Donald v. Rosato - Plastics E.nd Use Applications

SpringerBriefs in Materials
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Donald V. Rosato
Plastics End Use Applications

Donald V. Rosato
PlastiSource, Inc.
Concord, MA 01742, USA
[email protected]
ISSN 2192-1091 eISSN 2192-1105

ISBN 978-1-4614-0244-2 e-ISBN 978-1-4614-0245-9
DOI 10.1007/978-1-4614-0245-9
Springer New York Dordrecht Heidelberg London
Library of Congress Control Number: 2011931281
© Springer Science+Business Media, LLC 2011

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Preface
This SpringerBrief Plastics End Use Applications covers approximately 120+ plastics
applications and trends in the major end use areas of electrical and electronic, indus-
trial, transportation, consumer products, medical, emerging, and related subsectors.
Plastics play an indispensable role in a wide variety of markets, ranging from packaging
and building & construction to transportation, consumer and institutional products,
furniture and furnishings, electrical & electronic components, medical and others. This
enormous variety of end uses for plastics materials is what gives the industry its remark-
ably dynamic character. This also offers an exciting and significant challenge to com-
panies, to find the optimum mix of markets and customers to pursue that which fits with
the products it makes, the services it offers, and its financial goals.
Plastics End Use Applications provides a simplified, practical, and innovative
approach to understanding the design and manufacture of plastic products. This
unique review will expand the reader’s understanding of plastics technology by
defining and focusing on current and future technical trends. Plastics behavior is
presented to enhance the capability of fabricating products that meet performance
standards, low cost requirements, and profitability targets.
Application examples include toys, medical devices, cars, boats, underwater
devices, containers, springs, pipes, buildings, and aircraft. Also covered are
behaviors associated with different plastic materials (thermoplastics, elastomers,
reinforced plastics) and the many fabricating processes (extrusion, injection
molding, blow molding, forming, foaming, reaction injection molding, rotational
molding). This material is presented so that both technical and non-technical reader
can understand the interrelationships of materials to processes to applications. Also
examined are different plastic products and their related critical factors, from meet-
ing performance requirements in different environments, to reducing costs, and
targeting for zero defects. Examples used include small to large, and simple to
complex shapes. Major specific plastic end-use markets covered include packaging,
building and construction, automotive, electrical and electronic, appliance, medical,
consumer products, toy, recreation and leisure, furniture, office products, lawn and
garden, marine and boat, aerospace, industrial, agriculture, waste management,
government, export, and other and emerging.
v
vi Preface
This SpringerBrief is designed to keep professionals in the global plastics industry

abreast of key technical developments, business strategies, and marketing initiatives
in plastics and competitive materials from an applications standpoint that impact the
sales and usage of plastics. The customized interpretative nature of this SpringerBrief
encompasses material, processing, fabricator oriented, major end-use competitive
and/or complementary material trend (metal, rubber, paper & wood, glass & ceramic)
viewpoints, and displays a unique plastic technology knowledge building focus.
Plastics End Use Applications has been prepared with the awareness that its
usefulness will depend on its simplicity and its ability to provide essential informa-
tion. Preparation for this SpringerBrief drew on information from participating
industry personnel, global industry and trade associations, and the author’s world-
wide personal, industrial, and teaching experiences.
Donald V. Rosato
Contents
1 Executive Summary ................................................................................. 1

1.1 Overview ........................................................................................... 1
1.1.1 Overview ............................................................................... 1
1.1.2 Global Technology Highlights
(North America, Europe, Asia) ............................................. 1
1.1.3 Electrical and Electronic Applications ................................. 1
1.1.4 Industrial Applications.......................................................... 2
1.1.5 Transportation Applications ................................................. 3
1.1.6 Consumer Products Applications ......................................... 3
1.1.7 Medical, Emerging, and Other Applications ........................ 4
1.2 Scope and Methodology ................................................................... 4
1.2.1 Scope..................................................................................... 4
1.2.2 Methodology ......................................................................... 6
1.2.3 Plastics End Use Applications Webwatch Directory ............ 7
2 Plastics End Use Application Fundamentals ......................................... 11
2.1 Introduction ....................................................................................... 11
2.1.1 Markets Overview................................................................. 11
2.1.2 Packaging Market ................................................................. 12
2.2 Other Major Markets......................................................................... 14
2.2.1 Building and Construction Market ....................................... 14
2.2.2 Automotive Market ............................................................... 15
2.2.3 Electrical and Electronic Market .......................................... 16
2.3 Key Crossover Markets ..................................................................... 17
2.3.1 Consumer Goods Market ...................................................... 17
2.3.2 Industrial and Stock Shapes Markets .................................... 17
2.3.3 Other Markets ....................................................................... 18
3 Electrical and Electronic End Use Applications ................................... 19
3.1 Electrical and Electronic Applications.............................................. 19
3.1.1 Electrical and Electronic Applications Introduction............. 19
3.1.2 Fuel Cell Plates ..................................................................... 19
vii
viii Contents
3.1.3 PLED Flat Panel Displays .................................................. 20

3.1.4 Flexible Printed Transistors ................................................ 21
3.1.5 High-Performance Ignition Coil Bobbins ........................... 21
3.1.6 Smart Wallplates ................................................................. 22
3.1.7 Electronic Cloth .................................................................. 22
3.1.8 Intrinsic EMI Shielded Products ......................................... 23
3.1.9 Miniaturized DSL Transformers ......................................... 23
3.1.10 Electrodynamic Loudspeakers ............................................ 24
3.1.11 Visual/Tactile Electronic Enclosures .................................. 24
3.1.12 High-Performance Outdoor Cable ...................................... 25
3.2 Office Products Applications ............................................................ 26
3.2.1 Office Products Applications Introduction ......................... 26
3.2.2 Miniaturized Fuel Cells ...................................................... 26
3.2.3 Rollable Reading Displays ................................................. 27
3.2.4 Digital Pens ......................................................................... 28
3.2.5 Orbital Web Cameras .......................................................... 28
3.2.6 Removable Data Storage Media ......................................... 29
3.3 Appliance Applications..................................................................... 29
3.3.1 Appliance Applications Introduction .................................. 29
3.3.2 E/E Design for Recycle Appliances.................................... 30
3.3.3 Dyson Cyclone Vacuum Cleaner ........................................ 30
3.3.4 High-Performance Light Fixtures ....................................... 31
4 Industrial End Use Applications............................................................. 33
4.1 Packaging Applications .................................................................... 33
4.1.1 Packaging Applications Introduction.................................. 33
4.1.2 Stretch Hood Film Wrap ..................................................... 33
4.1.3 Electronic Product Codes (RFID) ....................................... 34
4.1.4 Transparent Paint Cans ....................................................... 35
4.1.5 Self-Heating Container ....................................................... 36
4.1.6 Elastic Shrinking Stretch Film ............................................ 37
4.1.7 Rectangular Beverage Bottles ............................................. 37
4.2 Building and Construction Applications........................................... 38
4.2.1 Building and Construction Applications Introduction ........ 38
4.2.2 Fiber-Based Composite Building Products......................... 38
4.2.3 Flexible Mouldings ............................................................. 39
4.2.4 Artistically Designed Floor Coverings ............................... 39
4.2.5 Sandwich Construction Plate .............................................. 40
4.2.6 Secure Window Film .......................................................... 41
4.3 Industrial Applications ...................................................................... 42
4.3.1 Industrial Applications Introduction ................................... 42
4.3.2 Energy-Saving Freezer Apparatus ...................................... 42
4.3.3 Plastic Pallets ...................................................................... 43
4.3.4 Sterile Disposable Flasks .................................................... 43
4.3.5 Mechanically Efficient Microplates .................................... 44
Contents ix
4.3.6 Aerodynamic Truck Brackets ............................................. 44

4.3.7 High Tech Fasteners............................................................ 45
4.4 Agricultural Applications.................................................................. 46
4.4.1 Agricultural Applications Introduction............................... 46
4.4.2 Farmland Demining Equipment.......................................... 46
4.4.3 Engineered Horseshoes ....................................................... 46
4.4.4 Ag Equipment Large Parts .................................................. 47
4.4.5 High Durability Irrigation Filters........................................ 47
4.4.6 Ag Pesticide Recyclable Containers ................................... 48
5 Transportation End Use Applications .................................................... 49
5.1 Automotive Applications .................................................................. 49
5.1.1 Plastics and Transportation ................................................. 49
5.1.2 Automotive Applications Introduction ............................... 50
5.1.3 Carburetor and Air Intake System Firsts ............................ 50
5.1.4 LESA Part Adhesive Technology ....................................... 51
5.1.5 Optical Glazing ................................................................... 52
5.1.6 Class A Roof Appliques ..................................................... 52
5.1.7 Carbon Fiber Concept Cars ................................................ 53
5.1.8 Metal/Plastic Antenna Modules .......................................... 53
5.1.9 High-Value Oil Valve Covers.............................................. 54
5.1.10 Composite Front Hood ....................................................... 55
5.1.11 Ford’s GloCar ..................................................................... 55
5.2 Aerospace Applications .................................................................... 56
5.2.1 Aerospace Applications Introduction ................................. 56
5.2.2 Unmanned Aerial Vehicles ................................................. 56
5.2.3 A380 Composite Floor Panels ............................................ 57
5.2.4 Ultra Lightweight Global Flyer .......................................... 57
5.2.5 Mars Tested Circuit Materials............................................. 58
5.2.6 Robotic Jet Bombers ........................................................... 58
5.2.7 Parachute Safe Air Transport .............................................. 59
5.2.8 7E7 Dreamliner Composites ............................................... 59
5.3 Marine and Boat Applications .......................................................... 60
5.3.1 Marine and Boat Applications Introduction ....................... 60
5.3.2 State-of-the-Art Outboard Engines ..................................... 60
5.3.3 High Tech Pontoon Boats ................................................... 61
5.3.4 Subsea High-Strength Moorings......................................... 61
5.3.5 Small Craft Rotomolding .................................................... 62
5.3.6 Corrosion-Resistant Pier Sleeves ........................................ 62
5.3.7 Lightweight Engineered Dock Pilings ................................ 63
6 Consumer Products End Use Applications ............................................ 65
6.1 Consumer Products Applications ..................................................... 65
6.1.1 Consumer Products and the Consumer ............................... 65
6.1.2 A New Wine Cork Twist ..................................................... 65
6.1.3 High Tech Gloves ............................................................... 66
x Contents
6.1.4 Consumer Durable Cushioning........................................... 66

6.1.5 High-Capacity Blu-Ray DVDs ........................................... 67
6.1.6 Electronic Book Binding .................................................... 68
6.1.7 EU Food Compliant Containers.......................................... 68
6.1.8 High-Temperature Cookware ............................................. 69
6.1.9 High Tech Power Shavers ................................................... 69
6.1.10 Blow Molded Standup Tubes.............................................. 70
6.1.11 Do-It-Yourself Faucets........................................................ 70
6.1.12 Time Expired DVDs ........................................................... 71
6.2 Toy Applications ............................................................................... 71
6.2.1 Toy Applications Market .................................................... 71
6.2.2 Rotomolded Toys ................................................................ 72
6.2.3 Large-Scale Building Toy ................................................... 72
6.2.4 Highly Precise Game Joy Sticks ......................................... 72
6.2.5 High Tech Learning Toys.................................................... 73
6.2.6 Import Proof Seasonal Toys ................................................ 73
6.3 Recreation and Leisure Applications ................................................ 74
6.3.1 Recreation and Leisure Applications Introduction ............. 74
6.3.2 Ultralight Foldable Kayak .................................................. 74
6.3.3 Clear Corrosion-Resistant Pool Cleaners ........................... 75
6.3.4 Cross Country Skiing/Skating ............................................ 75
6.3.5 Snow Skates ........................................................................ 76
6.3.6 Laserline Golf Tees ............................................................. 76
6.3.7 Light, Efficient Golf Club Merchandising Carts ................ 77
6.4 Furniture Applications ...................................................................... 77
6.4.1 Furniture Applications Introduction ................................... 77
6.4.2 Polyurethane Foam Quilting Replacement ......................... 78
6.4.3 Lightweight Composite Tables ........................................... 78
6.4.4 Naturally Flexing Office Chairs.......................................... 79
6.4.5 Performance Enhanced Window Shades ............................ 79
6.4.6 Renewable Resource Sleep Products .................................. 80
6.4.7 Environmentally Friendly Chairs........................................ 80
6.5 Lawn and Garden Applications ........................................................ 81
6.5.1 Lawn and Garden Introduction ........................................... 81
6.5.2 Novel Plastic Fencing ......................................................... 81
6.5.3 Miracle-Gro Multipurpose Pails ......................................... 81
6.5.4 Non-Slip Garden Tools ....................................................... 82
6.5.5 Functional Stylized Glazing ............................................... 82
7 Medical, Emerging, and Other End Use Applications ......................... 85
7.1 Medical Applications ........................................................................ 85
7.1.1 Medical Applications Introduction ..................................... 85
7.1.2 High Tech IV Catheters ...................................................... 85
7.1.3 Life-Saving Items Safely Packaged .................................... 86
7.1.4 Highly Maneuverable Surgical Microscope ....................... 86
Contents xi
7.1.5 Surgical Microtools............................................................. 87

7.1.6 Micro-sized Assay Disks .................................................... 87
7.1.7 Home Healthcare CPAP Systems ....................................... 88
7.2 Emerging Applications ..................................................................... 88
7.2.1 Emerging Applications Introduction .................................. 88
7.2.2 Plastic Bone Wound Repair ................................................ 89
7.2.3 Satellite TV Car Antennas .................................................. 90
7.2.4 Luminescent Handbags ....................................................... 90
7.2.5 “Virtual Layering” Clothing Fabrics................................... 91
7.3 Other Applications ............................................................................ 91
7.3.1 Government Applications Introduction .............................. 91
7.3.2 Driver Safe Lamp Posts ...................................................... 92
7.3.3 Ageless Underground Pipe ................................................. 92
7.3.4 Super Strong Water Pipe ..................................................... 93
7.3.5 Composite UCAVs.............................................................. 93
7.3.6 Waste Management Applications Introduction................... 94
7.3.7 Recycled PET Mine Shaft Reinforcement .......................... 94
7.3.8 Waste Carpet Fiber Products............................................... 94
7.3.9 Nylon Car Parts Recycling ................................................. 95
7.3.10 Eco-efficient Mechanical Recycling ................................... 96
7.3.11 Environmentally Marketed Irrigation Pipe ......................... 96
8 Plastics End Use Applications Company Source Guide ....................... 97
8.1 Plastic and Related Materials Segments ........................................... 97
8.1.1 Source Guide Introduction .................................................. 97
8.1.2 Plastic, Metal, Paper & Wood, Rubber,
Glass & Ceramic Companies .............................................. 98
8.2 Major and Intermediate Plastic End Use Market Segments ............. 102
8.2.1 Major Packaging, Building & Construction,
Automotive, Electrical & Electronic,
and Appliance Companies .................................................. 102
8.2.2 Intermediate Medical, Consumer Products, Toy,
Recreation & Leisure, and Furniture Companies ............... 106
8.3 Specialty and Niche Plastic Enduse Market Segments ..................... 110
8.3.1 Specialty Office Products, Lawn & Garden,
Marine & Boat, Aerospace, and Industrial Companies ...... 110
8.3.2 Niche Agriculture, Waste Management, Government,
Export, and Other & Emerging Companies ........................ 114
About the Author ........................................................................................... 119
Chapter 1
Executive Summary
Keywords฀ Plastic฀•฀Electronics฀•฀Prototypes฀•฀Packaging฀•฀Urethane฀•฀Composites฀
•฀Polyphthalamide฀•฀Ergonomic฀•฀Medical฀•฀Electroluminescence
1.1 Overview
1.1.1 Overview
This฀“Plastics฀End฀Use฀Applications”฀SpringerBrief฀covers฀approximately฀120+฀plas-
tics฀ applications฀ and฀ trends฀ in฀ the฀ major฀ applications฀ areas฀ of฀ (1)฀ plastics฀ industry฀
fundamentals,฀(2)฀electrical฀and฀electronic฀applications,฀(3)฀industrial฀applications,฀
(4)฀ transportation฀ applications,฀ (5)฀ consumer฀ products฀ applications,฀ (6)฀ medical,฀
emerging,฀and฀other฀applications,฀and฀(7)฀plastics฀applications฀company฀sourceguide.
1.1.2 Global Technology Highlights (North America,

Europe, Asia)
Let฀us฀take฀a฀brief฀tour฀of฀the฀nearly฀120+฀emerging,฀global฀plastics฀applications฀
highlights฀covered฀in฀the฀SpringerBrief฀as฀follows.
1.1.3 Electrical and Electronic Applications
•฀ Plastic฀Logic฀Ltd.฀(UK),฀a฀leading฀developer฀of฀plastic฀electronics฀including฀
printed฀lexible฀thin฀ilm฀transistor฀(TFT)฀arrays,฀is฀developing฀and฀exploiting฀
a฀portfolio฀of฀intellectual฀property฀based฀on฀inkjet฀printing฀of฀active฀electronic฀
D.V. Rosato, Plastics End Use Applications, SpringerBriefs in Materials, 1

DOI 10.1007/978-1-4614-0245-9_1, © Springer Science+Business Media, LLC 2011
2 1฀ Executive฀Summary
circuits฀using฀advanced฀plastic฀materials฀to฀form฀thin฀ilm฀transistors฀that฀can฀
be฀used฀in฀active฀matrix฀back฀planes฀that฀drive฀displays.฀Other฀potential฀appli-
cations฀include฀smart฀labels,฀smart฀packaging,฀and฀radio฀frequency฀identiica-
tion฀(RFID)฀devices.฀Plastics฀electronics฀can฀be฀produced฀directly฀at฀high฀speed฀
from฀ CAD฀ data฀ to฀ large,฀ lexible฀ surfaces฀ using฀ ink฀ jet฀ printing฀ equipment฀
rather฀ than฀ ฀complex฀ photolithography฀ and฀ vacuum฀ systems฀ used฀ to฀ make฀
today’s฀ transistors.฀ With฀ the฀ process’฀ low฀ temperatures,฀ substrates฀ used฀ can฀
also฀be฀plastic.
•฀ Dyson฀Ltd.฀(UK)฀realized฀that฀with฀most฀vacuum฀cleaners฀the฀bag฀quickly฀clogs฀
with฀dust฀as฀the฀suction฀had฀to฀pass฀through฀the฀bag,฀and฀a฀clogged฀bag,฀even฀with฀
as฀little฀as฀10฀oz.฀of฀dirt,฀can฀cut฀the฀suction฀in฀half฀so฀the฀more฀a฀bag฀is฀used฀the฀
less฀effective฀it฀becomes.฀Entrepreneur฀James฀Dyson฀set฀out฀to฀solve฀the฀problem.฀
Five฀years฀and฀5,000฀prototypes฀later,฀the฀world’s฀irst฀cyclonic฀bagless฀vacuum฀
arrived.฀When฀none฀of฀the฀major฀manufacturers฀were฀interested,฀Dyson฀launched฀
his฀own฀vacuum฀cleaner฀company.฀Now,฀Dyson฀Cyclonic฀Vacuum,฀Europe’s฀hottest฀
home฀appliance,฀has฀come฀to฀America.
1.1.4 Industrial Applications
•฀ OnTech฀(U.S.)฀has฀one฀of฀the฀most฀innovative฀packaging฀solutions฀recently฀intro-
duced฀ as฀ North฀ America’s฀ irst฀ self-heating฀ container,฀ designed฀ to฀ heat฀ liquid฀
contents฀such฀as฀coffee,฀tea,฀cocoa,฀soups,฀and฀alcoholic฀beverages.฀Created฀by฀
OnTech,฀Inc.,฀the฀new฀self-heating฀container฀is฀a฀safe฀and฀easy-to-activate฀฀concept฀
that฀heats฀up฀the฀contents฀of฀its฀package฀to฀approximately฀145°F฀within฀minutes.฀
The฀company฀now฀has฀102฀approved฀utility฀patent฀claims฀in฀the฀US฀and฀patents฀
in฀36฀other฀countries,฀including฀the฀UK,฀China,฀and฀Japan฀covering฀any฀multi-
chamber฀ plastic฀ product฀ that฀ must฀ be฀ retorted,฀ or฀ sterilized฀ during฀ a฀ heating฀
process.฀In฀Europe,฀some฀metal฀containers฀can฀self-heat฀and฀others฀have฀tried฀a฀
mix฀of฀materials฀to฀create฀the฀same฀result฀but฀with฀limited฀commercial฀results.฀
Metal฀has฀a฀tendency฀to฀collapse฀or฀crush฀during฀the฀sterilization฀process,฀when฀
the฀container฀has฀to฀be฀heated฀to฀250°F.
•฀ According฀to฀Style฀Solutions฀Inc.฀(U.S.),฀customized฀construction฀products฀and฀
large฀builders฀will฀drive฀the฀growth฀of฀urethane฀millwork฀in฀2005.฀The฀irm฀has฀
created฀more฀than฀300฀customized฀products฀in฀the฀past฀year฀for฀builders฀across฀
the฀US.฀The฀building฀and฀construction฀industry฀has฀seen฀unprecedented฀advances฀
in฀the฀acceptance฀and฀use฀of฀urethane฀millwork฀on฀both฀exteriors฀and฀interiors฀of฀
commercial฀and฀residential฀buildings.฀Just฀5฀years฀ago,฀wood฀moulding฀proiles฀
was฀predominate฀with฀few฀engineered฀plastic฀ones฀seen.฀Today฀the฀reverse฀is฀true฀
with฀low-maintenance฀products,฀such฀as฀urethane,฀composite,฀and฀plastic฀mould-
ings฀prominent฀in฀all฀regions฀of฀the฀country.฀Urethane฀millwork,฀which฀stands฀up฀
to฀ high฀ temperatures฀ in฀ the฀ summer฀ and฀ frigid฀ snowy฀ weather฀ in฀ the฀ winter฀
months,฀is฀being฀increasingly฀used฀with฀other฀products฀such฀as฀doors,฀windows,฀
and฀vinyl฀siding.
1.1฀ Overview 3
1.1.5 Transportation Applications
•฀ Johnson฀Controls฀(U.S.)฀states฀that฀a฀top฀of฀the฀line฀car฀is฀now฀equipped฀with฀an฀
average฀of฀ten฀antennae,฀and฀that฀number฀is฀expected฀to฀soon฀increase฀to฀as฀many฀
as฀16฀as฀car฀manufacturers฀introduce฀systems฀for฀monitoring฀and฀automatically฀
regulating฀the฀distance฀from฀the฀vehicle฀in฀front,฀and฀install฀warning฀sensors฀to฀
avoid฀collisions฀when฀reversing.฀These฀numerous฀antennae฀have฀been฀generally฀
spread฀over฀the฀entire฀bodyshell,฀presenting฀a฀challenge฀to฀designers฀who฀have฀to฀
guarantee฀optimum฀reception.฀A฀new฀antenna฀module฀developed฀as฀a฀joint฀project฀
by฀ Johnson฀ Controls฀ and฀ Volvo฀ demonstrates฀ a฀ way฀ round฀ the฀ problem.฀ The฀
module฀accommodates฀all฀the฀antennae฀and฀relevant฀receivers฀(radio,฀TV,฀GPS)฀
in฀one฀unit.฀Made฀of฀steel฀and฀Durethan฀BM฀130฀H2.0฀polyamide฀supplied฀by฀
Bayer฀MaterialScience,฀it฀is฀manufactured฀using฀the฀plastic/metal฀hybrid฀tech-
nology฀already฀established฀for฀production฀of฀vehicle฀front-ends.
•฀ Scaled฀Composites฀(U.S.)฀and฀Virgin฀Atlantic฀(UK)฀have฀unveiled฀the฀GlobalFlyer฀
V.฀ The฀ pioneering฀ aircraft,฀ said฀ to฀ be฀ the฀ world’s฀ most฀ eficient฀ jet฀ plane,฀ has฀
been฀ piloted฀ in฀ an฀ attempt฀ to฀ achieve฀ the฀ irst฀ solo,฀ nonstop฀ around฀ the฀ world฀
light.฀The฀aircraft฀completed฀the฀80-h฀voyage฀on฀one฀tank฀of฀fuel.฀Virgin฀Atlantic฀
is฀the฀sponsor฀the฀38.7-foot฀long,฀single฀engine฀jet,฀with฀a฀114-foot฀wingspan.฀
Scaled฀Composites฀spent฀more฀than฀4฀years฀designing฀and฀building฀the฀aircraft.฀
The฀company฀used฀computer-aided฀aerodynamic฀studies฀and฀built฀the฀structure฀
entirely฀from฀ultra-light฀carbon,฀Kevlar,฀glass,฀and฀a฀combination฀of฀reinforced฀
epoxy฀and฀polyester฀composite฀materials.
1.1.6 Consumer Products Applications
•฀ Solvay฀Advanced฀Polymers’฀(U.S.,฀Belgium)฀Amodel฀Polyphthalamide฀(PPA)฀has฀
broken฀into฀the฀wine฀industry.฀Typically฀found฀in฀automotive,฀electrical,฀and฀indus-
trial฀ product฀ applications,฀ Solvay฀ Advanced฀ Polymers฀ LLC’s฀ high-performance฀
polymer฀has฀found฀a฀new฀use฀as฀a฀threaded฀anchor฀for฀the฀patented฀twist-to-uncork฀
wine฀packaging฀designed฀by฀Gardner฀Technologies,฀Inc.,฀a฀Napa,฀CA,฀based฀manu-
facturer.฀The฀new฀product฀carries฀the฀MetaCork฀trade฀name฀and฀was฀on฀display฀at฀
the฀recent฀K฀Fair฀in฀Düsseldorf.฀MetaCork™฀consists฀of฀a฀hard฀plastic฀capsule฀with฀
a฀threaded฀interior฀surface,฀a฀matching฀plastic฀threaded฀cap,฀and฀a฀natural฀or฀syn-
thetic฀cork฀itted฀with฀a฀threaded฀anchor,฀made฀from฀Amodel฀PPA,฀that฀is฀screwed฀
into฀the฀cork฀during฀the฀bottling฀process.
•฀ An฀attractive฀new฀chair,฀part฀of฀contract฀furnishings฀manufacturer฀Allsteel฀Inc.’s฀
(U.S.)฀ ‘Get฀ Set’฀ line฀ of฀ ofice฀ chairs,฀ tables,฀ and฀ accessories,฀ is฀ its฀ Get฀ Set฀
฀multi-purpose฀ room฀ seating/ofice฀ side฀ chair.฀ The฀ new฀ chair,฀ a฀ comfortable,฀
฀lexible฀ solution฀ for฀ learning฀ environments,฀ is฀ designed฀ for฀ both฀ horizontal฀
฀nesting฀and฀vertical฀stacking฀(up฀to฀four฀high)฀for฀versatile,฀easy฀transportation฀
and฀storage.฀Though฀portability฀is฀a฀plus,฀the฀beneit฀of฀Get฀Set฀chairs฀is฀the฀hours฀
of฀ comfortable฀ seating฀ they฀ provide.฀ Unlike฀ non-padded฀ folding฀ or฀ stacking฀
chairs฀often฀used฀in฀a฀learning฀setting,฀Get฀Set฀chairs฀focus฀on฀comfort,฀featuring฀
seat฀cushions฀and฀a฀unique฀‘lex฀back,’฀which฀has฀a฀structure฀that฀lexes฀naturally,฀
to฀counterbalance฀body฀weight฀and฀conform฀to฀support฀users฀of฀different฀shapes฀
and฀sizes.฀An฀ergonomic฀sloping฀arm฀option฀also฀allows฀for฀natural฀movement฀of฀
the฀ body.฀ Perforations฀ in฀ the฀ chair฀ back฀ allow฀ air฀ circulation,฀ an฀ important฀
฀consideration,฀as฀well.฀Durable฀multi-surface฀casters฀make฀movement฀easy.
1.1.7 Medical, Emerging, and Other Applications
•฀ Puratech฀GmbH’s฀(Switzerland)฀operating฀microscopes฀play฀a฀crucial฀role฀in฀the฀
operating฀room.฀They฀must฀deliver฀top฀performance฀in฀a฀highly฀demanding฀environ-
ment฀and฀they฀must฀be฀lightweight,฀always฀accessible฀but฀never฀in฀the฀way฀during฀
demanding฀and฀detailed฀work.฀Consequently,฀these฀instruments฀are฀equipped฀with฀
highly฀sophisticated฀balancing฀systems฀that฀ensure฀high-precision฀movement฀of฀the฀
complex฀optical฀system฀without฀manual฀involvement฀on฀the฀part฀of฀the฀surgeon.฀The฀
arm฀which฀the฀microscope฀moves฀on฀must฀therefore฀be฀as฀light฀as฀possible.฀High-
performance฀plastics฀like฀the฀lightweight,฀robust,฀Baydur฀110฀polyurethane฀system฀
from฀Bayer฀MaterialScience฀AG฀are฀ideal฀for฀use฀in฀this฀application.
•฀ Bree฀Collection฀GmbH฀(Germany),฀an฀international฀leather฀and฀bag฀specialist,฀
has฀ created฀ an฀ illuminated฀ business฀ handbag฀ using฀ Smart฀ Surface฀ Technology฀
(SST).฀ Bree฀ had฀ been฀ toying฀ with฀ the฀ idea฀ of฀ illuminating฀ the฀ dark฀ insides฀ of฀
handbags฀for฀some฀time,฀but฀lacked฀an฀elegant฀solution.฀The฀answer฀is฀now฀avail-
able฀as฀Smart฀Surface฀Technology฀developed฀by฀Bayer฀Polymers,฀in฀partnership฀
with฀Lumitec,฀a฀specialist฀in฀electroluminescence฀(EL)฀and฀precision฀electronic฀
components.฀ EL฀ is฀ method฀ of฀ generating฀ light฀ reminiscent฀ of฀ the฀ chemical฀
method฀employed฀by฀irelies.฀Engineers฀are฀using฀a฀ilm฀that฀lights฀up฀on฀appli-
cation฀of฀a฀voltage฀to฀achieve฀electroluminescence.฀An฀advantage฀of฀EL฀is฀that฀it฀
does฀not฀produce฀heat.฀However฀until฀now,฀only฀lat฀surfaces฀of฀limited฀size฀could฀
be฀ achieved.฀ Smart฀ Surface฀ Technology฀ makes฀ it฀ possible฀ for฀ the฀ ilms฀ to฀ be฀
shaped฀to฀illuminate฀any฀conceivable฀geometry.฀Incorporated฀in฀a฀nonconductive฀
layer,฀the฀ilm฀in฀Bree’s฀handbag฀lights฀up฀at฀the฀press฀of฀a฀button.฀Bayer฀Polymers฀
sees฀the฀main฀application฀for฀this฀technology฀in฀the฀auto฀industry.฀Incandescent฀
lamps฀in฀cars฀will฀become฀obsolete.฀Instrument฀panels฀will฀be฀designed฀to฀take฀
up฀less฀room฀and฀a฀car’s฀interior฀headliner฀will฀glow฀in฀a฀soft฀glare-free฀light.
1.2 Scope and Methodology
1.2.1 Scope
The฀Plastics฀End฀Use฀Applications฀scope฀encompasses฀emerging฀technology฀and฀
trends฀in฀the฀following฀major฀and฀subtopic฀plastics฀applications฀focused฀areas:
1.2฀ Scope฀and฀Methodology 5
Electrical and electronic applications Agricultural applications

