Some exciting developments in polymers will be unveiled at K 2007.
While the majority of new material developments fall in the engineering thermoplastic category, several interesting polyolefins will also make their debut. Some of the promising polyolefin developments are:

HDPE foam grade for coaxial cable
Borealis will showcase what it terms a �cutting-edge,� fully compounded HDPE for gas-injected cellular insulation of small to medium-size coaxial cables. Borcell HE1106 is reported to allow cost-effective production of cables with greater or more reliable data transmission at higher frequencies. This would allow network providers to minimize signal loss, raise performance and use more bandwidth to offer a greater range of services over the same cable. It is expected to give consistent foaming performance during extrusion, providing upto 80% expansion. The compound also contains a uniformly dispersed nucleating agent to give a wide processing window and the lowest possible dielectric loss, even at high frequencies of 3000 MHz. Insulation made with this compound features uniform cell structure and surface smoothness, making the material more difficult to crush. By strengthening the finished cable, this compound is expected to allow manufacturers to achieve longer production runs by winding bigger rolls without potential cable damage.

Fictionalized PE adhesive tie layer polymers
Dow will introduce two additions to its line of Amplify fictionalized polyolefin adhesive tie-layer resins, which are specially formulated for HDPE pipe. GR 380 (that complements the performance of Dowlex PE-RT) is designed to bond layers of polar barrier materials such as EVOH, PET, or epoxy to layers of non-polar PE in making multi-layer hot/cold water pipes.

Odourless PP moulding grade for caps
A unique PP grade by Borealis is designed to produce caps for bottled water and sports and energy drinks. This new grade RE450MO preserves the taste of the liquid contents of the bottle while providing design possibilities not previously available from PE or PP cap polymer grades. It contains no additives that could taint the taste or odor of the bottled product, contains ultra-low levels of VOCs and matches the excellent taste and odor properties of standard HDPE grades used for beverage caps.

Detergent resistant glass filled PP compound for appliances
Borealis will introduce a detergent-resistant, glass-reinforced PP for appliances. Grade GB266WG, due to its detergent resistance, can be used for the interior of washing machines and dishwashers as an effective alternative to steel for dishwasher frames and other structural parts.
Borealis attributes its performance to a novel stabilization system that also enhances the lifetime of important structural components. It is expected to resist the ageing effects of light, oxygen, and wear-and-tear, such as scratching, discoloration or gloss reduction. It also boasts high stiffness and low CLTE, which would ensure watertight connection between components.

Scratch resistant TPO for automobile
Borealis will showcase its new talc-filled TPO for injection molded auto interior components, selected by Daimler Chrysler for all visible trim in the interior of the 2008 Mercedes C-Class. Daplen EE188HP provides excellent scratch resistance and low gloss. Its high dimensional stability and wide processing window provide consistent surface quality. The material�s balance of toughness and stiffness helps parts meet industry crash-test requirements.

Styrenics
BASF has a new extrusion grade for sheet and profiles-Terluran SP-6 that has a low yellowness index of 16.
BASF will launch Terlux 2812 HD, a transparent MABS for medical applications � with higher flow than the company�s previous clear ABS grade, thus filling multi-cavity molds more easily.
Lanxess will introduce Triax KU 2-3050 nylon/ABS alloy as an alternative to PC/ABS in auto interior parts. It has a matte finish that eliminates painting, good light stability, chemical resistance, and toughness. The company attributes the high-quality surface to the material�s high flow.

TPEs
GLS Corporation will introduce a range of proprietary, blow mouldable Versaflex TPEs that come in clear and translucent grades and hardness from 35 Shore A to 40 Shore D. Barrier applications are among the targeted uses in medical and consumer products.
GLS will also highlight a new line of vibration and sound-damping TPE alloys � claimed as an �industry first� because they use unique chemistries for sound damping across wide frequency ranges (10Hz-20kHz). Hardness range is 20 to 80 Shore A and specific gravities are 0.9-1.3. The materials also offer UV protection.
Kraiburg, Germany, has introduced a new generation of soft-touch transparent TPEs, based on hydrogenated styrenics block copolymers (HSBCs). They reportedly offer a previously unattainable level of adhesion to PC and ABS. When used in over moulding, their clarity allows the base product to show through clearly.

Engineering thermoplastics (ETP)
* Lanxess will introduce a highly filled nylon for external car door handles. Durethan DP BKV 60 H2.0 EF is a 60% glass-filled nylon 6 with high flexural strength and tensile modulus. Surface quality and flow characteristics are likely to be comparable to those of standard 30% glass-filled nylon 6. The material has low moisture absorption and high dimensional stability and it can be coated and electroplated.

* Rhodia will unveil a new super high-impact nylon 6. Technyl SI is a new range of nylons that balance exceptional impact resistance with good stiffness, targeted towards applications including machine components, power tools and sporting goods. The material�s stiffness improves structural characteristics and screw retention in power tools, eliminating the need for inserts and simplifying assembly.

* Rhodia will also introduce a range of modified nylons for extrusion and blow moulding. Technyl XT is claimed to have unique rheology that boosts its processability without sacrificing performance. The product family includes Technyl C 502XT, Technyl C 507XT (heat stabilized), Technyl C 52XT (UL 94V2 version), and Technyl C 536XT (for blow molding). Applications range from corrugated pipe and bag-in-can packaging to fuel tanks for motorcycles and power tools. A high-flow nylon 6 series that delivers outstanding surface finish, high stiffness, and high heat resistance, is also new.

