Demand is growing for innovative 'green' polymer-based solutions

Paul Boughton

Demand for electronic components, architectural cladding and new plastic packaging solutions are driving the latest developments in polymer-based materials innovation.

With the emphasis on next generation technologies, SABIC Innovative Plastics introduced a number of new material concepts at the Berlin-based 2008 Electronics Goes Green conference.

The company's Valox iQ and Xenoy iQ resin technology is sparking new ideas to help electronics manufacturers become more environmentally compliant. This material, which is derived in part from post-consumer plastic waste, has been validated in several major computer components including internal cooling fans, heat sink shrouds, connectors and external bezel covers. In addition, flexible Noryl resins for electronic wiring can also enhance eco-responsibility with halogen-free flame retardance.

"Valox iQ resins aren't just good possibilities for greener electronics - they have already been used commercially in computer cooling fans," said Hiroshi Yoshida, global market director, electronics, Sabic Innovative Plastics. "In addition, we're expanding the iQ portfolio to encompass other environmentally responsible materials such as Xenoy iQ blends of amorphous polycarbonate and semi-crystalline PBT resins, a good option for housings and bezels. As a pioneer of advanced material solutions, Sabic Innovative Plastics believes innovative products such as iQ and Flexible Noryl resins can help electronics manufacturers achieve business success."

Valox iQ polybutylene terephthalate (PBT) resins meet requirements for halogen-free parts through the use of proprietary flame-retardant technology. Further, they are derived in part from post-consumer plastic waste including polyethylene terephthalate (PET) water bottles, helping reduce the use of fossil fuels (Fig.1). They also cut process energy and carbon dioxide emissions from plastics manufacturing by over 50 per cent versus other plastics in the market today. In addition to helping electronics manufacturers comply with environmental regulations such as the European Union's Waste Electrical and Electronic Equipment (WEEE) directive, Valox iQ resins can meet optional material selection requirements in the Electronic Product Environmental Assessment Tool (EPEAT) that could help OEMs achieve a gold certification.

Today's computers can gain significant eco benefits from non-halogenated, flame-retardant, Flexible Noryl resins for electronic wiring. Noryl modified polyphenylene ether (PPE) resins deliver the flexibility and processing performance of polyvinyl chloride (PVC) while adding advantages of halogen-free flame retardance, lower specific gravity and improved abrasion resistance. Flexible Noryl resins can replace PVC in a variety of applications, including power cords, SATA cables and DC cables. In addition to meeting existing regulations, such as RoHS and WEEE, the materials have certifications under UL1581 specifications for 80°C, 90°C, and 105°C and are used commercially in a wide variety of cable configurations around the globe.

Based in Weert, The Netherlands, Trespa International specialises in the manufacture of high quality panels for exterior cladding, interior surfaces and other applications.

Its Trespa Meteon architectural cladding panels are based on thermosetting resin, homogeneously reinforced with 70 per cent wood fibres and manufactured under high pressure and high temperature. The result is a panel that is very tough and exceptionally durable, with dimensional stability and workability similar to hardwood. The smooth, non-porous surface resists the accumulation of dirt and retains its high physical performance and appearance in any weather or in extremes of temperature. The high impact-resistance of the panel means that it cannot easily be damaged, scratched or abused and is very easily cleaned.

The latest size to be introduced by Trespa is known as the Meteon ZF panel. The new 4270x2130mm format is available in all standard colours and thicknesses (Fig.2).

The new large format Trespa Meteon panels offer exciting new design options for façade grids that were previously not possible, according to Trespa project manager Claire Pépin: "Projects can be completed with improved cost effectiveness. Analysis on a random selection of projects confirms that an improved yield can be achieved through cutting optimisation. In addition to the design and cost benefits, Trespa Meteon ZF also lowers the overall burden on the environment. Lowering the amount of cutting losses will significantly reduce the product's overall environmental impact in terms of waste material and energy."

"We are excited about the introduction of ZF, which will make Trespa Meteon literally the biggest panel available on the market today. This opens up many new opportunities for our customers, both in commercial and aesthetic terms. Meanwhile Borealis is expanding the capacity of its polypropylene (PP) packaging materials with the inauguration of its new Borstar plant in Burghausen, Germany (Fig.3).

The 330000t/y facility will use Borealis' proprietary Borstar PP2G (second generation) multi-modal technology to produce products offering a step change in purity, processing output and performance. The plant more than doubles Borealis' current Borstar PP capacity to 570000t/y.

Borstar PP 2G is a major step forward from bimodal technology, yielding new possibilities in polymer design. The advanced Borealis technology consists of a new emulsion-based Ziegler-Natta (ZN) catalyst system in combination with a more simplified process. This enables the most precise molecular tailoring of PP to date, helping achieve an optimal balance between processability and mechanical strength. As a result, extremely pure PP grades with low amounts of catalyst residue can be produced under safe and reliable operating conditions.

Furthermore, cost and environmental benefits will be achieved through the increased plant capacity and lower energy consumption of up to 5-10 per cent per tonne, depending on the grade, made possible with Borstar 2G PP technology.

Borstar 2G PP extends Borealis' existing product range with innovations focused on unique combinations of outstanding, highly-differentiated properties. In addition to new levels of purity, the packaging industry will be able to take advantage of materials with excellent transparency, softness, toughness and good sealing strength after sterilisation.

From a processing perspective, the improved stiffness and impact balance of 2G PP aids processability and output levels by supporting high line speeds