–฀ Electrical฀and฀electronic฀introduction –฀ Agricultural฀applications฀introduction
–฀ Fuel฀cell฀plates –฀ Farmland฀demining฀equipment
–฀ PLED฀lat฀panel฀displays –฀ Engineered฀horseshoes
–฀ Flexible฀printed฀transistors –฀ Ag฀equipment฀large฀parts
–฀ High-performance฀ignition฀Coil฀Bobbins –฀ High฀durability฀irrigation฀ilters
–฀ Smart฀wallplates –฀ Ag฀pesticide฀recyclable฀containers
–฀ Electronic฀cloth Automotive applications
–฀ Intrinsic฀EMI฀shielded฀products – Plastics and transportation
–฀ Miniaturized฀DSL฀transformers –฀ Automotive฀applications฀introduction
–฀ Electrodynamic฀loudspeakers –฀ Carburetor฀and฀air฀intake฀system฀irsts
– Visual/tactile electronic enclosures –฀ LESA฀part฀adhesive฀technology
–฀ High-performance฀outdoor฀cable –฀ Optical฀glazing
Office products applications –฀ Class฀A฀roof฀appliques
–฀ Miniaturized฀fuel฀cells –฀ Carbon฀iber฀concept฀cars
–฀ Rollable฀reading฀displays –฀ Metal/plastic฀antenna฀modules
– Digital pens –฀ High฀value฀oil฀valve฀covers
–฀ Orbital฀web฀cameras –฀ Composite฀front฀hood
–฀ Removable฀data฀storage฀media –฀ Ford’s฀GloCar
Appliance applications Aerospace applications
–฀ Appliance฀applications฀introduction –฀ Aerospace฀applications฀introduction
–฀ E/E฀design฀for฀recycle฀appliances –฀ Unmanned฀aerial฀vehicles
–฀ Dyson฀cyclone฀vacuum฀cleaner –฀ A380฀composite฀loor฀panels
–฀ High-performance฀light฀ixtures –฀ Ultra฀lightweight฀global฀lyer
Packaging applications –฀ Mars฀tested฀circuit฀materials
–฀ Packaging฀applications฀introduction –฀ Robotic฀jet฀bombers
–฀ Stretch฀hood฀ilm฀wrap –฀ Parachute฀safe฀air฀transport
–฀ Electronic฀product฀codes฀(RFID) –฀ 7E7฀dreamliner฀composites
– Transparent paint cans Marine and boat applications
–฀ Elastic฀shrinking฀stretch฀ilm –฀ Marine฀and฀boat฀applications฀introduction
–฀ Rectangular฀beverage฀bottles –฀ State-of-the-art฀outboard฀engines
Building and construction applications –฀ High฀tech฀pontoon฀boats
– Building and construction applications –฀ Subsea฀high฀strength฀moorings
introduction –฀ Small฀craft฀rotomolding
–฀ Fiber-based฀composite฀building฀products –฀ Corrosion฀resistant฀pier฀sleeves
–฀ Flexible฀mouldings –฀ Light฀weight฀engineered฀dock฀pilings
–฀ Artistically฀designed฀loor฀coverings Consumer products applications
–฀ Sandwich฀construction฀plate –฀ Consumer฀products฀and฀the฀consumer
–฀ Secure฀window฀ilm –฀ A฀new฀wine฀cork฀twist
Industrial applications –฀ High฀tech฀gloves
– Industrial applications introduction –฀ Consumer฀durable฀cushioning
–฀ Energy฀saving฀freezer฀apparatus –฀ High฀capacity฀Blu-Ray฀DVDs
– Plastic pallets –฀ Electronic฀book฀binding
–฀ Sterile฀disposable฀lasks –฀ EU฀food฀compliant฀containers
–฀ Mechanically฀eficient฀microplates –฀ High-temperature฀cookware
–฀ Aerodynamic฀truck฀brackets –฀ High฀tech฀power฀shavers
–฀ High฀tech฀fasteners –฀ Blow฀molded฀standup฀tubes
(continued)
(continued)
–฀ Do-it-yourself฀faucets –฀ Non-slip฀garden฀tools
–฀ Time฀expired฀DVDs –฀ Functional฀stylized฀glazing
Toy applications Medical applications
–฀ Toy฀applications฀market – Medical applications introduction
–฀ Rotomolded฀toys –฀ High฀tech฀IV฀catheters
–฀ Large-scale฀building฀toy –฀ Life-saving฀items฀safely฀packaged
–฀ Highly฀precise฀game฀joy฀sticks –฀ Highly฀maneuverable฀surgical฀microscope
–฀ High฀tech฀learning฀toys –฀ Surgical฀microtools
–฀ Import฀proof฀seasonal฀toys –฀ Micro-sized฀assay฀disks
Recreation/leisure applications –฀ Home฀healthcare฀CPAP฀systems
– Recreation/leisure applications introduction Emerging applications
–฀ Ultralight฀foldable฀kayak –฀ Emerging฀applications฀introduction
– Clear corrosion-resistant pool cleaners –฀ Plastic฀bone฀wound฀repair
–฀ Cross฀country฀skiing/skating – Satellite TV car antennas
–฀ Snow฀skates –฀ Luminescent฀handbags
– Laserline golf tees –฀ ‘Virtual฀layering’฀clothing฀fabrics
–฀ Light,฀eficient฀golf฀club฀merchandising฀carts Other applications
Furniture applications –฀ Government฀applications฀introduction
–฀ Furniture฀applications฀introduction –฀ Driver฀safe฀lamp฀posts
–฀ Polyurethane฀foam฀quilting฀replacement –฀ Ageless฀underground฀pipe
–฀ Lightweight฀composite฀tables –฀ Super฀strong฀water฀pipe
–฀ Naturally฀lexing฀ofice฀chairs –฀ Composite฀UCAVs
–฀ Performance฀enhanced฀window฀shades –฀ Waste฀management฀applications฀
–฀ Renewable฀resource฀sleep฀products introduction
–฀ Environmentally฀friendly฀chairs –฀ Recycled฀PET฀mine฀shaft฀reinforcement
Lawn and garden applications –฀ Waste฀carpet฀iber฀products
–฀ Lawn฀and฀garden฀introduction –฀ Nylon฀car฀parts฀recycling
–฀ Novel฀plastic฀fencing –฀ Eco-eficient฀mechanical฀recycling
–฀ Miracle-gro฀multipurpose฀pails –฀ Environmentally฀marketed฀irrigation฀pipe
1.2.2 Methodology
The฀methodology฀to฀create฀Plastics฀End฀Use฀Applications฀included฀globally฀devel-
oping฀ and฀ reviewing฀ data,฀ information,฀ and฀ analysis฀ in฀ emerging฀ technology฀ and฀
trends฀from฀multiple฀sources฀such฀as:
฀1.฀ Direct฀company฀input฀from฀120+฀technology฀sources฀as฀outlined฀below฀in฀the฀
webwatch฀directory฀and฀Chapter฀eight’s฀applications฀company฀sourceguide
฀2.฀ 10+฀major฀trade฀shows฀(i.e.,฀NPE,฀Fakuma,฀K฀Fair,฀etc.)
฀3.฀ 5+฀major฀annual฀trade฀association฀meetings฀(i.e.,฀ANTEC,฀APME,฀PPI,฀etc.)
฀4.฀ 15+฀ major฀ trade฀ journals฀ (i.e.,฀ Plastics฀ Technology,฀ Kunststoffe฀ Plast฀ Europe,฀
Modern฀Plastics฀International,฀etc.),฀and
฀5.฀ 15+฀ major฀ database฀ (i.e.,฀ Derwent฀ World฀ Patents,฀ etc.),฀ reference฀ work฀ (i.e.฀
Plastics฀ Institute฀ of฀ America฀ Plastics,฀ Engineering,฀ Manufacturing฀ and฀ Data฀
Handbook,฀etc.)฀and฀study฀sources฀(i.e.,฀Freedonia,฀etc.).
1.2.3 Plastics End Use Applications Webwatch Directory
A฀global฀webwatch฀directory฀of฀120+฀company฀names฀and฀web฀addresses฀arranged฀
chronologically฀from฀Chaps.฀3–7฀are฀summarized฀for฀your฀reference฀convenience฀
immediately฀below.฀Additional฀contact฀information฀for฀625฀global฀plastics฀applica-
tions฀oriented฀companies฀is฀contained฀in฀Chap.฀8.
3.฀Electrical and electronics end use applications

Bulk฀Molding฀Compounds฀Inc. www.bulkmolding.com
Cambridge฀Display฀Technologies฀Ltd. www-cdtltd.ellipsismedia.net
Plastic Logic Ltd. www.plasticlogic.com
MSD฀Ignitions฀Div.,฀Autotronic฀Controls฀Corp. www.msdignition.com
Cooper Industries, Inc. www.cooperindustries.com
University฀of฀California฀at฀Berkeley www.eecs.berkeley.edu
DuPont www.plastics.dupont.com
Epcos฀AG www.epcos.com
Cabasse www.cabasse.com
Inclosia฀Solutions,฀Dow฀Chemical฀Co. www.inclosia.com
Teknor฀Apex฀Vinyl฀Division www.teknorapex.com
MTI฀MicroFuel฀Cells฀Inc. www.microfuelcell.com
PolymerVision,฀Philips฀Technology฀Incubator www.hightechcampus.nl
Logitech,฀Inc. www.logitech.com
Imation฀Corp. www.imation.com
Mitsubishi฀Electric฀Co.,฀Ltd. www.mitsubishi.com
Dyson฀Ltd. www.dyson.com
Miele฀&฀Cie.฀KG www.miele.de
4. Industrial end use applications
Lachenmeier฀A/S www.lachenmeier.com
Wal-Mart฀Stores,฀Inc. www.walmartstores.com
PCC฀Group www.plastic-can.com
OnTech,฀Inc. www.ontech.com
Easiwrap฀International฀Ltd. www.easiwrap.net
Owens-Illinois,฀Inc. www.o-i.com
Kadant฀Composites,฀Inc. www.kadant.com; www.geodeck.com
Style฀Solutions,฀Inc. www.stylesolutionsinc.com
Bayer฀MaterialScience฀AG www.bayermaterialscience.com;
www.artwalk-bayer.com
Intelligent฀Engineering฀Ltd. www.ie-sps.com
CPFilms฀Inc. www.cpilms.com
Creative฀Plastics฀&฀Design,฀Inc. www.cpdesign-inc.com
Kiga฀GmbH www.kiga-gmbh.de
Nalge฀Nunc฀International,฀Inc. www.nalgenelabware.com
Tecan฀Group฀Ltd. www.tecan.com
RTP Co. www.rtpcompany.com
Icotec฀AG www.icotec.ch
Countermine฀Technologies฀AB www.countermine.se
Senior฀and฀Dickson www.jameg-sprinters.co.uk
Bemis฀Plastics www.bemisplastics.com/agriculture
(continued)
(continued)
Irritrol฀Systems฀Europe฀S.r.l. www.irritrol.it
Ag฀Container฀Recycling฀Council www.acrecycle.org
5. Transportation end use applications
Solvay฀Advanced฀Polymers฀LLC www.solvayadvancedpolymers.com
Dow฀Automotive www.dow.com/automotive
Schefenacker/Freeglass฀AG www.schefenacker.com
DuPont Canada Inc. www.ca.dupont.com
Meridian฀Auto.฀Systems,฀Inc. www.meridianautosystems.com
Bayer฀MaterialsScience฀AG www.bayermaterialscience.com
Bruss฀North฀America www.brussna.com; www.bruss.de
Stamax฀BV,฀SABIC฀Europe //polymers.sabic-europe.com
General฀Motors฀Corp. www.gm.com
Ford฀Motor฀Co. www.ford.com
Northrop฀Grumman www.northropgrumman.com
MC฀Gill฀Corp. www.mcgillcorp.com
Scaled฀Composites,฀LLC www.scaled.com
DuPont Co. www.dupont.com/et
Boeing฀Phantom฀Works www.boeing.com/phantom
Ballistic฀Recovery฀Systems฀Inc. //brsparachutes.com
Boeing Co. www.boeing.com
Mercury฀Marine www.mercurymarine.com
Genmar฀Holdings฀Inc. www.genmar.com
Victrex฀plc www.victrex.com
Brigham฀Young฀University www.byu.edu
MFG฀Construction฀Products฀Co. www.mfgcp.com
ArmorDock www.armordock.com
6. Consumer products end use applications
Ergodyne www.ergodyne.com
Rogers Corp. www.rogerscorporation.com
Sony฀Disc฀Technology฀Inc. www.sdt.sony.co.jp
Sagoma฀Plastics www.sagomaplastics.com
Rubbermaid฀Europe www.rubbermaid-europe.com
BASF฀Engineering฀Plastics www.basf-ag.de
The฀Gillette฀Company www.gillette.com
Graham฀Packaging฀Co. www.grahampackaging.com
Moen Inc. www.moen.com
Flexplay฀Technologies,฀Inc. www.lexplay.com
Step2 Co. www.step2.com
Sagoma฀Plastics www.sagomaplastics.com
Logitech฀Inc. www.logitech.com
LeapFrog฀Enterprises,฀Inc. www.leapfrog.com
Grand฀Venture฀Ltd. www.grandventure.com
Firstlight฀Kayaks www.irstlightkayaks.com
GE฀Advanced฀Materials www.geadvancedmaterials.com
GateSkate,฀Inc. www.gateskate.com
Salomon www.salomonsports.com
Spirit฀of฀Golf฀GmbH E-mail:฀[email protected]
(continued)
(continued)
Meese฀Orbitron฀Dunne฀Co. www.modroto.com
Bayer฀MaterialsScience฀AG www.bayermaterialscience.com
Allsteel฀Inc. www.allsteelofice.com
Hunter฀Douglas,฀Inc. www.hunterdouglas.com
Paciic฀Coast฀Feather฀Co. www.paciiccoast.com
Herman฀Miller฀Inc. www.hermanmiller.com
Kroy฀Building฀Products,฀Inc. www.kroybp.com
Unimark฀Plastics www.unimarkplastics.com
Fiskars฀Corp. www.iskars.i
Wendland฀Conservatories฀Ltd. www.wendland.uk.com
7. Medical, emerging and other end use applications
NDH฀Medical,฀Inc. www.ndhmedical.com
Storopack฀Hans฀Reichenecker฀GmbH www.storopack.com
Puratech฀GmbH www.puratech.ch
ERBE฀Elektromedizin฀GmbH www.erbe-med.de
Tecan฀Group www.tecan.com
RTP Co. www.rtpcompany.com
Advanced฀Ceramics฀Research,฀Inc. www.acrtucson.com
Sarnatech฀BNL฀Ltd. www.sarnatech-bnl.com
BREE฀Collection฀GmbH฀&฀Co.฀KG www.bree.de
Malden฀Mills฀Industry,฀Inc. www.polartec.com
Euro฀Projects฀(LTTC)฀Ltd. www.europrojects.co.uk
Dow฀Chemical฀Co. www.dowcontinuum.com
Sekisui฀Chemical฀Co. www.sekisui.co.jp
Northrop฀Grumman฀Integrated฀Systems www.northropgrumman.com
Jennmar฀Corp. www.jennmar.com
Carpet฀America฀Recovery฀Effort฀(CARE) www.carpetrecovery.org
DuPont฀Engineering฀Polymers,฀ATC www.plastics.dupont.com
PlasticsEurope www.apme.org
Delta Plastics www.deltapl.com
Chapter 2
Plastics End Use Application Fundamentals
Keywords฀ Polypropylene฀ •฀ Polyethylene฀ •฀ Polystyrene฀ •฀ Polyvinyl฀ chloride฀

•฀ Polyethylene฀ terephthalate฀ •฀ Markets฀ •฀ Applications฀ •฀ End฀ use฀ •฀ Extrusion฀
•฀Injection฀molding
2.1 Introduction
2.1.1 Markets Overview
Plastics฀play฀an฀indispensable฀role฀in฀a฀wide฀variety฀of฀markets,฀ranging฀from฀packaging฀
and฀building฀&฀construction฀to฀transportation,฀consumer฀and฀institutional฀products,฀
furniture฀and฀furnishings,฀electrical฀and฀electronic฀components,฀medical฀and฀others.฀
This฀enormous฀variety฀of฀end฀uses฀for฀plastics฀materials฀is฀what฀gives฀the฀industry฀
its฀ remarkably฀ dynamic฀ character.฀ This฀ also฀ offers฀ an฀ exciting฀ and฀ signiicant฀
challenge฀ to฀ companies,฀ to฀ ind฀ the฀ optimum฀ mix฀ of฀ markets฀ and฀ customers฀ to฀
pursue฀ that฀which฀its฀with฀the฀products฀it฀makes,฀ the฀services฀ it฀offers,฀and฀ its฀
inancial฀goals.
Some฀companies฀concentrate฀their฀efforts฀principally฀on฀the฀larger฀end฀use฀markets,฀
but฀many฀others฀ind฀it฀safer฀to฀spread฀their฀business฀over฀a฀number฀of฀application฀
areas.฀The฀type฀of฀products฀a฀company฀makes฀deines฀its฀marketing฀efforts.฀Packaging฀
is฀the฀largest฀end฀use,฀followed฀by฀building/construction,฀automotive,฀and฀electrical/
electronic.฀Extrusion฀is฀the฀primary฀process฀used฀in฀plastics฀since฀most฀packaging฀
and฀building/construction฀products฀sold฀in฀are฀extruded.฀Injection฀molding,฀the฀next฀
most฀important฀process,฀is฀used฀for฀most฀complex฀parts.฀Blow฀molding฀is฀also฀exten-
sively฀used฀in฀the฀manufacture฀of฀packaging฀products.฀‘Other’฀processes฀used฀are฀
mainly฀thermoset฀processes,฀such฀as฀compression฀and฀transfer฀molding,฀and฀reac-
tion฀injection฀molding.
While฀ somewhat฀ arbitrary฀ and฀ not฀ always฀ consistent฀ within฀ the฀ industry,฀ an฀
application฀ is฀ typically฀ categorized฀ by฀ its฀ main฀ attributes;฀ therefore,฀ an฀ electrical฀

