endurance, fuel and oil resistance, and mechanical durability. Underhood and structural applications such as engine oil pans, transmission oil pans, engine mounts, and strut mounts—until recently in the realm of metal—are notable examples of parts now being made of nylon compounds. The combined goals of weight and cost reduction, often coupled with performance advantages, drive material selection and prompt collaboration by leading nylon producers, Tier 1 suppliers, and OEMs—and this frequently yields parts consolidation and reduction of secondary operations, compared with conventional approaches.

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RESIN MARKET FOCUS

With the recent demand slowdown in China, this capacity increase is putting pressure on operating rates and ensur- Resin Market Focus, by IHS Chemical, provides ongoing ing at least a sufficient supply of nylon 66 during the midrange insights into key industry topics and trends for major plas- outlook. tics and engineering resins, covering all major regions. IHS Lower prospects for economic activity in China, combined Chemical provides extensive industry insight, analytics, with ample supply, could prompt Asian nylon producers to and data for over 300 chemical markets world- increase their efforts to sell more resin and compounds in wide, including global plastics, polymers, and Europe and North America. The key question facing the engineering resins. Learn more or inquire industry is how quickly the emerging supply will be absorbed about IHS Chemical content at 877-225- through rising demand from innovative applications. 8188, or email us at [email protected].

The author Brendan Dooley is director, Engineering Resins North America, for IHS Chemical and can be reached at [email protected].

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DESIGN NOTES

Additive Manufacturing Faces Challenges as it Grows But new technologies may open up options for designers for producing 3-D-printed parts better & faster

By Robert Grace

ere is today’s multiple-choice quiz. Pick the right tooling process—and going to straight to commercial part answer below: production. (That usage now often is labeled “additive man- Three-dimensional printing/additive manufactur- ufacturing” (AM), though many still tend to use AM and 3-D Hing technology is: printing interchangeably.) a) a new sensation that is going to revolutionize how we make things; b) massively hyped with overheated rhetoric; c) a maturing technology, but one that has a long way to go; or d) all of the above. In many ways, curiously, the correct answer is: “d) all the above.” Many of you may realize that 3-D printing has been around for more than a quarter-century, but it’s only in recent years that it has really exploded on to the scene, often gar- nering the types of headlines usually reserved for cancer cures and moon landings. It is not the next industrial revo- lution. It will not render obsolete injection molding or other traditional forms of plastics processing. What it will do, is become an integral part of the product development and manufacturing process; speed the concept of agile, flexible production; drive mass-customization for certain types of highly personalized products; enable the manufacture of extremely complex components; and increasingly become an option for low-volume, mainstream manufacturing, especially of plastic and metal parts.

For many years, 3-D printing has been associated with In 2014, direct-part production accounted for 42.6%, or rapid prototyping, and it remains ideal for that purpose. But about $1.75 billion, of the world’s total AM-related product as materials and processes have advanced, the technology and service revenues of $4.1 billion that year (data source: is being used more for direct manufacturing—skipping the Wohlers Associates).

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But as AM process speeds increase, Caffrey says he expects Direct-Part Production some of the inherent benefits of AM—such as the ability to In its “Wohlers Report 2015,” Colorado-based consultants consolidate many parts that need assembly into a single part Wohlers Associates Inc. estimates that direct-part production or to reduce a part’s weight considerably—will lead to AM use in 2014 accounted for 42.6%, or about $1.75 billion, of the in other applications that might be higher volume or might be world’s total AM-related product and service revenues of slightly less-complex and less-valuable single parts. $4.1 billion that year. That’s up sharply from less than 20% Another key benefit is that AM enables more agile manu- five years prior, and from just 6.6% a decade ago (see graph). facturing. “You don’t have to tool for something,” he notes. It’s clear that direct-part production is climbing steadily, but “You can introduce a product in a very low quantity and if it’s additive manufacturing, in its many forms and variations, still a hit, you can tool for it. If it’s a dud, you move on to the next faces significant challenges when it comes to broader appli- thing. You don’t have to tie up money and capital cost in tooling, cation. These include high material costs, slow production and have warehouses full of inventory.” This can lower man- speeds, a lack of universal quality and certification standards, ufacturing risk, allowing companies to fall back on low quantities insufficient operator training, and a general misunderstanding and on just-in-time and on-demand business models. by many manufacturers as to how to effectively design and manufacture for the process. Perhaps the best-known drivers of 3-D-printed production CLIPped Parts plastic parts to date are aircraft makers such as Boeing and As lead systems engineer at California-based Legacy Effects Airbus. In Boeing’s case, according to Tim Caffrey, senior con- (formerly Stan Winston Studio), Jason Lopes is a leading sultant with Wohlers Associates, the company has been making practitioner of 3-D printing technology. Leveraging multiple environmental control system ducting, for both military and AM systems, along with a host of other tools, he has helped commercial airplanes, for many years. He says Boeing has to create props and special effects for many blockbuster upwards of 100,000 AM-produced parts flying in its planes Hollywood movies, including Avatar, Thor, Terminator Salva- today. These ducting components are all made of laser-sintered tion, and Iron Man, among others. nylon, and are now produced by suppliers to Boeing. About 18 months ago, Lopes was handpicked by red-hot Airbus, meanwhile, recently has become more open about Silicon Valley startup Carbon 3D to be a beta user of its its use of 3-D printing, and says it’s making numerous interior much-anticipated CLIP 3-D printing technology. CLIP—which electrical components with SABIC’s Ultem 9085, an amorphous stands for Continuous Liquid Interface Production—claims thermoplastic polyetherimide that meets all of the Federal Avi- to be 25 to 100 times faster than existing 3-D printing. ation Administration’s strict fire, smoke, and toxicity standards. CLIP is a chemical process that balances light and oxygen “The conventional thinking in recent years,” says Caffrey, to eliminate mechanical steps and material layers. It works “is that the sweet spot for production AM is highly complex, by projecting light through an oxygen-permeable window highly valuable parts that are produced in very low volumes. into a reservoir of UV-curable resin. By controlling the oxygen That makes perfect sense, and that is [the] case now.” flux through the window, CLIP creates a “dead zone”—a thin

“The conventional “Now, an idea thinking in recent doesn’t get stifled years,” says based on the Caffrey, “is that traditional way of the sweet spot bringing it to for production market. … That’s AM is highly the real complex, highly fascinating part valuable parts for me,” Lopes that are produced says. “Any design in very low can move forward, volumes. That and have potential makes perfect and possibilities, sense, and that is and that’s going to Tim Caffrey, Wohlers Associates. [the] case now.” Jason Lopes, Legacy Effects. change things.”

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DESIGN NOTES Additive Manufacturing ______

layer of uncured resin between the window and the object. This makes it possible to “grow” it without stopping. The build platform lifts continuously, rising from a resin bath, as the object is grown. Citing the commercial quality of the final parts, Carbon 3D—which in 2015 raised $100 million in funding and gained Ford Motor Co. as a partner—says this of CLIP: “Traditionally made 3-D printed parts are notoriously inconsistent. The mechanical properties vary depending on the direction the parts were printed due to the layer-by-layer approach. Parts printed with CLIP are much more like injection-molded parts.” CLIP offers a much broader range of engineering resins, such as rigid polyurethanes. “These are unlike any materials that I’ve had access to in my other technologies,” Lopes says. Caffrey, who has not yet used a CLIP machine first- hand, urges healthy skepticism and does question whether Carbon 3D’s photopolymers will prove to be UV-stable enough. More time is needed on that. Legacy Effects has used 3-D printing and multiple AM systems to create props and special effects for many block- But Lopes, for one, is a believer. He also uses AM to pro- buster Hollywood movies (photos courtesy of Jason Lopes duce movie-themed collectibles. In the past, he often used at Legacy Effects). a traditional 3-D printing system to make those items. “Now,

How CLIP works (graphic provided by Legacy Effects).

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DESIGN NOTES Additive Manufacturing ______

with [CLIP’s] speed and flavors of materials, we’re just push- “Multi Jet Fusion” ing all of that work as much as possible over to that The industry also is eagerly awaiting the rollout, by the end machine.” of 2016, of another potentially disruptive process—Multi Jet He recently did a collectibles project on the CLIP machine Fusion technology from Hewlett Packard (HP). that had a finished product size of 2 feet wide by 2 feet tall HP plans initially to build parts using production thermo- (60 x 60 cm) and comprised 139 parts. He says such a job plastic materials and then eventually, perhaps, with ceramics previously would have taken him 4 to 6 weeks to print and and metals. With the high number of nozzles per inch for clean up using a traditional process. Using CLIP, he com- its thermal inkjet arrays, the firm’s proprietary synchronous pleted all of it in less than two weeks. “And all we had to do architecture is capable of printing more than 30 million was remove supports. There was no need to go back in and drops per second across each inch of the working area. HP add more detail to the prints. What you see is what you get claims its Multi Jet Fusion technology and its materials are on that screen.” “set to define new levels of part quality, high part function- Beyond the entertainment industry, Lopes sees huge ality, at 10 times the build speed, and at breakthrough potential benefits for product development in general. economics.” “Once you have a part that you can build directly, and it is With HP’s global footprint and deep resources, Caffrey, suitable for use as an end-use part, I see that as an auto- for one, believes this technology “could be very significant.” mated application.” There are new examples almost daily of additive manu- What this means for Lopes is the potential for more solu- facturing technologies being applied to creative end-use tions to current problems. “Now, an idea doesn’t get stifled applications—from medical prosthetics, to custom sports based on the traditional way of bringing it to market. … That’s shoes (Nike, Adidas, New Balance), to automotive engine the real fascinating part for me,” Lopes says. “Any design parts (like the “Polimotor 2,” using Solvay materials). Many can move forward, and have potential and possibilities, and challenges certainly remain, but 3-D printing technology, in that’s going to change things.” one form or another, is here to stay, and it will indeed help to reshape the manufacturing landscape.

A red “buckyball” part rises from a vat of liquid photopolymer during the “CLIP” 3-D printing process.

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COVER STORY

Plastics Get Flexible for Electronics Integrated circuitry, “wraparound” electronics, and other conductive applications are being made possible using plastics

By Geoff Giordano

This molded reference design demonstrates the integrated, molded-in printed circuitry enabled by DuPont Microcircuit Materials’ in-mold electronic inks. (See also the sidebar article on p. 18; photo courtesy of the molder TactoTek.)

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magine an entire smartphone wrapped around your wrist. Or, how about a smartphone that doubles in size thanks to a wraparound display? Imagine the freedom in being able Ito design electronic displays around even the most complex contours of a car’s interior.

Whether plastics are in electronics—or even are the elec- ultra-thin, shatterproof, and flexible products including tronics—in consumer and industrial applications, novel mobile devices, wearables, surface displays, and imaging conductive polymers and processing methods are helping systems. 21st-century plastics engineers realize new performance and the company’s production process mimics the approach aesthetics benchmarks. used to make flat-panel displays on glass, he says, “except In particular, the skyrocketing popularity of portable, per- we laminate a plastic film to the glass that can easily be sonal, or more visually pleasing electronics is driving industry detached at the end.” their production process uses much innovation across the board—from flexible electronics used lower process temperatures than conventional transistors, in wearable, automotive, or appliance displays, to high- enabling the use of cost-effective plastic substrates and impact plastics for protecting sensitive electronics on the demount mechanisms that allow the glass to be recycled, go. conductive inks for in-mold use and polymers modified he continues. with conductive metal nanoparticles are also spurring search- es for commercial uses of novel materials. At least one forecast illustrates the level of activity in this market segment. For example, the global market for “electroactive” (shape-changing and conductive) polymers is expected to reach $6.38 billion in value by 2022, according to a 2015 report by california-based grand View Research— with an expected compound annual growth of 9.7% from 2015 to 2022. With the plastics electronics market poised for such vig- orous growth, here’s a look at some notable advances that are changing the way manufacturers think about product design and performance, for meeting or exceeding customers’ desires for cutting-edge goods.

Thin-Film Transistors FlexEnable of cambridge, UK, is a pioneer in developing organic transistor technology that allows electronics to be manufactured on flexible plastic film “the thickness of a sheet of paper,” the company says. “FlexEnable has developed a unique way of manufactur- Flexible-display product concepts like this wrist ing electronics on plastic substrates which will create phone show how new levels of utility might be revolutionary products whilst challenging conventional man- unlocked for smart watches and other wearable ufacturing economics,” says technical director Mike devices (this and other flexible-display photos in this Banach. “Plastic electronics enables the development of article courtesy of FlexEnable Ltd.).

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Plastics Get Flexible for Electronics ______

“the most efficient manufacturing approach would be to wrap a display around the wrist or body means significant- remove the glass carrier altogether and process circuits ly larger display areas are possible, bringing higher levels of directly on the plastic using a roll-to-roll approach,” he utility [and] better comfort and user experience, as well as explains. “this is very much the target for the team—and making the device rugged and lightweight. the thinness of our low-temperature processing approach on flexible sub- flexible displays also leaves more room for a battery in the strates give us a great head start on the conventional product.” technology.” in the automotive realm, cain cites three reasons for the company has optimized a manufacturing process flexible displays: “today, the only flat surface in the vehi- compatible with the ubiquitous resin PEt, Banach explains, cle is the display, and the car has to be designed around “to take advantage of the economy of scale present in the the flat constraint of the glass display. Flexible displays market. the temperature profile of our manufacturing mean the display can be designed around the car, rather process (sub-100°c) is also compatible with [cellulose triac- than the other way round. secondly, curved (concave) dis- etate], which is widely used to make lcD displays because plays reduce reflections from the driver’s perspective, and of its ultralow birefringence.” increase visibility [and] readability of displays. Finally, flex- FlexEnable’s technology can activate surfaces to input or ible displays open completely new uses … for displays in output information through flexible sensors and displays, cars—for example, for activating surfaces such as the ‘a’ without constraining the design of the product, says company pillar, thereby removing blind spots from the driver’s per- strategy director Paul cain. “For wearables, the ability to spective by making solid objects see-through.”

This concept shows a smartphone with a wraparound display that opens out into a tablet, doubling the size of the device.

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______

FlexEnable’s success has reportedly caught the eye of the printed electronics industry, with the company fielding offers to discuss its technology at various conferences. “The core message we have been conveying at those events is that the ability to seamlessly integrate electronics with everyday objects can only be achieved with flexible electronics,” Cain notes. “Our organic transistor technology platform can activate surfaces for wearables and ‘everywhere-ables’” in many industries, he adds, including “mobile, automotive, aerospace, biometrics, and health care.”

Glass-Free, Flexible Displays Plastic Logic of Dresden, Germany, which licenses FlexEn- able’s technology, develops and manufactures shatterproof, glass-free EPDs, or electrophoretic displays. Available in a wide range of sizes, these EPDs are being used in smart An example of FlexEnable’s OLCD (organic liquid crystal cards, wearables, mobile devices, and signage. display) curved around a coffee cup.

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Plastics Get Flexible for Electronics ______

“Our displays are unique, being extremely robust and glass-free EPD technology is comparable to standard shatterproof,” says Rachel Trovarelli, head of marketing com- devices currently available in the market with respect to munications for Plastic Logic. “The award-winning technology power use—no power is needed unless the display is updat- and manufacturing process was developed in-house and is ed.” She says it’s “truly e-paper”—the display is readable backed by over 100 patents, applied [for] and granted. We in sunlight. “However, the fact that we use plastic as a sub- were the first to industrialize a process for the manufacture strate instead of silicon on glass, as is the case with of flexible displays using polymers. Our production process traditional EPDs, provides our displays with unique char- is proven with a high yield, comparable with LCD, and we acteristics like true flexibility, thinness (of less than 1 mm), already have product in the market.” light weights (a few grams depending on the size), and, Compared to glass-based EPD, she says, “our flexible, naturally, robustness.”

