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Components and elements subjected to higher mechanical stresses are increasingly hybrid, i.e. made of two or more materials, e.g. metal and plastic. A combination of different measurement methods is usually required to check the quality of the structures.
By introducing gas or water, hollow mouldings can be produced by injection moulding. These processes are still rarely used today, but developers are already working on the so-called bi-injection technique, which is a combination of two-component injection moulding and fluid injection technology - FIT.
Film manufacturers have to decide whether to produce some common types of packaging film in large quantities on high-performance machines or to take on the challenge of meeting customers' specific needs, which require special machines, constant development and frequent model changes. Volume production is preferred in the countries of the Middle East, the former Soviet Union and China, while quality production is sought in the developed industrialised countries.
Plastic films are produced in huge quantities all over the world, and this requires large-scale processing machines. And the increasing quality requirements can only be met with state-of-the-art automatic control. Performance can be enhanced by direct extrusion, where the flat film is produced directly from the slurry after compounding, without intermediate granulation. This process can be used to produce complex multilayer and bioriented films. State-of-the-art automatic control can also be used by film producers whose older extruders are not yet widely used.
In injection moulding, thermoplastic foam products have the advantage not only of lower density, but also of the foam structure itself, which modifies the mechanical properties of the product. Some recent results of injection moulding of PBT, elastomers and silicone rubber are presented below.
Today, laser-based equipment and technologies allow for a wide range of applications. The marking of plastic surfaces is already widespread, but the potential is not yet exploited. Laser polishing is advantageous for machining tool surfaces. The development of a special compound for the production of injection moulded interconnect devices (MIDs) helps to use lasers even more efficiently.
New foil blowing machine with an air ring. Reifenhäuser Kiefel Extrusion (Worms, Germany) has installed a cooling ring on top of its new film blowing machine. The method, called counter-cooling, means that the cooling air flows not only upwards, as on previous machines, but also downwards to another air outlet. This allows a single air ring to stabilise the film seal. In addition, higher performance can be achieved and even the properties of the foil such as transparency, gloss and mechanical strength are improved.
Engineering plastics. The price of engineering plastics changed significantly during 2009. Prices were high in the first few months of the year, then fell sharply and then stabilised. There were no changes at the end of the year, in November and December.
From mid-2008 to the end of 2009, Europe's economy experienced its worst crisis in 60 years. The European Economic Recovery Plan (EERP), which has been drawn up to help the economy recover, is highly appreciated by the plastics industry, especially as it is one of the big losers in the crisis.
Thermoplastic elastomers - TPEs - have been the success stories of recent years. Their thermoplastic matrix makes them easy to process, and their elastomer phase can be used as a substitute for rubber. Their chemical composition is very diverse and the limits of their performance are being extended. Some are produced by compounding, others by block copolymerisation. There are also „green” versions based on renewable sources. Due to its length, this summary is presented in two parts.
The preparation and properties of mixtures containing nickel and iron oxide have been investigated to increase conductivity and to produce polymers with shape memory. The results of this research are of interest for electronic applications.
Advances in electronics are bringing ever more spectacular solutions for the everyday person, with the focus on functionality, economy and safety, as well as on products that do not harm health or the environment. The plastics industry is responding to these challenges with new materials.
Plastics are essentially electrically insulating. To achieve antistatic and conductive properties, various additives need to be mixed with the plastic or conductive blocks need to be incorporated into the plastic matrix. The demand for such nuts and bolts is increasing due to the expanding range of applications.
Power plants „produce” millions of tonnes of ash every year, the recovery of which is of huge importance for the protection of the environment. In the UK, a major investment has been made to start up a plant to recycle ash. One of the fractions obtained using a patented technology could be a cheap additive for the plastics industry in the future.
In addition to the previously widespread PP and PVC-based wood-plastic (WPC) composites, several companies have started to develop thermo-reactive melamine resin filled products. The Austrian melamine producer Borealis Agrolinz Melamine (AMI) has developed HipeResin melamine in collaboration with the consultancy Wood K Plus and the extruder manufacturer Greiner.
DSM Engineering Plastics has developed a heat treatment technology to further improve the properties of its Stanyl-type polyamides.
Today, more and more countries are recognising that it is not enough to support innovation by funding ideas, but to support teams with different skills and experience. In the UK and Germany, such support has been in place for a long time.