12 2฀ Plastics฀End฀Use฀Application฀Fundamentals
connector฀in฀a฀car฀wiring฀harness฀is฀usually฀considered฀to฀be฀an฀automotive฀application,฀
while฀electrical฀connectors฀employed฀in฀a฀variety฀of฀end฀uses฀are฀considered฀to฀be฀
electrical/electronic฀ applications.฀ The฀ following฀ segments฀ are฀ primary฀ market฀
groupings฀used฀by฀most฀industry฀analysts.
2.1.2 Packaging Market
Packaging฀constitutes฀the฀single฀largest฀end฀use฀for฀plastic฀materials,฀accounting฀for฀
approximately฀30%฀of฀all฀plastics฀used.฀Plastics฀are฀enjoying฀substantial฀growth฀as฀
a฀packaging฀medium,฀at฀the฀expense฀of฀traditional฀materials฀such฀as฀glass,฀metals,฀
and฀ paper,฀ in฀ spite฀ of฀ environmental฀ pressures฀ on฀ plastics฀ materials฀ in฀ general,฀
because฀plastic฀packages฀are฀lighter฀weight,฀more฀lexible,฀and฀easier฀to฀process.฀
Plastic฀packaging฀also฀displays฀product฀more฀attractively฀than฀do฀most฀competing฀
materials,฀offers฀better฀protection฀against฀spoilage/breakage,฀and฀provides฀savings฀
in฀freight฀costs฀(primarily฀fuel฀economy).฀Plastic฀resins฀most฀often฀used฀in฀packaging฀
are฀polypropylene,฀polyethylene,฀polystyrene,฀polyvinyl฀chloride,฀and฀polyethylene฀
terephthalate,฀ though฀ nylon฀ 6฀ is฀ also฀ used,฀ largely฀ as฀ ilm฀ in฀ food฀ packaging฀ for฀
meat.฀Post-consumer฀recycling฀is฀also฀an฀important฀consideration฀for฀PE-฀and฀PET-
based฀packaging;฀some฀major฀end฀users฀and฀some฀government฀entities฀even฀specify฀
recycled฀content.฀Because฀economics฀are฀frequently฀a฀principal฀factor฀in฀choosing฀
one฀material฀over฀another,฀commodity-type฀materials฀tend฀to฀be฀favored฀for฀their฀
lower฀cost.฀The฀growth฀of฀plastics฀packaging฀is฀due฀in฀no฀small฀part฀to฀the฀technologies฀
available฀to฀convert฀materials฀into฀packs฀of฀different฀forms,฀lexible,฀semi-lexible฀
and฀rigid,฀at฀high฀speed,฀which฀has฀had฀a฀crucial฀role฀in฀minimizing฀the฀cost฀of฀
plastics฀packaging.
Plastic฀packaging฀can฀be฀grouped฀into฀four฀areas฀as:
•฀ Primary฀packaging฀for฀the฀inal฀product,฀in฀the฀form฀of฀bags,฀pouches,฀bottles,฀or฀
other฀containers.
•฀ Secondary฀packaging฀for฀the฀primary฀packaged฀product,฀in฀the฀form฀of฀shrink฀or฀
stretch฀ilms,฀bottle฀crates,฀and฀transit฀containers.
•฀ Retail฀packaging฀in฀supermarkets฀and฀other฀outlets,฀in฀the฀form฀of฀bags฀on฀the฀
reel,฀wicketed฀bags,฀check฀out฀bags,฀and฀shoppers.
•฀ Consumer฀packaging,฀in฀the฀form฀of฀freezer฀bags฀and฀cling฀ilms.
Film฀ and฀ containers฀ for฀ consumer฀ goods฀ and฀ food฀ constitute฀ the฀ bulk฀ of฀ the฀
packaging฀ market฀ and฀ are฀ truly฀ commodities,฀ using฀ commodity฀ polymers.฀
Polymethylpentene-I฀has฀found฀some฀specialty฀food-packaging฀applications฀where฀
its฀unusual฀combination฀of฀transparency,฀gas฀permeability,฀and฀heat฀and฀chemical฀
resistance฀properties฀can฀sometimes฀offer฀greater฀value฀than฀the฀commodity฀polymers.฀
One฀ of฀ the฀ attractive฀ aspects฀ of฀ the฀ packaging฀ market฀ is฀ its฀ relative฀ resistance฀ to฀
economic฀cyclicality,฀at฀least฀in฀food฀packaging.฀The฀ongoing฀transition฀in฀beverage฀
and฀ food฀ packaging฀ from฀ other฀ materials฀ to฀ plastics฀ has฀ beneited฀ processors,฀
฀particularly฀ blow฀ molders,฀ serving฀ the฀ aseptic฀ and฀ hot-illed฀ packaging฀ markets฀
2.1 Introduction 13
where฀global฀demand฀has฀more฀than฀doubled฀in฀the฀last฀3฀years.฀In฀the฀U.S.,฀the฀area฀
of฀highest฀growth฀in฀consumer฀packaging฀(20–30%฀AAGR)฀is฀polypropylene฀retort฀
pouches,฀which฀are฀needed฀to฀keep฀food฀fresh฀for฀the฀military.฀Retort฀packaging฀is฀
being฀used฀in฀brand-new฀applications,฀such฀as฀rice,฀tuna฀ish,฀yogurt,฀puddings,฀and฀
even฀pet฀foods.฀The฀market฀is฀quickly฀moving฀from฀standard฀polyethylene฀pouches฀
to฀PP฀retort฀pouches.
A฀number฀of฀specialty฀uses,฀such฀as฀industrial฀machinery฀and฀custom฀packaging,฀
are฀much฀smaller฀in฀volume฀but฀offer฀better฀earnings฀potential฀to฀both฀the฀supplier฀
and฀the฀user.฀These฀uses฀can฀range฀from฀made-to-order฀polystyrene฀foam฀protective฀
moldings฀ to฀ injection฀ molded฀ acrylic฀ cases฀ for฀ small฀ tools.฀ Three฀ key฀ packaging฀
markets฀ –฀ healthcare,฀ high-visibility,฀ and฀ protective฀ –฀ are฀ expected฀ to฀ see฀ strong฀
growth฀of฀4.7฀to฀5.2%฀from฀2010฀through฀2015,฀with฀government฀regulations฀and฀
consumer฀buying฀trends฀driving฀the฀increases.
With฀emphasis฀on฀healthcare฀cost฀control,฀plastics฀ind฀increased฀use฀in฀applications฀
in฀healthcare฀packaging.฀Factors฀inluencing฀the฀increased฀penetration฀of฀plastics฀in฀
healthcare฀packaging฀are฀increased฀use฀of฀disposable฀products,฀an฀aging฀population,฀
continuing฀cost฀pressures฀on฀suppliers,฀increasing฀inluence฀of฀hospital฀and฀healthcare-
related฀purchasing฀groups,฀continued฀shift฀to฀outside฀contract฀packaging,฀and฀more฀and฀
more฀emphasis฀on฀child-resistant/senior-friendly฀and฀tamper-evident฀packaging.฀The฀
major฀plastic฀healthcare฀packaging฀products฀are฀segmented฀into฀two฀groups:฀medical฀
and฀pharmaceutical.฀The฀former฀include฀intravenous฀(IV)฀bags,฀other฀bags฀and฀parts,฀
kits,฀tubing฀and฀containers,฀syringes,฀trays,฀and฀a฀miscellaneous฀group.฀Pharmaceutical฀
packaging฀ products฀ are฀ made฀ up฀ of฀ closures,฀ bottles/vials,฀ blister฀ packaging,฀ and฀ a฀
miscellaneous฀category.฀Bottles/vials,฀tubing/containers,฀syringes,฀kits,฀are฀estimated฀to฀
be฀ the฀ leading฀ healthcare฀ packaging฀ applications,฀ accounting฀ for฀ over฀ 83%฀ of฀ total฀
plastic฀volume฀in฀2010.
In฀pharmaceuticals,฀blister฀packs฀will฀grow฀fastest฀followed฀by฀plastic฀bottles.฀
Unit-dose฀regulations฀for฀institutional฀drugs,฀along฀with฀clinical฀trials฀and฀over-the-
counter฀medication,฀are฀factors฀inluencing฀blister฀packs’฀strong฀6.3%/year฀growth.
In฀medical฀packaging,฀several฀major฀producers฀of฀high-tech,฀highly฀layered฀lexible฀
ilms฀for฀barrier฀food฀wrap฀have฀recently฀qualiied฀their฀irst฀coextruded฀ilms฀for฀
medical฀packaging.฀Food-ilm฀companies฀had฀tried฀for฀years฀to฀apply฀their฀low-cost฀
production,฀economies฀of฀scale,฀and฀experience฀with฀highly฀layered฀structures฀to฀the฀
medical฀market.฀Now฀they฀are฀becoming฀factors฀to฀reckon฀with฀in฀this฀high-priced฀
specialty฀ business.฀ Requirements฀ for฀ medical฀ packaging฀ are฀ very฀ different฀ from฀
those฀for฀food฀wraps.฀Flexible฀food฀packages฀have฀to฀provide฀tight฀oxygen฀barrier฀to฀
preserve฀processed฀meats฀and฀cheese.฀Extruded฀ilms฀for฀medical฀packages฀have฀to฀
provide฀a฀microbial฀barrier,฀resist฀puncture,฀and฀survive฀sterilization.฀What฀the฀food฀
ilm฀companies฀have฀to฀offer฀is฀expertise฀in฀highly฀layered฀structures.฀Coextrusion฀
cuts฀cost฀in฀several฀ways.฀It฀can฀replace฀expensive฀materials฀and฀use฀resins฀more฀
eficiently.฀It฀can฀also฀in฀some฀cases฀reduce฀the฀number฀of฀production฀steps฀by฀elimi-
nating฀coating฀or฀laminating.
In฀high-visibility฀packaging฀such฀as฀clamshells฀and฀blisters,฀consumer฀spending฀
on฀larger฀and฀costlier฀items,฀coupled฀with฀retailers’฀needs฀to฀deter฀theft฀while฀letting฀
buyers฀inspect฀package฀contents฀will฀drive฀growth฀of฀5.1%/year.฀Demand฀for฀clamshells฀
will฀remain฀strong,฀despite฀their฀high฀cost,฀for฀the฀beneits฀they฀provide฀in฀packaging฀
large,฀heavy฀products฀as฀well฀as฀multiple฀components.฀They฀can฀also฀be฀displayed฀
on฀pegs฀as฀well฀as฀shelves.
Burgeoning฀internet฀and฀mail-order฀sales฀along฀with฀specialized฀packaging฀needs฀in฀
electronics,฀medical,฀and฀other฀markets฀will฀increase฀demand฀for฀protective฀฀packaging฀
by฀5.2%/year.฀But฀there฀will฀be฀gains฀for฀foamed฀rolls,฀and฀inlatable฀bags฀will฀post฀the฀
fastest฀growth.฀Foams฀will฀grow฀5.3%/year,฀while฀protective฀mailers฀will฀gain฀5.0%/
year,฀insulated฀shipping฀containers฀6.2%/year,฀and฀inlatable฀bags฀8.1%/year.
The฀digital฀video฀disc฀(DVD)฀market฀has฀also฀inspired฀packagers’฀attention.฀The฀
DVD฀has฀been฀a฀breakaway฀winner฀in฀the฀multibillion-dollar฀home฀entertainment฀
industry.฀More฀than฀60%฀of฀U.S.฀households฀now฀own฀a฀DVD฀player,฀and฀by฀2011฀
so฀will฀more฀than฀67%฀of฀European฀homes.฀Money฀spent฀buying฀and฀renting฀DVDs฀
overtook฀spending฀on฀VHS฀cassettes฀in฀2010,฀and฀by฀2015฀will฀account฀for฀93%฀of฀
spending฀ on฀ video฀ software.฀ DVDs฀ are฀ purchased฀ at฀ much฀ higher฀ rates,฀ making฀
packaging฀ more฀ important฀ to฀ consumers.฀ DVD฀ packaging฀ is฀ almost฀ exclusively฀
produced in polypropylene.
2.2 Other Major Markets
2.2.1 Building and Construction Market
Building฀and฀construction฀is฀the฀second฀largest฀end฀use฀market฀for฀plastics฀with฀28%฀
of฀plastics฀materials฀consumed฀in฀this฀market฀sector.฀As฀in฀packaging,฀plastics฀have฀
displaced฀such฀traditional฀materials฀as฀wood,฀glass,฀and฀metal,฀based฀on฀improved฀
performance฀and฀lower฀cost.฀For฀pipes,฀valves,฀and฀ittings,฀plastics฀offer฀superior฀
corrosion฀resistance฀and฀are฀lighter,฀easier฀to฀install,฀and฀more฀cost-effective฀than฀
their฀alternatives.฀Impervious฀to฀chemicals฀and฀sulfur-bearing฀compounds,฀plastic฀
piping฀safely฀transports฀everything฀from฀fresh฀water฀to฀salt฀water,฀and฀from฀crude฀
oil฀ to฀ laboratory฀ waste.฀ These฀ qualities฀ also฀ have฀ combined฀ with฀ plastics’฀ high฀
strength-to-weight฀ ratio฀ to฀ produce฀ materials฀ for฀ bridge฀ and฀ other฀ infrastructure฀
construction,฀ including฀ tough฀ reinforcement฀ rods,฀ nonskid฀ surfacing฀ and฀ quickly฀
installed฀ replacement฀ decking.฀ In฀ this฀ distinctly฀ cyclical฀ industry,฀ most฀ of฀ the฀
volume฀usage฀is฀processed฀by฀extrusion,฀such฀as฀for฀piping,฀conduit,฀wire฀insulation,฀
siding,฀reservoir฀liners,฀erosion฀control฀netting,฀or฀architectural฀sheeting.฀Sometimes฀
this฀ category฀ includes฀ such฀ agricultural฀ end฀ uses฀ as฀ irrigation฀ pipe฀ and฀ ittings,฀
mulch฀ilms,฀and฀fencing.฀For฀market฀participants,฀there฀are฀a฀number฀of฀regulatory฀
hurdles฀to฀overcome฀such฀as฀the฀Underwriters฀Laboratories฀(UL)฀listings฀and฀the฀
National฀Sanitation฀Foundation฀(NSF)฀listings฀for฀both฀potable฀and฀waste฀water.฀For฀
proprietary฀ processors,฀ parts฀ must฀ comply฀ with฀ applicable฀ building฀ codes฀ at฀ the฀
local,฀regional,฀and฀national฀levels.
In฀ the฀ construction฀ of฀ buildings,฀ plastics฀ abound฀ in฀ plumbing฀ ixtures,฀ siding,฀
looring,฀ insulation,฀ panels,฀ doors,฀ windows,฀ glazing,฀ bathroom฀ units,฀ gratings,฀
2.2฀ Other฀Major฀Markets 15
r฀ ailings,฀and฀a฀growing฀list฀of฀both฀structural฀and฀interior฀or฀decorative฀uses.฀For฀
commercial฀buildings฀that฀contain฀sensitive฀electronic฀equipment,฀plastics฀can฀฀provide฀
a฀highly฀protective฀housing฀that฀does฀not฀interfere฀with฀radio฀frequency฀or฀magnetic฀
waves.฀In฀residential฀buildings,฀single-families฀increasingly฀opt฀to฀refurbish฀existing฀
older฀homes฀to฀suit฀their฀growing฀needs.฀Remodeling฀contractors฀and฀do-it-yourselfers฀
increasingly฀turn฀to฀light,฀strong,฀easily฀handled฀plastics฀to฀make฀improvements฀and฀
repairs,฀from฀ceiling฀tiles฀to฀advanced฀wiring฀and฀modern฀bathroom฀ixtures.฀In฀build-
ing฀additions฀as฀well฀as฀new฀construction,฀bathroom฀ixtures฀such฀as฀tubs,฀showers,฀
and฀sinks฀can฀be฀constructed฀in฀one฀piece,฀walls,฀pipes,฀and฀all,฀then฀positioned฀and฀
attached฀ to฀ the฀ building฀ frame,฀ producing฀ signiicant฀ savings฀ in฀ construction฀ and฀
installation฀ costs.฀ In฀ older฀ home฀ restoration,฀ plastics฀ can฀ provide฀ the฀ best฀ of฀ both฀
worlds฀duplicating฀yesterday’s฀beauty฀using฀today’s฀superior฀materials.฀Architectural฀
touches฀ such฀ as฀ decorative฀ wall,฀ door฀ and฀ window฀ moldings฀ can฀ be฀ achieved฀ that฀
mimic฀marble฀or฀hand฀carvings฀but฀offer฀the฀ease฀of฀care฀and฀฀damage฀resistance.
2.2.2 Automotive Market
Durable,฀lightweight฀and฀corrosion฀resistant,฀plastics฀offer฀fuel฀savings,฀design฀lex-
ibility฀ and฀ high฀ performance฀ at฀ lower฀ costs฀ to฀ designers฀ facing฀ today’s฀ complex฀
transportation฀needs฀whether฀on฀land฀or฀sea,฀in฀the฀air฀or฀in฀space.
Auto฀ makers฀ choose฀ plastic฀ parts฀ for฀ their฀ durability,฀ corrosion฀ resistance,฀
toughness,฀ ease฀ of฀ coloring฀ and฀ inishing,฀ resiliency฀ and฀ light฀ weight.฀ Plastics฀
have฀signiicantly฀reduced฀the฀weight฀of฀the฀average฀passenger฀car฀saving฀millions฀
of฀gallons฀of฀gas฀each฀year.฀Plastics฀have฀found฀their฀way฀into฀automobile฀compo-
nents฀such฀as฀bumpers,฀fenders,฀doors,฀safety฀and฀rear-quarter฀windows,฀headlight฀
and฀ sideview฀ mirror฀ housings,฀ trunk฀ lids,฀ hoods,฀ grilles฀ and฀ wheel฀ covers.฀
Automobile฀designers฀also฀discovered฀that฀plastics฀solve฀one฀of฀their฀most฀compli-
cated฀design฀problems,฀namely,฀what฀to฀do฀with฀the฀fuel฀tank.฀Using฀plastic฀gives฀
them฀the฀฀freedom฀to฀it฀tanks฀into฀the฀overall฀concept฀rather฀than฀designing฀around฀
the฀unwieldy฀but฀essential฀part.฀Advances฀in฀engine฀technology,฀fuel฀management,฀
and฀ emissions฀ requirements฀ continue฀ to฀ drive฀ up฀ under-the-hood฀ temperatures.฀
Where฀certain฀high-temperature฀plastics฀were฀adequate฀a฀few฀years฀ago,฀today฀that฀
is฀no฀longer฀the฀case.฀These฀automotive฀advances฀are฀driving฀the฀use฀of฀higher฀end฀
plastics฀under฀the฀hood,฀as฀well฀as฀the฀development฀of฀new฀plastics฀and฀coating฀to฀
better฀perform฀in฀new฀under-the-hood฀environments.฀In฀automotive฀interiors,฀plastics฀
used฀in฀looring,฀seats,฀dashboards,฀and฀paneling฀maintain฀their฀attractive฀appear-
ance and are easy to clean.
Plastics฀versatility฀is฀aiding฀the฀automotive฀industry฀to฀meet฀ever฀more฀challenging฀
requirements฀ in฀ terms฀ of฀ economical฀ performance,฀ safety,฀ comfort,฀ and฀ environ-
mental฀ considerations.฀ The฀ automotive฀ industry฀ is฀ the฀ single฀ largest฀ end฀ user฀ for฀
many฀ engineering฀ plastics,฀ such฀ as฀ nylon,฀ polycarbonate,฀ acetal,฀ or฀ modiied฀
polyphenylene฀ether.฀It฀is฀also฀an฀important฀market฀for฀commodity฀polymers฀such฀
PP,฀PE,฀and฀PVC.฀Automotive฀business฀is฀notoriously฀cyclical,฀and฀suppliers฀can฀
easily฀ ind฀ their฀ orders฀ canceled฀ literally฀ overnight฀ if฀ demand฀ takes฀ a฀ downturn.฀
Automotive฀business฀cycles฀not฀only฀include฀the฀ups฀and฀downs฀of฀the฀overall฀economy฀
but฀also฀those฀of฀individual฀brands฀and฀models.฀Operating฀successfully฀in฀a฀cyclical฀
industry฀requires฀companies฀to฀have฀considerable฀lexibility฀with฀respect฀to฀manu-
facturing฀capacity,฀and฀inancial฀reserves.฀Nevertheless,฀companies฀have฀prospered฀
by฀ learning฀ how฀ to฀ cope฀ with฀ these฀ problems฀ successfully.฀ Recent฀ industry฀ esti-
mates฀expect฀the฀use฀of฀engineering฀thermoplastics฀in฀exterior฀automotive฀applica-
tions฀to฀grow฀by฀4.8%฀annually฀through฀2010.
2.2.3 Electrical and Electronic Market
The฀electrical฀and฀electronic฀(E/E)฀end฀use฀market฀is฀the฀third฀largest฀market฀for฀
plastics฀applications฀ranging฀from฀miniature฀connectors฀to฀large฀housings.฀An฀ever-
growing฀universe฀of฀electronic฀equipment,฀components,฀and฀gadgets฀is฀expanding฀
the฀ world฀ and฀ improving฀ lives.฀ In฀ this฀ age฀ of฀ electronics,฀ computers฀ power฀ the฀
฀business฀world฀and฀teach฀skills฀to฀toddlers.฀Communications฀systems฀reach฀the฀far฀
฀corners฀of฀the฀earth฀and฀beyond,฀tasks฀that฀once฀took฀many฀hours฀now฀can฀be฀accom-
plished฀in฀minutes฀and฀leisure฀hours฀have฀become฀more฀varied.฀In฀E/E฀uses฀in฀the฀
home,฀plastics฀with฀premium฀thermal฀and฀insulating฀properties฀are฀used฀to฀insulate฀
nearly฀all฀house฀wiring฀and฀are฀also฀used฀in฀electric฀switches,฀connectors,฀and฀recep-
tacles.฀Lightweight,฀durable,฀attractive,฀and฀cost-effective฀plastics฀are฀used฀in฀nearly฀
all฀small฀appliances฀from฀coffee฀makers฀to฀hair฀dryers฀and฀shavers.฀The฀materials฀
are฀also฀indispensable฀in฀major฀appliances,฀which฀would฀cost฀at฀least฀25%฀more฀and฀
use฀30%฀more฀energy฀than฀similar฀products฀produced฀without฀plastics.฀All฀refrigerators฀
today,฀ for฀ example฀ are฀ insulated฀ with฀ thermally฀ eficient฀ plastic฀ foam,฀ and฀ their฀
interiors฀are฀made฀of฀durable,฀easy-to-clean฀plastics.
An฀important฀aspect฀of฀the฀electrical/electronic฀market฀in฀many฀applications฀is฀
the฀fast฀time-to-market฀demands฀of฀the฀industry฀of฀6฀months฀or฀less฀and฀the฀rela-
tively฀short฀product฀life฀cycles฀from฀one฀to฀one฀and฀a฀half฀years.฀This฀requires฀that฀
suppliers฀work฀with฀end฀users฀on฀new฀applications฀from฀the฀beginning,฀but฀this฀also฀
prevents฀other฀suppliers฀from฀displacing฀or฀even฀sharing฀business฀with฀an฀existing฀
supplier฀except฀in฀the฀case฀of฀major฀quality฀or฀delivery฀failures.฀Cell฀phones฀are฀a฀
typical฀example฀of฀such฀applications.฀Without฀plastics,฀most฀of฀the฀electronic฀prod-
ucts฀used฀today฀would฀not฀be฀practical฀or฀economical.฀Designers฀of฀computers฀and฀
business฀equipment฀choose฀plastics฀for฀their฀toughness,฀durability,฀ease฀of฀fabrica-
tion฀into฀complex฀shapes,฀and฀their฀electrical฀insulation฀qualities.฀Plastics฀have฀been฀
fundamental฀ to฀ electronic฀ progress฀ for฀ decades,฀ housing฀ electronics,฀ insulating฀
components฀from฀all฀types฀of฀interference,฀and฀protecting฀parts.฀In฀fact,฀micropro-
cessor฀miniaturization฀would฀not฀have฀been฀impossible฀without฀the฀quality฀and฀cost-
effectiveness฀ of฀ plastics.฀ The฀ continuing฀ miniaturization฀ of฀ circuit฀ boards฀ and฀
components฀such฀as฀computer฀chips฀increasingly฀relies฀on฀high-performance฀plastics฀
to฀provide฀tough,฀dimensionally฀stable฀parts฀that฀can฀withstand฀both฀the฀stress฀of฀
assembly฀and฀the฀strain฀of฀use.฀With฀plastics,฀electronic฀designers฀simultaneously฀
can฀decrease฀size฀and฀increase฀the฀functionality฀of฀circuitry฀in฀consumer,฀business,฀and฀
2.3฀ Key฀Crossover฀Markets 17
industrial฀electronics.฀In฀the฀modern฀factory,฀automated฀production฀relies฀on฀plastics฀
for฀control฀panels,฀housings,฀printed฀wiring฀boards,฀sensors,฀and฀robotic฀components.฀
Corrosion-resistant,฀lexible฀plastic฀also฀serves฀as฀conduit฀for฀electrical฀wiring.
The฀ E/E฀ market฀ requires฀ that฀ both฀ materials฀ and฀ parts฀ for฀ each฀ new฀ product฀ be฀
evaluated฀against฀Underwriters฀Laboratories฀(UL)฀requirements.฀Materials฀must฀be฀
offered฀in฀lame-resistant฀formulations฀if฀they฀are฀not฀already฀inherently฀lame฀resis-
tant.฀Regulatory฀requirements฀in฀Europe฀also฀mandate฀that฀lame฀resistance฀be฀achieved฀
without฀the฀use฀of฀halogenated฀components.฀While฀a฀UL฀listing฀for฀lame฀resistance฀
for฀a฀qualiied฀product฀is฀relatively฀quick฀and฀inexpensive฀to฀get,฀another฀important฀
UL฀requirement,฀the฀limiting฀temperature฀index฀(LTI),฀which฀speciies฀the฀maximum฀
continuous฀use฀(operating)฀temperature฀for฀a฀material฀typically฀takes฀from฀one฀to฀one฀
and฀a฀half฀years฀to฀obtain.฀The฀expense฀of฀obtaining฀and฀maintaining฀these฀listings฀
demands฀that฀the฀market฀potential฀for฀each฀product฀be฀suficient฀to฀justify฀them.
2.3 Key Crossover Markets
2.3.1 Consumer Goods Market
Consumer฀products฀cover฀many฀applications,฀from฀cosmetics฀and฀toothbrushes฀to฀
housewares,฀ toys,฀ recreational฀ goods,฀ furniture,฀ lawn/garden฀ equipment,฀ and฀
฀others.฀Considering฀the฀diversiication฀of฀this฀category,฀it฀is฀extremely฀dificult฀to฀
assign฀overall฀growth฀igures฀though฀there฀are฀a฀number฀of฀very฀proitable฀niche฀
opportunities.฀ Trends฀ in฀ disposable฀ personal฀ income฀ play฀ a฀ major฀ role฀ in฀ the฀
฀purchase฀ of฀ these฀ products฀ with฀ any฀ growth฀ in฀ real฀ wages฀ boosting฀ consumer฀
spending฀in฀this฀sector.฀The฀downside฀of฀business฀in฀consumer฀goods฀is฀that฀the฀
product฀life฀cycles฀are฀often฀short,฀and฀most฀applications฀are฀price฀sensitive.฀Also,฀
many฀of฀the฀end฀uses฀have฀seasonal฀patterns.฀Consumer฀non-durables฀are฀deined฀
as฀items฀expected฀to฀last฀less฀than฀3฀years฀and฀consist฀mostly฀of฀single฀use,฀dispos-
able฀items,฀such฀as฀single฀use฀cups,฀picnic฀tableware,฀and฀disposable฀diaper฀com-
ponents,฀and฀specialty฀packaging฀(e.g.,฀cosmetics฀cases).฀Cost฀is฀king,฀as฀one฀would฀
expect฀in฀such฀commodity฀applications.
Although฀synthetic฀ibers฀are฀not฀widely฀thought฀of฀as฀part฀of฀the฀plastics฀industry,฀
they฀are฀and฀strongly฀affect฀the฀supply฀and฀prices฀of฀their฀base฀resins.฀The฀great฀majority฀
of฀ibers฀are฀used฀for฀consumer฀goods,฀such฀as฀carpeting฀and฀clothing.฀When฀housing฀
starts฀or฀consumer฀purchasing฀passes฀through฀a฀dip฀in฀their฀economic฀cycles,฀inte-
grated฀polymer/iber฀producers฀have฀more฀capacity฀to฀divert฀to฀plastic฀resin฀sales.
2.3.2 Industrial and Stock Shapes Markets
Industrial฀components฀mainly฀deal฀with฀machinery฀parts,฀such฀as฀pump฀housings฀and฀
impellers,฀conveyor฀links,฀or฀gears฀and฀bearings.฀This฀market฀is฀highly฀fragmented฀
with฀low฀competitive฀visibility฀and฀high฀value฀in฀use,฀and฀therefore฀high฀proitability.฀
Product฀life฀cycles฀are฀typically฀long.฀End฀users฀are฀often฀local,฀and฀volumes฀often฀
tend฀to฀be฀small.฀The฀materials฀used฀are฀mainly฀engineering฀and฀high-performance฀
polymers฀ though฀ the฀ full฀ range฀ of฀ plastics฀ from฀ commodities฀ to฀ specialties฀ are฀
employed฀in฀this฀sector.
Rod,฀tubing,฀and฀sheet฀are฀typical฀semi-inished฀shapes฀which฀are฀mechanically฀
fabricated฀into฀other฀parts฀for฀a฀range฀of฀unidentiied฀end฀uses.฀Semi-inished฀shapes฀
are฀often฀used฀to฀make฀prototype฀parts฀for฀evaluation฀or฀even฀small฀numbers฀of฀com-
mercial฀parts.฀Though฀this฀market฀segment฀is฀important฀in฀terms฀of฀size,฀its฀growth฀
rate฀is฀less฀than฀many฀others฀and฀it฀is฀very฀competitive฀with฀considerable฀consolida-
tion฀taking฀place฀in฀recent฀years.฀Shape฀producers฀rarely฀have฀direct฀contact฀with฀
end฀users,฀their฀route฀to฀market฀being฀almost฀entirely฀through฀stock฀shape฀distribu-
tors,฀a฀group฀separate฀from฀plastic฀material฀distributors.
2.3.3 Other Markets
Several฀ other฀ major฀ market฀ segments฀ include฀ (1)฀ medical฀ and฀ (2)฀ aerospace฀ and฀
military.
The฀medical฀market฀is฀a฀fast฀growth,฀recession฀proof฀plastics฀market฀application฀
area.฀Medical฀products฀typically฀are฀divided฀into฀two฀categories,฀disposables฀and฀
durable฀equipment.฀Though฀medical฀disposables฀are฀commodity-type฀products฀with฀
emphasis฀on฀cost,฀reliability฀demands฀are฀high฀making฀proit฀margins฀much฀better฀
than฀most฀commodity฀markets.฀Many฀medical฀disposables฀such฀as฀catheters,฀blood฀
bags,฀IV฀bags,฀etc.,฀are฀relatively฀high฀tech.฀The฀high฀tech฀nature฀of฀durable฀medical฀
equipment฀also฀provides฀the฀opportunity฀for฀higher฀margin฀business,฀but฀as฀reliabil-
ity฀demands฀are฀also฀high,฀exposure฀to฀product฀liability฀claims฀can฀be฀signiicant.
Aerospace฀and฀military฀end฀use฀areas฀are฀among฀the฀most฀challenging฀plastics฀
markets.฀Market฀end฀users฀are฀highly฀fragmented,฀volumes฀are฀relatively฀small฀to฀
medium,฀and฀application฀developments฀have฀very฀long฀timelines,฀though฀product฀
life฀cycles฀tend฀to฀also฀be฀long.฀Once฀a฀material฀is฀approved,฀a฀supplier฀can฀usually฀
look฀forward฀to฀a฀very฀long฀run฀of฀many฀years฀to฀even฀several฀decades.฀Competitors฀
are฀unlikely฀to฀be฀able฀to฀qualify฀their฀material฀as฀an฀alternate฀source.฀Parts฀contracts฀
however฀are฀generally฀put฀up฀for฀bids฀annually,฀so฀that฀a฀processor฀must฀defend฀the฀
business฀every฀year.
Chapter 3
Electrical and Electronic End Use Applications
Keywords฀ Electrical฀•฀Electronic฀•฀Fuel฀cell฀•฀Transistors฀•฀EMI฀•฀LCP฀•฀PEEK฀
•฀Ofice฀products฀•฀Appliance฀•฀Recycle
3.1 Electrical and Electronic Applications
3.1.1 Electrical and Electronic Applications Introduction
Plastics฀is฀an฀indispensable฀material฀for฀the฀electrical฀and฀electronics฀sector฀(E/E).฀
Many฀of฀today’s฀new฀technical฀developments฀capitalize฀on฀the฀latest฀versions฀of฀new฀
generation฀plastics.฀As฀a฀result,฀devices฀such฀as฀cell฀phones฀are฀becoming฀smaller฀
and฀ lighter.฀ Lightweight,฀ durable,฀ attractive,฀ and฀ cost-effective฀ plastics฀ are฀ also฀
being฀used฀in฀nearly฀all฀our฀small฀appliances.฀Some฀sectors฀of฀the฀E/E฀market฀have฀
been฀evolving฀toward฀becoming฀commodity฀businesses฀but฀there฀are฀still฀a฀number฀
of฀high-performance,฀attractive฀opportunities฀in฀specialty฀sectors.฀A฀need฀exists฀for฀
higher฀temperature฀resistance฀materials฀with฀processing฀characteristics฀suitable฀for฀
use฀in฀thinner฀walled,฀smaller฀components.฀Even฀the฀largest฀subcategory฀of฀the฀E/E฀
market,฀ wire฀ and฀ cable,฀ which฀ has฀ a฀ range฀ of฀ commodity,฀ and฀ semi-commodity฀
applications฀still฀has฀many฀specialty฀applications,฀and฀new฀product฀and฀application฀
development฀ across฀ the฀ E/E฀ sector฀ continues฀ to฀ result฀ in฀ signiicant,฀ proitable฀
business฀as฀performance฀requirements฀keep฀ratcheting฀up.
3.1.2 Fuel Cell Plates
Equipment฀and฀materials฀suppliers฀are฀making฀progress฀in฀the฀compression฀molding฀
of฀thermoset฀bipolar฀plates฀for฀fuel฀cells.฀Bulk฀Molding฀Compounds฀Inc.฀(BMCI)฀
says฀ graphite-illed฀ thermoset฀ vinyl฀ ester฀ bipolar฀ plate฀ technology฀ offers฀ the฀ best฀
overall฀ performance,฀ productivity,฀ and฀ cost฀ for฀ use฀ in฀ PEM฀ (proton฀ exchange฀