In-Mold Electronic Inks

o streamline electronic devices by reducing the need of stretching over 70% while providing consistent perform- for rigid circuit boards, DuPont Microcircuit Materials ance through the aggressive thermoforming and injection launched a range of in-mold electronic inks in October molding processes,” he explains. “Our third-party teardowns thatT allow circuits to be directly printed onto plastic sub- and internal analysis show that in-mold electronics will reduce strates. cost by up to 50% and weight by up to 70% versus traditional These inks, which the company says “offer important buttons. And in-mold electronics offers simpler assembly, design, manufacturing, weight, and cost advantages,” allow up to 20% cost savings, more curvature, and better per- touch controls like buttons, switches, and slides to be seam- formance than PCB-based capacitive touch solutions.” lessly integrated into high-value items like cars and home Potential applications include appliances like washers, dry- appliances. ers, and refrigerators, as well as automotive overhead “Twenty years ago, washers and dryers were big white consoles and instrument panels, he continues. “We have boxes in the basement,” says John Voultos, segment manager been working closely with various companies in the appliance for DuPont Microcircuit Materials. “Today, they have made and automotive industries, and there is strong interest in their way upstairs, and as they have become more visible, this technology to reduce weight, improve aesthetics, and their style and design has become more important. At the eliminate manufacturing steps.” same time, consumers have become comfortable using touch screens and touch buttons with the growth of smart phones and tablets. Consumers no longer require physical buttons to feel comfortable using a device of any kind—from phones to washing machines.” However, printed circuit boards (PCBs) have continued to limit designers to flat shapes and a standard palette of designs and complex assemblies, he says, meaning “next-generation touch designs have not yet flourished.” DuPont’s in-mold electronic inks “allow designers to print electronics in plastic,” he explains. “Functions such as touch controls and lighting can be directly embedded inside plastic parts by printing circuits directly onto plastic sheets, which are thermoformed and injection molded. This means electronic controls can take on almost any shape, while moving closer to the surface for the strongest signal.” An example of in-mold circuits printed with DuPont What differentiates DuPont’s inks is that they’re “capable conductive inks.

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______

In terms of producing their EPDs, Plastic Logic obtains “The main market segments are mobile devices, for polymers—organic semiconductors and dielectrics—“engi- instance: a secondary screen for a mobile phone, embed- neered to meet our specifications, which include parameters ded either on the back or in a protective cover; smart cards for electrical performance, but other aspects like, e.g., vis- like ID, security, or bank cards with embedded displays; sig- cosity [and] degree of purity, as well as standard nage, such as displays for … bus, tram, and train stops; and environmental, health, and safety aspects,” she explains. wearables like smart wristbands, bracelets, and intelligent Beyond design and performance benefits, Plastic Logic’s jewelry. We see also demand for our technology to be used manufacturing method of printing on a plastic substrate in sensors—for instance, as a backplane for a portable X- “allows up-scalability and economy of scales with cost effi- ray detector, which is currently under development.” ciency,” she continues. Meanwhile, the low temperature of the company’s processes—all below 100°C—“implies environment-friendly industrial production compared with the Nanomodifier Breakthrough? traditional silicon semiconductor industry.” For Mackinac Polymers, based in Fort Myers, Florida, an acci- Plastic Logic sees several market segments with great dental discovery led to a remarkable advance in electroactive potential with respect to market share and revenue in the polymers: a process that inserts transitional nanometals first two quarters of this year. “You will see more and more into the chemical backbone of materials like polyester poly- products coming on the market enabled by our displays,” ols, copolyesters, and olefins to produce conductive Trovarelli asserts. polymers. Mackinac’s creation earned the company a patent

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Plastics Get Flexible for Electronics ______

in July, and it says its commercialization is on the horizon. In process was working across the board. Looking back, we fact, when the company gave a presentation at NASA in are [wondering], ‘Why hasn’t this been done before?’” November, the aerospace agency claimed to have numer- The findings led Mackinac to search for how to apply its ous applications for Mackinac’s material and called the technology. “We initially focused on electroactive polymers, science “revolutionary,” the company says. because the market currently consumes a lot of these mate- In the process of seeking to create a heavier, glass-like rials,” says Don Phillips, Mackinac’s president. “These acrylic, “We thought we could achieve this by inserting some materials are also created by compounding methods with metal nanoparticles into the formulation,” explains Mack- metals in various forms. Knowing the limitations of com- inac chief chemist Ralph Locke. “During experimentation, pounding, we thought a homogeneously conductive material we noticed several key indicators that something was hap- would be of value. It turns out that we were correct, as we pening with these particles that was of significance. After a are getting a lot of interest in our materials.” couple of more experiments and testing, we concluded and Phillips feels the need for electroactive materials “will con- proved that we were actually getting the nanoparticles into tinue to grow in various industries as consumers and the chemical backbone of the polymer. This was our ‘eure- manufacturers continue to look for more functionality from ka moment’.” their materials and to streamline their processes. Addition- Mackinac’s new non-traditional synthesis process “differ- ally, in the automotive and aerospace markets, they’re also entiates us from other producers because we are not doping concerned with weight reduction. By combining the elec- or compounding,” Locke explains. “We are creating homo- troactive characteristics into a polymer, weight can be saved geneously conductive polymers that are consistent, by switching from metal components to a polymer-based repeatable, and controllable without the need to compound component. Or weight can be saved by using nanosized par- with additives or fillers. We are not aware of any other com- ticles instead of other larger materials.” panies who are utilizing this new synthesis process. We are the true pioneers of this technology.” The transitional metal nanoparticles Mackinac is insert- “Homogenous, Controllable, and ing into polymer backbones are transitional metal salts, Repeatable” “preferably with particle sizes between 30 and 50 nm,” Locke “Additionally, our materials are homogenous, controllable, notes. “They are readily available.” and repeatable,” Phillips adds. “Compounded materials vary In terms of performance, “the conductivity and surface batch to batch. The repeatability [of our material] alone will resistivity of our materials are very similar to those of exist- lead to superior performance compared to compounded ing compounded materials,” Locke says. “We can create materials. materials with a surface resistivity anywhere from 1012 ohm- “Also, compounded materials are sometimes overloaded sq. to 10-4 ohm-sq. to ensure functionality. As a result, the integrity of the orig- “One difference with our materials, however, is that we inal polymer is diminished while the cost is increased can create highly conductive materials without sacrificing considerably. We feel that our materials are basically a drop- the physical properties of the base polymer. Compound- in replacement for current compounded materials with the ed materials typically have a hard time getting to the low addition of superior performance at a reduced price.” end of the surface resistivity chart without sacrificing these The flexibility of Mackinac’s process provides a valuable physical characteristics, due to the heavy loading required. spin on traditional methods. “The current process for creating Because we are using nanomaterials and at significant a conductive material is to take a virgin PP, for example, and lower levels, physical characteristics can be maintained. mix it with 20% to 40% … carbon black, carbon nanotubes, Our nanoparticles are also locked into the backbone and or some other conductive material,” Locke says. “With our thus will not leach out of the polymer. Our materials are materials, the same spec can typically be achieved by using much more stable.” 3% to 10% nanomaterials.” Development of the technology did not present signifi- The compounding process, he says, also involves pur- cant challenges or hurdles, Locke continues. “Once we figured chasing the raw material from one supplier, purchasing the out what we had, we were able to repeat it with various tran- conductive material from another supplier, mixing the two sitional metal nanoparticles. We then started working with together and then shipping the final product. “With our new polymers and metal combinations and found that our process, the homogenous conductive material comes straight

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out of the reactor ready to ship. The post-processing sup- compounding step can increase material costs anywhere pliers, mixing steps, and transportation are eliminated.” from 150% to 700% over the base polymer cost, due to the As far as cost goes, “our process does create a modest additional costs for the conductive additive material and or very small increase in the polymerization cost,” Phillips the processing costs of compounding. We’re finding that notes. “However, this small incremental cost increase in the our materials, on the other hand, only have a marginal polymerization process is typically less than the current increase over the base polymer cost, depending on the compounding process. We feel that we have a very strong application.” value proposition for converters who are looking for func- Mackinac sees a prime opportunity to sell to “existing tionalized polymers. In fact, recent business case analysis raw-material providers and convertors,” Phillips projects. has proven that we can save significant dollars.” “Convertors can contact us direct for functionalized mate- Mackinac says its materials should also save wear and rials, which we can supply or develop for them, while the raw tear on processing equipment because they “have far less materials suppliers have the ability to license the technol- metal in them, and the sizes are much smaller,” Locke says. ogy to create their own materials. Additionally, we’re “This should increase the life of the equipment and reduce speaking with compounders who are looking to master- maintenance costs.” batch our functionalized materials into their compounded Based on initial business-case analyses, Phillips says “the products.”

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Plugging Into the Power of Polymers Lithium-ion and other battery technologies will increasingly be getting more solid support and energy density from polymers

By Jon Evans

ur modern, always-on, 24/7 lifestyle is powered For a start, they still need to be recharged fairly regular- by lithium-ion (Li-ion) batteries, without which we ly, especially with our electronic devices becoming ever wouldn’t be able to use all our portable electronic more powerful and therefore power-hungry, and this usu- devices,O from laptops to tablets to smartphones. Never- ally takes a few hours. Furthermore, their energy capacity theless, anyone who uses these portable electronic devices steadily degrades over time, requiring them to be recharged knows that the current generation of Li-ion batteries are not more and more regularly until eventually they need to be without their problems. replaced.

Electric vehicles plugged into one of the 36 charging stations in the U.S. National Renewable Energy Laboratory’s parking garage. (Photo by Dennis Schroeder courtesy of the NREL.)

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Solving these problems would not just prove beneficial for cobalt oxide or lithium manganese oxide. The liquid users of electronic devices, they could also help usher in the electrolyte comprises a lithium salt such as lithium hexaflu- widespread adoption of electric cars and renewable energy. orophosphate dissolved in an organic solvent like ethylene Ideally, electric cars need batteries that are powerful enough carbonate or propylene carbonate. to take them the same kind of distances between charges as Researchers know of several substances that would make a full tank of gasoline. And renewable energy technologies better electrode materials for Li-ion batteries, but they each such as solar and wind require batteries that can efficient- come with problems. A pure lithium metal anode would be ly store excess energy produced when it’s sunny or windy, better than a graphite anode, and a sulfur-based cathode and then quickly release that energy when it’s not. would be better than a metal oxide cathode, as both could Researchers in both academia and industry are hard at theoretically store many more lithium ions. work exploring various approaches for solving these prob- The problem with lithium metal anodes is that the lithium lems and improving Li-ion batteries, as well as developing ions tend to arrive faster than they can be incorporated alternative battery technologies. And polymers are at the within the anodes and thus build up as deposits on the sur- heart of many of these efforts. face. Given enough time, these deposits, known as dendrites, can extend right across the electrolyte to the cathode, causing the battery to short out. These dendrites form on graphite The Guts of Li-Ion Batteries anodes as well, but they’re more of an issue with lithium met- As with any battery, Li-ion batteries consist of a negative elec- al anodes. The problem with sulfur-based cathodes is that the trode (anode) and a positive electrode (cathode) separated sulfur and lithium react to produce various compounds that by a liquid electrolyte. When releasing power, lithium ions dissolve in the electrolyte, contaminating it and causing the travel from the anode through the electrolyte to the cathode, sulfur-based electrode to degrade over time. driving an associated flow of electrons through an external circuit. This process goes into reverse when the battery is charged by an external power source, with the opposite Liquid Electrolytes Become Solid flow of electrons driving lithium ions from the cathode to the Polymers anode. Handily, though, both of these problems could be resolved The amount of charge that a Li-ion battery can hold by replacing the liquid electrolyte with a solid polymer depends on how many lithium ions can be stored in each of one, which would physically stop the spread of dendrites the electrodes. The power the battery can generate when dis- and the dissolving of compounds produced by the reaction charging and the speed at which it can be recharged depends between sulfur and lithium. Solid polymer electrolytes on how fast the lithium ions travel through the electrolyte. would also have several other advantages. In the current generation of Li-ion batteries, the anode is For a start, they would be safer, because the liquid elec- graphite, while the cathode is a metal oxide such as lithium trolyte used in current Li-ion batteries is flammable and has

SolidEnergy says its advanced battery has around double the energy density of a conventional Li-ion battery (graphic courtesy of the company).

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Plugging Into the Power of Polymers ______

been known to burst into flames if the battery gets too hot. that incorporates an ultra-thin metal anode, made of thin lithi- They could also allow the creation of flexible batteries with um on copper, and a solid polymer electrolyte. The company a range of different shapes, as the liquid electrolyte would claims that its advanced battery also has around double not need to encased in robust packaging. (As this packag- the energy density of a conventional Li-ion battery. ing is usually made from a polymer, current Li-ion batteries are sometimes rather confusingly known as polymer Li-ion batteries, even though they contain liquid electrolytes.) PEO Progress Conductive polymers such as polyethylene oxide (PEO) Academic researchers, meanwhile, are busy finding ever doped with lithium ions have shown promise as solid poly- more innovative ways to formulate PEO as a solid elec- mer electrolytes, but scientists have struggled to develop trolyte. For example, chemical engineers at Cornell University PEO materials that transport lithium ions anywhere near as have tethered short-chain PEO oligomers to silica particles well as liquid electrolytes. Nevertheless, several companies, and linked these particles together with polypropylene including the U.S. companies Seeo and SolidEnergy, are oxide. This produces a crosslinked nanoparticle-polymer actively developing advanced versions of Li-ion batteries composite that is then soaked in a conventional liquid elec- that incorporate solid polymer electrolytes. trolyte comprising a lithium salt dissolved in propylene Seeo’s polymer electrolyte technology is called DryLyte carbonate.1 and was originally developed by researchers at Lawrence The great advantage of this crosslink structure is that it cre- Berkeley National Laboratory. Seeo is combining DryLyte ates a system of porous conductive pathways which lithium with a lithium metal anode to produce batteries for electric ions can pass through almost as easily as through a con- vehicles and claims that these batteries have an energy den- ventional liquid electrolyte. Combining this composite with sity of 350 watt-hours per kilogram. This is more than a lithium metal anode and a metal oxide cathode produces double the energy density of a conventional Li-ion battery a battery that maintains a high current density and dis- and would be sufficient to take an electric car as far as a full charge capacity for over 150 charge/discharge cycles. tank of gasoline on a single charge. (The German technol- PEO could also help in the development of perhaps the ogy company Bosch is obviously convinced, because it most promising class of lithium-based battery. This is the lithi- acquired Seeo in September 2015.) um-air battery, which uses gaseous oxygen as the cathode. SolidEnergy is a spin-off from the Massachusetts Insti- In addition to being much lighter than conventional Li-ion bat- tute of Technology. It’s developing an advanced Li-ion battery teries (as it no longer has the weight of a solid cathode), a lithium-air battery can theoretically store ten times as much energy. This is because rather than lithium ions being incorporated in a solid material, they are stored via a reversible reaction with oxygen that creates lithium peroxide. Unfortunately, this process can also generate oxygen radicals that gradually oxidize liquid electrolytes over time, meaning that lithium-air batteries tend to stop working after only a few charge/discharge cycles. Recently, though, two chemists from Sapienza University in Italy showed that a plasticized PEO-based material doped with lithium ions made a very effective solid electrolyte for lithium-air batteries.2 Not only is this plasticized PEO-based material chemical- ly stable, preventing it from being oxidized by the oxygen radicals, but it’s also more conductive than most other solid electrolytes developed from PEO. When used with a lithium metal anode, this plasticized PEO produced a lithi- A plug-in electric vehicle in its charging station at the NREL’s um-air battery with a likely energy density of more than 300 Vehicle Testing and Integration Facility. (Photo by Dennis watt-hours per kilogram. Schroeder courtesy of NREL.)

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Redox-Flow Batteries

Lithium-based batteries are not the only option for polymers in batteries, for there’s an alternative battery technology that not only does away with lithium but also does away with solid electrodes. Known as a redox-flow battery, it works by flowing two liquids, each of which contains ions that can exist in one of two oxidation states, on either side of a pro- ton-exchange membrane. As the ions in each liquid shift between oxidation states, they drive a flow of protons through the membrane and an associated flow of electrons through an external circuit. Charging the battery from an external power source reverses the flow of electrons and protons, causing the ions to revert to their original oxidation states. The liquids are held in external tanks and then pumped past the membrane. This means that the energy capacity of a University of Jena researchers (left to right) Ulrich Schubert, redox-flow battery can be increased simply by increasing Tobias Janoschka, and Martin Hager holding their redox- the size of the tanks, which makes them an excellent battery flow battery (photo courtesy of Anne Guenther/FSU). technology for storing excess energy generated by wind and solar power. Most of the redox-flow battery systems that have so far been installed for this purpose use ions of vanadium, a heavy metal, and the well-known perfluorinated polymer Nafion as vanadium, these polymers can also be dissolved in salt water the membrane. Because vanadium ions can exist in one of rather than sulfuric acid, allowing the Nafion membrane to be four oxidation states, they can be used in both liquids, with replaced by a much cheaper cellulose membrane. the ions in each liquid alternating between a different pair of Their initial resulting redox-flow battery only had an ener- oxidation states. gy density of 10 watt-hours per liter, but it could withstand up Unfortunately, vanadium is expensive, as is the Nafion to 10,000 charge/discharge cycles without losing any of this membrane, and this cost is hampering the widespread adop- capacity. The team is already working on larger, more efficient tion of redox-flow batteries. In addition, the vanadium ion systems—all of which should help ensure our electronic liquids are produced by dissolving vanadium salts in sulfuric devices stay charged in the future. acid, which is highly corrosive and limits the lifetime of the battery. The use of sulfuric acid also explains why a robust, expensive membrane such as Nafion is required. Recently, however, a team of chemists from the Universi- References ty of Jena and a spin-off company from the university called 1. Nature Communications, 2015, 6, 10101 (DOI: 10.1038/ ncomms10101). JenaBatteries have discovered two redox-active polymers 2. Scientific Reports, 2015, 5, 12307 (DOI: 10.1038/srep12307). that work just as well.3 In addition to being much cheaper than 3. Nature, 2015, 527, 78–81 (DOI: 10.1038/nature15746).

