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The advantageous properties of engineering plastics can be further improved by adding additives and combining them with other polymers. However, the task is not easy, because improving some properties will influence others in the wrong direction. Mineral fillers and special silicone copolymers have been used to extend the range of materials for the automotive, medical and office equipment industries.
The disadvantage of aluminium hydroxide (ATH), an environmentally friendly inorganic flame retardant used in large quantities in cable and rubber production, is that it only has an acceptable protective effect when added in 50-65%, but at such high levels it adversely affects the properties of the polymer blend and makes it difficult to process. A new type of ATH, while retaining its good flame retardancy, mitigates the latter disadvantages. In unfilled or low filler systems, halogenated flame retardants are often replaced by phosphorus containing ones. A new representative of these has appeared on the market, which is mainly recommended for PP, but in the future versions for other thermoplastics will also be available.
Although new types of filler are not very common on the market, developers are trying to improve or modify the properties of filler compounds. In addition to mineral-based fillers, glass-ball admixtures of appropriate strength are also worthy of attention.
In the world's injection moulding plants, it is still undecided which drive machine will be preferred. In Europe, electric machines are more popular in the lower clamping force range and hybrid machines in the higher clamping force range. Electric machines are considered to be more energy efficient, but hydraulic machine manufacturers have also made significant progress in this area with recent developments.
In injection moulding, the collision lines are primarily valued by processors for aesthetic reasons, although often an inadequate pour front can lead to a loss of strength. A complex approach to the task is required.
Two-component injection moulding of thermoplastics is now a routine operation in plastics processing. Injection moulding of thermosetting liquid silicones onto a thermoplastic requires more preparation on the part of both the designer and the processor.
The mass production of commercial plastic films is increasingly being exported to the Far East, and film producers in industrialised countries will only remain competitive if they move to more advanced, multi-functional multilayer films. This requires investment, but the costs are quickly recovered. Among their innovations are films made from new polymers such as polylactic acid.
From time to time, film extruder manufacturers present their latest innovations to invited professionals at their own premises. Windmöller & Hölscher presented six new products at its latest event.
In Europe, the price of standard plastics in January 2009 was lower than at any time in the previous five years. Thereafter, it remained little changed until mid-year and then, apart from minor fluctuations (except for PVC), increased by a factor of around one and a half. The upward trend was not broken in April and early May 2010.
In the interests of sustainable development and lower energy consumption, there is a continuous drive to replace metals with plastics. Newly developed polyamides play a major role in this. One of the main problems to be solved is to reduce the hygroscopicity of polyamides in order to achieve greater dimensional stability, another important objective is to reduce flammability.
Nanotechnology, which is currently developing at a dizzying pace and is emerging in almost all sectors of the economy, is expected to be the dominant technology of the 21st century. Nanocomposites containing nano-sized fillers are already having a rapidly expanding market and applications, but will soon be joined by transparent scratch-resistant coatings. Functional nanostructured coatings are the newest branch of this technology, which will allow the properties (reflection, scattering, self-transmission) to be controlled as desired.
The share of plastics used in cars has been steadily increasing in recent years. Today, the proliferation of electronic equipment is turning the attention of developers towards this area. And the emergence of biofuels is posing new challenges for plastics manufacturers in terms of chemical resistance.
Fluoropolymers have many advantageous properties, but until now they could not be processed using the same productive methods as thermoplastics. Structural modification has solved this problem, opening up new applications for fluorinated polymers.
Copper tubes can be replaced in many places by multi-layer pipes made of radiation-cross-linked plastic and metal, so the rising price of copper should no longer threaten the production of pipes. The outstanding properties of radiation-treated reinforced engineering plastics offer designers new applications in the electrical and mechanical engineering, automotive and architectural sectors.
Plastics have long been helping the development of sport as a new material for sports equipment and sportswear. Today, the amount of plastics in stadiums is also increasing rapidly. Plastic roofs are no longer a novelty, except for their size. The latest favourite is plastic turf, which many claim is better than the real thing.
More and more people know that the much-loathed plastic waste is not rubbish, but a valuable raw material. Recycling it or using its energy content costs money, which they try to raise by charging fees. The mass of plastic landfilled in previous decades may become an important source of energy in the future, and several companies are already mining it.