20 3฀ Electrical฀and฀Electronic฀End฀Use฀Applications
membrane)฀ fuel฀ cell฀ applications฀ compared฀ to฀ metallic฀ and฀ other฀ composites.฀
Conductivity฀ of฀ the฀ plates฀ is฀ now฀ around฀ 70฀ Siemens/cm฀ versus฀ 20–30฀ S/cm฀ for฀
plates฀launched฀a฀few฀years฀back.฀BMCI฀attributes฀this฀to฀more฀homogeneous฀distri-
bution฀of฀conductive฀additives฀in฀the฀compound.฀In฀addition,฀BMCI฀has฀introduced฀
a฀new฀high-temperature฀cure฀(370°F)฀package,฀which฀reduces฀cure฀times฀by฀50%฀(to฀
around฀15฀s)฀and฀eliminates฀the฀15–20฀min฀post-bake฀required฀to฀remove฀residual฀
volatiles฀such฀as฀styrene฀monomer.
BMCI฀has฀also฀developed฀a฀vinyl฀ester฀adhesive/sealant฀for฀use฀in฀bonding฀the฀
cooling฀channel฀side฀of฀the฀plates฀from฀adjoining฀cells฀to฀form฀a฀well-sealed฀path฀for฀
the฀ stack฀ coolant.฀ Like฀ the฀ bipolar฀ plate฀ compound,฀ this฀ adhesive฀ is฀ also฀ highly฀
conductive.฀Compared฀to฀other฀adhesives฀used฀in฀this฀application,฀it฀is฀also฀substan-
tially฀less฀expensive฀and฀reduces฀the฀voltage฀drop฀between฀plates฀by฀30–50%.฀As฀
fuel฀ cell฀ usage฀ becomes฀ commercial฀ and฀ volumes฀ grow,฀ the฀ recycle฀ of฀ fuel฀ cell฀
components฀ will฀ become฀ an฀ issue.฀ BMCI฀ has฀ completed฀ regrind฀ trials฀ with฀ very฀
encouraging฀results฀and฀work฀is฀currently฀underway฀with฀companies฀such฀as฀Plug฀
Power,฀Inc.฀and฀General฀Motors.
3.1.3 PLED Flat Panel Displays
Cambridge฀Display฀Technology฀(CDT),฀a฀global฀leader฀in฀the฀research,฀development,฀
and฀commercialization฀of฀light฀emitting฀polymers,฀targeted฀for฀use฀in฀electronic฀display฀
products฀ used฀ for฀ information฀ management,฀ communications,฀ and฀ entertainment,฀ is฀
working฀jointly฀with฀Sumitomo฀Chemical฀(www.sc-sumitomo-chem.co.jp)฀to฀develop/
scale-up฀ a฀ new฀ range฀ of฀ solution฀ processable฀ polymer฀ light฀ emitting฀ diode฀ (PLED)฀
materials฀designed฀for฀use฀in฀lat฀panel฀displays.฀Features฀include฀reduced฀power฀con-
sumption,฀size,฀thickness,฀and฀weight,฀very฀wide฀viewing฀angle,฀superior฀video฀imag-
ing฀performance,฀and฀the฀potential฀for฀use฀on฀lexible฀display฀substrates.฀The฀companies฀
are฀focusing฀on฀new฀solution฀processable,฀฀phosphorescent฀materials,฀such฀as฀dendrim-
ers,฀ which฀ exhibit฀ very฀ high฀ eficiencies฀ and฀ good฀ stability.฀ Dendrimers฀ are฀ nearly฀
perfect฀ monodisperse฀ macromolecules฀ with฀ well฀ deined,฀ starlike฀ structures.฀ High-
eficiency฀emitters฀are฀especially฀important฀in฀printable฀portable฀electronic฀displays฀for฀
devices฀such฀as฀cell฀phones฀and฀digital฀cameras,฀where฀battery฀supplies฀are฀used.฀The฀
materials฀are฀also฀expected฀to฀ind฀applications฀for฀TV฀displays฀and฀lighting฀devices.
In฀ the฀ US,฀ companies฀ operating฀ in฀ the฀ same฀ ield฀ as฀ CDT฀ include฀ Gyricon,฀ a฀
spin-off฀ of฀ Xerox,฀ and฀ E-Ink.฀ Their฀ displays฀ differ฀ from฀ CDT’s฀ in฀ that฀ they฀ use฀
relection฀rather฀than฀transmission,฀and฀are฀easier฀to฀apply฀onto฀lexible฀substrates.฀
The฀displays฀entail฀a฀layer฀of฀microscopic฀spheres฀of฀black฀and฀white฀particles฀with฀
negative฀and฀positive฀charges฀respectively฀sandwiched฀between฀two฀ilms.฀Depending฀
on฀the฀charge฀put฀across฀the฀ilms,฀the฀spheres฀look฀black฀or฀white฀and฀can฀make฀a฀
monochrome฀image.฀E-Ink฀has฀already฀demonstrated฀color฀images฀in฀a฀similar฀way.฀
Gyricon฀ is฀ targeting฀ remotely฀ updatable฀ signage,฀ and฀ E-Ink฀ is฀ concentrating฀ on฀
portable฀ e-readers.฀ Its฀ technology฀ is฀ currently฀ used฀ in฀ display฀ for฀ Sony’s฀ Librié฀
e-book฀ reader.฀ CDT฀ is฀ mainly฀ concerned฀ with฀ displays฀ in฀ more฀ conventional฀
equipment฀like฀laptops.
3.1฀ Electrical฀and฀Electronic฀Applications 21
3.1.4 Flexible Printed Transistors
Plastic฀Logic฀Ltd.,฀a฀leading฀developer฀of฀plastic฀electronics฀including฀printed฀lex-
ible฀ thin฀ ilm฀ transistor฀ (TFT)฀ arrays,฀ is฀ developing฀ and฀ exploiting฀ a฀ portfolio฀ of฀
intellectual฀ property฀ based฀ on฀ inkjet฀ printing฀ of฀ active฀ electronic฀ circuits฀ using฀
advanced฀plastic฀materials฀to฀form฀thin฀ilm฀transistors฀that฀can฀be฀used฀in฀active฀
matrix฀back฀planes฀that฀drive฀displays.฀Other฀potential฀applications฀include฀smart฀
labels,฀smart฀packaging,฀and฀radio฀frequency฀identiication฀(RFID)฀devices.฀Plastics฀
electronics฀can฀be฀produced฀directly฀at฀high฀speed฀from฀CAD฀data฀to฀large,฀lexible฀
surfaces฀using฀ink฀jet฀printing฀equipment฀rather฀than฀complex฀photolithography฀and฀
vacuum฀systems฀used฀to฀make฀today’s฀transistors.฀With฀the฀process’฀low฀tempera-
tures,฀substrates฀used฀can฀also฀be฀plastic.
The฀ company฀ recently฀ announced฀ a฀ non-exclusive฀ agreement฀ with฀ E฀ Ink฀ of฀
Cambridge,฀ MA,฀ the฀ leading฀ developer฀ and฀ marketer฀ of฀ electronic฀ paper฀ display฀
technology,฀to฀cooperate฀on฀the฀design฀and฀fabrication฀of฀lexible฀all฀plastic฀elec-
tronic฀displays.฀E฀Ink฀and฀Plastic฀Logic฀will฀to฀combine฀their฀technologies฀to฀pro-
duce฀ high-resolution฀ active-matrix฀ displays฀ suitable฀ for฀ applications฀ from฀ smart฀
cards฀and฀cell฀phones฀to฀wireless฀electronic฀readers฀(e.g.,฀e-newspapers,฀e-books,฀
e-maps).฀The฀liquid฀crystal฀active-matrix฀displays฀commercially฀available฀today฀are฀
produced฀ using฀ two฀ sheets฀ of฀ heavy,฀ fragile฀ glass฀ and฀ require฀ multiple฀ vacuum฀
deposition฀and฀high฀precision฀lithographic฀steps.฀In฀contrast,฀the฀E฀Ink฀and฀Plastic฀
Logic฀displays฀are฀lexible,฀thin,฀light฀weight,฀bright,฀high฀contrast,฀shatterproof฀and฀
can฀be฀produced฀at฀low฀cost฀in฀high฀volume.฀Plastic฀Logic฀is฀currently฀expanding฀its฀
existing฀plastic฀electronics฀mini-lab,฀installing฀a฀prototype฀line,฀and฀is฀targeting฀for฀
further฀production฀scale฀up.
E฀Ink฀provides฀electronic฀ink฀in฀sheets฀of฀imaging฀ilm฀that฀are฀ideally฀suited฀for฀
lexible฀display฀applications฀due฀to฀their฀thin฀form฀factor฀and฀inherent฀lexibility.฀
E฀ Ink’s฀ electronic฀ ink฀ is฀ an฀ image฀ stable฀ relective฀ display฀ technology฀ that฀ uses฀
ultra-low฀ power฀ but฀ is฀ easily฀ read฀ under฀ any฀ lighting฀ condition฀ including฀ direct฀
sunlight.฀Unlike฀liquid฀crystal฀displays,฀the฀image฀on฀E฀Ink฀displays฀looks฀the฀same฀
from฀all฀viewing฀angles฀and฀will฀not฀distort฀when฀touched฀or฀lexed,฀making฀them฀
suitable฀for฀lexible฀displays฀and฀portable฀devices.฀E฀Ink฀Imaging฀Film฀entered฀mass฀
production฀last฀year฀as฀an฀enabling฀component฀in฀the฀unique฀SONY฀LIBRIé฀elec-
tronic฀reading฀device฀currently฀available฀in฀Japan.
3.1.5 High-Performance Ignition Coil Bobbins
MSD฀Ignition,฀a฀world฀leader฀in฀performance฀auto฀ignition฀technology,฀is฀moving฀
up฀to฀DuPont฀Thermx฀PCT฀high-performance฀polyester฀for฀coil฀forms฀in฀its฀ignition฀
coils.฀The฀irst฀MSD฀coil฀to฀make฀use฀of฀Thermx฀is฀its฀Blaster฀SS,฀found฀in฀both฀
automobiles฀and฀NASCAR฀racers.฀With฀eficient฀E-core฀windings,฀the฀Blaster฀SS฀
generates฀300฀mA฀at฀up฀to฀40k฀V.฀The฀coils,฀with฀a฀bobbin฀molded฀from฀PCT,฀have฀
withstood฀tests฀at฀70,000฀V,฀the฀limit฀of฀MSD฀Ignition’s฀test฀rig,฀with฀no฀arcing,฀or฀
cracking฀of฀the฀coil฀form.
MSD฀Ignition฀is฀transitioning฀to฀Thermx฀PCT฀for฀bobbins฀in฀all฀high-performance฀
racing/street฀use฀coils.฀In฀new฀designs,฀PCT฀also฀allows฀smaller฀bobbins฀and฀reduced฀
coil฀size.฀The฀material฀has฀excellent฀dielectric฀properties฀at฀elevated฀temperature฀
and฀a฀high฀melting฀temperature.฀Vibration฀resistance฀is฀another฀key฀beneit฀of฀the฀
PCT฀coils.฀Most฀MSD฀ignition฀coils฀are฀potted฀in฀epoxy,฀which฀adheres฀well฀to฀the฀
PCT.฀The฀result฀is฀less฀vibration฀separation.฀The฀Blaster฀SS฀coil’s฀housing฀and฀cover฀
are฀both฀molded฀from฀DuPont฀Rynite฀FR530฀PET฀polyester,฀which฀provides฀good฀
strength,฀stiffness,฀and฀toughness฀at฀under฀the฀hood฀temperatures.฀MSD฀Ignition฀has฀
adopted฀PET฀for฀a฀range฀of฀coil฀forms,฀housings,฀and฀other฀ignition฀system฀compo-
nents.฀At฀the฀Atlanta฀Motor฀Speedway฀NASCAR฀series,฀the฀three฀lead฀teams฀of฀Dale฀
Earnhardt฀ Jr.,฀ Jeremy฀ Mayield,฀ and฀ Kasey฀ Kahne฀ all฀ used฀ MSD฀ 6HVC฀ Ignition฀
Control.
3.1.6 Smart Wallplates
Cooper฀Wiring฀Devices฀subsidiary฀of฀Cooper฀Industries,฀a฀worldwide฀manufacturer฀
of฀electrical฀products฀and฀tools/hardware,฀has฀switched฀to฀Bayer฀Polymers’฀Makrolon฀
PC฀for฀use฀in฀its฀new฀line฀of฀mid-size฀thermoplastic฀wallplates.฀Polycarbonate฀was฀
selected,฀versus฀other฀materials฀such฀as฀thermoset฀urea,฀for฀its฀processing฀ease,฀high฀
structural฀rigidity,฀and฀superior฀resistance฀to฀warping,฀impact,฀and฀abrasion.฀Using฀
this฀material฀in฀an฀injection฀molding฀process฀allowed฀Cooper฀to฀reduce฀cycle฀times฀
and฀eliminate฀costly฀secondary฀operations฀required฀to฀remove฀lash฀during฀the฀molding฀
process.฀The฀company’s฀new฀line฀of฀mid-size฀wallplates฀adds฀a฀full฀0.375″ on all
sides฀to฀NEMA฀standard-size฀plates,฀providing฀needed฀gap฀coverage฀for฀over฀cuts฀or฀
other฀large฀wallboard-to-box฀openings.฀With฀polycarbonate,฀Coopers’฀new฀line฀of฀
wallplates฀has฀a฀high฀gloss฀inish฀and฀is฀resistant฀to฀soil฀adherence.฀In฀addition,฀the฀
wallplates฀are฀easily฀cleaned฀in฀comparison฀to฀other฀material฀surfaces.฀The฀line฀is฀
UL฀listed฀and฀CSA฀certiied,฀and฀meets฀NEMA฀WD-1฀and฀WD-6฀compliance.฀The฀
thermoplastic฀wallplates฀are฀available฀in฀multiple฀colors฀and฀various฀conigurations฀
for฀ toggle฀ switches,฀ receptacles,฀ decorator,฀ blank,฀ power฀ receptacles,฀ telephone/
coaxial฀cable,฀combination฀devices,฀and฀pre-marked฀special฀uses.
3.1.7 Electronic Cloth
Researchers฀ at฀ the฀ University฀ of฀ California฀ at฀ Berkeley฀ in฀ an฀ industry฀ irst฀ have฀
printed฀plastic฀pentacene฀transistors฀directly฀onto฀cloth฀ibers.฀The฀approach฀may฀be฀
used฀to฀embed฀sensing,฀actuation,฀and฀displays฀into฀clothing฀and฀surface฀coverings.
The฀ process,฀ which฀ is฀ compatible฀ with฀ textile฀ manufacturing,฀ does฀ away฀ with฀
expensive฀masks,฀or฀negatives,฀which฀are฀normally฀used฀in฀printing฀circuits฀on฀฀silicon.฀
Instead,฀ the฀ researchers฀ developed฀ a฀ new฀ mask฀ that฀ is฀ made฀ up฀ entirely฀ of฀ textile฀
ibers.฀The฀transistors฀created฀by฀the฀Berkeley฀research฀team฀were฀fabricated฀using฀a฀
125 mm฀diameter฀aluminum฀wire฀as฀the฀gate฀line.฀This฀wire฀can฀be฀woven฀directly฀into฀
an฀‘e-textile’฀to฀serve฀as฀a฀gate฀interconnect.฀The฀iber฀was฀masked฀with฀orthogonal฀
overwoven฀50฀mm฀diameter฀wires,฀which฀served฀as฀channel฀masks฀with฀a฀transistor฀
formed฀at฀every฀intersection,฀while฀100฀nm฀gold฀was฀evaporated฀to฀form฀source฀or฀
drain฀contacts.฀All฀the฀transistors฀were฀~125/50฀mm,฀since฀transistors฀were฀formed฀
only฀on฀the฀surface฀of฀the฀gate฀wire,฀which฀was฀exposed฀during฀pentacene฀evaporation.฀
The฀transistors฀that฀resulted฀are฀similar฀to฀conventional฀inverted฀top฀contacted฀penta-
cene฀ thin฀ ilm฀ transistors฀ (TFTs).฀ However,฀ the฀ entire฀ transistor฀ was฀ formed฀ on฀ a฀
metallic฀gate฀wire,฀permitting฀easy฀e-textile฀integration฀to฀create฀‘smart฀cloth’.
3.1.8 Intrinsic EMI Shielded Products
Autotronic฀Controls฀Corp.’s฀(ACC)฀new฀MSD฀digital฀ignition฀tester฀used฀to฀check฀
ignition฀performance฀in฀racing฀cars฀and฀other฀high฀powered฀vehicles฀has฀a฀housing฀
molded฀from฀Dupont’s฀Zytel฀EMX฀nylon฀shielding฀resin.฀The฀material฀effectively฀
shields฀ sensitive฀ microprocessor฀ circuitry฀ against฀ electromagnetic฀ interference฀
(EMI),฀ or฀ noise.฀ ACC฀ evaluated฀ an฀ unshielded฀ housing฀ but฀ found฀ that฀ electrical฀
noise฀caused฀problems฀with฀the฀unit.฀The฀Zytel฀EMX฀provides฀effective฀shielding฀in฀
a฀sturdy฀housing฀produced฀using฀standard฀injection฀molding฀technology฀at฀a฀lower฀
total฀ cost฀ than฀ using฀ coated฀ shielding.฀ The฀ new฀ housing฀ show฀ virtually฀ no฀ noise฀
problems฀during฀ield฀trials,฀a฀signiicant฀accomplishment฀since฀MSD฀ignition฀coils฀
used฀in฀high฀powered฀racing฀cars฀can฀generate฀up฀to฀50,000฀V฀of฀electrical฀potential฀
in฀repeated฀bursts,฀generating฀intense฀electrical฀noise.
Racing฀crews฀use฀the฀MSD฀ignition฀tester฀to฀check฀ignition฀control฀and฀coil฀oper-
ation฀without฀having฀to฀remove฀them฀from฀the฀car.฀The฀tester฀produces฀a฀simulated฀
trigger฀signal฀that฀ires฀the฀car’s฀ignition฀coil฀just฀as฀if฀the฀engine฀were฀running.฀
If฀the฀spark฀fails฀to฀jump฀the฀gap฀in฀the฀tester,฀there฀is฀an฀ignition฀problem,฀which฀
the฀tester฀can฀help฀trace฀down.฀With฀the฀built-in฀housing฀shielding฀protection฀pro-
vided฀by฀Zytel฀EMX,฀Autotronic฀Controls฀eliminates฀the฀cost฀of฀applying฀a฀conduc-
tive฀shielding฀coating฀required฀with฀a฀conventional฀plastic฀housing.฀While฀a฀metal฀
housing฀would฀have฀provided฀effective฀shielding,฀it฀would฀have฀required฀a฀greater฀
tooling฀investment฀and฀costly฀inishing฀steps฀for฀each฀part.
3.1.9 Miniaturized DSL Transformers
Epcos฀AG,฀a฀major฀developer฀and฀manufacturer฀of฀electronic฀components,฀chose฀
DuPont฀ Zenite฀ LCP฀ for฀ its฀ coil฀ formers฀ to฀ produce฀ SMD฀ transformers฀ used฀ in฀
telecommunications฀equipment.฀This฀liquid฀crystal฀polymer฀has฀the฀high฀dielectric฀
strength/thermal฀ resistance,฀ and฀ good฀ melt฀ low฀ properties฀ essential฀ for฀ making฀
miniaturized฀ electronic฀ components฀ for฀ mounting฀ on฀ circuit฀ boards฀ using฀ SMD฀
technology.฀Digital฀subscriber฀line฀(DSL)฀technology฀is฀one฀of฀the฀fastest฀growing฀
technologies฀for฀broadband฀internet฀access฀and฀calls฀for฀interface฀transformers฀with฀
minimal฀signal฀distortion฀and฀loss.฀Epcos’฀specially฀developed฀EPX฀and฀EPO฀series฀
core฀geometries฀made฀of฀T66฀and฀T57฀ferrite฀materials฀offer฀good฀data฀transmission฀
rates฀combined฀with฀greater฀miniaturization.
Dupont’s฀Zenite฀7130฀glass฀iber฀reinforced฀LCP฀combines฀good฀toughness฀with฀
a฀heat฀delection฀temperature฀of฀289°C฀and฀high฀dimensional฀stability฀to฀make฀the฀
coil฀formers฀for฀these฀applications.฀As฀the฀material฀uses฀no฀halogen฀additives,฀it฀is฀
recognized฀by฀Underwriters฀Laboratories฀as฀UL฀94฀V-O฀at฀0.75฀mm.฀Since฀the฀injec-
tion฀molded฀parts฀do฀not฀need฀to฀be฀delashed,฀processing฀costs฀with฀LCP฀is฀less฀than฀
that฀with฀thermoset฀resins.฀The฀company฀can฀injection฀mold฀very฀ine฀coil฀formers฀
with฀a฀0.4฀mm฀wall฀thickness฀and฀a฀25฀mm2฀footprint.฀The฀liquid฀crystal฀polymer’s฀
high฀ strength฀ and฀ impact฀ resistance฀ allows฀ these฀ precision฀ parts฀ to฀ withstand฀ the฀
stresses฀ that฀ occur฀ during฀ coil฀ winding฀ and฀ the฀ material’s฀ high฀ thermal฀ delection฀
temperature฀allows฀parts฀to฀withstand฀temperature฀peaks฀up฀to฀260°C,฀which฀occur฀
during฀relow฀soldering,฀when฀the฀transformers฀are฀mounted฀on฀the฀circuit฀board.
3.1.10 Electrodynamic Loudspeakers
Cabasse,฀an฀ultra฀high฀yield฀speaker฀systems฀manufacturer฀based฀in฀France,฀has฀turned฀
to฀ Victrex฀ PEEK฀ polymer฀ to฀ produce฀ the฀ spiders฀ on฀ its฀ latest฀ range฀ of฀ professional฀
loudspeakers.฀This฀innovative฀use฀of฀the฀high-performance฀polymer฀allows฀Cabasse฀to฀
signiicantly฀improve฀the฀power฀capacity฀of฀the฀transducer.฀An฀electrodynamic฀loud-
speaker฀is฀a฀transducer฀with฀a฀very฀poor฀yield.฀All฀parts฀surrounding฀the฀movable฀unit฀
inside฀these฀1,000฀W฀speakers฀(acoustic฀diaphragm,฀coil,฀spider฀and฀front฀suspension)฀
must฀exhibit฀outstanding฀heat฀resistance,฀as฀97%฀of฀the฀electrical฀power฀delivered฀by฀
the฀ampliier฀is฀dissipated฀in฀the฀form฀of฀heat.฀Spiders฀are฀traditionally฀manufactured฀
from฀a฀cotton฀fabric฀coated฀with฀phenolic฀resin.฀However,฀at฀full฀power,฀Cabasse฀has฀
measured฀temperatures฀as฀high฀as฀270°C฀in฀the฀coil฀area฀of฀its฀new฀range฀of฀profes-
sional฀speakers.฀With฀a฀very฀high฀melt฀temperature฀(343°C),฀and฀a฀continuous฀operat-
ing฀temperature฀of฀up฀to฀260°C฀(UL746B),฀monoilament฀yarn฀made฀of฀Victrex฀PEEK฀
polymer฀gave฀the฀company฀the฀necessary฀high-temperature฀resistance.
An฀ additional฀ factor฀ Cabasse’s฀ in฀ material฀ selection฀ was฀ strength฀ and฀ fatigue฀
resistance,฀ as฀ guide฀ parts฀ such฀ as฀ the฀ spider฀ must฀ withstand฀ signiicant฀ displace-
ments.฀The฀PEEK฀polymer฀fabric฀delivers฀an฀ideal฀combination฀of฀stiffness,฀elonga-
tion฀ at฀ yield฀ and฀ very฀ high฀ fatigue฀ resistance฀ and฀ the฀ polymer’s฀ inherent฀ ease฀ of฀
processing฀ has฀ also฀ simpliied฀ Cabasse’s฀ manufacturing฀ process฀ and฀ improved฀
productivity.
3.1.11 Visual/Tactile Electronic Enclosures
EXO,฀ an฀ overmolding฀ system฀ developed฀ by฀ Inclosia฀ Solutions,฀ a฀ unit฀ of฀ Dow฀
Chemical฀Co.,฀is฀an฀innovative฀technology฀that฀allows฀fur,฀leather,฀various฀fabrics,฀
and฀even฀wood฀and฀metal฀to฀be฀incorporated฀into฀the฀surface฀of฀casings฀for฀portable฀
devices฀such฀as฀cell฀phones,฀laptop฀computers,฀and฀pocket฀calculators฀and฀brings฀
new฀opportunities฀for฀co-branding฀to฀original฀equipment฀manufacturers฀(OEMs).฀In฀
a฀market฀where฀state-of-the-art฀electronics฀performance฀features฀are฀no฀longer฀the฀
only฀differentiating฀factors฀in฀electronics฀purchase฀decisions,฀branding฀and฀appear-
ance฀enhanced฀by฀molded฀in฀fabrics฀and฀other฀materials฀are฀increasingly฀important฀
฀drivers฀in฀motivating฀consumer฀purchase.
The฀family฀of฀EXO฀system฀solutions฀developed฀by฀inclosia฀is฀designed฀for฀high฀
volume฀production฀of฀a฀wide฀range฀of฀enclosures,฀a฀variant฀of฀two฀shot฀overmolding฀
allows฀virtually฀any฀type฀of฀material฀to฀be฀incorporated฀in฀a฀covering฀while฀meeting฀
cost,฀ quality,฀ durability,฀ and฀ volume฀ requirements฀ critical฀ for฀ production฀ of฀ elec-
tronic฀devices.฀The฀process฀starts฀with฀placing฀a฀pre-cut฀decorative฀insert฀into฀an฀
injection฀mold.฀Once฀molding฀starts,฀the฀irst฀shot฀covers฀the฀insert฀with฀a฀thermoplastic฀
substrate,฀which฀also฀forms฀the฀enclosures฀structure฀as฀required฀by฀the฀application.฀
An฀optional฀second฀shot฀can฀be฀used฀to฀encapsulate฀the฀edges฀of฀the฀back฀molded฀
material.฀ The฀ overmolded฀ material฀ is฀ permanently฀ bonded฀ on฀ the฀ outside฀ of฀ the฀
enclosure฀so฀there฀are฀no฀issues฀with฀frayed฀edges฀compromising฀the฀integrity฀of฀the฀
internal฀components.฀As฀one฀mold฀can฀be฀used฀for฀different฀materials/fabrics,฀retool-
ing฀is฀not฀necessary฀between฀covering฀changes,฀which฀further฀increases฀speed฀and฀
cost฀advantages.
3.1.12 High-Performance Outdoor Cable
Sporting฀events฀and฀rock฀concerts฀are฀frequently฀electronic฀extravaganzas฀requiring฀
enormous฀quantities฀of฀cable฀for฀lighting,฀sound,฀and฀other฀media.฀Now,฀Flexalloy,฀
an฀advanced฀PVC-based฀TPE฀from฀the฀vinyl฀division฀of฀Teknor฀Apex,฀is฀allowing฀
the฀Entertainment฀Division฀of฀Coast฀Wire฀and฀Plastics฀Technology,฀a฀cable฀manu-
facturer฀specializing฀in฀these฀applications,฀to฀supply฀cable฀that฀is฀lighter,฀more฀lex-
ible,฀ and฀ more฀ resistant฀ to฀ extreme฀ cold฀ than฀ cable฀ produced฀ using฀ conventional฀
compounds.
Flexalloy-based฀ cable฀ products฀ have฀ half฀ the฀ weight฀ of฀ other฀ cable฀ products฀
making฀ it฀ possible฀ for฀ users฀ to฀ dramatically฀ increase฀ overhead฀ lighting฀ without฀
exceeding฀the฀limit฀to฀the฀weight฀that฀an฀event฀ceiling฀structure฀can฀support.฀Based฀
on฀ ultra฀ high฀ molecular฀ weight฀ (UHMW)฀ PVC฀ resin,฀ Flexalloy฀ compound฀ also฀
provides฀ greater฀ lexibility฀ than฀ conventional฀ vinyl,฀ even฀ at฀ low฀ temperature,฀ a฀
critical฀advantage฀at฀outdoor฀winter฀events฀such฀as฀the฀winter฀olympics.฀Even฀in฀
warmer฀ environments,฀ lexibility฀ is฀ important฀ for฀ timely฀ wiring฀ to฀ be฀ used฀ at฀
crowded฀entertainment฀venues.฀For฀these฀applications,฀Coast฀Wire฀has฀introduced฀
a฀new฀line฀of฀entertainment฀cable฀‘FlexOLite฀Touring฀Cable’฀based฀on฀Flexalloy฀
compound.฀ Flexalloy฀ products฀ provide฀ the฀ elasticity฀ of฀ non-vinyl฀ TPEs,฀ plus฀
greater฀ toughness,฀ abrasion฀ resistance,฀ and฀ low-temperature฀ performance฀ than฀
conventional฀vinyl.
3.2 Office Products Applications
3.2.1 Office Products Applications Introduction
As฀the฀economy฀continues฀to฀rebound,฀tech฀spending฀for฀computers฀and฀peripher-
als฀ has฀ increased฀ as฀ well,฀ although฀ not฀ to฀ pre-2008฀ levels.฀ The฀ computers฀ and฀
peripherals฀segment฀showed฀a฀14%฀annual฀increase฀from฀2005฀to฀2008.฀PC฀ship-
ments฀ globally฀ grew฀ by฀ 13.5%฀ in฀ 2008,฀ bringing฀ the฀ market฀ size฀ to฀ more฀ than฀
175฀million฀units.฀Growth฀rates฀for฀2010฀and฀subsequent฀years฀are฀forecast฀to฀rise฀
more฀slowly,฀with฀shipments฀expected฀to฀grow฀by฀nearly฀11%฀in฀2010฀and฀about฀
8%฀annually฀from฀2011฀to฀2015.฀Wireless฀capabilities,฀falling฀prices,฀and฀the฀grow-
ing฀need฀for฀mobility฀have฀increased฀demand฀for฀notebooks;฀however,฀many฀buyers฀
remain฀price฀sensitive฀and฀continue฀to฀evaluate฀the฀beneits฀of฀mobile฀computing.฀
While฀ portable฀ PCs฀ continue฀ to฀ grow฀ much฀ faster฀ than฀ desktops,฀ recent฀ results฀
demonstrate฀the฀continuing฀competitiveness฀of฀desktop฀systems.฀Worldwide฀ship-
ments฀of฀desktop฀PCs฀grew฀by฀13.4%฀year-on-year฀in฀2010,฀up฀from฀9.6%฀in฀2009,฀
while฀growth฀in฀portable฀PCs฀slowed฀to฀28.5%฀in฀2010,฀from฀more฀than฀35%฀in฀2008.฀
Desktops฀continue฀to฀represent฀more฀than฀70%฀of฀worldwide฀PC฀shipments,฀and฀their฀
strong฀growth฀helped฀boost฀growth฀expectations฀for฀total฀PC฀shipments฀in฀2010.
3.2.2 Miniaturized Fuel Cells
Trends฀in฀portable฀electronics฀require฀longer฀lasting฀power,฀more฀energy฀than฀cur-
rent฀technologies฀might฀be฀able฀to฀provide.฀MTI฀MicroFuel฀Cells฀Inc.฀is฀developing฀
miniaturized฀ fuel฀ cells฀ suitable฀ for฀ handheld฀ electronic฀ devices฀ to฀ replace฀ power฀
packs฀currently฀used฀by฀OEMs฀in฀many฀rechargeable฀handheld฀electronic฀devices฀
like฀PDAs฀and฀smartphones.฀Mobion฀cord฀free฀rechargeable฀power฀packs฀are฀based฀
on฀ direct฀ methanol฀ fuel฀ cell฀ (DMFC)฀ technology.฀ A฀ recent฀ Allied฀ Business฀
Intelligence฀(ABI)฀study฀sees฀almost฀22%฀of฀all฀handheld฀electronic฀devices฀with฀
rechargeable฀power฀packs฀being฀powered฀by฀DMFCs฀by฀2011.
MTI฀Micro’s฀DMFC฀system,฀based฀on฀work฀contained฀in฀more฀than฀50฀patents,฀
consists฀of฀a฀unique฀fuel฀cell฀array,฀custom฀fuel฀feed฀control฀and฀user฀replaceable฀
methanol฀fuel฀cartridges,฀is฀intended฀initially฀for฀integration฀into฀industrial฀hand-
held฀electronic฀OEM฀devices.฀Product฀launch฀is฀planned฀for฀early฀2011.฀Under฀a฀
strategic฀ alliance฀ agreement,฀ MTI฀ Micro฀ has฀ incorporated฀ DuPont’s฀ membrane฀
electrode฀assembly฀in฀the฀core฀of฀the฀proprietary฀fuel฀cell฀system.฀The฀best-known฀
and฀most฀widely฀used฀membrane฀material฀used฀in฀this฀application฀today฀is฀Naion,฀a฀
polyperluorosulfonic฀ acid฀ product฀ that฀ is฀ cast฀ into฀ ilm฀ and฀ supplied฀ by฀ DuPont฀
Fluoroproducts.฀Flextronics฀will฀assemble฀this฀initial฀product฀at฀Flextronics’฀spe-
cialized฀‘Product฀Introduction฀Center’฀in฀San฀Jose,฀CA.฀The฀power฀pack฀technology฀
is฀designed฀to฀increase฀run฀time฀(time฀between฀recharges)฀two฀to฀ten฀times฀over฀that฀
of฀existing฀battery฀technologies.
3.2฀ Ofice฀Products฀Applications 27
At฀the฀core฀of฀Mobion฀technology฀is฀its฀unique฀approach฀to฀managing฀water฀that฀
is฀produced฀by฀the฀chemical฀reaction฀at฀the฀cathode,฀and฀required฀for฀the฀chemical฀
reaction฀ at฀ the฀ anode.฀ MTI฀ Micro’s฀ Mobion฀ technology฀ simpliies฀ the฀ traditional฀
approach฀in฀which฀water฀must฀be฀externally฀pumped฀from฀the฀cathode฀to฀the฀anode฀
side฀ for฀ the฀ chemical฀ reaction฀ to฀ occur฀ and฀ energy฀ to฀ be฀ produced.฀ Using฀ MTI฀
Micro’s฀proprietary฀technology฀the฀water฀required฀for฀the฀process฀on฀the฀fuel฀side฀is฀
transferred฀internally฀within฀the฀fuel฀cell฀from฀the฀site฀of฀water฀generation฀on฀the฀air฀
side฀ of฀ the฀ cell.฀ This฀ internal฀ low฀ of฀ water฀ takes฀ place฀ without฀ the฀ need฀ for฀ any฀
pumps,฀complicated฀re-circulation฀loops฀or฀other฀micro-plumbing฀tools.฀As฀a฀result฀
of฀the฀water฀reallocation฀internal฀to฀the฀fuel฀cell,฀the฀system฀can฀accept฀100%฀‘neat’฀
methanol฀ and฀ the฀ elimination฀ of฀ ‘micro฀ plumbing’฀ makes฀ more฀ room฀ available฀
within฀the฀pack฀for฀the฀fuel.฀The฀net฀result฀is฀that฀Mobion฀fuel฀cells฀are฀easier฀to฀
manufacture.฀ They฀ are฀ also฀ more฀ compact,฀ making฀ Mobion-based฀ DMFCs฀ small฀
and฀light฀enough฀for฀handheld฀devices.
3.2.3 Rollable Reading Displays
Lightweight,฀ unbreakable,฀ large฀ area฀ displays฀ that฀ can฀ be฀ rolled฀ up฀ into฀ a฀ small฀
housing฀when฀not฀in฀use฀are฀particularly฀attractive฀for฀mobile฀applications.฀Work฀is฀
progressing฀at฀PolymerVision,฀a฀Philips฀Technology฀Incubator฀that฀will฀transform฀
the฀way฀information฀is฀viewed,฀particularly฀when฀we฀are฀on฀the฀move฀by฀providing฀
lexible฀displays฀not฀much฀smaller฀than฀a฀computer,฀that฀roll฀up฀and฀tuck฀away฀when฀
not฀in฀use.฀After฀years฀of฀work฀on฀polymer฀electronics฀Philips฀is฀producing฀proto-
types฀of฀ultra-thin,฀large฀area,฀rollable฀displays฀and฀intends฀to฀move฀rapidly฀toward฀
a฀ commercial฀ production฀ process.฀ One฀ prototype,฀ designed฀ for฀ e-newspapers,฀
suggests฀a฀dual฀screen฀foldable฀stick฀mechanism฀to฀allow฀dual฀functionality฀of฀the฀
product฀as฀both฀e-newspaper฀and฀e-book.฀News฀can฀be฀downloaded฀via฀subscrip-
tions฀direct฀to฀a฀PC฀inbox,฀or฀uploaded฀from฀news฀kiosks฀as฀one-time฀purchases.฀
Easy฀one-button฀browsing฀and฀simple฀elegant฀design฀would฀appeal฀to฀both฀tradi-
tional฀ reader฀ and฀ early฀ technology฀ adopters.฀ The฀ displays฀ combine฀ active฀ matrix฀
polymer฀ driving฀ electronics฀ with฀ a฀ relective฀ ‘electronic฀ ink’฀ front฀ plane฀ on฀ an฀
extremely฀thin฀sheet฀of฀plastic.฀Ultimately,฀lexible฀large฀area฀displays฀that฀can฀be฀
integrated฀into฀everyday฀objects฀like฀a฀pen฀could฀be฀feasible.฀Such฀displays฀would฀
greatly฀stimulate฀the฀advance฀of฀electronic฀books,฀newspapers,฀magazines,฀and฀news฀
services;฀ applications฀ that฀ currently฀ depend฀ on฀ fragile,฀ large฀ laptops฀ or฀ small,฀
low-resolution฀displays฀of฀mobile฀phones.
PolymerVision฀has฀made฀organics-based฀QVGA฀(320฀×฀240฀pixels)฀active฀matrix฀
displays฀with฀a฀5฀in.฀diagonal,฀a฀resolution฀of฀85฀dpi,฀and฀a฀bending฀radius฀of฀2฀cm.฀
The฀ displays฀ combine฀ an฀ active-matrix฀ back฀ plane฀ containing฀ polymer฀ driving฀
electronics฀with฀a฀relective฀front฀plane฀of฀‘electronic฀ink’฀developed฀by฀E฀Ink฀Corp.฀
Electronic฀ ink฀ based฀ displays฀ can฀ have฀ thin฀ lexible฀ construction,฀ as฀ they฀ do฀ not฀
require฀ cell฀ gap฀ control.฀ Displays฀ made฀ with฀ electronic฀ ink฀ technology฀ are฀ ideal฀
candidates฀for฀reading฀intensive฀applications฀because฀of฀their฀excellent,฀paper-like฀
readability฀ and฀ extremely฀ low฀ power฀ consumption.฀ Currently,฀ PolymerVision฀ is฀