CUSTOM-ENGINEERED TPE

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Putting a Charge into Conductive Plastics Demanding electronics require new conductive materials

By Doug Bathauer Integral Technologies, Bellingham, Washington, USA

he world of conductive plastics/polymers, introduced technologies based on conducting polymers, photolumi- several decades ago, features breakthrough technolo- nescent polymers, and quantum dots for gene detection. gies and novel usage of conductive polymers. These To date, conductive polymers have had few large-scale materialsT conduct electricity and are used in countless appli- applications aside from ESD (electrostatic dissipation). How- cations in many industries because they are easy to extrude ever, advances in the technological development of or injection mold into desired shapes and sizes. conductive polymers are leading to their incorporation in “Conductive polymers are already used in fuel cells, com- batteries, super capacitors, biomaterials, solar cells, flexible puter displays and microsurgical tools, and are now finding transparent displays, electromagnetic shielding, stealth air- applications in the field of biomaterials,” reports the jour- craft coatings, and more. nal Acta Biomaterialia.1 “These versatile polymers can be synthesized alone, as hydrogels, combined into composites or electrospun into microfibers. They can be created to be Current Needs, New Materials biocompatible and biodegradable.” Today the trend of “lightweighting” holds heavyweight impor- For example, The University of Auckland’s Polymer Elec- tance. Analysts predict that automotive lightweighting, the tronics Research Centre was “established in 2003 to promote, process of reducing weight for improving performance and facilitate, and advance research in the field of polymer elec- improving fuel efficiencies, will become a $300 billion annu- 2 tronics.” Their research projects include biomedical al market as global trends point to CO2 reduction and applications of conducting polymers and nanomaterials and resource efficiencies as being vital to meeting regulatory composite plastics for “smart” packaging and organic elec- and industry mandates in the transportation sector. New tronic devices. They are even developing DNA sensor materials development, including conductive plastics, is a major driver in this trend. The federal government’s new Corporate Average Fuel Economy (CAFE) standards require automakers to raise the average fuel efficiency of new cars and trucks to 54.5 miles per gallon by 2025. Electrically assisted vehicles can certainly meet or exceed CAFE requirements, but these vehicles car- ry their own weight issues, as batteries and electrical systems add hundreds of pounds to the vehicle. The added electronics add another problem that needs to be addressed: electromagnetic compatibility (or inter- ference, EMI). Conductive resins will play an ever increasing role in the lightweighting industry. At my company, we’re doing our part in the fight against vehicle obesity by utilizing our conductive hybrid plastics as EMI shielding solutions. Our patented material—ElectriPlast pellets (Figure 1), which utilize Long Fiber Technology—allow for superior Figure 1: ElectriPlast pellets. shielding of today’s high voltage components. Our process

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is compatible with nearly any resin. We typically utilize car- “The molding process for our bipolar battery allows us to bon fiber or stainless steel fiber, but essentially any metal produce a nearly unlimited number of 3-D shapes and sizes fiber can be used. which allow the bipolar plate and integral structures to be Our material is manufactured specifically for the cus- executed in any desired embodiment,” says Slobodan “Bob” tomer’s end-use application by using Flexible Content Pavlovic, vice president, engineering, of ElectriPlast Corp. Technology™. Depending on the application specifications, “And the inherent conductivity of ElectriPlast eliminates the ElectriPlast varies the composition of the pellet according- need for conductive vias or other means to connect electri- ly, ensuring that the final result is the most cost efficient. cally two sides of the plate—a common solution for We have developed numerous applications for connec- quasi-bipolar plates.” tors, covers, and enclosures, and are currently jointly The plates are lightweight and easy to assemble into the developing shielded cable with Delphi Automotive. We’re bipolar battery package; they can also be made as a drop- able to provide the same shield effectiveness as the alu- in replacement for some existing quasi-bipolar plates. Bipolar minum or cast aluminum parts, while providing on average technology eliminates the use of a top lead to connect the a 60% weight savings. plates, thereby reducing weight by over 50%. These unique characteristics allow the technology to be applied in other sectors such as motorcycles, golf carts, and forklifts. Bipolar Battery Plates However, the applications for bipolar plates are not lim- A bipolar battery concept was published in the early 1920s, ited to transportation, as the bipolar technology can be used and there are multiple patents awarded for the design of in stationary applications, including flow batteries that are bipolar batteries and bipolar plates. However, there are no being developed to improve grid efficiency and for fuel cells commercially viable, high-volume-capable design solutions for baseload power. for a true bipolar battery and bipolar plate due to the non- existence of a practical, fully defined, and high-volume manufacturable design of the bipolar plate using conven- Increasing Demands tional high-volume production processes. The fast growth in portable smart devices, as well as electric The evolution from monopolar to bipolar technology automobiles, has led to increasing demands for battery pow- reduces battery weight and overall size. However, commer- er. However, R&D and innovation of battery technology has cialization has been hampered by challenges ranging from not kept pace with strides on the consumer electronics and corrosion to current leakage. The bipolar capabilities remain “green” automotive side, or with the burgeoning demand attractive because of the energy and power capabilities that for power storage. could be packaged into a relatively low-cost offering. Conductive plastic will continue to innovate in the battery The development of an operationally reliable and manu- technology sector to meet growing demand in the trans- facturable bipolar battery will further extend lead acid portation and dynamic energy storage marketplaces. capabilities and prove disruptive to the energy storage indus- Advantages include high conductivity, corrosion resistance, try. By utilizing Long Fiber Technology, my company has flexibility, moldability, and cost effectiveness. been addressing hurdles to scalability by redefining the bipolar plate design based on a plate core made of conductive loaded resins with metal-covered surfaces. In several lead References acid battery technologies, including bipolar and lead/car- 1. www.sciencedirect.com/science/article/pii/S1742706114000671 2. www.chemistry.auckland.ac.nz/en/about/our-research/research- bon, the ElectriPlast material can be used as the electrode centres/polymer-electronics-research-centre.html plate (Figure 2).

About the Author: Doug Bathauer is CEO of Integral Technologies, whose wholly owned subsidiary, ElectriPlast Corp. (www.electriplast.com), engages in the discovery, development, commercialization, and licensing of electrically conductive hybrid plastics products used primarily as raw materials in the production of industrial, commercial, and consumer Figure 2: ElectriPlast bipolar plates. products and services worldwide.

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TECHNICAL PAPER

Innovations in Hybrid Structural Instant Adhesive Technologies

By Nicole Lavoie Henkel Corporation, Rocky Hill, Connecticut, USA

ver the last century, adhesive use has become The recent advancement in hybrid adhesive technologies increasingly popular over other assembly meth- has allowed manufacturers to overcome limitations by ods for structural design. To meet the demands of increasing manufacturing speeds and assembly durability. Othe latest product designs and manufacturing processes, new New structural instant adhesives, hybrids of epoxy and adhesives are continually being formulated. Current cyano- cyanoacrylate technologies, can be used to meet the demands acrylate and epoxy technologies have proved to be valuable of present and future production requirements. in today’s largest manufacturing companies. Despite the many advantages, each technology still has its disadvan- Introduction tages that limit the materials and situations in which they are Cyanoacrylates are one-part, room-temperature-curing adhe- used. sives. They have excellent adhesion to most substrates, including metals, plastics, elastomers, and porous substrates. When pressed into a thin film between two surfaces, cyanoacrylates cure rapidly to form a rigid thermoplastic. Cyanoacrylates undergo anionic polymerization in the presence of moisture, a weak base, which is present in trace amounts on virtually all surfaces. As the acid stabilizers present in the formula are neutralized by the moisture, rapid polymerization occurs.1 Adhesive fixture strength is achieved in just seconds, and full strength occurs in 24 hours. Along with the rapid room- temperature cure, cyanoacrylates are solvent-free and have a wide range of viscosities to choose from. They have excellent bond strength in shear and tensile modes. Cyanoacrylates, however, have limited gap-filling capabilities, with a maximum cure through gap of about 0.25 mm. When fully cured, cyanoacrylates are very brittle and have low impact strength. They also have poor resistance to polar solvents. With some cyanoacrylates, blooming—or the white haze that can form on the assembly around the bond line— may occur. Blooming occurs when cyanoacrylate monomers volatize, react with moisture in the air, and then settle on the part as a white dust. Cyanoacrylates are commonly used in the medical industry to bond medical tubing, endoscopes, and catheters. They can also be used in general assembly, including bond- Hybrid structural adhesive application example (photo cour- ing dissimilar substrates and hard-to-bond plastics, wire tesy of Henkel). tacking, and O-ring bonding.

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Epoxies are one- or two-part structural adhesives that cure at room temperature. Two-part epoxy systems have a resin and a hardener that polymerize when mixed together to form thermoset polymers. One-part pre-mixes that utilize a heat cure are also common. Epoxies bond a variety of substrates and shrink minimally upon cure. These adhesives have high cohesive strength and toughness, as well as very good heat and environmental resistance. They have excellent depth of cure and can fill large gaps. Though epoxies are a great choice for many structural applications, they still have their disadvantages. Mainly, epoxies have long fixture times that tend to be much slower than other chemistries. Typical fixture times for Figure 1: Shear strength of a cyanoacrylate/epoxy hybrid vs. epoxies range from 15 minutes to 2 hours. Though heat can other typical epoxies on multiple substrates. be used to accelerate the cure, the temperature limitations of the substrates, such as plastics, must be considered. Dur- ing the cure of a two-part system, the reaction can also exotherm, which again can be problematic for highly sen- Table 1: Typical Shear Strengths of a Cyanoacrylate/Epoxy 3 sitive parts. Hybrid on Different Substrates Epoxies are often used on metals and easy-to-bond plastics for structural bonding. Examples include electric motors, wire bonding, name plates, speakers, small engines, and potting applications such as printed circuit boards. They can be used in many manufacturing areas such as the aerospace, electronics, automotive, and medical industries.

Advancements Today’s industry production requirements are forever demanding new and improved adhesive technologies. To meet these demands, companies like Henkel have produced hybrid structural instant adhesives such as Loctite® 4090TM (referred to as a cyanoacrylate/epoxy hybrid). This is a two-part curable composition comprised of (1) a cyanoacrylate curing component and a cationic catalyst, and (2) a second part comprising a cationic curable epoxy, where- in, when mixed together the cationic catalyst, initiates cure of the epoxy component.2 This two-part, room-temperature-curable system bonds to a multitude of substrates including plastics, metals, and elastomers. This hybrid is a high-viscosity gel adhesive with a 1:1 mix ratio. The product is clear at no gap, to a light yellow color with larger gaps. Because it is a two-component mixture, the risk of blooming that can occur with a cyanoacrylate is greatly reduced. It has a 3-7 min. fixture time at 1-mm gap. This hybrid formulation combines the most critical attributes of a cyanoacrylate—fast fixture time and substrate versatility—with advantages of using a structural epoxy— high bond strength; temperature, environmental, and impact resistance; and the ability to fill gaps of up to 5 mm.

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Hybrid Structural Instant Adhesive Technologies ______

Strength removal of their parts on the line allows for more parts to be In regards to shear strength, epoxies perform very well with assembled per hour. most types of metal. Epoxies do fall short however when a customer expects the same range of shear strength of dif- Versatility ferent types of plastics. Combined with the cyanoacrylates’ Long-time users of adhesives know that there are not many ability to bond to many plastics and elastomers, hybrid options when bonding elastomers. Instant adhesives are structural instant adhesives have overcome this problem and one of the few adhesives that will accomplish the job. Now provide more consistent shear-strength values for a range with the help of hybrid adhesives, more structural assemblies of materials (Figure 1). that need to fill a gap as well as bond dissimilar or difficult- to-bond-to substrates can be bonded with structural instant Speed adhesives solutions. Typical fixture speeds for cyanoacrylates can range from 5 Typical epoxies are not suggested when bonding olefins to 90 seconds, depending on the composition of the adhe- such as polypropylene, or rubbers such as nitrile. Table 1 cap- sive and the substrate on which it’s applied. Epoxies tend to tures the range of materials that a hybrid adhesive can have much longer fixture times (hours vs. seconds). Even with bond, and shows that shear strength is achievable even on the help of additives, the fastest fixture times are typically those materials not designed for adhesive use. around 8-15 minutes. Hybrid structural instant adhesives have adapted the Impact resistance speed of a cyanoacrylate, allowing for a zero-gap fixture Structural assemblies often require not only high tensile time of less than 180 seconds, and 3-7 min. fixture times for strength but high impact resistance as well. Solenoid pumps, gaps ranging from 1 to 5 mm. This is a slightly longer fixture power-brake systems, and prosthetics are just a few exam- speed compared to instant adhesives, but it is still faster than ples where there are high-impact joints. In the past, the fastest epoxies. Fixture speed is the most important cyanoacrylates were not suggested for these types of appli- feature for customers in their final assembly lines, where fast cations because they are so brittle. One impact can cause

Figure 2: Typical impact resistance of a cyanoacrylate/epoxy Figure 3: Heat resistance of a cyanoacrylate/epoxy hybrid hybrid vs. a generic cyanoacrylate. vs. a generic cyanoacrylate on grit blasted steel (GBMS).

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Hybrid Structural Instant Adhesive Technologies ______

cracks that propagate throughout the cyanoacrylate bond line 121°C, but failed to hold the GBMS together at 149°C and and result in adhesive failure. 182°C. The hybrid adhesive had excellent strength retention Hybrid structural instant adhesives incorporate epoxy at 149°C. Even at 182°C, a temperature above the recom- performance properties to triple the impact vibration resist- mended value, it was still able to retain over half the strength ance of that seen with a generic cyanoacrylate (Figure 2). of the 121°C test. Heat resistance becomes important for adhesives in applications involving electromechanical systems Heat and humidity resistance or motors. Generic epoxies and cyanoacrylates have average heat Similar concerns are true for cyanoacrylates when they are resistance ranges of 82 to 121°C. Above these tempera- exposed to high humidity or moisture. Cyanoacrylates tend tures, epoxies can lose up to 75% of their initial strength, and to break down when they are exposed to high-humidity sit- cyanoacrylate bonds tend to fall apart. Hybrid structural uations for long periods of time. Hybrid structural instant instant adhesives have been designed to overcome these adhesives overcome this hurdle due to the epoxy portion of temperature limits to meet the demand of higher-perform- the adhesive. Even after exposing the bond line to 65.5°C and ing adhesives. 95% relative humidity for 1000 hours, the hybrid adhesive still Figure 3 shows a heat aging study that compares the bond retained 62% of its initial shear strength (Figure 4). The mois- of grit blasted mild steel (GBMS) using a cyanoacrylate/epoxy ture resistance of hybrid adhesives makes them an excellent hybrid and a generic cyanoacrylate. These parts were bond- choice for assemblies used in outdoor applications where ed at room temperature and brought up to the temperatures exposure to rain and sunshine are common. shown for 1000 hours before being brought back to room temperature and tested for shear strength. The generic Chemical and solvent resistance cyanoacrylate had a mediocre performance when held at Epoxies often have excellent chemical resistance. Epoxies and cyanoacrylates are typically unaffected by non-polar solvents like gasoline and motor oil, but when it comes to polar solvents such as acetone and isopropanol, cyano-

Table 2: Chemical and Solvent Resistance of a Cyanoacrylate/Epoxy Hybrid3

Figure 4: Lap shears of GBMS were bonded and then exposed to 65.5% and 95% relative humidity for the times shown. The lap shears were then pulled apart and the percentage of the original strength is shown for both the cyanoacrylate/epoxy hybrid and a typical cyanoacrylate product.

