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Polypropylene is used in almost all industries because of its versatility, but its potential is far from exhausted and its development is ongoing. The dynamic development of the Far East has led to a huge increase in the demand for PP and polyolefins in general, which is being met by the construction of huge polyolefin factories in this region, but above all in the Middle East, where raw materials are cheap. As a consequence, a large part of production, especially of standard grades, is shifting to the Middle East and Asia. European manufacturers can remain competitive if their smaller but more agile factories cater for the specific needs of users. An example of this is the efforts of a European manufacturer to develop a PP grade suitable for film blowing.
Since its launch in 1988, Campus, the plastics manufacturers' database, has spread worldwide. Designers, processors and applicators can get effective help in selecting the right type of material.
Researchers at Tulane University in New Orleans have investigated the properties of polyethylene-based nanocomposites. In one series of experiments, they sought to clarify how the properties of nanocomposites - most importantly their oxygen barrier properties - are influenced by the type of polyethylene (EVA, PE-LD, PE-HD) chosen as the matrix. In another series of experiments, the effect of added nanoclays was investigated in wall fibre reinforced polyethylene.
Most plastics are apolar, so their surfaces are not well wetted by paints, and adhesives give them poor strength. Surface treatments, such as corona discharge, are used to add functional groups to improve adhesion. Newer and more effective surface treatments may include plasma treatment and fluorination, which already have practical applications.
In laser welding, accurate measurement of the weld temperature has been developed, allowing the weld to be controlled for varying material quality. A Belgian company has used a special winding process and laser welding to produce pressure-resistant tanks from glass-fibre polypropylene.
Injection moulding, one of the most important methods of plastics processing, is rapidly evolving in technology and machinery. The main direction of development is the integration of post-processing into the injection moulding process. Electric, hydraulic and hybrid injection moulding machines are competing with each other.
Two-component injection moulding is an economical way to produce multifunctional mouldings. A German research team has studied how poorly compatible polymers, such as polar polyamide and apolar polypropylene, can be injection moulded to achieve good cohesion at the interface. And a company in Germany has developed a process for injection moulding thermoplastic polyamide and rubber that vulcanises under heat + pressure.
The importance of software for the design of injection moulding tools is growing. The new Visi-Flow software simulates the flow properties of unfilled and filled reinforced materials. Inserts enabling tunnel filling can reduce mould waste and improve quality. Mould design is often also used by raw material manufacturers to ensure successful production.
PUR is the most versatile type of plastic. For a long time, it was almost exclusively found in the form of foams, but thanks to advances in materials and technology, it is now being used in an increasing number of industrial applications: public lamp posts, profiles and flooring elements are the latest PUR products.
Sophisticated moulded plastic parts can only be produced if the temperature of the processing machine, and especially the moulding tool, is optimal. Conventional thermostats are not suitable for precise temperature control. Cooling and heating technology companies use different principles in their state-of-the-art temperature control equipment for plastic processing. Some of these are described below.
Welding is one of the most important plastic processing operations, as shown by the wide range of technologies and associated equipment that can coexist on the market. Laser and infrared welding are becoming increasingly common, while hot-tool or mirror welding is going out of fashion. Welding itself can also be omitted, e.g. by multi-component injection moulding or in-tool assembly.
By setting up your own injection moulding equipment, you can benefit from the advantages of long fibre reinforced thermoplastic matrix composites at a lower cost than buying the long fibre granules ready-made. In addition, injection moulding can be used to achieve a higher fibre length in the finished product than long fibre injection moulding of prefabricated granules.
The most common cause of wrinkles on the film bubble during film blowing is the instability of the bubble between the tool and the largest diameter part of the bubble. Due to the eccentricities here, the distance between each point along the bubble circumference and the baffle will be different.
The surface of plastics can also be modified by coatings, filming, additives and technological methods to suit the intended use. The leather effect coating (an invention of an outsider) is a real novelty. The antibacterial effect of the silver coating has been enhanced by nanotechnology.
One interesting application of plastics is as a roller component in devices for transporting frozen goods, for example. In many cases, only two-component rollers or hybrid structures are able to meet the demanding applications. Compared to metal rollers, plastic rollers increase the service life of the rollers, which contributes to the safety of the swinging handles.
The PET market is still growing faster than other mass-produced plastics, but not at double-digit rates as in previous years. Competition between raw material producers is partly reflected in the consolidation of the market and partly in the acceleration of new developments. As a result of these developments, gas-tight PET bottles are becoming cheaper, offering a viable alternative to glass bottles and metal cans.
In addition to passive pedestrian protection, active protection signalling systems are playing an increasingly important role in avoiding a significant proportion of collisions. In both cases, developers are taking into account the advantages of plastics in terms of low density, energy absorption, rapid installation, hybrid and sandwich structures, etc.
Several methods are available for sterilising plastic medical devices. Radiation sterilisation is the most suitable method for sterilising transplants that come into contact with or are to be incorporated into the human body.
The consolidation of the plastics sector has accelerated in recent years, with the closure of obsolete plants and the emergence of new owners as investors, with a more aggressive strategy than before to ensure competitiveness. Borsodchem's ownership structure has also changed. In the plastics processing sector, smaller companies have been bought up mainly by the „big fish”.
PVDF is a generally non-reinforced, crystalline fluoropolymer with good mechanical, thermal and electrical insulation properties and excellent chemical resistance, introduced to the market in 1961 by Pennwalt Corp.
The European Plastics Converters Association said in December that the price of plastic products will rise in the coming months. This is clearly due to the general increase in raw material prices caused by high oil prices and a shortage of raw materials in Europe. Compared to the beginning of 2004, for example, PP prices were on average 50% higher at the end of 2007 and PS prices doubled. Another forecast is that by the end of the first quarter of 2008, the price of polyethylene, and in particular PE-LD, is expected to increase by EUR 100-150. PP prices will increase more slowly and PVC prices will remain almost stagnant due to subdued orders. The price of PS increased by €30 per tonne in December, but this was compounded by an extra €10-20 for high quality granules.