capable฀of฀producing฀over฀5,000฀fully฀functional฀rollable฀display฀samples฀per฀year฀
and฀is฀in฀the฀process฀of฀deining฀a฀pilot฀production฀line.
3.2.4 Digital Pens
With฀Logitech’s฀new฀io2฀Personal฀Digital฀Pen,฀it฀is฀possible฀to฀take฀notes฀at฀a฀meeting฀
with฀pen฀and฀paper,฀return฀to฀the฀ofice฀and฀transfer฀the฀handwriting฀to฀computer.฀
This฀ application฀ provides฀ development฀ opportunities฀ for฀ polycarbonate,฀ PPO/PS,฀
and฀soft฀touch฀TPE฀type฀engineering฀plastics.฀The฀Logitech฀io2฀retail฀package฀consists฀
of฀ the฀ pen,฀ a฀ USB฀ cradle฀ and฀ recharging฀ station,฀ Logitech฀ io2฀ software,฀ special฀
฀preprinted฀ digital฀ paper,฀ an฀ AC฀ adaptor฀ and฀ ive฀ ink฀ reills.฀ The฀ pen฀ software฀ is฀
compatible฀with฀Windows฀98฀or฀higher.
An฀optical฀sensor฀located฀beneath฀the฀$200฀electronic฀pen’s฀ballpoint฀tip฀captures฀
the฀handwritten฀notes฀by฀recording฀a฀pattern฀of฀dots฀created฀when฀the฀pen฀is฀used฀to฀
write฀on฀special฀digital฀paper.฀The฀digital฀paper฀(with฀Anoto฀functionality)฀is฀created฀
by฀printing฀a฀proprietary฀pattern฀of฀very฀small฀dots฀on฀paper฀that฀is฀perceived฀by฀the฀
eye฀as฀slightly฀off฀white฀in฀color.฀The฀printed฀dot฀pattern฀locates฀words฀and฀images฀
on฀the฀paper฀and฀assures฀they฀appear฀in฀the฀same฀place฀in฀digitized฀iles.฀The฀pen,฀
used฀as฀a฀regular฀ballpoint฀pen,฀is฀activated฀by฀removing฀the฀cap฀and฀deactivated฀by฀
replacing฀the฀cap.฀When฀in฀continuous฀use฀the฀pen’s฀battery฀has฀typically฀a฀3-h฀life.฀
Up฀to฀40฀pages฀of฀handwriting฀can฀be฀stored฀in฀the฀pen’s฀856-kB฀lash฀memory.฀The฀
captured฀writing฀can฀then฀be฀transferred฀to฀a฀computer฀by฀placing฀the฀pen฀into฀a฀
dock฀connected฀to฀the฀PC฀via฀a฀USB฀port.฀The฀handwritten฀images฀can฀be฀pasted฀
into฀ various฀ applications฀ including฀ word.฀ The฀ Logitech฀ io2฀ pen฀ is฀ a฀ new฀ product฀
category฀and฀represents฀a฀platform฀with฀an฀enormous฀potential฀for฀growth฀particu-
larly฀as฀good฀handwriting฀recognition฀software฀becomes฀available.
3.2.5 Orbital Web Cameras
Logitech,฀ the฀ world฀ leader฀ in฀ Web฀ cameras,฀ has฀ a฀ new฀ web฀ camera,฀ Logitech฀
QuickCam฀Orbit,฀that฀offers฀unique฀features฀including฀mechanical฀pan฀and฀tilt฀as฀
well฀as฀an฀elegant฀form.฀The฀camera฀combines฀overmolded฀TPO฀to฀a฀polycarbonate฀
shell฀base฀in฀its฀unique฀sleek฀design.฀It฀is฀ideal฀for฀video฀instant฀messaging,฀since฀it฀
physically฀moves฀to฀keep฀a฀person’s฀face฀automatically฀centered฀in฀the฀ield฀of฀view.฀
A฀heavy฀base฀contains฀the฀motor฀to฀swivel฀the฀camera,฀topped฀by฀a฀globe฀slightly฀
smaller฀than฀a฀tennis฀ball,฀which฀houses฀the฀camera฀and฀a฀red฀LED฀behind฀a฀clear฀
plastic฀ shield.฀ The฀ camera฀ is฀ built฀ into฀ the฀ globe฀ and฀ positioned฀ on฀ a฀ motorized฀
mount฀that฀tilts฀up฀and฀down.
Logitech฀ designs,฀ manufactures,฀ and฀ markets฀ personal฀ interface฀ products฀ that฀
enable฀ people฀ to฀ effectively฀ communicate฀ in฀ the฀ digital฀ world.฀ The฀ Logitech฀
QuickCam฀Orbit฀is฀the฀industry’s฀premier฀webcam.฀The฀QuickCam฀Orbit฀mechanical฀
3.3฀ Appliance฀Applications 29
pan฀and฀tilt฀feature฀allows฀the฀webcam฀to฀physically฀turn฀128°฀side-to-side฀and฀54°฀
up-and-down,฀ freeing฀ users฀ from฀ manual฀ camera฀ maneuvering.฀ Logitech’s฀ face-
tracking฀software฀enables฀the฀camera฀to฀automatically฀follow฀a฀person’s฀face,฀keep-
ing฀it฀centered฀in฀the฀ield฀of฀view.฀Auto-zoom฀technology฀offers฀the฀option฀to฀zoom฀
in฀up฀to฀three฀times฀the฀normal฀viewing฀size.฀QuickCam฀Orbit฀captures฀up฀to฀1.3฀
megapixel฀still฀photos,฀and฀true฀640฀×฀480฀videos฀with฀its฀high-quality฀CCD฀sensor.฀
A฀ 9-in.฀ stand฀ is฀ included,฀ so฀ the฀ camera฀ can฀ be฀ elevated฀ to฀ eye-level,฀ and฀ also฀ a฀
built-in฀microphone฀for฀easy฀addition฀of฀audio฀to฀instant฀messaging฀or฀video฀clips.
3.2.6 Removable Data Storage Media
Imation฀Corp.,฀a฀worldwide฀leader฀in฀removable฀data฀storage฀media,฀has฀introduced฀
its฀new฀double฀layer฀DVD฀+฀R฀media,฀the฀industry’s฀next฀advancement฀in฀DVD฀tech-
nology,฀to฀meet฀the฀increasing฀storage฀requirements฀of฀consumers฀for฀high-capacity฀
applications฀such฀as฀digital฀video.฀The฀new฀disc฀nearly฀doubles฀the฀storage฀capacity฀
of฀a฀DVD฀recordable฀disc฀from฀4.7฀GB฀to฀8.5฀GB฀on฀a฀single฀side,฀without฀having฀
to฀turn฀the฀disc฀over฀during฀recording฀while฀remaining฀compatible฀with฀DVD฀video฀
players฀and฀DVD-ROM฀drives.
The฀new฀media฀achieves฀the฀higher฀capacity฀by฀using฀a฀dual฀layer฀DVD฀+฀R฀sys-
tem฀with฀two฀thin฀embedded฀organic฀dye฀ilms฀for฀data฀storage,฀which฀are฀separated฀
by฀a฀semi-relective฀layer฀and฀a฀spacer฀layer.฀The฀recording฀principle฀is฀based฀on฀
irreversibly฀modifying฀the฀dye’s฀physical฀and฀chemical฀structure,฀induced฀by฀heat-
ing฀with฀a฀focused฀laser฀beam.฀The฀recorded฀marks฀have฀different฀optical฀properties฀
than฀their฀unmodiied฀surroundings,฀giving฀the฀same฀read-out฀signals฀as฀read-only฀
discs,฀based฀on฀the฀length฀of฀the฀recorded฀marks฀and฀unmodiied฀spaces฀between฀
them.฀According฀to฀technology฀developers฀Philips฀and฀Mitsubishi฀Kagaku฀Media,฀a฀
key฀challenge฀to฀overcome฀was฀to฀minimize฀the฀interference฀between฀data฀recorded฀
in฀the฀irst฀recording฀layer฀(L0)฀while฀recording฀on฀the฀second฀layer฀(L1).฀In฀addition,฀
the฀irst฀layer฀requires฀the฀use฀of฀a฀transparent฀thin฀metal฀layer฀that฀should฀still฀have฀
enough฀cooling฀power฀allowing฀controlled฀recording฀of฀data฀in฀the฀irst฀layer.฀Philips฀
in฀ cooperation฀ with฀ MKM฀ were฀ able฀ to฀ reach฀ major฀ innovations฀ in฀ the฀ materials฀
used฀for฀the฀spacer฀layer,฀the฀transparent฀metal฀relector,฀and฀recording฀layers฀while฀
remaining฀within฀the฀boundaries฀set฀by฀the฀requirements฀for฀backwards฀compatibility฀
with฀double฀layer฀DVD-ROM.
3.3 Appliance Applications
3.3.1 Appliance Applications Introduction
A฀continued฀strong฀new-home฀market฀and฀an฀equally฀strong฀remodeling฀market฀is฀
keeping฀the฀demand฀for฀major฀and฀small฀appliances฀steady,฀with฀nearly฀all฀catego-
ries฀of฀large฀appliances฀expected฀to฀register฀a฀minor฀uptick฀in฀units฀sold.฀To฀propel฀
the฀appliance฀market฀into฀bigger฀and฀better฀times,฀many฀of฀the฀major฀manufacturers฀
are฀moving฀into฀the฀very฀high-end฀market.฀GE฀Appliances,฀Whirlpool,฀and฀others฀
are฀making฀a฀push฀into฀an฀area฀of฀the฀market฀where฀price฀points฀near฀$2,000฀are฀
common฀for฀big-ticket฀durables฀such฀as฀refrigerators,฀freezers,฀clothes฀washers/dryers,฀
and฀versatile฀stove/oven/refrigerator฀combos.฀Added฀features฀in฀these฀‘smart฀appli-
ances’฀are฀creating฀a฀value฀that฀the฀major฀appliance฀makers฀hope฀will฀translate฀into฀
bigger฀proits.
The฀other฀end฀of฀this฀market฀is฀crowded฀with฀products฀in฀the฀$500฀price฀range,฀
with฀entrants฀from฀China฀and฀Korea฀(LG฀Electronics,฀for฀one)฀squeezing฀this฀end฀of฀
the฀market.฀Competition฀in฀the฀small฀appliance฀category฀is฀not฀much฀better,฀with฀
small฀appliance฀manufacturing฀just฀about฀nonexistent฀in฀the฀US.฀Much฀of฀that฀mar-
ket฀went฀to฀Mexico฀a฀decade฀ago,฀and฀what฀did฀not฀move฀south฀then฀has฀now฀moved฀
to฀the฀Far฀East—China฀particularly.฀Mexico฀is฀still฀home฀to฀a฀number฀of฀appliance฀
manufacturing฀plants,฀where฀companies฀such฀as฀Maytag,฀Bissell,฀Hoover,฀Eureka,฀
and฀Whirlpool,฀among฀others,฀have฀maquiladora฀plants฀on฀the฀border.
3.3.2 E/E Design for Recycle Appliances
Japan’s฀home฀appliance฀recycling฀legislation,฀making฀it฀mandatory฀for฀manufactur-
ers฀ to฀ charge฀ consumers฀ for฀ collecting฀ old฀ appliances,฀ is฀ transforming฀ appliance฀
material฀ selection฀ and฀ design.฀ The฀ legislation฀ sets฀ minimum฀ recycling฀ rates฀ by฀
appliance฀weight;฀with฀60%฀of฀an฀air฀conditioner’s฀weight฀to฀be฀recycled,฀50%฀of฀a฀
refrigerator,฀50%฀of฀a฀washing฀machine,฀and฀so฀on.฀It฀is฀expected฀that฀these฀rates฀
will฀be฀increased฀to฀80–90%฀by฀2011.
In฀response฀to฀the฀legislation฀Japan’s฀appliance฀makers฀are฀making฀their฀products฀
more฀ readily฀ recyclable฀ by฀ using฀ fewer฀ plastics฀ and฀ grades,฀ and฀ plastics฀ that฀ are฀
easier฀ to฀ recycle.฀ PS,฀ considered฀ easier฀ to฀ recycle,฀ is฀ used฀ rather฀ than฀ ABS฀ over฀
concern฀that฀toxic฀substances฀derived฀from฀acrylonitrile฀may฀be฀emitted฀if฀ABS฀is฀
incinerated.฀ Both฀ Fujitsu฀ and฀ Matsushita฀ switched฀ from฀ using฀ ABS฀ in฀ air฀ condi-
tioner฀drain฀pans฀to฀an฀alloy฀of฀syndiotactic฀polystyrene฀(SPS)฀and฀polystyrene.฀
A฀PS/SPS฀alloy฀is฀also฀being฀used฀in฀place฀of฀glass฀iber฀reinforced฀PBT฀in฀a฀vacuum฀
cleaner฀blower.฀Similarly,฀polypropylene฀is฀replacing฀ABS฀in฀vacuum฀cleaner฀hous-
ings.฀ In฀ refrigerator฀ designs,฀ trays฀ now฀ are฀ more฀ likely฀ to฀ be฀ chemical-resistant฀
GPPS฀than฀AS฀resin฀and฀PVC฀is฀also฀being฀avoided฀with฀elastomers฀used฀in฀place฀
of฀PVC฀for฀refrigerator฀gaskets,฀and฀vacuum฀cleaner฀hoses.฀The฀number฀of฀grades฀
employed฀ in฀ appliances฀ is฀ also฀ being฀ reduced,฀ for฀ example,฀ in฀ refrigerators,฀ the฀
number฀of฀grades฀used฀has฀dropped฀from฀30฀to฀10฀or฀less.
3.3.3 Dyson Cyclone Vacuum Cleaner
With฀most฀vacuum฀cleaners,฀the฀bag฀quickly฀clogs฀with฀dust฀as฀the฀suction฀had฀to฀
pass฀through฀the฀bag,฀and฀a฀clogged฀bag,฀even฀with฀as฀little฀as฀10฀oz.฀of฀dirt,฀can฀cut฀
3.3฀ Appliance฀Applications 31
the฀suction฀in฀half฀so฀the฀more฀a฀bag฀is฀used฀the฀less฀effective฀it฀becomes.฀Entrepreneur฀
James฀Dyson฀set฀out฀to฀solve฀the฀problem.฀Five฀years฀and฀5,000฀prototypes฀later,฀the฀
world’s฀irst฀cyclonic฀bagless฀vacuum฀arrived.฀When฀none฀of฀the฀major฀manufacturers฀
were฀interested,฀Dyson฀launched฀his฀own฀vacuum฀cleaner฀company.฀Now,฀Dyson฀
Cyclonic฀Vacuum,฀Europe’s฀hottest฀home฀appliance,฀has฀come฀to฀America.
The฀Dyson฀has฀seven฀ABS฀plastic฀conical฀cylinders฀with฀100,000฀G’s฀of฀spinning฀
centrifugal฀ force.฀ No฀ bag฀ or฀ ilters฀ are฀ in฀ the฀ main฀ cyclone฀ chamber฀ to฀ obstruct฀
฀airlow,฀so฀there฀is฀no฀clogging฀to฀reduce฀suction.฀Dirt฀and฀debris฀are฀literally฀thrown฀
out฀of฀the฀airstream,฀which฀can฀readily฀be฀seen฀through฀the฀clear฀PP฀chamber.฀Deep฀
inside,฀a฀lifetime฀Hepa฀Filter฀with฀Bactisafe฀screen฀kills฀harmful฀bacteria฀and฀traps฀
microscopic฀particles,฀protecting฀sufferers฀from฀airborne฀pollutants.฀Ergonomically฀
designed,฀ the฀ Dyson’s฀ agility฀ and฀ ingenious฀ lexibility฀ makes฀ tedious฀ vacuuming฀
into฀a฀satisfying฀pleasure.฀The฀vacuum฀is฀perfectly฀balanced฀and฀adjusts฀automatically฀
to฀different฀carpet฀heights.฀Although฀technically฀an฀upright,฀the฀Dyson฀outperforms฀
the฀best฀canisters฀on฀bare฀loors.฀A฀17-foot฀hose฀accessed฀by฀detaching฀the฀handle฀
can฀be฀used฀to฀reach฀under฀furniture,฀or฀use฀on฀staircases.฀The฀collection฀chamber฀
releases฀from฀the฀main฀unit฀for฀emptying.
3.3.4 High-Performance Light Fixtures
Appliance฀ manufacturer฀ Miele฀ is฀ using฀ Ticona’s฀ Fortron฀ 6165A4฀ polyphenylene฀

sulide฀(PPS)฀in฀Miele฀washing฀machine฀drum฀light฀ixtures฀for฀the฀materials฀resis-
tance฀to฀humidity,฀repeated฀exposure฀to฀detergents฀and฀the฀heat฀generated฀by฀the฀
halogen฀ bulb.฀ Fortron฀ PPS,฀ by฀ Ticona,฀ a฀ Celanese฀ AG฀ subsidiary,฀ is฀ also฀ a฀ good฀
substrate฀for฀overmolding฀with฀liquid฀silicone฀rubber฀(LSR).฀Installed฀in฀Miele’s฀top฀
of฀ the฀ line฀ washing฀ machines,฀ the฀ light฀ illuminates฀ the฀ drum฀ when฀ the฀ door฀ is฀
opened.฀The฀PPS฀gives฀the฀light฀socket฀long-term฀dimensional/mechanical฀stability฀
in฀the฀face฀of฀the฀hot฀wash฀cycles฀and฀prolonged฀exposure฀to฀175°C฀from฀the฀drum฀
light.฀ Fortron฀ PPS฀ is฀ lameproof฀ and฀ meets฀ electrical฀ use฀ speciications฀ without฀
undesirable฀current฀leakage฀as฀it฀has฀such฀a฀low฀level฀of฀ionic฀impurities.฀It฀also฀is฀a฀
good฀relector,฀improving฀lighting฀eficiency.
A฀diffuser฀made฀of฀polymethylpentane฀is฀placed฀on฀the฀light฀socket.฀To฀prevent฀
the฀ seal฀ between฀ the฀ diffuser฀ and฀ socket฀ from฀ breaking฀ when฀ changing฀ halogen฀
bulbs,฀ Miele฀ places฀ a฀ silicone฀ rubber฀ layer฀ on฀ the฀ PPS฀ socket.฀ This฀ is฀ done฀ by฀
overmolding฀the฀PPS฀socket฀with฀GE฀Bayer฀Silicone฀Silopren฀LSR฀2740.฀The฀light฀
sockets,฀brought฀to฀market฀through฀the฀efforts฀of฀Miele,฀Ticona,฀GE฀Bayer฀Silicones,฀
and฀ the฀ light฀ manufacturer฀ Hurst฀ &฀ Schröder฀ are฀ mass฀ produced฀ by฀ Hurst฀ &฀
Schröder,฀which฀injection฀molds฀the฀PPS฀components,฀and฀Junker฀&฀Halverscheid,฀
which฀places฀the฀LSR฀overmold฀seal฀onto฀the฀PPS฀parts.
Chapter 4
Industrial End Use Applications
Keywords฀ Packaging฀•฀RFID฀•฀Container฀•฀Stretch฀ilm฀•฀Building฀•฀Construction฀
•฀Industrial฀•฀Fasteners฀•฀Pallets฀•฀Agricultural
4.1 Packaging Applications
4.1.1 Packaging Applications Introduction
Plastics฀remain฀the฀material฀of฀choice฀for฀packaging,฀increasingly฀substituting฀for฀
other฀more฀traditional฀materials฀because฀they฀are฀lightweight,฀lexible,฀and฀easy฀to฀
process.฀ Packaging฀ constitutes฀ the฀ single฀ largest฀ end฀ use฀ for฀ plastic฀ materials,฀ in฀
2010฀accounting฀for฀approximately฀34%฀of฀all฀plastics฀used฀in฀the฀US฀and฀37%฀of฀
all฀plastics฀used฀in฀Europe.฀Plastics฀used฀in฀packaging฀are฀primarily฀the฀commodity฀
resins:฀polypropylene฀(PP),฀polyethylene฀(PE),฀polystyrene฀(PS),฀polyvinyl฀chloride฀
(PVC),฀and฀polyethylene฀terephthalate฀(PET).฀Semi-commodity฀nylon฀6฀(PA6)฀is฀an฀
important฀ exception,฀ because฀ ilm฀ for฀ food฀ (mostly฀ meat)฀ packaging฀ is฀ a฀ major฀
market฀ for฀ this฀ polymer.฀ Packaging฀ has฀ become฀ the฀ major฀ market฀ for฀ plastics฀
because฀plastics฀offer฀better฀protection฀against฀spoilage/breakage,฀display฀products฀
more฀attractively฀than฀do฀conventional฀materials,฀are฀lighter฀in฀weight฀than฀tradi-
tionally฀ used฀ paper,฀ glass,฀ and฀ metal฀ products,฀ and฀ offer฀ savings฀ in฀ freight฀ costs฀
(primarily฀fuel฀economy).฀The฀need฀for฀improved฀product฀performance,฀faster฀pack-
aging฀speeds฀and฀downgauging฀is฀driving฀the฀development฀of฀leading฀edge,฀cost-
effective฀packaging฀solutions.
4.1.2 Stretch Hood Film Wrap
Lachenmeier,฀one฀of฀the฀leading฀manufacturers฀of฀end-of-line฀packaging฀machin-
ery,฀ has฀ developed฀ a฀ new฀ generation฀ of฀ stretch฀ hood฀ machines,฀ which฀ presents฀