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SUN - May 22 Pilot Our A collaborative, open discussion session 4:30 - 6 PM moderated by Students and Young Professionals Future in the industry to discuss ways to utilize SPE to navigate their professional and academic careers.

MON - May 23 Learn how polymer technologies drive innovation Plastics 8 AM - 11 AM in the automotive industry in an interactive, University museum-style exhibit titled “Plastics University: How do they do it?”

Plastics The Plastics Race is an app-driven scavenger 1 - 3 PM hunt designed to entertain any attendee – Race from students to veteran industry professionals.

Celebration Come celebrate the Students and Young 7:30 - 9 PM Night Professionals in our Society! Watch the winners of the Plastics Race receive their prizes!

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Hybrid Structural Instant Adhesive Technologies ______

acrylates perform poorly. Hybrid structural instant adhesives Gap filling is an important design consideration, espe- have adapted the chemical resistance attribute of epoxies to cially with structural assemblies where gasses or liquids are produce a bond that is highly resistant to gasoline, motor oil, present. Hybrid structural instant adhesive that can fill a gap ethanol, isopropanol, water, and more (Table 2). up to 5 mm opens up another realm of applications where cyanoacrylates were once not typically considered for use. Gap-filling capabilities While epoxies tend to fill a large gap, especially when applied Uses and applications in multiple steps, cyanoacrylates do not. When cyanoacrylates Hybrid structural instant adhesives are technological break- cure, the adhesive relies on the surface moisture on a sub- throughs suitable for a broad range of applications. They strate to neutralize the acidic stabilizer in the adhesive to demonstrate the greatest benefit in applications where the initiate polymerization. With large gaps, there is too little sur- combination of speed, toughness, moisture resistance, and face moisture for the large amount of acidic stabilizer gap filling is required. These adhesives are suitable for tech- present, resulting in poor or incomplete curing. This limits nologies where outdoor use, UV protection, and low cyanoacrylates’ gap-filling capabilities to an average of 0.25 blooming are needed. They also provide a solution when mm maximum. standard cyanoacrylates prove to be too brittle, and high-tem-

Stuck on your Project? Industry Academia Collaborations can help!

This kind of partnership allows us to accomplish “ what often doesn’t get accomplished. -Lehigh University Collaborates with Beaumont ”

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perature resistance is required. rials. These assemblies will beable to handle harsher chem- Structural applications that require the bonding of multi- icals, higher heat, and other environmental conditions not ple substrates, including metals, plastics, elastomers, and typically supported by adhesives, for production at a faster rubber, will benefit from the use of these hybrid technologies. rate than ever before. Some application ideas include electric motors, textile Now that the adhesive industry is bridging the gap between machines, railways and rail cars, and marine applications cyanoacrylate and epoxyadhesives, engineers, design teams, where good moisture resistance is needed, such as saunas companies, and manufacturers have an option for a better- and hot tubs. Other areas include light assemblies such as performing structural adhesive that allows for high LED luminaries and outdoor lighting housings. production volume demands. Hybrid structural instant adhesives can also be used for electronic components such as antennas and outdoor lighting housings and loudspeakers, plus sporting goods, modern References furniture, jewelry, prostheses, plastic tanks, and for use in 1. Henkel Design Guide for Bonding Plastics. Vol. 6, 2011. 2. Rachel M. Hersee, Barry N. Burns, Rory B. Barnes, Ray P. Tully, general and vehicular maintenance and repair. and John Guthrie. “Two-part, Cyanoacrylate/Cationically Curable Adhesive Systems.” Henkel Ireland Limited, assignee. Patent US20130178560 A1. 11 July 2013. Conclusion 3. Loctite® 4090 Technical Data Sheet. July 2014. The development of hybrid structural instant adhesives will assist manufacturers in overcoming common adhesive prob- Note: This article was the author’s ANTEC® Orlando 2015 paper; lems. Using a cyanoacrylate epoxy hybrid technology, to see other ANTEC papers, call SPE customer service at U.S. 203- companies can make assemblies with a wide range of mate- 775-0471.

SPE invites you to attend a 1-day1-day technical conference & exhibitionexhibition showcasing innovative developments in the design, materials, S JJ QLJQHIRHVXGQDJQLVVHFRUS SJ J RWXDODEROJHKWURIVFLWVDOSJQLUHH \ HFQHUHIQRFVLK7\UWVXGQLHYLWRPR J\S PURIQLRWGHQJLVHG\OODFȴLFHSVVLH P update and educate the OEM and supplier communities about advances in both thermosetthermoset and thermoplastic engineering polymers. Learn how these widely used materials can help improveimprove performance and productivity,productivity, while reducing cost and mass.

Call for Technical Presentations Sponsorship Opportunities Sandra McClelland Edward Luibrand [email protected] [email protected] PH: +1 586-292-1794 PH: +1 248-512-0641

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CONSULTANT’S CORNER

Cold Runner Design: Sizing Up Your Runner System Designing runners for multi-cavity injection molds is no straightforward process

By David A. Hoffman American Injection Molding (AIM) Institute, Erie, Pennsylvania, USA

he topic of runner sizing always comes up during our plastics education courses at the AIM Institute. Every- The Science behind the Theory one wants a magic formula for sizing every runner Let’s presume that you want to use a graduated runner Tfor every mold, regardless of machine capabilities, pressure design. Now the discussion naturally leads into how to deter- to fill the part, cycle-time requirements, and packing. There mine which diameters you should use. Our industry has is much confusion in the industry about this topic, so let’s several methods for determining the sizes of a graduated take a look at various thought processes for sizing cold runner systems. Consider the 16-cavity, geometrically balanced mold layout shown in Figure 1. Think about the questions you would ask yourself when trying to determine how to size the runner system. Then consider this question: “Should each diameter of each leg of the runner system be the same diameter, or should the diameters of each leg change whenever the runner splits/branches?” The typical response to this question is that the diameters should change at every branch. The next question to answer then is “Why?” Typically I get two responses to this question: either a blank stare or “Well, that’s the way we always have done it.” There are other explanations we’ve heard over the years about why we think we need to change runner sizes at every branch. These include: to maintain a constant shear rate in the runner, maintain a constant velocity in the runner, maintain a constant pressure drop per unit length in the runner, or minimize runner volume. (Note: for discussion purposes we’ll call a geometrically balanced runner that uses different sizes at each progressive branch a “graduated” runner.) Figure 1: A 16-cavity, geometrically balanced mold layout.

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runner, including standard formulas, rules of thumb, mold Graduated or Constant-Diameter filling simulation, and “whatever the next cutter size is.” Each Runners? method has its own scientific-sounding theory behind it (except maybe the cutter size method), and each method As you can see, it’s important to understand the methods may work for a given scenario. But we need to understand you may be using to size your graduated runner design. To the science (or lack of science) behind each theory and deter- throw a curve-ball into the discussion, now consider making mine if it’s important to the part, material, and/or process. the runner branches all the same size. Many of you are prob- As an example, this formula is used by many designers in ably saying: “Who would ever do such a thing? You always our industry to size runner systems: have to step the runner sizes.” But please bear with me. Figure 2 shows two different runner sizing approaches for the eight-cavity mold shown. In this case study, the minimum x 1/3 diameter of 0.150” (3.8 mm) was selected to help ensure feed = branch good packing of the part. Therefore, if that is our minimum d d N runner size, then the graduated runner branches become larger as they progress back toward the sprue. The result is In fact, some simulation software companies will even ref- that the graduated runner has roughly twice as much mate- erence this formula, if for some reason simulation cannot rial volume than the constant-diameter runner design. In be used to engineer the runner system. (The d stands for addition, the graduated runner may also increase the overall the runner diameter at each section of the runner, and N cycle time due to the size of the primary runner. stands for the number of branches at the split. For example, Another design approach to consider would be to utilize if the feed runner splits in two directions, then N = 2.) a graduated runner that has the same runner volume as The science behind this formula relates to shear heating the constant-diameter runner. This is shown in Figure 3. Now and thermal cooling. However, an interesting outcome of we have not wasted any additional material with the grad- this formula is that it provides runner sizes where each leg uated runner as we did in the previous scenario. But when of the runner will experience the same shear rate. This is looking closer at the designs, it appears that the graduated one of the theories mentioned earlier, and this may sound runner system would still need a longer cooling time, along like a good thing, but you have to ask some more questions: with creating a potential packing problem due to the smaller • Is having the same shear rate in each runner leg impor- tertiary runner diameter. tant to you, considering the shear rate is probably not All of these considerations tend to frustrate people, and the same everywhere within the part? so the next question they ask is: “Which runner sizing tech- • What material are we molding? nique works on every mold, material, and part?” The answer: • How much available pressure does the molding machine None. When sizing a runner system you need to ask yourself: have? What’s important to you? Below are five common replies to • How much pressure drop through the runner system that question. and part is acceptable? 1. Material volume And so on. 2. Cycle time To further explore this, consider only the material you’re 3. Maximum injection pressure molding. The formula above would provide you with the 4. Packing same runner sizes regardless of whether you’re molding the 5. Degradation part out of a polypropylene material or a polycarbonate. Typically the replies are not only one specific answer, but Does that sound right to you? rather a combination of two or three of them. But if you can

Diameter

Increased Primary Secondary Tertiary Runner Runner (in) (in) (in) Volume Scrap Constant Diameter 0.150 0.150 0.150 0.228 Graduated Diameter 0.238 0.189 0.150 0.467 105%

Figure 2: Different runner sizing approaches for the eight-cavity mold shown.

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CONSULTANT’S CORNER Cold Runner Design ______

Diameter

Primary Secondary Tertiary Runner (in) (in) (in) Volume Constant Diameter 0.150 0.150 0.150 0.228 Graduated Diameter 0.167 0.132 0.105 0.230

Figure 3: A graduated runner that has the same runner volume as the constant-diameter runner.

prioritize your answers, it will serve as your guide on how About the author… David A. Hoffman is senior instructor, Plas- best to size the runner system to meet your objectives. You tics Education & Training, for the American Injection Molding may find out that a graduated runner is best for one mold, Institute and has worked as a part and mold designer, process but a constant-diameter runner is best for the next mold; engineer, and engineering manager for various companies, in and yet a runner system where the sizes only change on addition to working as technical sales manager for Beaumont some runner legs may be best for another mold. This article Technologies, Inc. Contact him at U.S. 866-344-9694 or only scratches the surface of the science behind runner [email protected]. sizing techniques. If you would like to learn more about this topic, please visit www.aim.institute.

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16th-Annual

ATTEND THE WORLD’S LEADING AUTOMOTIVE COMPOSITES FORUM The Automotive and Composites Divisions of the Society of Plastics Engineers (SPE®) invite you to attend the 16th-annual SPE Automotive Composites Conference and Exhibition (ACCE), September 7-9, 2016 in the Detroit suburbs. The show – which has become the world’s leading automotive composites forum – will feature technical paper sessions, panel discussions, keynote speakers, networking receptions, & exhibits highlighting advances in materials, processes, and applications technologies for both thermoset and thermoplastic composites in a wide variety of ground-transportation applications. Call for Papers PRESENT BEFORE AN ENGAGED, GLOBAL AUDIENCE The SPE ACCE draws over 900 attendees from 15 countries on 5 continents who are interested in learning Exhibit & Sponsorship about the latest composites technologies. Fully a third of attendees work for a transportation OEM, and Opportunities roughly a fifth work for a tier integrator. Few conferences of any size offer such an engaged, global audience vitally interested in hearing the latest composites advances. Interested in presenting your latest research? Abstracts are due March 31, 2016 and Papers on May 31, 2016 to allow time for peer review. For More Information E-mail abstracts or papers to [email protected]. Approved papers will be accessible +1.248.244.8993 ext. 4 to attendees on a cloud-based server and later will be available to the general public. http://speautomotive.com/comp SHOWCASE YOUR PRODUCTS & SERVICES A variety of sponsorship packages – including displays, conference giveaways, advertising and publicity, signage, tickets, and networking receptions – are available. Companies interested in showcasing their products and/or services should contact Teri Chouinard of Intuit Group at [email protected].

2016 Early Bird Sponsors

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Modern Molding for Polycarbonates

Emerging techniques optimize the appearance and production of PC-based parts

By Mark Matsco Covestro LLC, Pittsburgh, Pennsylvania, USA

olycarbonates and polycarbonate blends are versa- closer to the softening point of the polymer is needed; how- tile and proven materials for producing components ever, this can lead to longer cycle times using conventional found in a wide range of markets and applications. molding and cooling technology. PFor most applications, the surface quality of a plastic com- In the RH&C process, the mold surface is heated before ponent is important from an aesthetic and functional injection occurs. Once the mold is filled, the mold is cooled perspective. The surface quality of the plastic part depends rapidly during the holding and cooling phases before the on the properties of the thermoplastic, the mold surface fin- part is ejected (see Figure 1). ish, and the parameters of the injection molding process. The benefits of RH&C include the ability to eliminate sur- For parts using polycarbonate, the injection molding face defects, such as the visibility of material fillers, surface process has been the primary technology for mass pro- blush, and weld lines, while also being able to generate high- duction. This has allowed engineers and designers to design and low-gloss parts—all within a single cavity. Importantly, polycarbonate components with varying geometric com- with RH&C, the surface quality and aesthetics of injection plexity having excellent part-to-part repeatability and meeting molded parts can be improved while keeping the cycle time tight tolerances. as short as possible. Injection molding technology has continually evolved to Using RH&C technology together with polycarbonates and meet changing application and market requirements. This PC blends (e.g., PC/ABS) provides an opportunity to achieve advancement continues today with innovative methods for Class A surfaces with high gloss or matte finishes on the enhancing plastic part surface quality “in the tool.” Now, advanced techniques like rapid heating and cooling (RH&C) and “DirectCoating/DirectSkinning” (DC/DS) are helping molders and original equipment manufacturers (OEMs) meet challenging performance and appearance targets while reducing costs.

Rapid Heating and Cooling During the typical injection molding process, a thin frozen skin layer is formed due to the temperature difference between the mold tool surface and the polymer as they come into contact during injection. The temperature difference can cause poor surface quality and highly visible weld lines in some instances. Weld lines on a polycarbonate part can cause structural issues and be visually unacceptable for Figure 1: Mold-temperature profiles using conventional cool- use. To improve part surface quality, a mold temperature ing vs. RH&C.

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same part, while reducing or eliminating weld lines. Thin- lines between the manifold and the mold, as well as the wall parts with defect-free surfaces can be achieved even cooling lines within the mold. (To reduce the delay, cooling with a glass-filled polycarbonate blend. Significantly improved lines should be short in length and the manifold positioned surfaces are also seen in applications using foaming agents, as close as possible to the mold.) compared to conventional molding/cooling. Taking advantage of dual circuits, a water-based system RH&C is used by manufacturers in the consumer elec- has the ability to switch over to the hot circuit during the tronics, automotive, medical, lighting, and information cooling cycle. Before ejection, the cooling circuit is active, technology/electrical markets for applications where sur- removing heat from the mold and part. Since a delay occurs face quality is vital. Applications include auto interiors, when switching from one circuit to another, the heating cir- component housings, and mobile devices (for example, see cuit can be activated toward the end of the cooling phase. Figure 2). This reduces the time it takes for the unit to heat the mold to the desired set temperature. When designing a tool to be used with RH&C, placement Controlling RH&C of the cooling lines close to the surface of the cavity is crit- Special equipment is required to control the rapid heating ical to improving process quality and efficiency (Figure 3). and cooling of the mold. There are fluid-, electrical-, and For complex-shaped parts, conformal cooling can be used induction-based temperature control systems. Polymer to ensure the cooling channels remain close to the mold materials supplier Covestro recently installed a water-based surface in visual regions of the part. Coupling RH&C togeth- dynamic mold temperature controller at its Pittsburgh-based er with conformal cooling has been shown to reduce cycle North American headquarters to optimize the surface qual- times by 20 to 40% while achieving high-quality surface ity of polycarbonates and PC blends. appearance. The uniform cooling of the mold also lowers The dynamic mold temperature controller has a hot and rejects and molded-in stress. cold water circuit. This allows the user to adjust each temperature to optimize the heating and cooling of the mold during all phases of the injection molding process. DC/DS: “DirectCoating/DirectSkinning” At the start of the cycle, the tool surface temperature can In cases where a plastic component needs an applied sur- reach 300°F (150°C) during injection. Since the unit has two face using a second material, such as painting, coating, or circuits, a switchover from the hot circuit to the cold circuit foaming, secondary steps outside the mold have generally occurs during the cycle, typically once the controller detects been needed. Two new technologies enable premium qual- the end of the filling phase. When this switchover occurs, ity surfaces to be efficiently manufactured from high-grade there can be a delay from the time the switch takes place materials in a single step within the mold. DC/DS is a ver- to the time the mold temperature drops. This is because satile method for over-molding injection-molded the cold water must replace the hot water present in the polycarbonate parts with polyurethane foams or coatings

Figure 2: Automotive mirror housing part surface quality Figure 3: Cooling line placement in the injection mold using conventional cooling (left) and RH&C (right). enhances the surface effects of using RH&C.