* New nylon developments from DuPont include corrosion-free Zytel HTN PPAs for electrical circuits and connectors in high-temperature automotive environments. Zytel HTN FR52G30NH, a halogen-free, 30% glass-filled PPA with UL 94V-0 flame resistance at 0.8 mm and UL CTI >500V, finds application for connectors, heavy-duty circuit breakers and contactors. DuPont will introduce Thermx TE 4004, a new PCT polyester for pencil-coil auto-ignition systems - parts that are getting smaller while delivering higher energy, thus requiring a material that flows easily in thin walls and has high dielectric strength at elevated temperatures, excellent adhesion to epoxy encapsulants. Also new is Rynite RE 19041 PET, a halogen-free compound with UL94V-0 flame resistance at 0.8 mm and UL CTI greater than 500V.

* DuPont will highlight two new LCP grades. Zenite ZE55201 is an ultra-low-warp LCP designed to maintain flatness in connectors, chip-card holders, and large parts for ovens and other appliances. Zenite ZE55801 is a palladium-doped, 30% glass-filled grade that enables selective electroless chrome plating of connectors for MIDs when used with standard LCP in a two-shot molding process. Another Bio-PDO introduction, expected later this year, is in Cerenol polyols used to make automotive paints and new grades of DuPont�s Hytrel copolyester TPE. These Hytrel RS grades will contain rubbery soft blocks made from Cerenol polyols.

* Ticona will show its new Hostaform EC140XF, a carbon black-filled acetal that provides electrical conductivity in automotive components. It meets the requirements of SAE J1645 for fuel systems. Ticona is also working on other formulations that will incorporate new conductive nano-fillers.

* Bayer will be showing the PC automotive roof module�said to be the industry�s largest�for the new �Smart Fortwo� from DaimlerChrysler�s Smart subsidiary. The 13-ft roof is made by injection-compression molding on a swivel-platen press. It weighs 40% less than glass.

* New all-polymeric wear-resistant compounds from RTP are considered to provide comparable or better performance than PTFE-based low-wear compounds, as well as lower density and better impact resistance, especially in polycarbonate. The �eco-friendly,� non-fluorinated compounds have a low loading of a polymeric additive in polycarbonate, nylon, and other engineering resins.

* BASF will unveil an online-paintable nylon for auto exterior body panels. Ultramid TOP 3000 is an impact-modified, mineral-filled nylon with a considerably lower CLTE than competing resins. The partially aromatic nylon can be used in coating processes at temperatures above 200 C.
The Ultramid CR line of nylons is tailored for high-energy absorption and dynamic loads in automotive uses. These �crash-worthy� grades are based on nylon 6 and 66 and contain 30-50% glass fiber.
BASF will launch two acetal copolymers for medical applications. Ultraform S2320 003 PRO and W2320 003 PRO have high load-bearing capacity, and good sliding friction resistance. Applications include valves, metering systems, springs, slides, and gears.
BASF�s Ultradur high-flow PBT line has been expanded to include thermally conductive, flame-retardant, and low-warp grades. Ultradur B4300 M12 has thermal conductivity of 1 W/mK.

* In high-performance polymers, BASF will introduce two new Ultrason polyethersulfone (PESU) grades for automotive headlights. Ultrason E2010 MR black HM is a black product that reduces heat build-up by providing better permeability to heat radiation. The key is a new pigment system that absorbs visible light but allows infrared to pass through. The other grade, Ultrason E2010 MR HP, is a blend with 10-20% better flow than straight PESU. It also offers impact strength comparable to higher-molecular-weight PESU and reduced swelling during processing. BASF has made quantities available for sampling.

* BASF announced the launch of a new polyphenylsulfone (PPSU) line as an addition to the Ultrason family. The first grade is Ultrason P 3010, said to combine the high melting point of Ultrason E PESU with the low water absorption of Ultrason S polysulfone. Other advantages are high chemical resistance to strong cleansers and disinfectants and better resistance to steam sterilization than other amorphous resins in its class, withstanding up to 2000 hot-steam cycles without damage. Especially interesting is its Charpy notched impact resistance 10 times greater than other amorphous high-temperature resins, which tend to be notch sensitive.

Nanocomposites
DuPont will nano and long-fiber composites. DuPont has been experimenting with a proprietary nanoclay having a 10:1 aspect ratio. Just 1.5% by weight of this additive in PET reduces creep by the same amount as 30% to 45% fiberglass. DuPont is also looking at organic nano-fillers, such as highly branched, star-shaped polymers. These materials are incompatible with other thermoplastics and can add reinforcement while dramatically improving flow relative to other nano-fillers.
In the long-fiber area, DuPont is in advanced development of �engineered fabric composites� involving woven glass or carbon fibers embedded in a thermoplastic matrix. Their strength/weight ratio is said to be competitive with aluminum and steel, and DuPont hopes their economics will be suitable for broad industrial markets, not just aerospace, marine, or sports applications.
This article has been developed from inputs available through Plastics Technlogy and various company press releases