34 4฀ Industrial฀End฀Use฀Applications
considerable฀advantages฀for฀end฀users.฀The฀innovative฀stretch฀technology,฀offering฀
signiicant฀cost฀reduction,฀improved฀optical฀properties,฀and฀outstanding฀load฀stability,฀
is฀positioning฀stretch฀hood฀as฀the฀number฀one฀choice฀as฀an฀end-of-line฀wrapping฀
method฀for฀a฀wide฀range฀of฀industries.฀The฀blown฀ilm฀business฀for฀stretch฀hood฀
applications฀is฀projected฀to฀increase฀by฀22%/year฀through฀2011฀in฀Europe฀alone฀
compared฀to฀5.5%/year฀for฀stretch฀ilm.฀Stretch฀hoods฀are฀elastic฀ilm฀tubes฀used฀to฀
wrap฀a฀stacked฀pallet.฀Stretch฀(mono฀or฀multilayer)฀ilm,฀circularly฀wrapped,฀domi-
nates฀the฀pallet฀wrap฀market฀with฀a฀67%฀market฀share.฀Another฀competitor,฀shrink฀
hood฀ilm฀(ilm฀tubes฀shrunk฀around฀a฀stacked฀pallet฀by฀applying฀heat),฀is฀expected฀
to฀decline฀by฀2.3%/year฀through฀2011.฀The฀total฀European฀market฀for฀pallet฀wrap฀
is฀ 1.5฀ million฀ tonnes/year.฀ While฀ the฀ pallet฀ wrapping฀ ilm฀ market฀ will฀ advance฀
signiicantly฀in฀volume฀terms,฀stretch฀ilm฀capacity฀utilization฀is฀forecast฀to฀remain฀
below฀80%,฀based฀on฀announced฀capacity฀increases.฀Thus฀margins฀will฀be฀under฀
pressure฀and฀supply฀will฀restructure฀with฀numerous฀shrink฀hood฀ilm฀and฀stretch฀
ilm฀players฀exiting฀the฀business.
When฀hood฀stretching,฀an฀undersized฀ilm฀hood฀is฀stretched฀hydraulically฀to฀a฀
dimension฀matching฀the฀exact฀outer฀circumference฀of฀the฀load.฀The฀four฀grippers,฀
which฀have฀stretched฀the฀ilm,฀travel฀down฀the฀load฀applying฀the฀ilm฀and฀inally฀
securing฀it฀underneath฀the฀pallet.฀This฀bottom฀stretch฀ensures฀a฀reliable฀hold฀between฀
pallet฀ and฀ load฀ and฀ secures฀ the฀ pallet฀ for฀ storage฀ and฀ transportation.฀ Test฀ results฀
show฀that฀a฀wide฀range฀of฀products฀can฀beneit฀from฀this฀technology,฀not฀only฀bagged฀
products฀like฀cement฀or฀chemicals,฀but฀also฀bricks,฀appliances,฀food,฀beverages,฀and฀
other฀bottled฀goods฀which฀were฀initially฀too฀unstable฀for฀this฀wrapping฀method.
Lachenmeier’s฀new฀stretch฀unit฀provides฀a฀controlled฀application฀of฀the฀stretch฀
hood฀ ilm฀ with฀ every฀ step฀ of฀ the฀ application฀ procedure฀ fully฀ controllable฀ from฀
stretching฀ the฀ ilm,฀ to฀ the฀ application฀ over฀ the฀ load,฀ and฀ inal฀ release฀ of฀ the฀ ilm฀
under฀the฀pallet.฀A฀ilm฀hood฀with฀a฀smaller฀circumference฀than฀the฀load฀is฀wound฀
up฀on฀four฀stretch฀units฀and฀stretched฀to฀a฀size฀matching฀the฀exact฀outer฀circumference฀
of฀the฀load.฀Thanks฀to฀the฀Lachenmeier฀top฀stretch฀ilm฀unwinding฀system฀(patent฀
pending฀EP฀1.184.281),฀by฀means฀of฀which฀a฀controlled฀amount฀of฀ilm฀is฀unwound฀
during฀stretching,฀thin,฀fragile฀ilm฀areas,฀especially฀on฀the฀corners฀of฀the฀product,฀
are฀avoided.
4.1.3 Electronic Product Codes (RFID)
Wal-Mart฀Stores฀Inc.฀with฀$245฀billion฀in฀revenues฀is฀the฀world’s฀largest฀company.฀
It฀is฀three฀times฀the฀size฀of฀the฀world’s฀No.฀2฀retailer฀France’s฀Carrefour.฀With฀costs฀
a฀primary฀focus฀Wal-Mart฀has฀taken฀a฀major฀interest฀in฀RFID฀(radio฀frequency฀iden-
tiication),฀where฀tiny฀computer฀chips฀on฀packages฀allow฀radio฀frequencies฀to฀monitor฀
their฀location฀in฀the฀supply฀chain.
Though฀ RFID฀ is฀ gaining฀ interest฀ among฀ retailers฀ such฀ as฀ Target฀ Corp.฀ and฀
Carrefour,฀Wal-Mart฀is฀the฀leading฀force.฀The฀retail฀colossus฀is฀asking฀its฀top฀300฀
suppliers฀ to฀ produce฀ radio฀ controlled฀ microchip฀ tags฀ to฀ be฀ applied฀ to฀ shipping฀
4.1฀ Packaging฀Applications 35
containers/pallets.฀The฀company฀began฀a฀new฀era฀in฀supply฀chain฀management.฀
At฀ that฀ time,฀ Wal-Mart฀ and฀ eight฀ product฀ manufacturers฀ started฀ testing฀ electronic฀
product฀ codes฀ (EPCs),฀ that฀ is฀ RFID฀ tags฀ marked฀ with฀ an฀ EPCglobal฀ symbol,฀ at฀
select฀ Supercenters฀ and฀ one฀ regional฀ distribution฀ center฀ in฀ the฀ Dallas/Fort฀ Worth฀
metroplex.฀EPCglobal฀is฀a฀joint฀venture฀of฀EAN฀International฀and฀the฀Uniform฀Code฀
Council.฀It฀is฀the฀organization฀chosen฀by฀industry฀to฀develop฀standards฀for฀RFID฀
technology฀in฀the฀global฀supply฀chain฀based฀on฀user฀needs฀and฀business฀require-
ments.฀Simultaneously,฀Wal-Mart’s฀top฀100฀suppliers฀–฀plus฀37฀volunteers฀–฀have฀
been฀working฀toward฀being฀live฀with฀EPCS฀in฀North฀Texas฀by฀Q1฀2011.฀The฀company฀
has฀also฀discussed฀implementation฀plans฀with฀their฀next฀top฀200฀suppliers฀with฀the฀
expectation฀ that฀ these฀ suppliers฀ will฀ begin฀ EPC฀ tagging฀ of฀ cases฀ and฀ pallets฀ by฀
January฀2012.
The฀radio฀tags฀will฀allow฀every฀package฀to฀be฀identiied฀and฀tracked฀en฀route฀to฀
every฀destination฀through฀a฀signal฀sent฀by฀complex฀circuitry.฀In฀the฀supply฀chain฀
application,฀passive฀RFID฀chips฀with฀small฀antennae฀are฀attached฀to฀cases฀and฀pallets.฀
When฀ passed฀ near฀ a฀ ‘reader,’฀ the฀ chip฀ activates฀ and฀ its฀ unique฀ product฀ identiier฀
code฀is฀transmitted฀back฀to฀an฀inventory฀control฀system.฀Readers฀used฀by฀Wal-Mart฀
have฀an฀average฀range฀of฀15฀feet.
As฀Wal-Mart฀is฀reshaping฀plastics฀packaging,฀adopting฀RFID฀technology,฀plastics฀
processors฀ face฀ a฀ daunting฀ cost฀ containment฀ challenge.฀ Thirty฀ billion฀ tags฀ are฀
required,฀ which฀ currently฀ cost฀ 30¢/tag.฀ That฀ price฀ needs฀ to฀ be฀ less฀ than฀ 5¢,฀ and฀
suppliers฀want฀a฀1¢฀tag฀to฀respond฀cost-effectively.
4.1.4 Transparent Paint Cans
Following฀their฀strong฀success฀in฀Europe,฀all฀plastic฀gallon฀paint฀cans฀are฀entering฀
North฀America’s฀retail฀paint฀market,฀with฀the฀PCC฀Group฀(The฀Plastic฀Can฀Company)฀
recently฀introducing฀an฀injection฀stretch฀blow฀molded฀clear,฀one฀piece฀PET฀can.฀The฀
company฀expects,฀based฀on฀superior฀cost,฀functionality,฀and฀manufacturability,฀that฀
15%฀of฀steel฀cans฀in฀the฀US฀will฀be฀converted฀to฀the฀PCC฀Group’s฀PET฀design฀by฀
early฀2011.฀PCC’s฀technology,฀which฀is฀available฀for฀license,฀molds฀the฀rim฀into฀the฀
preform,฀allowing฀one฀piece฀PET฀cans,฀for฀the฀irst฀time฀to฀be฀blown฀on฀single฀stage฀
injection฀stretch฀blow฀machines.฀The฀snap฀lid฀is฀also฀PET.฀What฀distinguishes฀PET฀
cans฀ from฀ other฀ plastic฀ versions฀ is฀ their฀ resistance฀ to฀ both฀ water-฀ and฀ oil-based฀
paints,฀and฀their฀ability฀to฀be฀either฀clear฀or฀colored.฀Blow฀molded฀PET฀containers฀
will฀transform฀paint฀packaging฀economics฀in฀the฀US.฀A฀round฀PET฀can฀is฀able฀to฀
drop฀into฀the฀existing฀paint฀industry฀infrastructure฀with฀minor฀modiications.
Initial฀use฀of฀PET฀cans฀in฀North฀America฀was฀by฀Innopack฀in฀Mexico,฀which฀
recently฀ launched฀ four฀ sizes฀ (1/4–4฀ L)฀ for฀ a฀ Mexican฀ customer.฀ Three฀ sizes฀ are฀
molded฀on฀a฀Husky฀one-stage฀Index฀SB-125฀machine,฀while฀the฀4฀L฀container฀is฀
molded฀on฀Aoki฀one-stage฀machines.฀Innopack฀is฀a฀leading฀Mexican฀PET฀beverage฀
containers/caps฀molder.฀The฀company฀developed฀a฀see-through฀label฀and฀snap-on฀
PE฀handle฀for฀the฀4฀L฀cans.
4.1.5 Self-Heating Container
One฀ of฀ the฀ most฀ innovative฀ packaging฀ solutions฀ recently฀ introduced฀ is฀ North฀
America’s฀ irst฀ self-heating฀ container,฀ designed฀ to฀ heat฀ liquid฀ contents฀ such฀ as฀
฀coffee,฀tea,฀cocoa,฀soups,฀and฀alcoholic฀beverages.฀Created฀by฀OnTech,฀Inc.,฀the฀new฀
self-heating฀container฀is฀a฀safe฀and฀easy-to-activate฀concept฀that฀heats฀up฀the฀฀contents฀
of฀its฀package฀to฀approximately฀145°F฀within฀minutes.฀The฀company฀now฀has฀102฀
approved฀utility฀patent฀claims฀in฀the฀US฀and฀patents฀in฀36฀other฀countries,฀including฀
the฀UK,฀China,฀and฀Japan฀covering฀any฀multichamber฀plastic฀product฀that฀must฀be฀
retorted,฀or฀sterilized฀during฀a฀heating฀process.฀In฀Europe,฀some฀metal฀฀containers฀
can฀self-heat฀and฀others฀have฀tried฀a฀mix฀of฀materials฀to฀create฀the฀same฀result฀but฀
with฀limited฀commercial฀results.฀Metal฀has฀a฀tendency฀to฀collapse฀or฀crush฀during฀
the฀sterilization฀process,฀when฀the฀container฀has฀to฀be฀heated฀to฀250°F.
The฀OnTech฀self-heating฀container฀has฀three฀main฀parts,฀the฀six-layer฀plastic฀
container,฀an฀inner฀plastic฀cone,฀and฀a฀water฀holding฀activation฀‘puck.’฀The฀inner฀
cone฀holds฀the฀crushed฀calcium฀oxide฀or฀‘quicklime,’฀used฀in฀the฀heating฀process,฀
and฀the฀outer฀container฀body฀holds฀the฀beverage฀product.฀The฀puck,฀which฀holds฀
the฀water฀to฀react฀with฀the฀calcium฀oxide฀when฀activated,฀its฀inside฀the฀cone,฀and฀
a฀tamper-evident฀foil฀membrane฀seals฀the฀operating฀mechanism.฀To฀activate,฀the฀
consumer฀removes฀the฀tamper-proof฀foil฀and฀firmly฀presses฀down฀on฀a฀button฀
on฀the฀container฀end.฀This฀releases฀the฀water฀contained฀in฀the฀puck฀into฀the฀cal-
cium฀oxide฀within฀the฀cone฀and฀begins฀a฀thermal฀reaction฀that฀heats฀the฀inner฀cone฀
to฀250°F.฀This฀heats฀the฀beverage฀in฀the฀container฀to฀145°F฀in฀6–8฀min,฀while฀the฀
lukewarm฀outer฀shell฀remains฀a฀comfortable฀temperature฀to฀hold.฀The฀beverage฀
will฀stay฀hot฀for฀at฀least฀20฀min฀and฀warm฀for฀up฀to฀an฀hour.฀The฀high฀barrier฀
disposable฀ container฀ is฀ shelf฀ stable฀ and฀ does฀ not฀ require฀ refrigeration฀ prior฀ to฀
opening.
The฀six-layer฀plastic฀container฀consists฀of฀four฀FDA฀approved฀plastic฀materials:฀
polypropylene,฀an฀EVOH฀oxygen฀barrier฀material,฀a฀tie฀layer,฀and฀a฀regrind฀layer.฀
The฀result฀is฀a฀strong,฀safe฀container฀that฀may฀be฀used฀with฀many฀different฀types฀
of฀products.฀The฀container฀is฀designed฀to฀withstand฀normal฀manufacturing฀proce-
dures฀for฀the฀can฀illing฀industry฀and฀can฀therefore฀survive฀the฀retort฀process฀as฀
required฀by฀the฀FDA฀for฀canning฀certain฀food฀products.฀The฀OnTech฀container฀is฀
a฀ standard฀ 16฀ ounce฀ size฀ and฀ will฀ hold฀ 10฀ ounces฀ of฀ product฀ (the฀ remaining฀
6฀ounces฀is฀occupied฀by฀the฀inner฀heating฀cone).฀It฀is฀designed฀to฀accommodate฀
standard฀fill฀lines฀and฀is฀suitable฀for฀hot฀fill,฀retort฀or฀ionized฀pasteurization.฀
A฀ smaller,฀standard฀12฀ounce฀OnTech฀container฀is฀planned฀to฀hold฀7฀ounces฀of฀
product,฀suitable฀for฀baby฀formula,฀sake,฀specialty฀drinks,฀etc.฀The฀container฀can฀
also฀be฀molded฀into฀custom฀shapes฀to฀it฀speciic฀needs฀(soup฀bowl,฀mug,฀baby฀
bottle).฀Each฀of฀the฀containers฀will฀bear฀the฀label฀‘Powered฀by฀OnTech,’฀to฀remind฀
consumers฀of฀the฀technology฀behind฀the฀product.฀The฀company฀is฀also฀working฀on฀
the฀next฀iteration,฀a฀self-cooling฀plastic฀container฀that฀would฀chill฀the฀liquid,฀such฀
as฀beer฀or฀soft฀drinks.
4.1฀ Packaging฀Applications 37
4.1.6 Elastic Shrinking Stretch Film
Easiwrap,฀the฀signature฀product฀from฀Easiwrap฀International,฀is฀made฀with฀a฀new฀
technology฀that฀transforms฀conventional฀thinking฀about฀stretch฀ilm.฀The฀engineered฀
palletizing฀ ilm฀ is฀ a฀ stretch฀ ilm฀ that฀ acts฀ more฀ like฀ a฀ shrink฀ ilm.฀ Elastic฀ like฀
Easiwrap’s฀stretch฀‘memory’฀is฀pre-programmed฀at฀the฀manufacturing฀stage฀through฀
a฀unique฀technique฀that฀makes฀it฀seem฀more฀like฀a฀shrink฀ilm.฀The฀proprietary฀ilm฀
and฀manufacturing฀process฀was฀the฀brainchild฀of฀Irish฀engineer฀Phillip฀Dorn,฀who฀
invented฀the฀technology฀to฀make฀the฀blown฀ilm฀and฀the฀mix฀of฀materials฀that฀go฀into฀
it.฀When฀the฀corners฀of฀the฀Easiwrap฀ilm฀are฀tugged,฀it฀shrinks฀to฀it฀as฀tight฀as฀an฀
elastic฀stocking.฀A฀slight฀tug฀in฀the฀corner฀orients฀the฀molecular฀structure,฀starting฀it฀
shrinking฀for฀20–30฀min฀after฀it฀is฀wrapped฀around฀a฀skid.฀Since฀reactivity฀of฀the฀
ilm฀starts฀with฀that฀tug,฀the฀wrap฀can฀be฀applied฀loosely฀to฀a฀pallet฀load฀then฀tight-
ened฀making฀the฀pallet฀wrapping฀operation฀easier฀and฀quicker.฀With฀its฀300%฀bilat-
eral฀stretch,฀the฀ilm฀can฀conform฀to฀irregular฀dimensions฀on฀the฀pallet฀and฀reduces฀
ilm฀usage,฀reducing฀material฀waste,฀increasing฀productivity,฀and฀making฀the฀cost฀
per฀pallet฀more฀competitive.฀By฀forming฀a฀tight฀it฀the฀ilm฀resists฀nicks฀and฀punc-
tures฀ providing฀ excellent฀ product฀ protection฀ from฀ damage฀ in฀ transit.฀ Customers฀
include฀window฀fabricators,฀building฀supply฀irms฀and฀food/beverage฀distributors.
4.1.7 Rectangular Beverage Bottles
Gatorade’s฀‘Thirst฀Quencher’฀brand฀in฀now฀packaged฀in฀a฀redesigned฀container,฀the฀
irst฀hot฀illed฀rectangular฀PET฀gallon฀bottle฀to฀reach฀the฀market฀domestically฀or฀inter-
nationally..฀The฀new฀bottle,฀created฀by฀Owens-Illinois฀(O-I)฀Plastics฀Group,฀replaces฀
the฀round฀‘space-consuming’฀shape฀previously฀used.฀The฀redesigned฀gallon฀bottle฀is฀
easier฀to฀handle,฀allows฀retailers฀to฀display฀more฀product฀on฀store฀shelves฀and฀customers฀
can฀store฀the฀bottle฀more฀easily฀in฀the฀refrigerator฀door฀or฀other฀tight฀places.
Considering฀that฀a฀gallon฀weighs฀8฀pounds,฀the฀container฀can฀be฀cumbersome฀
and฀dificult฀to฀grip.฀To฀improve฀handling,฀O-I฀designed฀a฀bale฀handle฀for฀the฀bottle฀
to฀give฀users,฀particularly฀children,฀something฀to฀hold฀on฀to฀when฀taking฀the฀product฀
from฀ the฀ refrigerator฀ and฀ pouring฀ it฀ into฀ a฀ cup.฀ The฀ custom฀ HDPE฀ Uni-Pak฀ bail฀
handle,฀which฀is฀applied฀to฀the฀bottle฀prior฀to฀illing฀is฀supplied฀by฀PakTech.฀In฀addition฀
to฀ creating฀ a฀ rectangular฀ package฀ that฀ was฀ easy฀ to฀ handle฀ and฀ pour,฀ Gatorade฀
required฀ a฀ bottle฀ that฀ could฀ be฀ illed฀ on฀ existing฀ bottling฀ lines.฀ This฀ necessitated฀
positioning฀the฀handle฀so฀that฀the฀neck฀could฀still฀be฀gripped฀during฀the฀illing฀oper-
ation.฀The฀bottle฀is฀molded฀with฀recessed฀hand฀grips฀on฀either฀side฀that฀and฀ribbed฀
panels฀that,฀together฀with฀the฀recessed฀grips,฀make฀the฀heavy฀bottle฀easier฀to฀maneu-
ver฀while฀preventing฀paneling฀during฀hot฀illing฀at฀temperatures฀up฀to฀180°F.฀From฀
initial฀concept฀of฀the฀container฀to฀production,฀the฀new฀monolayer฀PET฀bottle฀took฀
6฀months฀to฀complete.
4.2 Building and Construction Applications
4.2.1 Building and Construction Applications Introduction
Building฀and฀construction฀(B&C)฀is฀the฀second฀largest฀end฀use฀market฀for฀plastics.฀
The฀building฀and฀construction฀industry฀uses฀plastics฀for฀a฀range฀of฀applications฀from฀
insulation฀ to฀ piping,฀ window฀ frames฀ to฀ interior฀ design.฀ It฀ is฀ plastics฀ durability,฀
strength,฀resistance฀to฀corrosion,฀low฀maintenance฀and฀aesthetically฀pleasing฀inish฀
that฀ensures฀their฀continued฀popularity฀in฀the฀sector.฀Most฀of฀the฀volume฀usage฀is฀
processed฀by฀extrusion,฀such฀as฀for฀piping,฀conduit,฀wire฀insulation,฀siding,฀reservoir฀
liners,฀erosion฀control฀netting,฀or฀architectural฀sheeting.฀As฀in฀packaging,฀plastics฀
have฀ displaced฀ such฀ traditional฀ materials฀ as฀ wood,฀ glass,฀ and฀ metal,฀ based฀ on฀
improved฀ performance฀ and฀ lower฀ cost.฀ Considering฀ the฀ volumes฀ involved,฀ the฀
marketplace฀tends฀to฀favor฀commodities฀wherever฀possible.
4.2.2 Fiber-Based Composite Building Products
Kadant฀Composites฀Inc.฀is฀using฀a฀paper฀sludge฀by-product฀mixed฀with฀plastic฀to฀
produce฀extruded฀deck฀boards.฀Biodac,฀a฀Kadant฀patented฀product,฀is฀a฀synthe-
sized฀recovery฀of฀short฀and฀long฀cellulose฀ibers,฀precipitated฀calcium฀carbonate฀
and฀kaolin฀clay฀that฀would฀otherwise฀go฀to฀a฀landill.฀A฀Kadant฀sister฀company฀
produces฀a฀granule฀from฀paper฀sludge,฀a฀paper฀recycling฀waste฀product,฀which฀
has฀ found฀ application฀ in฀ a฀ variety฀ of฀ industrial฀ uses฀ particularly฀ as฀ a฀ carrying฀
agent฀for฀fertilizer.฀In฀the฀process฀of฀extruding฀that฀granule,฀a฀very฀microscopic฀
granule฀is฀created฀that฀was฀too฀small฀to฀be฀used฀in฀any฀of฀the฀applications฀that฀the฀
sister฀ company฀ was฀ selling฀ into,฀ and฀ it฀ was฀ being฀ hauled฀ off฀ to฀ landill.฀ Now฀
instead,฀the฀material฀is฀mixed฀with฀recycled฀polyethylene฀and฀rice฀hulls฀to฀make฀
GeoDeck.
The฀Biodac฀granules,฀which฀are฀uniform฀in฀size฀and฀shape,฀and฀mix฀extremely฀
well฀with฀HDPE,฀are฀a฀critical฀element฀in฀the฀production฀of฀a฀composite฀building฀
material฀ being฀ used฀ to฀ produce฀ Kadant’s฀ extruded฀ Geodeck฀ deckboards.฀ Unlike฀
wood฀ibers,฀which฀contain฀lignin฀and฀tannin฀that฀inhibit฀resin฀bonding,฀Biodac฀is฀
low฀in฀those฀chemicals฀and฀compounds฀more฀readily฀with฀plastics.฀Kadant฀devel-
oped฀GeoDeck฀deck฀proiles,฀hollow฀tongue-in-groove฀boards฀of฀HDPE฀with฀up฀to฀
30%฀Biodac฀plus฀additional฀iber฀from฀rice฀hulls.฀The฀composites฀are฀approximately฀
one-third฀ plastic,฀ one-third฀ mineral,฀ one-third฀ iber.฀ Up฀ to฀ 70%฀ Biodac฀ could฀ be฀
used,฀but฀these฀high฀levels฀are฀too฀abrasive฀for฀the฀compounding฀extruders.฀Whiteners฀
and฀brighteners฀from฀the฀paper฀boost฀the฀effect฀of฀colorants฀in฀GeoDeck,฀making฀it฀
less฀subject฀to฀fading฀than฀wood–plastic฀composites.฀The฀product฀has฀greater฀dimen-
sional฀ stability฀ and฀ less฀ moisture฀ absorbance฀ than฀ competing฀ composites.฀ That฀
granule฀is฀the฀key฀ingredient฀that฀gives฀Geodeck฀its฀fade฀resistance฀as฀well฀as฀forming฀
a฀very,฀strong฀product.
4.2฀ Building฀and฀Construction฀Applications 39
GeoDeck฀sales฀have฀grown฀from฀under฀$2฀million฀in฀2007฀to฀more฀than฀$15฀million฀
last฀year.฀Kadant฀Composites฀has฀developed฀other฀new฀building฀products฀containing฀
Biodac,฀including฀corrugated฀roof฀tiles฀that฀look฀like฀red฀clay,฀and฀lat,฀square฀tiles฀that฀
resemble฀slate฀and฀is฀also฀introducing฀new฀Geodeck฀products.
4.2.3 Flexible Mouldings
According฀ to฀ Style฀ Solutions฀ Inc.,฀ customized฀ construction฀ products฀ and฀ large฀
builders฀will฀drive฀the฀growth฀of฀urethane฀millwork฀in฀2010.฀The฀irm฀has฀created฀
more฀than฀300฀customized฀products฀in฀the฀past฀year฀for฀builders฀across฀the฀US.฀The฀
building฀and฀construction฀industry฀has฀seen฀unprecedented฀advances฀in฀the฀accep-
tance฀and฀use฀of฀urethane฀millwork฀on฀both฀exteriors฀and฀interiors฀of฀commercial฀
and฀residential฀buildings.฀Just฀5฀years฀ago,฀wood฀moulding฀proiles฀were฀predominate฀
with฀few฀engineered฀plastic฀ones฀seen.฀Today฀the฀reverse฀is฀true฀with฀low฀mainte-
nance฀products,฀such฀as฀urethane,฀composite,฀and฀plastic฀mouldings฀prominent฀in฀all฀
regions฀of฀the฀country.฀Urethane฀millwork,฀which฀stands฀up฀to฀high฀temperatures฀in฀
the฀summer฀and฀frigid฀snowy฀weather฀in฀the฀winter฀months,฀is฀being฀increasingly฀
used฀with฀other฀products฀such฀as฀doors,฀windows,฀and฀vinyl฀siding.
Style฀Solutions฀recently฀introduced฀a฀new฀line฀of฀decorative฀moulding฀pieces฀that฀
can฀be฀manipulated฀to฀it฀most฀any฀curve฀or฀bend,฀making฀it฀easy฀for฀homeowners฀to฀
add฀moulding฀accents฀to฀their฀homes.฀The฀new฀‘Flexible฀Mouldings’฀with฀the฀irm’s฀
most฀popular฀moulding฀proiles฀allows฀consumers฀to฀trim฀radius฀walls,฀curved฀stair-
ways,฀and฀arched฀entryways.฀Each฀piece,฀made฀of฀tough,฀high-performance฀urethane,฀
vinyl,฀or฀styrenic฀elastomer฀materials,฀can฀be฀bent฀more฀than฀one฀way,฀making฀it฀
possible฀to฀‘snake’฀lexible฀moulding฀down฀a฀staircase฀or฀curve฀it฀completely฀around฀
a฀column.฀For฀interior฀and฀exterior฀applications,฀the฀mouldings฀resist฀insect฀infesta-
tion,฀ rotting,฀ decay,฀ and฀ splintering.฀ The฀ closed฀ cell฀ structure฀ used฀ also฀ prevents฀
water฀ penetration฀ and฀ absorption.฀ Each฀ moulding฀ piece฀ comes฀ pre-primed.฀ The฀
unique฀lexible฀pre-primer฀topcoat฀stretches฀with฀the฀moulding฀to฀minimize฀cracking.฀
Once฀installed,฀the฀lexible฀mouldings฀can฀be฀painted,฀stained,฀or฀faux฀inished.
4.2.4 Artistically Designed Floor Coverings
Bayer’s฀Artwalk฀marries฀the฀practical฀with฀the฀beautiful.฀A฀successful฀ marketing฀
concept,฀Artwalk฀innovative฀coatings฀is฀the฀brand฀name฀for฀a฀new฀line฀of฀polyure-
thane฀raw฀materials฀from฀Bayer฀MaterialScience฀for฀creating฀individual฀and฀highly฀
decorative฀loors฀for฀indoor฀and฀outdoor฀applications.฀Among฀the฀loor฀coverings฀
formulated฀ with฀ Bayer’s฀ Desmodur฀ (blocked฀ polyisocyanates)฀ and฀ Desmophen฀
(polyether,฀ polyester฀ and฀ acrylic฀ polyol)฀ are฀ cast฀ resin฀ coatings฀ or฀ terrazzo-look฀
granular฀rubber฀looring.฀One฀design฀advantage฀shared฀by฀these฀systems฀is฀that฀they฀
can฀be฀laid฀on฀seamlessly฀on฀site฀and฀very฀intricate฀designs฀can฀be฀applied฀over฀the฀
surface฀and฀particularly฀to฀the฀curved฀surfaces฀at฀columns,฀sharp฀corners,฀or฀irregular฀
lengths฀of฀wall.฀It฀is฀also฀possible฀to฀create฀parquet-type฀inlays฀and฀logos.฀The฀mate-
rials฀offer฀a฀variety฀of฀unique฀design฀options฀to฀produce฀one-of-a-kind฀loor฀surfaces฀
that฀can฀impart฀a฀clear฀identity.
With฀the฀large฀assortment฀of฀colors฀available฀for฀both฀systems,฀the฀loor฀design฀
possibilities฀ are฀ almost฀ endless.฀ In฀ addition฀ to฀ the฀ cast฀ resin฀ coatings฀ with฀ their฀
myriad฀design฀possibilities,฀the฀Artwalk฀line฀also฀includes฀colored฀granular฀rubber฀
loor฀ coverings.฀ Depending฀ on฀ the฀ system฀ selected,฀ a฀ combination฀ with฀ various฀
special฀effect฀additives฀such฀as฀aluminum฀particles,฀glitter,฀wood฀pieces,฀or฀chips฀is฀
also฀possible.฀Both฀coating฀systems฀can฀also฀be฀formulated฀to฀meet฀speciic฀stringent฀
functional฀requirements,฀i.e.฀high฀abrasion฀resistance,฀mechanical฀strength,฀color-
fastness,฀ resistance฀ to฀ chemicals,฀ crack฀ bridging,฀ and฀ ease฀ of฀ maintenance.฀ They฀
adhere฀to฀almost฀any฀substrate.฀Both฀coating฀system฀surfaces฀deaden฀the฀sound฀of฀
footsteps.฀Another฀important฀characteristic฀is฀their฀high฀yellowing฀resistance,฀which฀
ensures฀a฀long-lasting,฀pleasing฀appearance฀of฀the฀loors.
Hard-wearing฀ granular฀ rubber฀ loors฀ combine฀ optimum฀ creative฀ freedom฀ with฀
maximum฀wear฀resistance.฀A฀mixture฀of฀rubber฀granules฀and฀a฀polyurethane฀binder฀
(Desmodur/Desmophen)฀ makes฀ it฀ possible฀ to฀ produce฀ seamless฀ graphic฀ designs.฀
The฀material฀can฀be฀used฀to฀achieve฀smooth฀and฀gradual฀color฀transitions,฀as฀well฀as฀
interplays฀of฀light฀and฀dark.฀Depending฀on฀the฀composition฀of฀the฀rubber฀granule/
binder฀mixture,฀the฀loor฀covering฀ranges฀from฀soft฀through฀lexible฀to฀ductile.฀The฀
polyurethane฀granular฀rubber฀looring,฀by฀its฀very฀nature,฀can฀be฀used฀to฀level฀out฀
signiicant฀irregularities฀in฀the฀substrate.฀No฀screed฀is฀required฀under฀granular฀rub-
ber฀looring.
Bayer฀is฀targeting฀both฀the฀public฀and฀private฀sectors฀with฀Artwalk,฀in฀particular฀
showcase฀buildings฀such฀as฀chain฀stores,฀restaurants,฀sports฀stadiums,฀hotels,฀banks,฀
insurance฀ofices,฀itness฀studios,฀and฀ilm฀studios.฀A฀ixture฀of฀the฀successful฀mar-
keting฀concept฀is฀the฀Bayer฀MaterialScience฀offer฀extended฀to฀architects฀and฀plan-
ners฀to฀coordinate฀all฀aspects฀of฀project฀implementation.฀Project฀teams฀comprising฀
designers,฀formulators,฀and฀applicators฀can฀be฀assembled฀for฀each฀property฀and฀custom฀
solutions฀developed฀upon฀request.
4.2.5 Sandwich Construction Plate
British฀ Canadian฀ company฀ Intelligent฀ Engineering฀ Ltd.,฀ in฀ cooperation฀ with฀