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Modern Molding for Polycarbonates ______

inside the tool. The result is a rigid, PC blend substrate with textures, and softness. The same tool can produce a prod- a soft, ultraviolet-stabilized, scratch- and chemical-resistant, uct with a surface that is hard or soft to the touch. aliphatic polyurethane self-skinning foam, solid polyurethane A typical coating or skinning process is expensive, labor- skin, or polyurethane coating. intensive, and requires several secondary steps. DirectSkinning is a cost-effective process for the finishing Conventionally, manufacturers first mold the hard substrate of parts with colored decorative polyurethane surfaces, and then move the part to a fixture or other operation to including surfaces with multiple colors, variable softness, apply the coating or skin. This often requires the storage, and tactile textures (Figure 4). DirectCoating technology transportation, cleaning, and pretreatment of the part, which enables the efficient application of colored coatings, soft- is susceptible to contamination and damage. Other disad- touch coatings or clear-coats, including high-gloss surfaces. vantages include long production time, complex logistics, With both DirectCoating and DirectSkinning, the coating high investment cost, and high energy consumption. or skin is molded onto the first-shot plastic substrate using The ultra-low volatile organic compound DirectCoating the reaction injection molding (RIM) process. This is usual- process also eliminates the need for painting and the asso- ly achieved using a single shuttle mold, which moves the ciated overspray common in traditional in-mold painting. core between an injection molding cavity (first shot) and a Utilizing direct coating over standard coating can reduce the RIM cavity (second shot). The two production steps can be production time from hours to 90 seconds per part. performed concurrently, resulting in a short cycle time and DC/DS offers many advantages to molders as it provides high productivity. an opportunity to expand on existing capabilities. Conven- DC/DS is suited for manufacturers in consumer and indus- tional injection molding machinery can be used with the trial markets seeking a high-end, cost-effective solution for addition of a fitted RIM unit modified to run the DC/DS products such as electronic device housings, arm rests for process. The ability to run two different molding processes office seating, and automotive door trim, instrument panels, in a single tool is more efficient, resulting in cost savings and and exterior pillars. Using DC/DS allows for design flexibili- a higher-value finished product. OEMs simplify the supply ty and freedom with a wide range of customizable colors, chain and see better yields of a product that has a superi-

Figure 4: Automotive interior trim panels using DirectSkinning.

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or appearance, feel, and performance. Note: Thanks to Covestro’s Jessica Boyer, Ian Menego, and Jessee When building a tool for DC/DS, it is important to keep in McCanna for valuable contributions to this article. mind that a shuttle or rotary design is needed. This will typically require either multiple cores or cavities. Tool costs can About the author… Mark Matsco is currently director of appli- be expected to be 20 to 30% higher than for a multi-cavity cation development in the injection mold. However, both the injection molding and Polycarbonates business unit RIM process will be integrated into the single tool. at Covestro LLC (formerly Bayer MaterialScience LLC). He helps customers with Conclusion part/mold design, engineer- OEMs continually search for ways to improve part aesthet- ing, cost estimations, CAE, ics and optimize production to meet performance and cost process optimization, challenges. RH&C and DC/DS offer many possibilities for advanced processing, part enhancing plastic part surface quality while reducing cost, testing, and on-site technical cycle time, scrap, and labor, while eliminating secondary service. Matsco has more operations. These benefits, combined with a low capital than 30 years of experience investment, make RH&C and DC/DS attractive options for in the plastics industry in var- OEMs seeking to produce quality plastic parts for diverse ious managerial/technical markets and applications. leadership positions.

10 th EUROPEAN THERMOFORMING CONFERENCE 2016

10 - 11 MARCH 2016 SITGES (BARCELONA)

THIS IS A SPECIAL ‘MILESTONE’ EVENT SO MARK YOUR CALENDARS AND DO NOT MISS THE ONLY EVENT THAT IS DEDICATED TO EUROPE’S THERMOFORMING INDUSTRY

The European Thermoforming Division invites you to the 10th European Thermoforming Questions? Conference to be held in Sitges (Barcelona) from 10th to 11th March 2016 at the Melia Hotel. Contact: Yetty Pauwels [email protected] Join us in Sitges, Barcelona where we will be celebrating 20 years of the ETD supporting Tel. +32 3 541 77 55 your industry, you will be most welcome. www.e-t-d.org

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ACCE 2015 Highlighted Interesting Shifts in the Composites Industry: Part II Here, more innovations are presented from last year’s SPE event, in this continuation of the review from the November/December issue of Plastics Engineering

By Peggy Malnati

s noted in “Part I” of our SPE Automotive Compos- duction to help OEMs lower the weight and costs of com- ites Conference & Exhibition (ACCE) overview ponents for land as well as air transport. The 2015 ACCE, (November/December 2015, p. 40), many changes held in September in Detroit, broke exhibition and atten- Aare occurring in the composites industry and exciting new dance records and was a hotbed of discussion and technologies are near commercialization or just coming to networking about the challenges facing all transportation market. The global composites supply chain is under intense OEMs. What follows are two additional technologies this pressure to drive down costs and cycle times on part pro- writer saw at the show that hold great promise.

A new inline prepreg (InPreg) production method utilizes a four-part epoxy-resin system and a unidirectional, non-crimp fabric featuring 50K tow carbon fiber rovings to produce single layers of prepreg with precise fiber/resin ratios (feeding in from far right). After applying resin to the fabric (right), the web of material is heated to 90ºC for 4 min. to B-stage the epoxy (middle table), then cooled to room temperature to stop the reaction and make the material manageable to handle (left table). Next the release liners are removed, and the prepreg is cut before being stacked and molded. (Photo courtesy of Fraunhofer Institute for Chemical Technology.)

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prepreg. Further, by producing and impregnating a single Another Way to Turn Molders into layer at a time, very precise fiber/resin ratios are achieved, Prepreggers and voids are eliminated, yielding a high-quality product. As noted previously, laminate composites (usually supplied Instead of forming the part via vacuum-bag or autoclave as B-stage sheets of unidirectional (UD) carbon fiber rov- cure, InPreg material is designed to be processed in a stan- ings impregnated with epoxy resin) are of great interest to dard compression press widely available in the automotive transportation OEMs, owing to their high mechanical per- industry. Both forming and curing are done in the press, formance at very-thin cross-sections and very-low part weight, eliminating the time, equipment, space, and cost of the pre- low voids, and good drapeability. The downside is that these forming step that normally precedes laminate molding. materials can’t produce the complex geometries of a process Eliminating steps, labor, and scrap, helps lower costs. like resin-transfer molding (RTM), they have relatively high A key aspect of the process is access to the four-com- labor and scrap rates (increasing costs), and they have rel- ponent epoxy resin system supplied by Huntsman atively slow production speeds when cured via conventional Advanced Materials (Basel, Switzerland) that consists of vacuum-bagging or autoclave systems (also increasing costs). resin (Araldite LY1556), hardener paste (Aradur 1571), accel- Even the newer out-of-autoclave (OOA) systems are still slow erator paste (Accelerator 1573), and a polyamine-based versus a process like conventional thermoset compression hardener (Hardener XB3471). Pre-curing to achieve B-stage molding, which can produce big parts in 2.5- to 3-min. but- is done at 90ºC for 4 min. and final/full cure is done at ton-to-button cycles. 150ºC and 7.5-8 bar pressure for 10 min. Pre-impregna- Much work has been done on so-called snap-cure resin tion and cutting/stacking steps can be done parallel to systems (2 min. or shorter) and on further developing OOA molding; since InPreg prepreg will remain stable for several processes and equipment to reduce cycle times, but the days after production, molders can build inventory to feed high labor and scrap rates of laminate composites still need the slower molding process without needing to freeze/thaw to be addressed. Based on two interesting papers present- material before molding. ed at the SPE ACCE, it seems that attention is now being focused on dealing with labor/scrap issues, which could help drive part costs down significantly and make these high-performance materials more affordable for higher-volume vehicles. If either approach proves viable, it could do for laminate composites what inline compounding (ILC) did for pelletized long-fiber thermoplastics (LFT) 15 years ago with the direct-LFT process. One approach was developed by Fraunhofer Institute for Chemical Technology (F-ICT, Pfinztal, Germany) and involves what the group calls the InPreg (inline-prepreg) process. Since F-ICT helped develop the original D-LFT process in the late ‘90s and the direct-sheet-molding compound (D-SMC) process about five years ago, the organization has a proven track record of helping molders eliminate compounders and semi-finished goods manufacturers to produce their own material just prior to molding. F-ICT’s approach this time involves using the same kind of four-part, B-stageable epoxy system that prepreg producers (prepreggers) use in industry. However, since the InPreg process assumes processors will mold parts physically close to and shortly after prepreg production, it eliminates the need to freeze and store semi-finished product prior to shipping to customers who must thaw the material before molding parts. They’ve also combined a lower cost heavy (50K) tow grade of carbon fiber (with properties more than adequate for A fairly large (550 x 500 x 35 mm) and reasonably complex automotive) that has been formed into a unidirectional, non- 2.5-D test part molded via InPreg/compression molding crimp fabric (NCF). This dry NCF impregnates faster and using a tool developed by Huntsman Advanced Materials more easily than unidirectional (UD) dry spread fiber tapes, (photo courtesy of Fraunhofer Institute for Chemical which are the usual intermediate step between rovings and Technology).

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ACCE 2015: Part II______

An interesting follow-on study at F-ICT compared per- egory and the subject of the event’s final keynote, present- formance of comparable conventional (purchased) prepreg ed by inventor Antony Dodworth, chief technology & vs. InPreg prepreg molded via autoclave and vacuum-bag manufacturing officer, Bright Lite Structures, LLC (BLS, Peter- (both single-sided tools), and compression molding (matched- borough, UK). metal dies), as well as a third laminate produced for/used in The components—front and rear bulkheads, floor pan, wet-compression molding. The InPreg/compression mold- and left and right side body-side panels bonded together ed material achieved performance comparable to as a single large module around a central aluminum spine— conventional/autoclave-cured laminates and superior to make use of a patent-pending honeycomb-sandwich vac-bag parts. It also was the second fastest process (after composite. It’s said to meet or exceed the vehicle’s com- wet-compression) but had better properties and lower voids pression, stiffness, and torsional rigidity requirements and than wet-compression molding. yield a chassis module that is stiffer, lighter (15-20%), and Current F-ICT calculations predict comparable parts in has more design versatility than conventional carbon com- InPreg/compression molding will cost 45% more than wet- posite materials. compression molding but one-eighth the cost of conventional Parts are produced from simple rolled goods via wet-com- prepreg/autoclave. To advance the project further, F-ICT pression molding, which can rapidly mold deep-draw 2.5-D seeks industry partners with suitable applications of signif- and 3-D designs that wouldn’t be possible without complex icant volume to justify further work. and expensive preforming operations in most other composite molding processes. The dry fiber/core/fiber Lowering Costs for Carbon Composite reinforcement stack is laid up on a table, then carried via Parts robot to the spray booth where both sides are coated with An attention-grabbing multi-piece set of carbon composite resin before being moved to the tool and manually laid in chassis components on the 2015 Zenos E10 sports car (from place and attached to a clamp frame. The tool closes in three Zenos Cars Ltd., Norfolk, UK), was both a winner of the ACCE’s distinct stages, allowing forming and curing to be done in a 2015 “Best Part” competition in the Materials Innovation cat- single step.

A novel multi-piece set of carbon composite chassis components (above) on the 2015 Zenos E10 sports car (right) was both a winner of the SPE ACCE’s 2015 “Best Part” competition in the Materials Innovation category and was the subject of the event’s final keynote. The components use a novel and patent-pending carbon composite sandwich panel formed via wet-compression molding. (Photos courtesy of Antony Dodworth.)

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Interestingly, for manufacturers seeking lower costs and/or assembly time and costs vs. metals and monolithic carbon “green” technology, the Zenos panels use significant recy- composites. Wet-compression molding is equally applica- cled content in both the honeycomb cores (made by BLS ble for prototyping and high-volume commercial production, from recycled polycarbonate (PC) “straws”) as well as the helping reduce component costs further so carbon com- fiber-reinforcement package (a proprietary blend of recy- posites become affordable for a wider range of vehicles. cled chopped carbon fiber mat plus a multilayer NCF layup Further, owing to significant use of recycled materials, and of other materials of varying densities for sections requiring part geometry and nesting efficiency on the cutting table, higher mechanical performance). the material/process combo uses less fiber and resin and A unique 70/30 blend of Vitrox polyurethane (PUR) resin generates less scrap than conventional carbon composite from Huntsman Polyurethanes (Auburn Hills, Michigan, USA) production systems, yet reportedly produces parts of com- and an unnamed RTM epoxy are mixed just before spraying parable performance at lower total material costs. with an AutoRIM five-component metering unit from Hen- Additionally, capital costs are significantly reduced vs. auto- necke Corp. (Lawrence, Pennsylvania, USA). The PUR provides clave, OOA, or preformed RTM processes owing to the a strong physical-property profile, excellent adhesion to the simplified manufacturing process, press, and tooling, which honeycomb core, and outstanding impact strength/tough- can be produced in aluminum or steel. ness for a given resin Tg. The epoxy improves crash energy BLS is currently molding with 6-bar molding pressures at management and seals micro-porosity in the foamed ure- a 12-min. button-to-button cycle, a figure that is expected to thane to prevent moisture transfer. The urethane uses a decrease towards 6 min. as process automation improves. novel catalyst, said to provide stable low viscosity (for rap- The company says their manufacturing cells can be quickly id fiber impregnation) and tunable/long working times until set up adjacent to OEM assembly facilities, and they can go snap cure, making it ideal for these large parts. The PC core from concept to production in under 12 months’ time. is very stiff and has a high Tg that is well matched to that of the PUR/epoxy blend. Note: Read more about both of these technologies and view 15 Owing to significant parts integration, the design saves years of ACCE proceedings free at speautomotive.com/aca.

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The Word on Plastics Recycling: Momentum Plastics recycling is growing: steadily, broadly, and expansively

By American Chemistry Council (ACC)

Note: This article continues the series of updates in Plastics together), saved “the same amount of energy consumed by Engineering from Plastics Make it Possible®, an initiative spon- almost 10 million U.s. households in a year” and reduced sored by America’s Plastics Makers® through the ACC. greenhouse gas emissions the equivalent of removing more than 33 million passenger vehicles from the road in a year. t’s useful every once in a while to remind ourselves why Plus, recycling industries can create significantly more jobs we recycle anything at all. imagine for a moment the long than simply hauling and burying garbage, the EPa adds. and winding path of something as commonplace as a looking specifically at plastics, a 2010 study found that plastici milk jug: from natural resources to petrochemical recycling HDPE and PEt can save enough energy each year facilities to plastics production to blow molding to filling, to power 750,000 homes. and recycling and reusing HDPE shipping, merchandizing, purchasing, and (finally) enjoying. can reduce greenhouse gas emissions 66%, compared to Does it make sense to simply discard all that? Materials often using virgin HDPE. have value even after we use them, so burying them in a so, combine energy savings, reduced waste and green- landfill is an egregious waste of resources. house gases, and more jobs, and recycling sounds pretty Furthermore, recycling can reduce energy use and cut smart. thankfully, recycling in the Usa continues to grow; greenhouse gas emissions. according to the U.s. EPa, recy- according to the EPa, the recycling rate has more than dou- cling, combined with composting (EPa often lumps these bled since 1990.

More types and greater amounts of used plastics are being collected and recycled.

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the rate for plastics recycling has grown even more than Polystyrene Foam that, in part because recycling these newer materials began in earnest only in the 1990s. companies that make plastics Access to curbside and drop-off recycling programs for foam invested billions of dollars over the past few decades to help polystyrene packaging is growing across the UsA. the EPs set up the recycling infrastructure (the topic of a future Plas- industry Alliance reported an all-time high recycling rate of tics Make it Possible article). so today the plastic bottle recycling 34% for foam polystyrene protective packaging for 2013. rate is approaching the rate for glass. to help increase recycling, a new interactive website allows While there still is a long way to go to catch aluminum and Americans and canadians to search for local foam packag- steel recycling rates, here’s a quick look at the success of ing recycling programs. For example, PSFoamRecycling.org recycling for some common plastics, based on the latest differentiates between programs that accept protective foam tracking data—and advances that may well increase the packaging (typically used for transporting electronics and momentum. other high-end products), programs that collect foam food packaging (such as coffee cups, clamshell containers, egg cartons, and meat trays), and programs that collect both Bottles types of packaging. the site also notes whether the foam the U.s. recycling rate for plastic bottles reached nearly 32% packaging is collected at curbside or drop-off programs, and in 2014. Plastic bottle recycling grew by 97 million pounds, identifies foam packaging “mail back” programs for areas to over 3 billion pounds (1.4 billion kg) for the year. that where local recycling does not exist. marks the 25th consecutive year that Americans have Recycled polystyrene is used to make numerous prod- increased the pounds of plastic bottles collected for recy- ucts, from picture frames and crown molding in building cling since surveying began in 1990. interiors, to egg cartons. the collection of polypropylene bottles, specifically, has jumped more than 28% to reach a recycling rate of nearly 45%, higher than the collective recycling rate for glass beer A New Recycling Fund and Facility and soft drink bottles. to help increase the momentum of recycling, ten of the Meanwhile, the recycled resins made from plastic bottles largest consumer products companies (including P&g, Wal- are used widely in plastic products and parts, from clothing mart, and coca-cola) have created the $100 million closed fabrics and automotive components to new bottles. loop Fund. the Fund provides zero- and low-interest loans to cities and companies that want to build new recycling facilities and projects for plastics and other materials. By Non-Bottles, or “Rigids” 2025, it aims to eliminate more than 50 million tons of green- Rigid plastics represent a category of non-bottle plastic con- house gas, divert more than 20 million tons of waste from tainers, along with caps and lids. More than one billion landfills, and create more than 20,000 jobs. pounds of rigids were collected for recycling in the UsA in 2013. that’s triple the amount collected in just 2007. these plastics are recycled primarily into auto parts, crates, buckets, pipe, and lawn and garden products.

Film instead of being collected at the curbside like bottles and rigids, plastic bags (for groceries, food/produce, newspaper delivery, dry cleaning), and plastic overwraps for products (beverage cases, diapers, napkins) are collected for recycling at more than 18,000 grocery and retail stores across the UsA. Even though this at-store collection program is relatively new, the recycling of this postconsumer plastic “film” packaging surged 11% in 2013 to reach more than 1.1 billion pounds (500 billion kg). Plastic film recycling has increased nearly 75% since 2005 and has reached a rate of 17%. Recycled plastic film is used to make a range of products, including durable composite lumber for outdoor decks and fencing, home building products, lawn and garden prod- The collection of polypropylene bottles has jumped more ucts, crates, pipe, and film for new packaging. than 28%, to reach a recycling rate of nearly 45%.

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The Word on Plastics Recycling______

the Fund’s first project opened in late 2015: a high-tech been separated according to type can be much more valu- recycling facility in Baltimore, Maryland, that’s able to sort able than streams of mixed plastics. the facility also plans 54,000 tons of plastics for recycling each year, including to process the plastics back into raw pellets for sale. some that today are not recycled often. as one of the largest the combination of funding source, advanced technolo- facilities of its kind, the Qrs Plastics recovery Facility is gies, and pellet processing are designed to make broader expected to collect plastics within a 500-mile radius across plastics recycling more cost-effective. according to the closed the U.s. East coast, and will process approximately 4,500 loop Fund, facilities like this could be replicated across the tons of materials each month, more than double what’s cur- nation—and beyond. rently possible in the Usa, according to its backers. the momentum in plastics recycling is encouraging, help- the facility uses technologies that can make it more eco- ing all of us reduce our environmental footprint. let’s keep nomical to sell these plastics in the market, which could it up. considerably increase the amount of plastics recycled. advanced, high-tech optical sorters “read” different types For more information on plastics recycling and applications, of plastics and then send puffs of air to blow specific items visit plasticsmakeitpossible.org. into the correct stream. these streams of plastics that have

# Energy Mapping Actions: 61 Before starting to try to reduce energy use at any site, you • Start building an energy map. need to know where you are using energy. This is so that Count the motors (and their sizes), count the lights, you do not spend time on the small things, but rather • estimate the actual duty load and operational hours, concentrate on where you will get the “biggest bang for your buck.” For example, people get fascinated by the and start to put values on the energy used per year. lights, but lighting uses less than 5% of the energy at most • If machine monitoring data is available, then this plastics processing sites. If you want to reduce your should be used to improve the accuracy of the energy energy bill by 30%, then this is not the place to start! map.

Energy mapping is a technique that we developed to • Use the actual energy bills for a year as a final “reality quickly assess how much energy a site is using in each check” for the total energy used. area (services, machines, and site). Energy mapping • Start to use the energy map to quantify the potential uses a simple spreadsheet approach; a sample energy savings, and prioritize your actions. map for an injection molding site is available at www.tangram.co.uk/energy. (This obviously can be modified for other processes/machines.)

Energy mapping focuses attention on the big energy users and makes the priorities for action clearer. A reasonable Dr. Robin Kent — ©Tangram Technology Ltd. energy map will take about four hours to produce, but it (www.tangram.co.uk) gives clarity in decision-making. You may be surprised with the results—especially the costs of services

Note: Dr. Robin Kent is the author of Energy Management in Plastics Processing, published by Plastics Information Direct, and managing director of Tangram Technology Ltd., consulting engineers specializing in energy management in plastics processing. [email protected].

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INSIDE SPI

Less is Less: The Battle to Wrap It Up in Plastic

By Michael Taylor SPI Vice President, International Affairs and Trade

hen it comes to packaging—plastic is the envi- • increase energy use by 80%—equivalent to the energy ronmental material of choice. Plastic products are from 91 oil supertankers; and environmentally friendly, and manufacturers who • result in 130% more global warming potential—equiv- Wproduce these versatile products take pride in their efforts alent to adding 15.7 million more cars to our roads. to implement sensible green policies and procedures. And plastics engineers continually work to do even more And, according to a talk given by David Tyler, a chemistry with less; this process of lightweighting can help boost the professor at the University of Oregon: “[P]lastic bags are environmental and economic efficiency of consumer prod- greener than paper bags, disposable plastic cups have few- uct packaging. Since 1977, the two-liter plastic soft-drink er impacts than reusable ceramic mugs, and owning a dog bottle shrank from 68 to 47 grams, a 31% reduction per bot- is worse than driving an SUV.”1 tle. This saved more than 180 million pounds (82 million kg) When you consider the entire life cycle of packaging mate- of packaging in 2006—just for two-liter soft-drink bottles rials, plastics compare favorably to other materials in areas alone. The one-gallon plastic milk jug succeeded on a simi- like energy and water use, air and greenhouse gas emis- lar diet, weighing 30% less today than it did 20 years ago. sions, and solid waste. It has been demonstrated that plastic Next to lightweighting (or source reduction), the U.S. Envi- packaging helps reduce energy use and greenhouse gas ronmental Protection Agency identifies “reuse” of packaging emissions, compared to alternative materials. as the next highest priority in managing waste. Plastics pack- How does plastic packaging help with sustainability? Sim- aging’s durability enables reusability in storage bins, sealable ply put, plastic does more with less. It’s more energy-efficient food containers, and refillable sports bottles. And 90% of to make plastic as opposed to other packaging materials, Americans report that they reuse plastic bags. and it takes less lightweight plastic to package a product. In summary, plastic is the smart material of choice because For example, two pounds of plastics can deliver roughly it’s light, inexpensive, versatile—and recyclable. ten gallons of beverages, as compared to three pounds of aluminum, eight pounds of steel or more than 40 pounds To learn more about plastic packaging, please view SPI’s latest of glass. Lighter packaging means less fuel is used in ship- Market Watch report, “Packaging Market Watch: Plastics Wraps ping. Meanwhile, plastic bags require less total energy to it Up,”2 at SPI’s website, www.plasticsindustry.org. produce than paper bags, and they also conserve fuel in shipping (i.e., one truckload for plastic bags versus seven for paper). References Replacing plastic packaging with non-plastic alternatives 1. www.opb.org/news/blog/ecotrope/which-is-greener-its-not-what- youd-expect/ in the USA would: 2. www.plasticsindustry.org/BusinessDevelopment/marketwatch.cfm? • require 4.5 times as much packaging material by weight, ItemNumber=13974 increasing the amount of packaging used by nearly 55 million tons;

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INDUSTRY NEWS

Herrmann Ultrasonics Inc. has worked with Florida-based To meet the increasing requirements for ultrasonic assem- medical products company Genicon to build one of the bly processes in sterile environments, Herrmann Ultrasonics largest ultrasonic medical weld tools ever designed. The introduced the new Medialog welder, which caters to med- product being welded—a newly designed suction irrigation ical device manufacturers. Together with stainless steel, handle—was displayed by Genicon at the recent MEDICA cleanroom-friendly surfaces, and modified pneumatics, the 2015 tradeshow in Germany. welder includes a unique FSC operator interface. The device is used for liposuction. The application was FSC stands for “FDA system component,” and it meets the very challenging due to the size of the joining partners and demanding requirements FDA CFR 21 part 11 of the Food and their three-dimensional shapes—especially the 12-mm dif- Drug Administration. FSC includes complete documentation ference in contour heights, which needed to be matched by of all actions performed by authorized users and records the contact surface of the weld tool, called a sonotrode. The time-stamped audit trails. The creation of customized indi- team at Herrmann made it work with a 220 x 180 mm alu- vidual access authorization, in combination with electronic minum sonotrode. signatures, ensures authenticity, completeness, and confi- dentiality of all data, Herrmann adds. www.herrmannultrasonics.com

To address an industry need for a broader processing filament, Eastman Chemical Co. and colorFabb BV have announced an enhanced product for the 3-D printing industry: nGen, a new product made with Eastman Amphora™ AM3300 3D polymer, adds functional properties and top print quality to the filament line, and has the ability to print within a wide processing range. The product is made from Eastman’s Amphora range of copolyesters designed specifically for 3-D printing. Like the colorFabb XT filament that came before it, nGen is a tough, low-odor, styrene-free offering that’s suitable for most day- to-day 3-D printing activities. It’s reportedly easy to use and reliable, being designed for a wide range of 3-D printing enthusiasts. With its ability to work at a large range of processing temperatures, nGen processes at 220-240°C and has an elevated heat resistance of 85°C. Its ability to dissipate heat faster than other types of filaments improves the performance on overhanging surfaces. All of this makes nGen an efficient filament that can print functional, durable, and attractive creations in less time. The filament “empowers a larger panel of users to create tough and useful items, as the filament is appropriate for anyone who wants to print a variety of objects without com- promising quality, performance, color, or strength,” says Ruud Rouleaux, managing director, colorFabb. “This industry is evolving, and the types of consumers and professionals who engage in 3-D printing are increasing, sparking a need for materials that support this growth.” Photo courtesy of Herrmann Ultrasonics The Eastman polymer provides maintains many advan-

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tages of the Amphora 3D polymer, but with a few differ- F4-55 liquid silicone rubber (LSR) dispensing equipment. entiating qualities. Amphora AM3300 has good flow The new F4-series systems are reportedly designed to properties through the printer nozzle, even at lower tem- keep the dispensing of two-component LSR consistently pre- peratures, and is not impacted by humidity and moisture cise, with two flow meters ensuring the material remains from the environment, resulting in stable printing results on-ratio. This is particularly critical in industries like med- with less waste. ical device manufacturing, where pharmaceutical properties “Eastman Amphora AM3300 3D polymer is reliable and added to the LSR make materials extremely expensive, and easy for people to use, so even casual users can work with in infant care product manufacturing, where off-ratio dis- an advanced filament,” says Alex Dudal, market develop- pensing can result in product defects, the company explains. ment representative, Eastman Chemical Co. “The introduction of the Graco Fluid Automation F4-5 and www.eastman.com. F-4-55 ushers in a new level of precision in the dispensing www.colorfabb.com of LSR,” says David Bordwell, global product manager for Graco’s Advanced Fluid Dispense division. “The equipment’s helical gear and unique flow meter construction allows the F4 series systems to measure material in extremely small Winsell Inc. has announced the launch of its 2016 Rota- tional Molding Product Design Competition. The goal of this annual contest is to inspire emerging industrial design students’ talents to create breakthrough consumer products that utilize the latest technologies in rotational molding. Judging criteria includes: originality, processability, growth potential, beauty and visual appeal, tool-building compatibility, and the use of appropriate Winsell materials. The entry deadline for this year’s competition is April 29, 2016. The first-place winner of the competition will receive $500, second place, $250, and ten honorable mention participants will each receive $150. The design competition is organized by Winsell, with support from 2016 sponsors Avantech, Diversified Mold & Castings, M. Holland, and Polimeros USA. Past participants have stated that their product sub- mission “will be a great portfolio piece,” and that “this competition helped me embark on new adventures that I would not have otherwise been exposed to.” “The rotational molding industry is fueled by the creative ideas of product designers,” adds Fred Shockey, Winsell chairman and CEO. “When we cultivate and celebrate emerging talent in the field, we will thrive. The Product Design Competition gives us a glimpse into the future of rotational molding, while also ensuring that future.” All entry information, criteria, and forms are available on the Winsell website: www.winsellinc.com

Graco Inc., a leader in fluid-handling products and systems, announced the release of Graco Fluid Automation F4-5 and Photo courtesy of Graco

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INDUSTRY NEWS

increments, which increases the operator’s ability to detect “This new agreement both expands and strengthens our even the smallest anomaly much sooner.” broad and growing portfolio of custom compounds,” says The Graco Fluid Automation F4-5 and F4-55 dispensing Scott Koberna, global general manager of wear and friction units help reduce costs by eliminating off-ratio dispensing materials for RTP. “Solvay’s advanced Torlon PAI technolo- and therefore waste caused by non-cured parts. Addition- gy will help us explore entirely new and unique solutions al benefits include a reduced machine footprint and the for customers in fast-growing markets, such as automotive, substitution of programmable logic controllers with the more industrial, off-road vehicles, building and construction, robust proprietary Graco Control Architecture (GCA). defense, and aerospace.” According to Bordwell, “The move to Graco Control Archi- Torlon PAI combines the performance of thermoset poly- tecture translates into easy startup and operation for the imides with the melt-processing advantage of thermoplastics end user. GCA controls are more user-friendly, thereby sav- to deliver industry-leading strength and stiffness at tem- ing the user time, service, and support requirements.” peratures up to 275°C. Wear-resistant grades offer www.graco.com unsurpassed performance at elevated pressures and veloc- ities in both dry and lubricated environments. The RTP 5000 family of compounds will incorporate new and existing additive packages to further extend the per- Solvay Specialty Polymers, a leading global supplier of formance range of Solvay’s PAI technology. Solvay will high-performance polymers, announced a new licensing continue to manufacture and sell Torlon compounds through agreement that enables RTP Company, a custom com- its normal direct supply channels. pounder of engineered thermoplastics, to manufacture and “RTP Company has been a well-recognized and trusted sell RTP custom compounds based on Solvay’s ultra-high compounder of Solvay’s advanced materials for many years, performance Torlon® polyamide-imide (PAI) polymer. and this new agreement improves on that relationship by The new business arrangement expands RTP’s capability combining Solvay’s industry-leading PAI polymer chemistry to meet growing demand for Torlon PAI-based compounds. with RTP Company’s world-class compounding and distri- Available under the RTP 5000 label, the new offering from bution capabilities,” says Chris Wilson, vice president of Ultra RTP Co. will target demanding applications that require high Polymers for Solvay Specialty Polymers. “This is a major win structural strength or excellent wear resistance, as well as for both companies and will expand the competitive solutions the ability to perform reliably at high temperatures, under of our global customers.” load, and in harsh chemical environments. www.solvayspecialtypolymers.com www.rtpcompany.com