Elastogran฀GmbH,฀a฀member฀of฀the฀BASF฀group,฀brings฀the฀marine฀and฀civil฀engi-
neering฀industries฀a฀unique฀concept฀in฀steel฀construction.฀The฀patented฀Sandwich฀
Plate฀System฀(SPS),฀in฀which฀polyurethane฀elastomer฀is฀injected฀between฀two฀steel฀
plates฀ represents฀ a฀ major฀ advance฀ in฀ steel฀ engineering,฀ in฀ all฀ applications฀ where฀
giant฀steel฀parts฀are฀used.฀Wide฀applications฀exist,฀from฀shipbuilding฀to฀repairing฀
steel-plate฀structures฀such฀as฀bridge฀decks,฀railcars,฀and฀ship฀decks,฀hulls,฀and฀hatch฀
covers.฀SPS฀also฀offers฀beneits฀for฀the฀construction฀of฀sport฀stadiums฀and฀arenas.฀
4.2฀ Building฀and฀Construction฀Applications 41
Licenses,฀ for฀ the฀ use฀ of฀ SPS฀ technology,฀ have฀ recently฀ been฀ awarded฀ to฀ major฀
companies฀in฀Europe฀and฀North฀America.
The฀huge฀steel฀elements฀used฀in฀shipbuilding฀or฀bridge฀structures฀are฀exposed฀to฀
enormous฀ mechanical฀ stresses.฀ In฀ conventional฀ steel฀ construction฀ steel฀ plates฀ are฀
reinforced฀ with฀ welded-on฀ longitudinal฀ ribs฀ to฀ maximize฀ stiffness฀ and฀ minimize฀
deformation฀in฀a฀process฀that฀requires฀appreciable฀labor.฀The฀welds฀of฀these฀ribs฀are฀also฀
typically฀ the฀ irst฀ point฀ of฀ attack฀ for฀ corrosion฀ and฀ fatigue.฀ SPS฀ is฀ a฀ much฀ more฀
effective,฀elegant฀method฀of฀reinforcing฀large฀steel฀components.฀The฀elastomer฀is฀
simply฀injected฀between฀the฀two฀steel฀plates฀in฀place฀of฀the฀welded฀longitudinal฀rib฀
reinforcements.฀ The฀ result฀ is฀ a฀ stiff฀ steel-polyurethane-steel฀ composite,฀ which฀
dramatically฀reduces฀construction฀complexity฀and฀removes฀the฀majority฀of฀fatigue฀
and฀corrosion฀prone฀details฀when฀compared฀to฀stiffened฀steel.฀SPS฀structures฀are฀
lighter฀and฀faster฀to฀build฀than฀conventional฀maritime฀and฀civil฀engineering฀structures฀
and฀also฀offer฀built-in฀protection฀against฀ire฀and฀vibration.฀Other฀beneits฀include฀
acoustic฀insulation฀and฀improved฀dimensional฀accuracy.
4.2.6 Secure Window Film
CPFilms฀Inc.฀is฀the฀world’s฀largest฀manufacturer฀of฀solar฀control฀and฀safety฀window฀
ilm฀ for฀ automotive฀ and฀ building฀ applications.฀ The฀ company,฀ with฀ DuPont฀ Teijin฀
Films฀(www.dupontteijinilms.com),฀is฀jointly฀developing฀and฀marketing฀LLumar฀
Magnum฀safety฀and฀security฀protective฀ilms฀made฀with฀Mylar฀from฀DuPont฀Teijin฀
Films.฀Damage฀and฀injury฀from฀projected฀glass฀can฀be฀extensive.฀The฀alliance฀brings฀
technology฀and฀expertise฀to฀commercial฀and฀residential฀markets฀to฀help฀control฀or฀
prevent฀damage฀and฀injuries฀through฀expanded฀application฀of฀well-designed฀safety฀
and฀security฀window฀ilm.
LLumar฀Magnum฀safety฀and฀security฀ilms฀provide฀a฀protective฀sheath฀on฀the฀
interior฀of฀glass฀that฀helps฀hold฀fractured฀shards฀of฀glass฀together฀should฀a฀break฀
occur,฀whether฀from฀natural฀disaster,฀terrorist฀act,฀vandalism,฀theft,฀or฀accident.฀
The฀micro฀thin฀ilm฀is฀composed฀of฀multiple฀layers฀of฀strong,฀clear,฀special฀grade฀
Mylar฀polyester฀ilm฀and฀metallized฀coatings฀bonded฀together฀with฀a฀unique฀adhe-
sive฀to฀form฀a฀shield฀that฀holds฀glass฀in฀place.฀The฀ilm฀also฀resists฀scratching฀and฀
provides฀solar฀protection฀by฀screening฀out฀radiant฀heat,฀and฀damaging฀ultraviolet฀
rays,฀ while฀ delecting฀ harsh฀ glare.฀ The฀ security฀ ilms฀ are฀ available฀ in฀ ive฀
฀thicknesses:฀4,฀7,฀8,฀11,฀and฀15-mil.฀The฀4-mil฀ilms฀are฀considered฀to฀be฀safety฀
ilms฀rather฀than฀true฀security฀ilms.฀The฀7-mil฀ilm,฀the฀standard฀security฀product,฀
offers฀resistance฀to฀breakage.฀The฀8-mil฀ilms฀offer฀both฀solar฀control฀as฀well฀as฀
security฀protection,฀while฀11-mil฀ilms฀are฀recommended฀for฀high-risk฀areas,฀such฀
as฀store฀windows,฀and฀offers฀some฀level฀of฀protection฀in฀case฀of฀explosions,฀where฀
the฀greatest฀danger฀to฀building฀occupants฀is฀lying฀glass.฀The฀15-mil฀ilms฀offer฀
the฀ ultimate฀ in฀ protection฀ in฀ highest-risk฀ areas,฀ and฀ give฀ signiicant฀ protection฀
from฀explosions.
4.3 Industrial Applications
4.3.1 Industrial Applications Introduction
Industrial฀is฀one฀of฀those฀categories฀that฀cover฀a฀lot฀of฀territory฀–฀everything฀from฀
heavy฀equipment฀to฀nuts฀and฀bolts.฀Caterpillar,฀the฀market฀leader฀in฀heavy฀equip-
ment,฀says฀its฀machine฀sales฀in฀North฀America฀for฀2010฀rose฀19%฀from฀a฀year฀ear-
lier,฀ the฀ biggest฀ gain฀ since฀ 2006.฀ Foreign฀ sales฀ were฀ down฀ 6%,฀ but฀ worldwide฀
infrastructure฀construction฀is฀pushing฀up฀sales฀of฀equipment฀globally฀by฀7%.฀Others฀
serving฀the฀construction฀equipment฀segment฀are฀also฀experiencing฀positive฀growth.฀
Ingersoll฀ Rand฀ Co.฀ reported฀ strong฀ sales฀ of฀ generators,฀ compressors,฀ and฀ Bobcat฀
construction฀equipment.฀In฀the฀nuts฀and฀bolts฀end฀of฀the฀industrial฀market฀segment,฀
industrial฀fastening฀systems฀are฀projected฀to฀grow฀5.6%฀through฀2011,฀fueled฀by฀a฀
healthy฀ increase฀ in฀ durable฀ goods฀ production฀ and฀ construction.฀ Strong฀ sales฀ of฀
higher-performance฀specialty฀products฀such฀as฀aerospace-grade฀fasteners฀will฀expe-
rience฀the฀fastest฀growth฀as฀manufacturers฀replace฀commodity฀items฀with฀custom฀
designs.฀Among฀the฀top฀45฀players฀in฀this฀market฀are฀Illinois฀Tool฀Works,฀Textron,฀
Emhart฀Fastening฀Technologies,฀SPS฀Technologies,฀Alcoa,฀and฀Park-Ohio.
In฀ between฀ heavy฀ equipment฀ and฀ fasteners,฀ industrial฀ conglomerates฀ include฀
Honeywell฀International฀Inc.,฀a฀$22฀billion฀manufacturer฀of฀products฀for฀both฀indus-
trial฀and฀residential฀markets.฀Honeywell฀makes฀controls฀for฀heating,฀cooling,฀venti-
lation,฀ humidiication,฀ industrial฀ process฀ automation,฀ and฀ video฀ surveillance,฀ as฀
well฀as฀access฀control฀equipment,฀security/ire฀alarm฀and฀industrial฀safety฀systems,฀
and฀ home฀ automation฀ systems฀ in฀ its฀ automation฀ and฀ control฀ products฀ segment,.฀
Honeywell’s฀2010฀earnings฀grew฀between฀9%฀and฀17%฀in฀all฀four฀of฀its฀operating฀
segments.฀ ITT฀ Industries฀ is฀ a฀ diversiied฀ industrial฀ manufacturer฀ whose฀ Fluid฀
Technology฀and฀Motion฀&฀Flow฀Control฀units฀produce฀switches,฀valves,฀pumps,฀and฀
luid฀handling฀systems.฀ITT฀expects฀improving฀conditions฀in฀its฀key฀markets฀to฀pro-
vide฀ solid฀ growth฀ opportunities.฀ Tyco฀ International’s฀ Engineered฀ Products฀ &฀
Services฀business,฀with฀2009฀revenues฀of฀$4.7฀billion,฀saw฀its฀market฀segments฀grow฀
in฀2010.฀Products฀for฀industrial฀process฀equipment฀and฀water/wastewater฀systems฀
include฀such฀things฀as฀valves,฀actuators,฀controls,฀and฀thermal฀control฀systems.
4.3.2 Energy-Saving Freezer Apparatus
Creative฀Plastics฀&฀Design฀(CPD)฀has฀designed฀and฀manufactured฀a฀plastic฀deck฀
pan฀ (patent฀ pending)฀ that฀ replaces฀ the฀ industry฀ standard฀ stainless฀ steel฀ pan฀ used฀
inside฀refrigerated/frozen฀food฀and฀beverage฀display฀cases.฀The฀deck฀pan฀created฀for฀
refrigeration฀systems฀company฀Hill฀Phoenix฀serves฀as฀a฀barrier฀that฀separates฀and฀
protects฀perishable฀foods฀from฀the฀freezer’s฀cooling/self฀defrost฀cycle.฀The฀new฀pan,฀
made฀from฀HDPE,฀features฀a฀blow-molded฀design฀that฀offers฀greater฀durability฀and฀
food฀safety฀than฀the฀original฀stainless฀steel฀pan,฀while฀cutting฀processing฀costs฀by฀
67%฀and฀weight฀by฀30%.
4.3฀ Industrial฀Applications 43
The฀CPD฀design฀features฀supporting฀ridges฀on฀the฀pan’s฀top฀and฀bottom฀surfaces.฀
Adding฀rigidity฀and฀durability฀to฀all฀sides฀of฀the฀pan,฀the฀new฀design฀enables฀it฀to฀
meet฀requirements฀for฀static,฀side,฀axial,฀and฀torsional฀loads฀as฀well฀as฀for฀impact฀
strength.฀According฀to฀CPD,฀the฀HDPE฀resin฀selected฀was฀the฀only฀plastic฀material฀
that฀could฀meet฀impact฀strength฀requirements฀without฀becoming฀brittle฀and฀weak฀
during฀ testing฀ at฀ refrigerator/freezer฀ operating฀ temperatures.฀ The฀ new฀ deck฀ pan฀
design฀also฀delivers฀an฀insulation฀factor฀of฀R-3฀without฀using฀any฀foam฀backing฀or฀
covering.฀The฀new฀display฀case฀deck฀pan฀has฀earned฀National฀Sanitation฀Foundation฀
(NSF)฀approval฀permitting฀contact฀with฀food฀and฀can฀serve฀not฀only฀as฀a฀barrier฀but฀
also฀as฀an฀attractive฀display฀rack,฀itting฀existing฀refrigerated฀cases.
4.3.3 Plastic Pallets
With฀stricter฀hygiene฀standards,฀concerns฀about฀pests,฀and฀greater฀design฀features,฀
the฀plastic฀pallet฀market฀is฀enjoying฀global฀demand฀growth฀of฀more฀than฀10%/year฀
At฀least฀four฀plastics฀processes฀are฀seeing฀extensive฀use:฀injection฀molding,฀rota-
tional฀molding,฀single-฀or฀twin-sheet฀thermoforming,฀and฀structural฀foam฀molding.฀
Responding฀to฀demand฀growth,฀Kiga฀GmbH฀has฀developed฀a฀light฀weight฀plastic฀
pallet฀that฀is฀cost฀competitive฀with฀untreated฀wooden฀ones.฀These฀single฀use฀pallets฀
made฀of฀recycled฀polyethylene฀or฀polypropylene฀are฀frequently฀used฀to฀ship฀prod-
ucts฀to฀the฀European฀Union,฀China,฀Japan,฀Australia,฀and฀other฀countries฀that฀do฀not฀
allow฀the฀entry฀of฀untreated฀wooden฀pallets฀for฀fear฀that฀insects฀may฀be฀harbored฀in฀
the฀wood.฀Single฀use฀pallets฀of฀recycled฀plastic฀typically฀cost฀€5–€6,฀while฀those฀
using฀virgin฀material฀designed฀to฀meet฀extreme฀hygienic฀standards฀and฀high-strength฀
requirements฀can฀cost฀as฀much฀as฀€50.
Plastic฀pallets฀are฀more฀durable฀than฀wooden฀pallets฀in฀multi-trip฀applications฀
where฀plastic฀pallets฀can฀often฀survive฀100฀trips,฀compared฀to฀10฀trips฀for฀wood.฀
Kiga฀uses฀recycled฀PET฀for฀some฀pallets฀as฀the฀material฀is฀stronger฀than฀PE฀and฀also฀
inserts฀iron฀bars฀in฀others฀to฀improve฀load฀strength.฀The฀company,฀which฀both฀injec-
tion฀molds฀and฀compression฀molds฀pallets,฀recently฀started฀thermoforming฀a฀col-
lapsible฀version฀for฀Chrysler.฀Collapsible฀versions฀require฀less฀storage฀space฀after฀
they฀have฀been฀emptied,฀an฀important฀point฀for฀many฀automotive฀OEMs฀and฀other฀
manufacturers.฀Thermoforming฀allows฀the฀use฀of฀much฀less฀expensive฀tooling฀–฀in฀
the฀range฀of฀€10,000฀vs.฀€250,000฀for฀injection฀molds฀and฀the฀tooling฀can฀be฀made฀
in฀3–4฀weeks.฀But฀injection฀molded฀pallets฀can฀be฀more฀precisely฀manufactured,฀an฀
important฀contrast฀to฀wooden฀pallets,฀which฀may฀have฀knot฀holes฀and฀eventually฀
sag,฀warp,฀or฀bend.฀Injection฀molded฀units฀show฀little฀change฀over฀time,฀and฀this฀is฀
critical฀in฀many฀irms฀where฀increasingly฀it฀is฀robots฀that฀are฀unloading฀pallets.
4.3.4 Sterile Disposable Flasks
Quality฀ labware฀ manufacturer,฀ Nalge฀ Nunc฀ International฀ (NNI),฀ an฀ ISO฀ 13485฀
certiied฀world฀leader฀in฀the฀production฀and฀supply฀of฀laboratory฀plasticware฀for฀use฀
in฀ research฀ and฀ educational฀ laboratories,฀ has฀ reduced฀ product฀ and฀ manufacturing฀
costs฀in฀their฀latest฀line฀of฀disposable฀lasks.฀The฀new฀Nalgene฀sterile฀disposable฀
lasks,฀ideal฀for฀shaker฀and฀suspension฀cell฀culture,฀media฀preparation฀or฀storage,฀
combine฀an฀innovative฀lightweight฀design฀with฀the฀versatility฀of฀Eastman฀Chemical’s฀
PETG฀plastic,฀Eastar฀copolyester฀6763,฀to฀deliver฀a฀cost฀effective,฀completely฀dis-
posable฀product.฀Lower฀material฀and฀processing฀costs฀allow฀NNI฀to฀offer฀the฀new฀
Nalgene฀sterile฀disposable฀lasks฀at฀roughly฀60%฀of฀the฀cost฀of฀competing฀brands.฀
The฀lasks฀are฀ready-to-use,฀in฀gamma฀sterilized฀individual฀packages.฀They฀are฀also฀
free฀from฀the฀yellowing฀typically฀associated฀with฀other฀polymers฀when฀exposed฀to฀
gamma฀sterilization.
Designed฀ for฀ disposability,฀ amorphous฀ copolyester฀ enabled฀ NNI฀ to฀ mold฀ an฀
extremely฀ light฀ weight,฀ thin฀ walled฀ product฀ with฀ the฀ performance฀ integrity฀ of฀ its฀
heavier฀polycarbonate฀counterpart.฀The฀readily฀disposable฀lasks฀weigh฀only฀a฀frac-
tion฀ of฀ that฀ of฀ other฀ materials฀ including฀ glass฀ or฀ polycarbonate,฀ making฀ disposal฀
more฀cost฀effective.฀Disposability฀greatly฀reduces฀the฀risk฀of฀cross-contamination,฀
and฀the฀lasks฀can฀be฀cleanly฀incinerated,฀allowing฀laboratory฀professionals฀to฀real-
ize฀process฀eficiencies฀from฀initial฀use฀to฀inal฀disposal.
4.3.5 Mechanically Efficient Microplates
Tecan,฀a฀leader฀in฀the฀Life฀Sciences฀supply฀industry,฀is฀working฀with฀Corning฀Inc.฀to฀
offer฀ an฀ innovative฀ microplate฀ handling฀ system฀ for฀ low฀ volume฀ microplate฀ assay฀
applications.฀While฀small฀liquid฀volumes฀can฀be฀dispensed,฀the฀ability฀to฀work฀with฀
low฀volumes฀(low฀ml฀or฀nl)฀for฀various฀assay฀and฀molecular฀biology฀applications฀has฀
been฀severely฀limited฀by฀rapid฀evaporation,฀especially฀at฀the฀elevated฀temperatures฀
typically฀ required฀ for฀ many฀ types฀ of฀ assays.฀ For฀ these฀ applications,฀ Tecan฀ and฀
Corning฀Life฀Sciences฀have฀assembled฀an฀innovative,฀new฀microplate฀handling฀sys-
tem,฀which฀combines฀Tecan’s฀Te-Lidder฀COC฀plastic฀microplate฀lid฀handling฀module฀
and฀Corning’s฀Robolid฀technology.฀The฀system฀provides฀an฀ideal฀solution฀for฀sealing,฀
unsealing,฀and฀resealing฀a฀variety฀of฀commonly฀used฀96฀and฀384฀well฀microplates.
Tecan’s฀Te-Lidder฀is฀a฀robotic฀workstation฀accessory฀designed฀for฀use฀with฀Corning’s฀
Robolid,฀a฀novel฀microplate฀seal฀that฀incorporates฀a฀silicone฀capmat฀into฀a฀standard฀
polystyrene฀plate฀lid.฀This฀combination฀provides฀each฀well฀on฀a฀standard฀plate฀with฀a฀
liquid฀tight฀seal฀in฀a฀format฀that฀is฀automation฀compatible.฀Tecan’s฀Te-Lidder฀is฀specii-
cally฀ designed฀ for฀ use฀ with฀ Robolid฀ technology฀ on฀ Tecan฀ Workstations฀ and฀ TRAC฀
Robotic฀Systems.฀This฀patented฀technology฀is฀designed฀for฀easy฀and฀quick฀removal฀of฀
tight฀sealing฀Robolids฀from฀a฀wide฀variety฀of฀96฀and฀384฀well฀plates.
4.3.6 Aerodynamic Truck Brackets
To฀reduce฀cost฀and฀weight,฀RTP฀Company฀teamed฀with฀Volvo฀to฀develop฀two฀types฀
of฀Volvo฀truck฀brackets,฀a฀pair฀of฀L-shaped฀faring฀brackets฀used฀to฀mechanically฀
4.3฀ Industrial฀Applications 45
fasten฀ the฀ truck฀ cab’s฀ aluminum฀ grab฀ handle฀ to฀ the฀ truck฀ cab฀ side,฀ and฀ brackets฀
designed฀to฀hold฀a฀roof฀mounted฀satellite฀dish.฀Requirements฀for฀the฀new฀injection฀
molded฀grab฀handle฀brackets,฀which฀are฀prominently฀located฀on฀the฀truck,฀included฀
a฀quality฀surface฀that฀could฀be฀top฀coat฀painted฀without฀primer฀to฀control฀cost.฀The฀
grab฀ handle฀ also฀ had฀ to฀ pass฀ testing฀ in฀ which฀ it฀ was฀ subjected฀ to฀ a฀ 250฀ lb฀ load,฀
necessitating฀ a฀ minimum฀ bracket฀ tensile฀ strength฀ of฀ 20,000฀ psi.฀ In฀ addition,฀ the฀
material฀ replacing฀ the฀ formerly฀ used฀ metal฀ had฀ to฀ display฀ shrinkage฀ rates฀ corre-
sponding฀to฀those฀of฀the฀existing฀tool.฀The฀satellite฀bracket฀required฀a฀lexural฀mod-
ulus฀of฀at฀least฀1.2฀million฀psi,฀and฀since฀it฀did฀not฀require฀painting,฀the฀material฀
would฀ have฀ to฀ withstand฀ chemical฀ and฀ ultra฀ violet฀ radiation฀ exposure฀ of฀ typical฀
highway฀conditions.
The฀truck฀brackets,฀formerly฀of฀banded฀steel,฀were฀injection฀molded฀from฀RTP’s฀
4700฀Series฀polytrimethylene฀terephthalate฀(PTT)฀compound,฀which฀contains฀both฀
a฀ UV฀ protection฀ package฀ and฀ glass฀ iber฀ reinforcement.฀ PTT฀ is฀ a฀ semicrystalline฀
polyester,฀closely฀related฀to฀the฀more฀common฀thermoplastic฀polyesters฀PET฀and฀
PBT,฀but฀is฀typically฀a฀less฀expensive฀material.฀RTP฀Co.’s฀new฀RTP฀4700฀Series฀bal-
ances฀ the฀ physical฀ properties฀ of฀ PET฀ with฀ the฀ processing฀ characteristics฀ of฀ PBT.฀
The฀PTT฀compounds฀offer฀strength,฀stiffness,฀and฀high฀heat฀delection฀temperatures฀
of฀PET;฀low฀melt/mold฀temperatures฀and฀wide฀processing฀window฀of฀PBT;฀basic฀
polyester฀beneits฀of฀dimensional฀stability,฀electrical฀insulation,฀and฀chemical฀resis-
tance;฀and฀cost฀savings.
4.3.7 High Tech Fasteners
Swiss-based฀ fastener฀ maker,฀ Icotec฀ AG฀ (Innovative฀ composite฀ technology),฀ pro-

duces฀fasteners฀for฀the฀aerospace,฀automotive,฀and฀medical฀industries฀using฀a฀novel฀
compression฀ low฀ molding฀ (CFM)฀ process฀ that฀ delivers฀ net฀ shape฀ thermoplastic฀
composites฀ with฀ strength฀ per฀ unit฀ weight฀ competitive฀ to,฀ or฀ exceeding฀ machined฀
steel,฀aluminum,฀and฀titanium.฀The฀innovative฀technology฀developed฀by฀Icotec฀is฀
used฀by฀the฀company฀to฀produce฀high฀strength฀light฀weight฀fasteners.฀With฀its฀CFM฀
process฀the฀company฀is฀able฀to฀put฀up฀to฀62%฀carbon฀iber฀by฀volume฀into฀thermo-
plastics฀such฀as฀PEEK,฀creating฀a฀high-strength,฀abrasion-resistant฀composite.
The฀lightweight฀nuts฀and฀bolts฀thus฀produced฀sport฀ultrahigh฀speciic฀strengths฀of฀
up฀ to฀ 2.4฀ million฀ psi/lb/in3฀ This฀ contrasts฀ to฀ aluminum฀ and฀ titanium฀ with฀ speciic฀
strengths฀of฀about฀0.2฀million฀and฀1.2฀million฀psi/lb/in3,฀respectively.฀The฀CFM฀pro-
cess฀feeds฀pultruded฀composite฀rods฀into฀a฀closed฀preheating฀cavity.฀From฀there,฀the฀
rods฀move฀to฀the฀mold฀and฀are฀formed฀to฀shape฀under฀pressure฀with฀helically฀rein-
forced฀threads.฀The฀high-volume฀CFM฀process฀produces฀fasteners฀in฀a฀single฀step฀
without฀ the฀ need฀ for฀ any฀ posttreatment.฀ Even฀ with฀ high฀ iber฀ loadings,฀ fastener฀
threads฀can฀sustain฀high฀mechanical฀loads฀without฀shearing,฀thanks฀to฀a฀transitional฀
iber฀orientation฀zone฀that฀transfers฀forces฀away฀from฀the฀threads฀to฀the฀fastener฀core.฀
In฀contrast,฀conventional฀thermoplastic฀processing฀techniques฀do฀not฀permit฀extremely฀
high฀iber฀content฀nor฀can฀they฀process฀long฀ibers฀without฀damaging฀them.
4.4 Agricultural Applications
4.4.1 Agricultural Applications Introduction
Agricultural฀ plastics฀ continue฀ to฀ account฀ for฀ just฀ 1.9–2.6%฀ of฀ the฀ total฀ plastics฀
consumed,฀in฀the฀United฀States฀and฀Europe,฀but฀they฀have฀a฀vital฀role฀to฀play.฀Plastics฀
based฀ agricultural฀ systems฀ provide฀ effective฀ solutions฀ to฀ crop฀ growing:฀ in฀ arid฀
regions,฀for฀example,฀plastics฀piping฀and฀drainage฀systems฀can฀cut฀irrigation฀costs฀
by฀one฀to฀two-thirds฀while฀as฀much฀as฀doubling฀crop฀yield.฀The฀agricultural฀sector฀
is฀also฀a฀signiicant฀application฀for฀plastic฀ilm฀used฀for฀soil฀conditioning,฀crop฀cover฀
and฀grows฀tunnels.฀Elsewhere฀plastics฀are฀used฀for฀pesticide฀and฀fertilizer฀packag-
ing,฀and฀to฀produce฀farm฀implements฀and฀equipment.฀Plastics฀also฀plays฀a฀growing฀
role฀in฀animal฀husbandry฀displacing฀traditional฀materials฀as฀wood,฀and฀metals฀for฀
products฀such฀as฀feed฀troughs,฀watering฀tanks,฀grain฀bins,฀and฀even฀horseshoes.
4.4.2 Farmland Demining Equipment
Land฀ mines฀ pose฀ a฀ lingering฀ threat฀ beyond฀ risks฀ to฀ life฀ and฀ limb.฀ Strewn฀ across฀
farmlands,฀ mines฀ can฀ cause฀ famine฀ by฀ rendering฀ ields฀ unusable.฀ In฀ cooperation฀
with฀Caterpillar฀Inc.,฀Countermine฀Technologies฀AB฀has฀developed฀Oracle฀(Obstacle฀
Removal฀and฀Clean฀Land฀Equipment)฀a฀complete฀unique฀demining฀and฀land฀recla-
mation฀system.
Oracle฀based฀on฀Caterpillar’s฀off฀the฀rack฀loaders฀costs฀1/100฀as฀much฀as฀a฀mili-
tary฀system฀to฀set฀up฀and฀run.฀The฀system฀consists฀of฀Spitire,฀a฀mine฀clearing฀tool,฀
which฀clears฀mines฀placed฀both฀in฀and฀on฀the฀ground฀to฀a฀depth฀of฀45฀cm,฀will฀in฀
excess฀of฀the฀UN฀20฀cm฀requirement.฀The฀patented฀tool฀destroys฀a฀mine฀before฀it฀
detonates.฀Mounted฀on฀a฀caterpillar,฀the฀Spitire฀tool฀can฀clear฀up฀to฀15,600฀m2/h฀
with฀a฀clearance฀rate฀of฀99.6%.฀Girded฀by฀steel฀plated฀armor,฀yet฀employing฀light-
weight฀RIM,฀SRIM฀and฀related฀reinforce฀plastic฀composite฀parts฀for฀interior฀weight฀
reduction฀and฀fueled฀by฀a฀tow฀along฀power฀plant,฀it฀uses฀its฀massive฀sharp฀toothed฀
rotor฀to฀shred฀mines฀before฀they฀go฀off,฀or฀if฀not,฀to฀simply฀smother฀the฀explosion.฀
Oracle฀ also฀ tills฀ the฀ ground฀ as฀ it฀ traverses฀ the฀ ield฀ so฀ that฀ the฀ land฀ can฀ be฀ used฀
directly฀ after฀ the฀ mine฀ clearance฀ operation.฀ Farmers฀ welcome฀ Oracle฀ with฀ open฀
arms,฀and฀typically฀throw฀the฀Oracle฀team฀a฀party.
4.4.3 Engineered Horseshoes
Senior฀&฀Dickson,฀a฀UK-based฀molder฀and฀toolmaker,฀has฀produced฀the฀irst฀ever฀
plastic฀horseshoe.฀The฀shoe,฀produced฀on฀behalf฀of฀Lightfoot฀Horseshoes฀Ltd.฀is฀a฀
two-shot฀injection฀molding฀using฀Nylon฀6.6,฀and฀a฀TPE฀compound.฀In฀addition฀to฀
4.4฀ Agricultural฀Applications 47
the฀ two฀ plastic฀ compounds,฀ the฀ horseshoe฀ contains฀ a฀ small฀ steel฀ strip,฀ which฀ is฀
inserted฀in฀the฀mold.
The฀ new฀ plastic฀ horseshoe,฀ the฀ Jameg฀ Sprinter,฀ offers฀ many฀ advantages฀ over฀
traditional฀steel฀or฀aluminum.฀Designed฀to฀be฀glued฀to฀the฀hoof,฀the฀shoe฀includes฀a฀
series฀of฀removable฀clips฀to฀aid฀in฀itting฀and฀a฀unique฀rubber฀lift฀on฀the฀foot฀side฀
surface฀to฀help฀create฀the฀correct฀acrylic฀adhesive฀thickness.฀No฀nails฀are฀required,฀
an฀important฀factor฀as฀nails,฀which฀damage฀the฀hoof฀can฀limit฀the฀number฀of฀times฀
an฀animal฀can฀be฀reshod,฀and฀in฀the฀case฀of฀racehorses,฀the฀frequency฀that฀it฀can฀
compete.฀ Equally฀ important,฀ because฀ a฀ horse’s฀ hoof฀ is฀ effectively฀ a฀ polymer,฀ the฀
nylon฀shoe฀base฀produces฀both฀strength฀and฀lexibility,฀working฀in฀harmony฀with฀the฀
hoof,฀not฀against฀it.฀Once฀attached,฀the฀shoe฀becomes฀part฀of฀the฀hoof,฀allowing฀it฀to฀
expand฀and฀contract฀naturally.฀Ultralight฀weight฀and฀slip฀resistant฀the฀Sprinter฀can฀
be฀itted฀with฀studs฀and฀used฀on฀horses฀involved฀in฀a฀range฀of฀disciplines.฀They฀are฀
less฀likely฀than฀steel฀shoes฀to฀cause฀injury฀to฀a฀fallen฀rider,฀and฀are฀ideal฀for฀brood฀
mares,฀horses฀at฀rest,฀and฀those฀with฀poor฀or฀badly฀broken฀feet.
4.4.4 Ag Equipment Large Parts
The฀John฀Deere฀7000฀Engine฀enclosure฀is฀the฀irst฀use฀of฀co-injection฀to฀produce฀
cost฀effective฀large฀parts฀from฀engineering฀grade฀material฀in฀thick฀walls฀–฀6฀mm฀to฀
8฀mm.฀Molder,฀Bemis฀Manufacturing฀Company฀a฀leading฀global฀manufacturer฀of฀
diverse฀proprietary฀and฀custom฀plastic฀products,฀uses฀coinjection฀molding,฀allowing฀
regrind฀to฀be฀used฀in฀the฀core฀to฀reduce฀costs.฀The฀hood฀and฀side฀panels฀of฀the฀John฀
Deere฀ 7000฀ engine฀ enclosure฀ consist฀ of฀ a฀ skin฀ of฀ polycarbonate/polybutylene฀
terephthalate,฀and฀a฀core฀of฀regrind฀ABS.฀This฀construction฀yields฀parts฀with฀excel-
lent฀high฀impact฀strength฀and฀very฀good฀part฀stiffness.฀The฀hood฀also฀includes฀a฀one฀
piece฀front฀grille฀frame฀allowing฀the฀entire฀grille฀and฀light฀system฀to฀be฀mounted฀to฀
the฀ frame฀ as฀ a฀ module.฀ Each฀ hood฀ assembly฀ contains฀ 15–20฀ pounds฀ reclaimed฀
material.฀A฀polyurethane฀topcoat฀is฀applied฀to฀the฀cosmetic฀body฀parts฀of฀the฀tractor฀
engine enclosure.
Three฀mold฀makers฀were฀involved฀to฀produce฀the฀required฀molds฀for฀the฀tractor฀
engine฀enclosure฀Triangle฀Tool฀Corporation฀and฀Tooling฀Technologies,฀Inc.,฀both฀of฀
Milwaukee,฀ WI,฀ and฀ CDM฀ Tool฀ &฀ Manufacturing฀ of฀ Hartford,฀ WI.฀ The฀ tooling,฀
made฀by฀Triangle฀Tool,฀includes฀two฀large฀core฀pulls,฀four฀sets฀of฀expanding฀lifter฀
units,฀and฀seven฀collapsing฀core฀sections.
4.4.5 High Durability Irrigation Filters
Systems฀ Europe฀ Srl,฀ a฀ Rome-based฀ European฀ subsidiary฀ of฀ Toro฀ Irrigation,฀ has฀
developed฀a฀large฀agricultural฀ilter฀that฀has฀high฀burst฀strength฀and฀excellent฀envi-
ronmental฀resistance.฀Taking฀over฀a฀year฀to฀develop,฀the฀new฀cartridge฀ilter,฀which฀
is฀positioned฀between฀the฀inlet฀and฀outlet฀systems฀of฀the฀irrigation’s฀main฀pipeline฀
serves฀to฀clean฀the฀water,฀eliminating฀dust฀and฀other฀particles฀and฀ensuring฀a฀smooth,฀
constant,฀and฀uninterrupted฀low฀of฀water.฀The฀ilter฀consists฀of฀three฀parts,฀the฀main฀
body,฀the฀thread,฀and฀the฀cylinder.
The฀company฀chose฀Zytel฀for฀the฀irrigation฀ilter฀as฀the฀nylon฀resin฀has฀excellent฀
mechanical฀and฀burst฀strength,฀and฀outstanding฀resistance฀to฀ultra-violet฀rays,฀water฀
and฀a฀range฀of฀chemicals฀and฀fertilizers,฀even฀at฀temperatures฀of฀80°C฀in฀hot฀sum-
mer฀sunshine.฀The฀ilter฀in฀product฀literature฀is฀described฀as฀resisting฀10฀bar฀pres-
sure,฀and฀Toro/Irritrol฀says฀it฀has฀resisted฀extensive฀trials฀at฀up฀to฀24฀bar฀pressure,฀
providing฀a฀safety฀margin฀of฀more฀than฀2:1.฀Toro/Irritrol฀is฀targeting฀this฀high฀qual-
ity฀ilter฀at฀mid-level฀farmers฀worldwide.
4.4.6 Ag Pesticide Recyclable Containers
More฀than฀7.3฀million฀lb฀of฀crop฀protection/pesticide฀containers฀were฀collected฀for฀
recycle฀in฀2010.฀Thirty฀member฀companies,฀through฀the฀Ag฀Container฀Recycling฀
Council฀(ACRC),฀fund฀pesticide฀container฀recycling฀programs฀to฀collect฀the฀HDPE฀
plastic฀containers฀throughout฀the฀US.฀If฀not฀managed฀properly฀pesticide฀containers฀
can฀pose฀an฀environmental฀hazard.฀Farmers฀were฀previously฀burying฀the฀containers฀
on฀the฀farm,฀sending฀them฀to฀the฀landill,฀or฀using฀them฀improperly฀to฀store฀other฀
chemicals.฀Faced฀with฀growing฀concerns฀about฀the฀handling฀of฀the฀empty฀contain-
ers,฀farmers฀and฀pesticide฀producers฀saw฀value฀in฀proactively฀creating฀a฀system฀to฀
address฀the฀environmental฀concerns฀surrounding฀pesticide฀jugs฀and฀bottles฀before฀
the฀government฀took฀legislative฀action.
One฀of฀the฀most฀successful฀and฀innovative฀recycling฀programs฀in฀the฀country,฀the฀
ACRC฀recovers฀more฀than฀30%฀of฀the฀30+฀million฀containers฀produced฀each฀year.฀
The฀ACRC฀pays฀for฀the฀collection฀and฀recycling฀of฀used฀containers฀of฀both฀council฀
members฀ and฀ nonmembers.฀ Containers฀ must฀ be฀ triple-rinsed฀ or฀ pressure฀ washed฀
before฀being฀collected.฀The฀empty฀bottles฀are฀inspected฀when฀they฀are฀returned฀to฀
ensure฀that฀they฀are฀properly฀cleaned.฀Some฀collection฀sites฀are฀operated฀through฀
public฀agencies,฀and฀many฀are฀located฀at฀crop฀protection฀products฀dealers.฀Contractors฀
often฀ grind฀ the฀ containers฀ at฀ the฀ collection฀ site฀ for฀ easier฀ transportation.฀ Recycle฀
applications฀are฀limited฀to฀nonconsumer฀products฀that฀do฀not฀pose฀a฀signiicant฀risk฀
of฀human฀exposure฀including฀the฀inner฀core฀of฀marine฀pilings,฀and฀drainage฀pipe.
Chapter 5
Transportation End Use Applications
Keywords฀ Transportation฀•฀Automotive฀•฀Thermoplastic฀•฀Thermoset฀•฀Adhesive฀
•฀Glazing฀•฀Carbon฀iber฀•฀Aerospace฀•฀Marine฀•฀Boat
5.1 Automotive Applications
5.1.1 Plastics and Transportation
The฀transportation฀industry฀is฀the฀largest฀consumer฀of฀engineering฀plastics,฀both฀as฀
thermoplastics฀and฀as฀thermosets.฀This฀industry฀is฀also฀the฀testing฀ground฀for฀new฀
products฀and฀processes,฀and฀a฀leading฀indicator฀of฀plastics฀usage฀in฀other฀industries.฀
The฀safe฀and฀cost-effective฀transportation฀of฀people฀and฀goods฀is฀vital฀to฀the฀global฀
economy.฀ As฀ modern฀ modes฀ of฀ transportation฀ have฀ evolved฀ to฀ meet฀ increasing฀
demands฀ for฀ safety,฀ environmental฀ protection,฀ and฀ speed,฀ the฀ use฀ of฀ p฀ lastics฀ in฀
transportation฀manufacturing฀has฀grown฀considerably.฀All฀forms฀of฀transportation฀
require฀energy฀to฀operate฀and฀fuel฀represents฀a฀signiicant฀part฀of฀operating฀costs.฀
Reducing฀ vehicle฀ weight฀ be฀ it฀ cars,฀ airplanes,฀ boats,฀ or฀ trains฀ can฀ cut฀ fuel฀
consumption฀ dramatically.฀ Used฀ in฀ the฀ service฀ of฀ vehicle฀ exterior฀ parts,฀ plastics฀
are฀ durable,฀ do฀ not฀ corrode,฀ and฀ require฀ little฀ maintenance.฀ They฀ allow฀ a฀ unique฀
freedom฀of฀design฀and฀the฀parts฀are฀fast฀and฀economical฀to฀manufacture.฀In฀vehicle฀
interior฀ applications,฀ the฀ various฀ plastics฀ ittings,฀ such฀ as,฀ looring,฀ seats,฀ dash-
boards,฀ and฀ paneling฀ maintain฀ their฀ attractive฀ appearance฀ and฀ are฀ easy฀ to฀ clean.฀
Durable,฀ lightweight,฀ and฀ corrosion-resistant฀ plastics฀ offer฀ fuel฀ savings,฀ design฀
lexibility,฀and฀high฀performance฀at฀lower฀costs฀to฀designers฀facing฀today’s฀com-
plex฀transportation฀needs.