With automakers increasingly exploring new ways to use light, SABIC says it’s actively working on developing car window technology with integrated lighting features. The company first disclosed its efforts to develop polycarbonate (PC) windows with integrated lighting at the International Symposium on Automotive Lighting, held in Darmstadt, Germany, in September 2015. There, the company showed a rear quarter window produced through two-shot injection molding with Lexan™ and Cycoloy™ resins, featuring two sets of decorative lighting components: two blue LED light pipes and a white LED light guide with white laser-etched graphics. While those elements are largely decorative, SABIC says integrated lighting can serve a variety of functional purposes. Photo courtesy of Solvay To illustrate one potential use, the company released a con-

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cept sketch in which a lighting component built into a light- • adding ambient lighting features to enhance interiors. weight polycarbonate window indicates the battery status Automakers already are adding lighting touches to various of an electric or hybrid vehicle, from green for fully charged, vehicle components like door handle pockets, side mirrors, to red for a critical condition. This feature could allow the door interiors, instrument panels, center consoles, and cup driver to understand the state of battery charge without any holders, the company notes. need to enter and start the vehicle. www.sabic-ip.com “Our customers are always looking for new ways to sur- prise and delight consumers,” says Scott Fallon, senior director of SABIC’s automotive business. “Combining PC glazing with lighting technologies opens up a whole new range of possi- Kemgo recently launched a new online platform that enables bilities to help them do this. Our long-standing expertise in each suppliers and buyers of petrochemicals to source the best application space and our capabilities to support product cre- deals in a global marketplace. This online marketplace is a ation lend themselves perfectly to help automakers develop new innovation that serves the needs of the petrochemical unique solutions and set new trends in vehicle design.” industry. The company says it’s the only marketplace specif- Beyond using a car window to indicate battery charge sta- ically designed for petrochemical products: polymers, tus, SABIC says lighting features in windows could also enable chemicals, and fertilizers. new styling and branding solutions and display other kinds Kemgo, based in Princeton, New Jersey, with a presence of useful information. Possibilities might include: in Germany, makes worldwide market data visible and new • adding signature lighting or side markers on window markets accessible without increasing costs to buyers and surfaces to help better distinguish vehicle models and sellers. Ralph de Haan and Joe Naaman founded Kemgo enhance consumer appeal; with the aim of creating a world where marketing, sales, and • using colored light for brand enhancement; distribution of petrochemicals would be automated. • using window lighting to put on a show outside of the “In the 21st century, geography and limited information vehicle when parked, including projecting patterns or shouldn’t be an obstacle when finding suppliers or buyers,” imagery on the ground; says Naaman. “We are going to help by creating this trust- • displaying warning messages; ed worldwide marketplace,” adds de Haan. • displaying dynamic turn indicators and hazard light sig- Naaman is described as a consultant by training and an nals; entrepreneur at heart, always looking for ways to improve • enhancing nighttime safety; the status quo. Together with Naaman, de Haan drives the • allowing for animated welcome and goodbye gestures; company’s vision, strategy, and growth. He’s an industry and insider with “a flare for the entrepreneurial.” His previous

Photos courtesy of SABIC

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INDUSTRY NEWS

stint in the German Luftwaffe provided him with the exact- It offers a reliable, high-performance weighing cell, and a ing German engineering discipline required to get Kemgo large, intuitive 4.5-inch (11.4-cm) color touchscreen, as well off the ground. as three interface connections for easy data handling. “It’s Kemgo creates effective deal-making opportunities by the perfect choice for day-to-day weighing in any lab or man- ensuring all trusted petrochemical industry stakeholders ufacturing environment where affordability is a priority,” the have access to global markets at dynamic pricing, 24/7, 365 company says. days a year. It accomplishes this through the use of a web Built-in applications and an intuitive user interface make application that provides buyers and sellers worldwide the the ME-T convenient and easy to use, even for untrained ability to connect with one another to share and act upon operators. The weighing-in guide and large touchscreen with requirements and facilitate transactions. red and blue digits help users to dose to target, and clearly While the company vets every member to ensure it’s a indicate if sample weights are over or under tolerances. legitimate player in the petrochemicals industry, the serv- Results, including statistical evaluations, can be sent direct- ice is free of charge for buyers and sellers to sign up for and ly to a printer or transmitted wirelessly to a PC, eliminating post product needs or products for sale. A small commis- transcription by hand and the potential for error that comes sion fee is charged to sellers when a transaction is confirmed. with it. Kemgo says it enables the petrochemical market to ME-T balances come standard with the company’s “elec- increase revenues and reduce costs by: tromagnetic force compensation” weighing cell and overload • Creating abundance and choice: increasing supply and protection to ensure solid performance and reliable results. purchasing options available to buyers and sellers to This reliability is enhanced by attributes such as passcode make the best business decisions for their companies. protection, which ensures balance settings are not changed • Expanding market presence: making worldwide mar- accidentally or by unauthorized personnel. Automatic sam- ket data visible and new markets accessible—for easily ple ID assignment, with the ability to record up to four IDs finding partners, without increasing costs. per sample, not only saves time and helps improve pro- • Speeding up the sourcing and ordering process: productivity, it also ensures traceability so applicable regulations viding petrochemical suppliers and buyers with the can be met. ability to connect with one another globally, facilitating transactions 24/7. • Building a community around petrochemicals: creating a global trade environment built on trust for the petrochemical community. Kemgo successfully raised capital in a round led by Mar- cus Hübel, a former senior executive in the chemicals industry (and most recently an executive committee member of a Middle East-based global market force), and Olivier van Dui- jn, entrepreneur and current eBay general manager, Benelux. Within its two first months of operation, Kemgo managed to acquire some strategic members to the platform, including a Fortune 100 company and a major Middle Eastern petrochemical manufacturer. It continues to expand its footprint into new markets and products globally. www.kemgo.com

After the successful market introduction of its MS-TS and ML-T balances, Mettler Toledo has completed the renew- al of its portfolio with the launch of its entry-level balance, the ME-T. Photo courtesy of Mettler Toledo

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In addition, ME-T balances offer a variety of connectivity 600 people and were extremely well-received. We’re already options and are easy to clean. Balance usability can be fur- planning more meeting rooms at the 2017 [Chem] Show to ther improved with Mettler Toledo accessories that help accommodate for an even larger program.” ensure accuracy for less common weighing processes, the chemshow.com company adds. mt.com/balances

The 2015 Chem Show, held in Novem- ber at the Javits Center in New York, welcomed 5,170 registered attendees at the chemical processing industries’ (CPI’s) leading event for processing technology. Thousands of engineers, researchers, JOIN THE RACE corporate managers, and plant person- TO FIND YOUR nel from chemical, pharmaceutical, food, T e FUTURE IN THE and other process industries interacted h c e a POLYMER & PLASTICS with the Show’s 282 exhibitors, while cap- R P INDUSTRY l s italizing on a wide scope of free seminars a s t i c and joining in the 100-year celebration of the biennial Chem Show’s history as WHAT IS IT? The Plastics Race is an app-driven a staple event for the North American scavenger hunt designed to entertain CPI. any attendee – from students to For the first time at the Show, the Kirk- veteran industry professionals. patrick Chemical Engineering Achievement Award was presented by Chemical Engi- WHEN ISIHW IT?IEN ?TS ANTEC® Indianapolis neering Magazine. The 2015 Award went Monday, May 23, 2016. 1:00 - 3:00 PM to Dow Performance Plastics for its Intune olefin block copolymers. This technology makes the blending of two previously SponsorshipssonpS Aspihsors Available! Contact:Cle!baliav :tcaton unmixable polymers—polyethylene and polypropylene—possible through use of Pete Dicks |+1 703.259.6132 | [email protected] parts-per-million levels of catalyst at very www.4spe.org/antec/tprw rpt/centa/gor.eps.4www specific temperatures. Additionally, the Show introduced a new “best practices” seminar program that was offered free to all attendees. Industry experts spoke on key and critical issues faced by today’s CPI market, linking strate- REGISTER YOUR TEAM TODAY! gies and solutions to products and services PRIZES TO BE AWARDED seen on the show floor. “We are incredibly pleased with the enthusiastic feedback we have received from seminar attendees,” says Clay Stevens, president of International Expo- sition Company. “The free seminars and other educational opportunities drew over

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INDUSTRY PATENTS

By Roger Corneliussen

mixture which includes cyanate ester monomers and oligomers. A 1 kHz to 10 MHz alternating magnetic field is Bio-Heat Sealing applied on top of a static magnetic field to complete curing U.S. Patent 9,181,010 (November 10, under controlled temperature conditions. The induction 2015), “Heat-Sealable Biodegradable heating of the silica-coated, magnetic nanoparticles induces Packaging Material, a Method for its cyanate ester crosslinking. Manufacture, and a Product Package Made from the Material,” Tapani Penttinen, Kimmo Nevalainen, Jurk- ka Kuusipalo, Tapio Koskinen, and Paper Powder Fillers Sami Kotkamo (Stora Enso OYJ, Helsinki, Finland). U.S. Patent 9,174,370 Cardboard packaging is often coated with a barrier to (November 3, 2015), “Fine water vapor and oxygen. An outer polyolefin layer makes Paper Powder-Containing the material heat-sealable; however, these coatings are not Resin Molded Object and biodegradable. Manufacturing Method Thereof,” Michio Komatsu and Penttinen et al. developed a multilayer, heat-sealable, Takamichi Matsushita (Eco Research Institute Ltd., Tokyo, biodegradable coating for cardboard based on a polylactide Japan). and a biodegradable polyester. The inner layer has more Fine powder from pulverized waste paper is an effective polylactide than the outer layer. Both have a small amount filler for many polymers, such as polyolefins (as in polypropy- of acrylic copolymer that improves adhesion and heat-seal- lene chopsticks). High paper content also improves ing ability. These coatings can be extruded onto cardboard incineration for disposal. However, high paper content structures. reduces flowability, making injection molding difficult. Komatsu and Matsushita incorporated 1 to 400 parts of paper powder per 100 parts of resin by weight by adding and injecting the resin in a supercritical state. After injec- Cyanurate Networks tion, the pressure is reduced and the mixture foams. The U.S. Patent 9,175,137 (November 3, 2015), “Method for Pro- paper particle size ranges from 25 to 200 microns. The foam ducing Cyanurate Networks via Inductive Heating of cell sizes range from 5 to 500 microns. The resin can be poly- Silica-Coated Magnetic Nanoparticles,” Christopher Saha- ethylene, polypropylene, polyester, polylactic acid, gun, Andrew Guenthner, and Joseph Mabry (The U.S. Air thermoplastic elastomer, polystyrene, or ABS. Force, Washington, D.C., USA). Thermosets with cyanurate crosslinks have outstanding thermal resistance; good flame, smoke, and toxicity properties; low cost; mechanical toughness; and processability. Electromagnetic Shielding However, forming the crosslinked networks requires high U.S. Patent 9,169,395 (October 27, 2015), “Polycarbonate temperatures. Catalysts can lower the required tempera- Composition and Articles Formed Therefrom,” Constant ture, but they lead to runaway chemical reactions. There’s Peek, Robert Dirk van de Grampel, Andries J. P. van Zyl, and a need for better temperature control. Adrianus A. M. Kusters (SABIC Global Technologies, B.V., Sahagun, Guenthner, and Mabry developed a method for Netherlands). curing a macromolecular cyanurate network using func- Polycarbonates are synthetic engineering thermoplastic tionalized silica-coated magnetic nanoparticles in a resin polymers with high impact strength as well as many other

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good properties. Recent demands for thinner and thinner Recycled mixed plastics from domestic and commercial walls and large display panels require better flowability, as wastes are generally incompatible. Available compatibiliz- well as impact properties with enhanced electromagnetic ers are usually toxic and expensive chemicals. Hence, there’s shielding. a need for compatibility and melt agents that are inexpen- Peek et al. developed a candidate material based on a sive as well as non-toxic. Foaming also requires expensive mixture of poly(aliphatic ester)-polycarbonate copolymer, equipment and/or materials. a polysiloxane-polycarbonate copolymer, and electro- Riebel and Tate developed biocomposite compositions magnetic shielding agents such as metal fibers. The using dried distiller’s solubles (DDS), which includes con- composition exhibits excellent impact properties and elec- densed distillers solubles (CDS) or corn syrup from alcohol tromagnetic shielding properties when formed into an processing and other additives. This DDS consists of 30 to article. Another composition includes the same resins with 90 wt% CDS, 5 to 20 wt% metal oxide and 5 to 50 wt% fibers. carbon fibers. The copolymers provide improved flowa- The DDS biocomposite additive can be also used as a foam- bilty and impact strength, while the metal fiber provides ing agent; as an agent to lower the melting and glass-transition the shielding properties. temperatures of a thermoplastic, thermoset, or adhesive material; and as a compatibilizing agent for mixtures of thermoplastics, thermosets, and adhesives.

Natural Reinforcing Fibers U.S. Patent 9,163,357 (Octo- ber 20, 2015), “Process for Polycarbonate Nanocomposites Providing and Processing U.S. Patent 9,163,125 (October 20, 2015), “Method of Prepar- Natural Fibres,” Michael ing a Transparent Polymer Material Comprising a Ludwig Gass (Biowert AG, Aarau, Switzerland). Thermoplastic Polycarbonate and Surface-Modified Min- Natural fibers such as hemp, flax, or wood fibers can rein- eral Nanoparticles,” Anne Christmann, Jean-Francois force plastics such as polyethylene. Such natural fibers are Hochepied, Jose-Marie Lopez-Cuesta, Laure Meynie, Alexan- fully biodegradable with a low density. However, these nat- dra Roos, Nathalie Cornet, Karine Cavalier, Didier Sy, and ural fibers often degrade rather than enhance mechanical Marc Lacroix (Armines and Essilor International (Compag- properties. nie Generale D’Optique), Paris, France, and Solvay SA, Gass processed natural fibers for reinforcement rather Brussels, Belgium). than for degradation. A water dispersion of biomass was Polycarbonate has excellent transparency, shock resist- macerated, producing fibers containing 20 to 30 wt% alpha ance, high refractive index, and relatively low density. But cellulose and 15 to 25 wt% hemicellulose, without the use it tends to be too flexible and sensitive to scratching and of chemicals. The alpha cellulose provides mechanical sta- abrasion. Mineral nanoparticles can improve these prop- bility, while the hemicellulose improves processability. Both erties, but particle aggregation remains a problem. types are necessary in the fibers, but there should be more Christmann et al. avoided this problem using mineral alpha cellulose than hemicellulose in each fiber. A variety nanoparticles coated with a monomer and a polymer for of additives can then be added to the fibers for improved optimizing interactions with the polymer and preventing mechanical strength, coloring, light fastness, adhesion, and aggregation. Binding of the monomer and polymer is pro- finishing, and reduced flammability. moted using chlorosilane or organosilane coupling agents. Alkaline-earth metal carbonates, alkaline-earth metal sul- fates, metallic oxides, oxides of metalloids, and/or siloxanes particles of 10- to 70-nm size can be added without aggre- Corn Syrup Additives gation by extrusion at up to 15 wt% loading. U.S. Patent 9,163,142 (October 20, 2015), “Multifunctional This material can be thermoformed, extruded, calen- Biocomposite Additive Compositions and Methods,” Michael dered, drawn, injection molded, injection-compression J. Riebel and Jeffrey L. Tate (GS Cleantech Corp., Alpharetta, molded, or blow molded without loss of mechanical and Georgia, USA). optical properties.

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INDUSTRY PATENTS

bles and surface imperfections. Constant flow rates lead to shorter cycle times. High-Pressure Composite Molding U.S. Patent 9,162,385 (October 20, 2015), “Closed Mold Com- posite Material Manufacturing Methods, Devices, and Systems,” Eric Escribano and Eric S. Escribano (ESE Indus- PHA from Wastewater tries Inc., Miami, Florida, USA). U.S. Patent 9,150,445 (October 6, 2015), “Polyhydroxyalka- Closed-mold composite tooling must be able to sustain noate Production during Wastewater Treatment,” Hsin-Ying very high cavity pressures with long cycles for complete lam- Liu and Michael Wayne Falk, Jr. (Sacramento, California, USA). inate saturation and curing. There’s a need for reducing Polyhydroxyalkanoates (PHAs) are biologically derived composite manufacturing cycle time while maintaining high polymers synthesized as intracellular storage materials by quality. microorganisms metabolizing renewable organic carbon Escribano and Escribano developed a molding system in sources. Their properties are similar to conventional plastics. which the injection and distribution systems are placed with- Biomass-derived PHAs are 100% biodegradable, and experts in the pressure chamber. This reduces the pressure within the field consider PHAs as a potential “green” sub- differences between the outside and inside of the intricate stitute to conventional plastics. injection and distribution systems. This also enables higher Liu and Falk, Jr. developed a wastewater treatment using molding pressure on the final product without damage to the microorganisms to convert a waste stream to PHA. A waste injection system. These higher pressures also eliminate bub- stream capable of producing enhanced levels of PHA is select-

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ed based on short-chain fatty acid, protein, and polysac- ites for packaging consisting of polylactic acid filled with a charide concentrations, as well as total suspended solids. modified phyllosilicate. This silicate is modified by interca- The waste stream is introduced into an aeration basin for the lating hexadecyl trimethyl ammonium cations between the microorganism synthesis. The PHA-laden biomass is then layers of the phyllosilicate. This is done by ultrasonically separated for use. treating water suspensions of the silicate with choline, acetyl choline, and hexadecyl trimethyl ammonium salts between 20 and 120°C. After drying and milling, the nanoparticles can be dispersed in a variety of polymers ranging from poly- Packaging with Nanocomposites ethylene to polyvinylidene chloride. The polymer U.S. Patent 9,169,389 (October 27, 2015), “Modified Phyl- nanocomposites are particularly useful for high-tempera- losilicate,” Susana Aucejo Romero, Maria Jorda Beneyto, Jose ture packaging of food or drink. Maria Alonso Soriano, Miriam Gallur Blanca, Jose Maria Berm dez Saldana, and Mercedes Hortal Ramos (Instituto Tec- nológico del Embalaje, Transporte y Logista (Itene), Paterna, Note: The above patents were selected from 100 to 400 plas- Spain). tics-related patents found each week by reviewing 3,000 to 7,000 Modified phyllosilicates are used as fillers for high-tem- U.S. patents published each Tuesday. A complete list of plas- perature packaging. However, these fillers can be unstable tics-related patents is listed by week and topic at at high temperatures, leading to unpredictable behavior. www.plasticspatents.com. Readers are invited to visit this site Aucejo Romero et al. developed polymer nanocompos- to see the latest patents, without charge.

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UPCOMING INDUSTRY EVENTS

June 5-8, 2016. Rotational Molding TopCon SPE CONFERENCES Site: Holiday Inn Cleveland South, Independence, Ohio, USA Mar. 10-11, 2016. 10th European Thermoforming Contact: Rob Donaldson Conference 2016 Email: [email protected] Site: Melia Hotel, Sitges (Barcelona), Spain Website: www.4spe.org/events Contact: Gabriel Bernar Email: [email protected] June 7-8, 2016. New Innovations – Decorating of Website: www.e-t-d.org Plastics Mar. 22-24, 2016. Shanghai TPO Conference Site: Marriott Conference Center – Cool Springs, Franklin, Site: Shanghai Marriott City Centre Shanghai, China Tennessee, USA Contact: Sassan Tarahomi Contact: Jeff Peterson Tel.: +1 248-244-8933 ext. 3 Email: [email protected] Email: [email protected] Website: www.4spe.org/events Website: www.4spe.org/events June 21-22, 2016. Design in Plastics 2016 Mar. 29-31, 2016. Shape Extrusion TopCon Site: Rhode Island School of Design, Providence, Rhode Site: Holiday Inn Express, Gurnee, Illinois, USA Island, USA Contact: Dave Bigio Contact: Bob Grace Tel.: +1 301-405-5258 Email: [email protected] Email: [email protected] Website: www.4spe.org/events Website: www.4spe.org/events Sept. 7-9, 2016. Automotive Composites Conference & Apr. 16-20, 2016. Thermoset 2016 TopCon Exhibition (ACCE) Site: The Westin, Cleveland, Ohio, USA Site: The Diamond Banquet & Conference Center at the Contact: Shelane Nunnery Tel.: +1 630-247-6733 Suburban Collection Showplace, Novi, Michigan, USA Email: [email protected] Contact: Rani Richardson Website: www.4spe.org/events Tel.: +1 201-675-8361 Email: [email protected] Apr. 19-21, 2016. Bioplastics Materials TopCon and Website: www.4spe.org/events Tutorial 2016 Site: Sheraton Bloomington Hotel, Minneapolis, Sept. 11-13, 2016. CAD RETEC® 2016 Minnesota, USA Site: Sawgrass Marriott Golf Resort, Ponte Vedra Beach, Contact: Kelvin Okamoto Florida, USA Tel.: +1 847-271-9285 Contact: Scott Aumann Email: [email protected] Email: [email protected] Website: www.4spe.org/events Website: www.4spe.org/events

May 10, 2016. AUTO EPCON Sept. 12-14, 2016. FOAMS® 2016 Site: Troy Marriott, Troy, Michigan, USA Site: Crowne Plaza, Seattle, Washington, USA Contact: Sandra McClelland Contact: Xiaoxi Wang Email: [email protected] Website: www.4spe.org/events Email: [email protected] Website: www.4spe.org/events May 23-26, 2016. ANTEC® Indianapolis 2016 Site: JW Marriott, Indianapolis, Indiana, USA Sept. 20-22, 2016. TPE TopCon Contact: Scott Marko Site: Hilton Fairlawn Hotel, Akron, Ohio, USA Tel.: +1 203-740-5442 Contact: Vivian Malpass Email: [email protected] Email: [email protected] Website: www.4spe.org/events Website: www.4spe.org/events

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UPCOMING INDUSTRY EVENTS

Sept. 26-29, 2016. SPE Thermoforming Conference® June 21, 2016. Detroit Section Golf Outing Site: Renaissance Schaumburg Convention Center Hotel, Site: Bay Pointe GC, West Bloomfield, Michigan, USA Schaumburg, Illinois, USA Contact: Karen Rhodes-Parker Contact: Lesley Kyle Tel.: +1 248-244-8993 ext. 3 Email: [email protected] Email: [email protected] Website: www.4spe.org/events Website: www.spedetroit.org

SPE E-LIVE® WEBINARS OTHER UPCOMING EVENTS

Mar. 3, 2016. “Failure of Plastics (Part 1)” Mar. 1-3, 2016. Plastics & Rubber Vietnam Mar. 10, 2016. “Failure of Plastics (Part 2)” Site: Saigon Exhibition and Conference Centre, Ho Chi Mar. 17, 2016. “Failure of Plastics (Part 3)” Minh City, Vietnam Apr. 14, 2016. “Creep Failure of Plastics” Contact: Messe Düsseldorf North America Tel.: +1 312-781-5180 (All webinars begin at 11:00 a.m. U.S. Eastern Time, Email: [email protected] unless otherwise noted) Website: www.mdna.com

Contact: Scott Marko Mar. 8-11, 2016. Plastimagen Mexico 2016 Tel.: +1 203-740-5442 Site: Centro Banamex, Mexico City, Mexico Email: [email protected] Contact: Sergio Munoz Ortega Website: www.4spe.org/Events/webinars.aspx Tel.: +55 3200 7679 Email: [email protected] Website: www.plastimagen.com.mx/en SPE MEETINGS Apr. 13-17, 2016. Iran Plast Mar. 14, 2016. Cleveland Section Meeting Site: Tehran Intl. Permanent Fairground, Tehran, Iran Topic: “Solar Power” Contact: Messe Düsseldorf North America Site: Case Western Reserve Univ., Cleveland, Ohio, USA Tel.: +1 312-781-5180 Contact: Tony Dean Email: [email protected] Tel.: +1 330-929-9916 Website: www.iranplast.ir/en/home Email: [email protected] Apr. 25-27, 2016. Re|focus Recycling Summit & Expo Apr. 1, 2016. Detroit Section Material Auction Site: Rosen Shingle Creek, Orlando, Florida, USA Site: MGM Grand, Detroit, Michigan, USA Contact: Kim Holmes Contact: Karen Rhodes-Parker Email: [email protected] Tel.: +1 248-244-8993 ext. 3 Website: www.refocussummit.org Email: [email protected] Website: www.spematerialauction.com Apr. 25-28, 2016. Chinaplas® 2016 Site: Shanghai New International Expo Centre, Shanghai, Apr. 11, 2016. Akron Section Meeting China Topic: “Industry/Teacher Collaboration” Contact: Winnie Leung Site: Hilton Fairlawn Hotel, Akron, Ohio, USA Email: [email protected] Contact: Tony Dean Website: www.chinaplasonline.com Tel.: +1 330-929-9916 Email: [email protected] May 8-11, 2016. Global Plastics Congress & Exhibit: “Plastics-in-Motion” May 9, 2016. Akron Section Awards Night Site: Francis Marion Hotel, Charleston, S. Carolina, USA Site: Hilton Fairlawn Hotel, Akron, Ohio, USA Contact: Executive Conference Management Contact: Tony Dean Tel.: +1 313-429-3905 Tel.: +1 330-929-9916 Email: [email protected] Email: [email protected] Website: www.executive-conference.com

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Society of EDITORIAL INDEX Plastics Engineers

American Chemistry Council...... 48 Hewlett Packard ...... 12 EDITORIAL STAFF Editor-in-Chief American Injection Molding Inst...... 36, 38 Huntsman ...... 45, 47 Briana Gilmartin Armines...... 61 IHS Chemical ...... 4, 7 Managing Editor Michael Tolinski Biowert AG ...... 61 Instituto Tecnológico del Embalaje ....63 Contributing Editors Dr. Roger Corneliussen Bright Lite Structures ...... 46-47 Integral Technologies ...... 26-27 Jon Evans Dr. Robin Kent Chem Show ...... 59 Kemgo ...... 57-58 Marketing & Communications colorFabb BV ...... 54-55 Legacy Effects ...... 9-10, 12 Sue Wojnicki Branding & Design Covestro LLC ...... 40-43 Mackinac Polymers...... 19-21 Liz Martland & Kim Wakuluk

DuPont ...... 2, 14, 18 Mettler Toledo...... 58 Art Director Gerry Mercieca Eastman Chemical Co...... 54-55 Nat’l Renewable Energy Lab. (U.S.) ...... 22, 24 Publisher Steven Ottogalli Eco Research Inst...... 60 Plastic Logic ...... 17-19 2015–2016 EXECUTIVE COMMITTEE ElectriPlast ...... 26-27 SABIC ...... 56-57, 60-61 President Dick Cameron ESE Industries Inc...... 62 Seeo...... 24 CEO, SPE Willem De Vos Essilor Intl...... 61 SolidEnergy...... 23-24 President-elect FlexEnable...... 15-17 Solvay ...... 56, 61 Scott Owens Senior Vice President Fraunhofer Inst. for Chem. Tech...... 44-46 SPE ...... 1 Olivier Crave

Graco Inc...... 55-56 SPI ...... 1, 52 Vice President/Web Innovation/ Communication/Treasurer Jaime Gómez Grand View Research...... 15 Stora Enso OY ...... 60 Vice President/Secretary GS Cleantech ...... 61 TactoTek ...... 2, 14 Monika Verheij Vice President Henkel Corp...... 28-29 Winsell Inc...... 55 Raed AlZubi

Hennecke Corp...... 47 Wohlers Assocs...... 8-9, 12 Vice President Thierry d'Allard Herrmann Ultrasonics ...... 54 Vice President Brian Landes 2014–2015 President Vijay Boolani

Plastics Engineering (ISSN 0091-9578) is published monthly, except bimonthly in July/August and November/December, by Wiley Subscription Services, Inc., a Wiley Company, 111 River Street, Hoboken, NJ 07030 USA. The magazine is compiled and edited by the Society of Plastics Engineers, Editorial and Business Office, 6 Berkshire Blvd., Suite 306, Bethel, CT 06801 USA. Telephone +1 203-775-0471, Fax +1 203-775-8490. SPE Home Page: www.4spe.org. Communications should be sent to the Editor. Send address changes and undeliverable copies to the Circulation Manager at the SPE address given above. Send subscription orders and claims for non-receipt to Wiley Subscription Services at the Wiley address given above. SPE members receive the magazine as a benefit of membership. Subscription rate for nonmembers is $151 for 1 year; add $100 per year for subscriptions outside North America. Single-issue price is $20. Plastics Engineering is printed by Dartmouth Printing Co., a Sheridan Group Company. Periodical postage paid at Hoboken, NJ, and additional entry office. Accepted at special postal rates provided in P.M., Sec. 132 122. Copyright 2016 by the Society of Plastics Engineers, Inc. POSTMASTER: Send address changes to Plastics Engineering, 6 Berkshire Blvd., Suite 306, Bethel, CT 06801 USA. Reproduction in whole or in part without written permission is prohibited. Plastics Engineering is indexed by Engineering Information Inc. Neither Wiley Subscription Services, Inc., nor the Society of Plastics Engineers, nor Plastics Engineering is responsible for opinions or statements of facts expressed by contributors or advertisers, either in the articles published in Plastics Engineering or in the technical papers that are presented at the meetings of the Society. Editorials do not necessarily represent the official policy of Wiley Subscription Services, Inc., or the Society. Display and classified advertisements are included as an educational service to readers of Plastics Engineering. Advertising appearing in Plastics Engineering is not to be taken as an endorsement, expressed or implied, of the respective company’s processes, products, or services represented in the ad. Printed in the U.S.A.

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ADVERTISERS INDEX

Aaron Equipment Company www.aaronequipment.com/sniff ...... 69 Allgrind Plastics www.allgrind.com ...... 68 ADVERTISING SALES ANTEC 2016 www.antec.ws ...... 31 FOR PRINT AND ON LINE DIGITAL ADVERTISING SALES in Conair www.conairgroup.com/thermolator...... Cover 4 Plastics Engineering magazine Connect With SPE www.4spe.org ...... 71 please contact: Coperion www.coperion.com/zsk26mc18...... 5 Dover Chemical www.Doverchem.com/LGP-11 ...... Cover 3 Global Advertising Director IMS Company www.imscompany.com/G1 ...... 7 Stephen Jezzard J.P. Curilla Associates Email: [email protected] ...... 68 E-mail: [email protected] Japan Steel Works www.jswcompounding-usa.com ...... Cover 2, 68 John Anderson & Associates www.plasticsjobsearch.com ...... 68 Sr. Account Manager Krailburg TPE www.kraiburg-tpe.com...... 25 Print & E Media Advertising Plastic Flow www.plasticflow.com...... 68 Roland Espinosa Plastics-In-Motion 2016 www.executive-conference.com...... 67 Tel: 201-748-6819 E-mail: [email protected] Polyhedron Laboratories, Inc. www.polyhedronlab.com ...... 68 Process Design & Technologies www.processdesigntech.com ...... 68 Rheo-Plast Associates, Inc. www.rheoplastusa.com...... 68 Product and news releases for SAM North America www.sam-na.com • Email: [email protected] ...... 68 Plastics Engineering can be sent Shepherd Color Company www.shepherdcolor.com ...... 19 directly to [email protected]. SPE Auto Epcon www.4spe.org ...... 35 SPE Automotive Composites Conference speautomotive.com/comp ...... 39 SPE Benefits www.4spe.org ...... 62 SPE Bioplastic Materials www.4spe.org ...... 47 SPE Career Change www.4spe.org/careers ...... 69 SPE Thermosets Topcon 2016 www.4spe.org ...... 13 111 River Street Hoboken, NJ 07030 USA SPE Design in Plastics www.4spe.org/events...... 38 SPE European Thermoforming Conference www.e-t-d.org ...... 43 SPE Foams 2016 www.4spe.org/events...... 21 SPE Industry Academia www.4spe.org/industry-academia ...... 34 SPE Join Today www.4spe.org ...... 53 SPE Mobile App www.4spe.org ...... 6 SPE Next Gen Advisory Board www.4spe.org/ngab ...... 33 SPE Plastics For Life Global Parts Competition www.speplasticsforlife.org....65 SPE Shanghai TPO Conference www.eiseverywhere.com/ehome/136915....51 6 Berkshire Blvd., Suite 306 SPE The Chain thechain.4spe.org ...... 63 Bethel, CT 06801 USA www.4spe.org SPE The Plastics Race www.4spe.org/antec/tpr...... 59 Struktol Company of America www.4struktol.com ...... 17 Tangram Technology www.tangram.co.uk ...... 68 Turkish Machinery www.turkishmachinery.org ...... 11

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