50 5฀ Transportation฀End฀Use฀Applications
5.1.2 Automotive Applications Introduction
Plastics฀play฀a฀major฀role฀in฀today’s฀vehicles.฀The฀automotive฀industry฀is฀the฀single฀
largest฀end฀user฀for฀many฀engineering฀plastics,฀such฀as฀nylons฀(PAs),฀polycarbonate฀
(PC),฀acetal฀(POM),฀or฀modiied฀polyphenylene฀ether฀(PPE).฀It฀is฀also฀an฀important฀
market฀for฀commodity฀polymers฀(e.g.,฀PP,฀PE,฀and฀PVC).฀Auto฀makers฀choose฀plastic฀
parts฀for฀their฀durability,฀corrosion฀resistance,฀toughness,฀ease฀of฀coloring฀and฀in-
ishing,฀resiliency฀and฀light฀weight.฀Automobile฀designers฀also฀discovered฀that฀plas-
tics฀solve฀one฀of฀their฀most฀complicated฀design฀problems:฀what฀to฀do฀with฀the฀fuel฀tank.฀
Using฀plastic฀gives฀them฀the฀freedom฀to฀it฀tanks฀into฀the฀overall฀concept฀rather฀than฀
designing฀around฀the฀unwieldy฀but฀essential฀part.฀More฀plastics,฀by฀volume,฀than฀steel฀
are฀now฀used฀in฀today’s฀cars฀for฀a฀myriad฀of฀components.฀At฀the฀end฀of฀a฀vehicle’s฀
working฀life,฀plastics฀components฀can฀be฀recycled฀or฀the฀energy฀can฀be฀recovered฀
through฀ incineration.฀ Plastics฀ versatility฀ aids฀ the฀ automotive฀ industry฀ in฀ meeting฀
ever฀more฀stringent฀requirements฀in฀terms฀of฀economical฀performance,฀safety,฀com-
fort,฀and฀environmental฀considerations.฀Recent฀industry฀estimates฀expect฀the฀use฀of฀
engineering฀ thermoplastics฀ in฀ exterior฀ automotive฀ applications฀ to฀ grow฀ by฀ 4.8%฀
annually฀through฀2011,฀which฀would฀equate฀to฀a฀total฀of฀more฀than฀one฀billion฀lb/
year.฀By฀2012,฀the฀igure฀is฀expected฀to฀climb฀to฀1.3฀billion฀lb.
5.1.3 Carburetor and Air Intake System Firsts
Solvay฀Advanced฀Polymers,฀LLC,฀a฀subsidiary฀of฀Solvay฀America,฀Inc.,฀produces฀
high-performance฀polymers฀that฀are฀used฀in฀a฀wide฀range฀of฀demanding฀applications฀
including฀automotive.฀Several฀recent฀automotive฀under-the-hood฀application฀devel-
opments฀ have฀ expanded฀ the฀ use฀ of฀ Solvay’s฀ high-performance฀ polyphthalamide฀
(PPA)฀in฀this฀market฀sector.
Carburetor฀expert,฀Willy฀Krup,฀developed฀a฀unique฀fuel฀pickup฀tube฀for฀use฀in฀
oval฀ track฀ racers,฀ where฀ the฀ nearly฀ constant฀ left฀ turns฀ otherwise฀ push฀ fuel฀ to฀ the฀
right฀side฀of฀a฀carburetor’s฀loat฀bowl,฀reducing฀low฀to฀the฀jets฀that฀feed฀the฀cylin-
ders฀on฀the฀left฀side฀of฀the฀engine.฀Krup฀innovated฀a฀fuel฀pickup฀tube฀that฀returns฀
this฀errant฀fuel฀to฀the฀fuel฀metering฀block,฀assuring฀constant฀low฀–฀and฀consistent฀
power฀ –฀ through฀ even฀ the฀ fastest฀ turns.฀ When฀ the฀ large฀ amounts฀ of฀ machining฀
required฀to฀make฀the฀parts฀in฀aluminum฀was฀demonstrated฀to฀be฀cost฀ineffective,฀the฀
designer฀turned฀to฀plastic฀for฀an฀affordable฀composite฀solution.฀Amodel฀AS-1133฀
HS,฀ a฀ heat฀ stabilized,฀ glass฀ reinforced฀ PPA฀ that฀ combines฀ a฀ high฀ heat฀ delection฀
temperature฀with฀high฀lexural฀modulus฀and฀high฀tensile฀strength฀proved฀to฀be฀up฀to฀
the฀task,฀when฀molded฀nylon฀failed฀to฀stand฀up฀to฀the฀heat/cool฀cycles฀and฀corrosive฀
alcohol฀fuel฀encountered฀in฀the฀race฀environment.
In฀other฀areas,฀a฀new฀coating฀designated฀IC-105,฀developed฀by฀TechLine฀Coatings,฀
Inc.฀ of฀ Murrieta,฀ CA,฀ is฀ expanding฀ the฀ window฀ of฀ opportunity฀ of฀ PPA฀ in฀ high-
temperature฀under-the-hood฀applications.฀The฀coating฀provides฀thermal฀relectivity฀
when฀applied฀to฀the฀surface฀of฀parts฀made฀of฀PPA.฀The฀company฀specializes฀in฀coatings฀
5.1฀ Automotive฀Applications 51
for฀the฀high-performance฀automotive฀market.฀The฀new฀product฀based฀on฀technology฀
used฀in฀its฀IC฀family฀of฀coatings฀for฀metals฀is฀the฀irst฀designed฀by฀Techline฀specii-
cally฀for฀application฀to฀plastic.฀In฀testing,฀PPA฀sample฀plaques฀coated฀with฀a฀thin฀
ilm฀of฀IC-105฀were฀subjected฀to฀direct฀contact฀with฀a฀heat฀source฀at฀600°F.฀After฀
extended฀exposure,฀the฀temperature฀of฀the฀plastic฀in฀the฀samples฀remained฀at฀approx-
imately฀400°F.
The฀190–200°F฀differential฀is฀signiicant฀for฀plastics฀such฀as฀polyphthalamide,฀
polyamides,฀or฀amide-imides฀that฀are฀intended฀for฀use฀in฀components฀of฀an฀auto-
mobile฀power฀train.฀While฀these฀plastics฀have฀excellent฀qualities,฀almost฀all฀begin฀
to฀lose฀their฀primary฀characteristics฀above฀500–550°F.฀Advances฀in฀engine฀technol-
ogy,฀fuel฀management,฀and฀emissions฀requirements฀continue฀to฀drive฀up฀under-the-
hood฀temperatures.฀Where฀these฀types฀of฀plastics฀were฀adequate฀a฀few฀years฀ago,฀
today฀that฀is฀no฀longer฀the฀case.฀A฀typical฀example฀is฀the฀engine’s฀air-induction฀
system฀where฀materials฀such฀as฀Amodel฀PPA฀are฀replacing฀aluminum.฀In฀contact฀
with฀ high-temperature฀ air,฀ the฀ end฀ tanks฀ surface฀ of฀ the฀ turbocharger฀ air฀ cooler฀
housing฀can฀undergo฀oxidation฀that฀can฀contaminate฀the฀turbocharger฀system.฀The฀
IC-105฀coating฀technology฀improves฀the฀window฀of฀opportunity฀for฀Amodel฀grades฀
to฀be฀used฀in฀higher-temperature฀applications,฀not฀only฀as฀a฀replacement฀for฀alumi-
num,฀ but฀ as฀ an฀ alternative฀ to฀ much฀ more฀ expensive฀ polymers฀ such฀ as฀ PEEK฀
(polyetheretherketone).
Solvay’s฀ PPA฀ has฀ also฀ been฀ speciied฀ in฀ the฀ irst฀ known฀ composite฀ automotive฀
performance฀aftermarket฀manifold.฀Amodel฀A-6135฀PPA฀was฀speciied฀for฀the฀new฀
LSX฀ air฀ intake฀ manifold฀ engineered฀ and฀ designed฀ for฀ performance฀ parts฀ provider฀
Fuel-Air-Spark฀ Technologies฀ (FAST).฀ FAST฀ wanted฀ a฀ part฀ that฀ outperformed฀ the฀
stock฀nylon฀manifold,฀but฀was฀not฀subject฀to฀the฀weight฀and฀heat฀penalties฀imposed฀
by฀an฀aluminum฀replacement.฀The฀LSX฀manifold฀will฀replace฀the฀stock฀air฀intake฀that฀
comes฀with฀the฀eight-cylinder฀engines฀in฀the฀Chevrolet฀Corvette,฀and฀Camaro฀as฀well฀
as฀Pontiac’s฀Firebird.฀Using฀A-6135,฀designers฀were฀able฀to฀increase฀airlow฀by฀25%฀
and฀make฀the฀runners฀longer฀to฀maintain฀low฀end฀torque,฀thereby฀adding฀20฀hp฀to฀the฀
360฀available฀from฀the฀V-8s฀the฀LSX฀is฀designed฀to฀it.฀Turbo฀or฀superchargers฀ele-
vate฀manifold฀pressure฀so฀material฀strength฀is฀also฀important.฀Flexural฀modulus฀of฀
the฀A-6135฀is฀at฀least฀20%฀greater฀than฀that฀of฀nylon฀6฀or฀6/6,฀and฀offers฀greater฀resis-
tance฀than฀nylon฀to฀tensile฀creep,฀which฀could฀cause฀air฀leakage฀at฀the฀manifold’s฀
gaskets.฀A-6135฀also฀has฀the฀chemical฀resistance฀required฀in฀under-the-hood฀applica-
tions฀and฀is฀more฀resistant฀than฀nylon฀to฀degradation฀from฀new฀long-life฀coolants.
5.1.4 LESA Part Adhesive Technology
Dow฀Automotive’s฀new฀LESA฀adhesive฀(Low฀Energy฀Surface฀Adhesive)฀technology฀
has฀enabled฀the฀division฀to฀introduce฀innovative฀and฀cost-effective฀construction฀of฀
front-end฀systems.฀The฀new฀approach฀addresses฀industry฀needs฀for฀improved฀quality฀
and฀performance฀while฀cutting฀costs฀and฀reducing฀weight.฀LESA฀is฀a฀two-part฀system฀
that฀cures฀at฀room฀temperature฀in฀the฀presence฀of฀oxygen฀from฀the฀air.฀Open฀time฀
after฀mixing฀can฀be฀varied฀from฀2฀to฀15฀min.฀Bonded฀assemblies฀can฀be฀handled฀
after฀a฀few฀minutes,฀though฀full฀cure฀takes฀24฀h.
The฀new฀front-end฀system฀produces฀an฀adhesively฀bonded฀two-piece฀construc-
tion฀front-end฀carrier฀that฀allows฀materials฀and฀manufacturing฀processes฀to฀be฀opti-
mized฀with฀reduced฀manufacturing฀investment.฀LESA฀can฀bond฀similar฀or฀dissimilar฀
substrates฀like฀plastic฀to฀plastic฀or฀plastic฀to฀metal฀without฀the฀need฀of฀a฀primer.฀The฀
modiied฀front-end฀carrier฀lowers฀the฀mass฀of฀metal฀and฀plastic฀to฀reduce฀cost฀while฀
LESA฀adds฀stiffness฀and฀overall฀durability฀by฀reducing฀fatigue฀and฀failure฀of฀spot฀
welds฀ and฀ other฀ traditional฀ fasteners.฀ Structural฀ noise฀ is฀ also฀ reduced฀ using฀ the฀
adhesive฀ by฀ limiting฀ vibration฀ caused฀ by฀ mechanical฀ fasteners฀ and฀ spot-weld฀
fatigue฀improvement.฀This฀new฀approach฀integrates฀advanced฀adhesive฀technology฀
with฀unique฀design฀of฀a฀plastic฀(polypropylene)฀molding฀and฀metal฀reinforcement.฀
The฀adhesive฀technology฀enables฀a฀continuous฀bond฀between฀the฀plastic฀and฀metal฀
part฀for฀added฀stiffness฀without฀pre-treatment฀of฀the฀substrates.฀The฀design฀incorpo-
rates฀a฀closed฀box฀section฀not฀possible฀with฀the฀traditional฀overmolding฀technique,฀
enabling฀maximum฀stiffness฀with฀minimum฀weight.
5.1.5 Optical Glazing
One฀of฀the฀leading฀developers฀of฀optical฀plastics฀for฀automotive฀glazing฀is฀Freeglass฀
GmbH,฀ a฀ joint฀ venture฀ between฀ glassmaker฀ Saint฀ Gobain฀ and฀ plastics฀ processor฀
Schefenacker,฀a฀specialist฀in฀exterior฀mirrors฀and฀lighting.฀In฀addition฀to฀the฀rear฀
sidelites฀for฀DaimlerChrysler’s฀Smart฀Fortwo฀coupe฀and฀Smart฀roadster,฀the฀busi-
ness฀ is฀ also฀ producing฀ four฀ polycarbonate฀ glazing฀ components,฀ including฀ a฀ 1฀ m2
sunroof฀for฀the฀4-door฀Smart฀Forfour฀sedan.
Freeglass฀ has฀ invested฀ in฀ Krauss-Maffei฀ swivel฀ platen฀ machines฀ for฀ multi-
component฀injection฀molding.฀The฀Krauss-Maffei฀expansion฀compression฀molding฀
process,฀ combined฀ with฀ swivel฀ platen฀ technology,฀ makes฀ it฀ possible฀ to฀ produce฀
large฀area฀parts฀virtually฀free฀of฀internal฀stresses.฀Post฀mold,฀the฀surface฀of฀the฀PC฀
parts฀are฀coated฀for฀ultraviolet฀and฀scratch฀protection.฀The฀plastic฀sunroof฀module฀is฀
7฀ lbs฀ lighter฀ than฀ an฀ equivalent฀ glass฀ module฀ when฀ the฀ frame฀ is฀ integrated.฀ This฀
weight฀reduction฀lowers฀the฀vehicle’s฀center฀of฀gravity,฀helping฀to฀improve฀driving฀
characteristics.฀ The฀ technology฀ also฀ opens฀ the฀ opportunity฀ for฀ innovative฀ design฀
and฀the฀integration฀of฀various฀functional฀elements฀such฀as฀lighting฀systems.
5.1.6 Class A Roof Appliques
Roof฀appliqués฀are฀being฀molded฀from฀DuPont฀Rynite฀PET฀thermoplastic฀polyester฀
resin฀for฀the฀Saturn฀VUE฀sports฀utility฀vehicle.฀The฀appliqués฀long฀curved฀exterior฀
parts฀are฀attached฀to฀the฀metal฀space฀frame฀above฀doors฀and฀behind฀rear฀side฀windows.฀
While฀providing฀a฀inished฀look,฀they฀also฀help฀channel฀rainwater฀away฀and฀provide฀
a฀rigid,฀smooth฀sealing฀surface฀for฀door฀edge฀weather฀stripping.
Saturn฀speciications฀for฀the฀appliqué฀call฀for฀a฀Class฀A฀inish฀A,฀a฀demanding฀
surface฀quality฀speciication฀for฀parts฀that฀are฀to฀be฀subsequently฀painted.฀The฀painted฀
Rynite฀gives฀the฀gloss฀required฀to฀match฀the฀other฀exterior฀surfaces฀of฀the฀vehicle฀at฀
signiicantly฀ lower฀ cost฀ than฀ the฀ alternatives.฀ SMC฀ or฀ metal฀ parts฀ would฀ require฀
extensive฀inishing฀steps฀prior฀to฀part฀painting,฀while฀Saturn’s฀Rynite฀PET฀appliqués฀
require฀only฀minimal฀surface฀preparation.฀The฀material฀with฀its฀dimensional฀stability,฀
low฀ coeficient฀ of฀ linear฀ thermal฀ expansion฀ and฀ warp฀ resistance฀ also฀ meets฀ the฀
consistent฀it฀requirement.฀The฀appliqués,฀which฀are฀subject฀to฀high฀thermal฀load฀in฀
sunlight,฀resist฀heat-related฀expansion฀and฀warping.฀Atmospheric฀humidity฀also฀has฀
no฀effect฀on฀the฀dimensions,฀strength,฀and฀toughness฀of฀the฀material.฀Rynite฀RE5309,฀
which฀ contains฀ glass฀ iber฀ and฀ mineral฀ reinforcements,฀ has฀ excellent฀ stiffness,฀ a฀
crucial฀ factor฀ to฀ assure฀ irm฀ door฀ sealing.฀ Molded-in฀ screw฀ holes฀ in฀ the฀ appliqué฀
eliminate฀the฀need฀for฀drilling฀and฀allow฀precision฀itting฀to฀the฀space฀frame.
5.1.7 Carbon Fiber Concept Cars
Carbon฀iber฀is฀appearing฀on฀concept฀cars฀at฀both฀ends฀of฀the฀market.฀While฀the฀$15/lb฀
price฀of฀carbon฀iber฀versus฀a฀market฀requirement฀of฀$5/lb฀limits฀wide฀acceptance,฀
its฀high฀strength,฀low฀weight,฀and฀prestige฀make฀the฀material฀attractive.฀In฀terms฀of฀
prestige,฀at฀the฀high฀end฀of฀the฀market,฀Chrysler’s฀concept฀ME฀Four-Twelve฀sports฀
car,฀which฀if฀produced฀would฀sell฀for฀over฀$100,000,฀has฀a฀carbon฀iber/aluminum฀
body,฀and฀carbon฀iber฀is฀also฀used฀for฀the฀seat฀structure฀frame.฀At฀the฀other฀end฀of฀
the฀market,฀Chrysler฀is฀looking฀at฀the฀material’s฀lightweight฀to฀squeeze฀more฀than฀
45฀mpg฀in฀fuel฀usage฀from฀its฀Slingshot฀concept฀vehicle,฀a฀small฀city฀car฀based฀on฀
the฀European฀Smart฀roadster.฀For฀now,฀however,฀the฀composite’s฀high฀cost฀will฀not฀
permit฀its฀use฀in฀a฀vehicle฀intended฀to฀sell฀for฀under฀$20,000.
While฀few฀concept฀cars฀may฀be฀commercially฀produced฀with฀carbon฀iber,฀its฀use฀
concept฀ applications฀ shows฀ there฀ is฀ growing฀ interest฀ in฀ the฀ material.฀ Many฀ from฀
composite฀experts,฀to฀universities฀and฀automakers฀are฀studying฀ways฀to฀make฀the฀
material฀more฀economical.฀Though฀the฀raw฀material฀cost฀is฀dropping,฀there฀is฀as฀yet฀
no฀ way฀ to฀ mold฀ carbon฀ iber฀ in฀ high฀ enough฀ volumes฀ to฀ production฀ costs.฀ Auto฀
companies฀are฀currently฀making฀limited฀use฀of฀the฀material฀strategically฀placing฀it฀
where฀it฀is฀needed.฀Meanwhile,฀companies฀like฀Meridian฀Automotive฀Systems,฀a฀
key฀North฀American฀producer฀of฀sheet฀molded฀composites฀(SMC),฀are฀working฀to฀
lower฀the฀composite’s฀cost.
5.1.8 Metal/Plastic Antenna Modules
A฀top฀of฀the฀line฀car฀is฀now฀equipped฀with฀an฀average฀of฀ten฀antennae,฀and฀that฀
number฀is฀expected฀to฀soon฀increase฀to฀as฀many฀as฀16฀as฀car฀manufacturers฀intro-
duce฀ systems฀ for฀ monitoring฀ and฀ automatically฀ regulating฀ the฀ distance฀ from฀ the฀
vehicle฀ in฀ front,฀ and฀ install฀ warning฀ sensors฀ to฀ avoid฀ collisions฀ when฀ reversing.฀
These฀ numerous฀ antennae฀ have฀ been฀ generally฀ spread฀ over฀ the฀ entire฀ bodyshell,฀
presenting฀a฀challenge฀to฀designers฀who฀have฀to฀guarantee฀optimum฀reception.
A฀ new฀ antenna฀ module฀ developed฀ as฀ a฀ joint฀ project฀ by฀ Johnson฀ Controls฀ and฀
Volvo฀demonstrates฀a฀way฀round฀the฀problem.฀The฀module฀accommodates฀all฀the฀
antennae฀ and฀ relevant฀ receivers฀ (radio,฀ TV,฀ GPS)฀ in฀ one฀ unit.฀ Made฀ of฀ steel฀ and฀
Durethan฀BM฀130฀H2.0฀polyamide฀supplied฀by฀Bayer฀MaterialScience,฀it฀is฀manu-
factured฀using฀the฀plastic/metal฀hybrid฀technology฀already฀established฀for฀produc-
tion฀of฀vehicle฀front-ends.
The฀1.8-kg฀antenna฀module฀is฀located฀under฀a฀plastic฀cover฀on฀the฀rear฀roof฀of฀
the฀VOLVO฀XC90฀SUV.฀The฀antennae฀are฀integrated฀into฀a฀ilm฀that฀forms฀part฀of฀
the฀ plastic฀ cover.฀ The฀ various฀ ixing฀ elements฀ and฀ backing฀ for฀ the฀ ilm,฀ which฀
extends฀across฀the฀width฀of฀the฀vehicle,฀are฀also฀made฀of฀polyamide.฀The฀receivers,฀
such฀ as฀ the฀ FM/AM,฀ Digital฀ Audio฀ Broadcasting฀ (DAB),฀ and฀ TV฀ tuners,฀ are฀
screwed฀to฀the฀metal฀support฀of฀the฀hybrid฀construction฀obviating฀the฀need฀for฀a฀
large฀number฀of฀cables.
5.1.9 High-Value Oil Valve Covers
North฀America’s฀irst฀high-volume฀thermoplastic฀valve฀cover฀was฀introduced฀on฀the฀
Chrysler฀Town฀&฀Country,฀Dodge฀Caravan฀and฀Grand฀Caravan฀with฀3.3฀and฀3.8฀L฀V6฀
engines.฀ The฀ valve฀ cover,฀ manufactured฀ by฀ Bruss฀ Sealing฀ Systems฀ from฀ DuPont฀
Minlon฀mineral฀reinforced฀nylon,฀reduces฀weight฀by฀more฀than฀65%฀and฀cuts฀cost฀
signiicantly฀compared฀to฀metal.฀The฀innovative฀thermoplastic฀valve฀cover฀also฀has฀
an฀integrated฀air/oil฀separator,฀which฀signiicantly฀reduces฀the฀amount฀of฀oil฀pulled฀
into฀the฀engine฀and฀an฀integrated฀positive฀crankcase฀ventilation฀(PCV)฀valve฀housing,฀
which฀helps฀reduce฀evaporative฀emissions฀to฀reduce฀environmental฀implications.
A฀Chrysler,฀Bruss,฀and฀DuPont฀Engineering฀Polymers฀team฀ensured฀this฀program฀
went฀ from฀ CAD฀ drawing฀ to฀ commercial฀ launch฀ in฀ less฀ than฀ 22฀ weeks฀ ensuring฀
introduction฀for฀the฀current฀vehicle฀model฀year.฀The฀valve฀cover฀is฀made฀of฀glass/
mineral฀ reinforced฀ Minlon฀ that฀ has฀ a฀ balance฀ of฀ stiffness,฀ strength,฀ dimensional฀
stability,฀and฀warpage฀resistance.฀The฀switch฀from฀metal฀to฀thermoplastic฀฀eliminated฀
costly฀e-coating฀and฀several฀secondary฀machining฀steps.฀Runners฀and฀scrap฀from฀the฀
injection฀molding฀manufacturing฀process฀are฀melt฀recycled.
Demand฀for฀long฀iber฀reinforced฀thermoplastic฀(LFT)฀composites฀in฀automotive฀
applications฀is฀continuing฀to฀grow,฀particularly฀in฀Europe.฀Unlike฀conventional฀short฀
iber฀reinforced฀materials,฀the฀longer฀ibers฀in฀molded฀parts฀mechanically฀interact฀
with฀each฀other฀to฀form฀an฀internal฀glass฀iber฀skeleton฀that฀limits฀anisotropic฀shrinkage฀
and฀greatly฀reduces฀warpage.฀The฀composite฀materials฀with฀high฀stiffness฀and฀low฀
weight฀are฀excellent฀metal฀replacements.฀ The฀high฀level฀of฀long฀glass฀ibers฀also฀
gives฀them฀metal-like฀coeficients฀of฀expansion.฀A฀nylon฀base฀material฀illed฀with฀
50%฀glass฀iber฀has฀excellent฀resistance฀to฀automotive฀luids฀and฀can฀tolerate฀the฀
high-temperature฀exposures฀of฀this฀application.
SABIC฀produces฀Stamax฀P฀polypropylene฀LFT,฀a฀material฀with฀good฀thermal/
mechanical฀ properties฀ suitable฀ for฀ semistructural฀ applications.฀ It฀ is฀ used฀ to฀ mold฀
front-end฀ modules฀ on฀ the฀ Porsche฀ Cayenne,฀ VW฀ Touareg,฀ and฀ Mini฀ Cooper.฀
Meanwhile,฀ LNP฀ Engineering฀ Plastics’฀ Verton฀ MFX,฀ a฀ 40%฀ LFT฀ PP฀ is฀ used฀ to฀
injection฀mold฀Mazda฀6฀front฀end฀and฀door฀modules.
Ticona’s฀Celstran฀30%฀LFT฀is฀used฀to฀produce฀door฀modules฀and฀a฀50%฀illed฀
nylon฀6/6฀Celstran฀is฀used฀in฀the฀grille฀opening฀retainer฀(GOR)฀of฀the฀Jaguar฀XJ.฀
DuPont฀Rynite฀PET฀polyester฀resin฀is฀used฀to฀mold฀a฀GOR฀for฀the฀Lincoln฀Navigator฀
and฀Ford฀Expedition.฀The฀material’s฀high฀resistance฀to฀heat฀sag฀allows฀it฀to฀with-
stand฀Ford’s฀e-coating฀curing฀process.฀Front฀end฀carriers฀of฀40%฀glass฀iber/PP฀are฀
produced฀by฀the฀Faurecia฀Group฀in฀France.฀These฀components฀are฀produced฀with฀a฀
Krauss-Maffei฀ IMC฀ machine,฀ which฀ compounds฀ the฀ formulation฀ on฀ a฀ twinscrew฀
extruder฀yoked฀to฀an฀injection฀molding฀machine.
5.1.10 Composite Front Hood
General฀ Motors฀ Chevrolet฀ Corvette฀ Z06฀ Commemorative฀ Edition฀ features฀ a฀ new฀

engine฀hood฀using฀carbon฀iber฀material.฀The฀carbon฀iber฀hood฀represents฀the฀irst฀
time฀this฀advanced฀material฀has฀been฀used฀as฀original฀equipment฀for฀a฀painted฀exterior฀
panel฀ on฀ a฀ North฀ American-production฀ vehicle.฀ The฀ lightweight,฀ race-inspired฀
฀carbon฀iber฀hood฀weighs฀just฀20.5฀pounds,฀10.6฀less฀than฀the฀standard฀hood,฀providing฀
another฀measure฀of฀weight฀savings฀for฀a฀car฀that฀already฀enjoys฀a฀very฀potent฀power-
to-weight฀ratio.฀Previously฀reserved฀for฀racing฀and฀exotic฀sports฀cars,฀carbon฀iber฀
combines฀extremely฀high฀strength฀and฀low฀weight.฀On฀most฀carbon฀iber฀parts,฀the฀
woven฀pattern฀of฀the฀material฀is฀easily฀seen฀beneath฀the฀exterior฀inish.฀To฀diminish฀
that฀effect฀and฀the฀carbon฀ibers฀are฀aligned฀in฀a฀single฀direction.฀The฀overall฀result฀
is฀a฀inish฀consistent฀with฀the฀rest฀of฀the฀car฀that฀gives฀just฀a฀slight฀hint฀at฀the฀carbon฀
iber฀construction.
The฀inside฀hood฀panel฀is฀a฀hybrid฀of฀carbon฀iber฀and฀Sheet฀Molded฀Compound฀
(SMC).฀ The฀ Class฀ A฀ outer฀ skin฀ supplied฀ by฀ Toray฀ Composites฀ (America),฀ Inc.,฀
Tacoma,฀ WA,฀ is฀ a฀ carbon฀ iber/epoxy฀ unidirectional฀ prepreg,฀ 1.2฀ mm฀ (vs.฀ SMC฀
2–2.5฀ mm)฀ thick,฀ comparable฀ to฀ stamped฀ metal฀ sheet฀ and฀ is฀ the฀ thinnest฀ plastic฀
composite฀skin฀on฀a฀production฀vehicle.฀The฀hood฀outer฀panel฀is฀molded฀and฀cured฀
in฀an฀autoclave฀similar฀to฀typical฀aerospace฀composites.฀However,฀aerospace฀auto-
clave฀cycles฀often฀take฀20฀h฀whereas฀this฀Toray฀formulated฀prepreg฀cures฀completely฀
in฀10฀min฀at฀300°F.
5.1.11 Ford’s GloCar
Ford฀Motor฀Co.฀is฀taking฀a฀lighter฀approach฀to฀design฀with฀its฀GloCar฀concept.฀The฀
car฀uses฀light฀emitting฀diodes฀to฀change฀body฀panel฀color,฀and฀brightness฀in฀response฀
to฀safety฀conditions฀and฀driver’s฀whim.฀Launched฀last฀year,฀the฀concept฀car฀is฀on฀
display฀ at฀ the฀ Cooper-Hewitt,฀ National฀ Design฀ Museum฀ as฀ part฀ of฀ its฀ exhibit฀
‘National฀ Design฀ Triennial:฀ Inside฀ Design฀ Now.’฀ The฀ customizable฀ GloCar฀ was฀
designed฀to฀be฀safe,฀fun,฀and฀evoke฀emotion.฀Illuminated฀by฀translucent฀body฀panels฀
and฀LED฀lights,฀the฀soft฀glowing฀vehicle฀offers฀enhanced฀visibility.฀An฀additional฀
safety฀feature฀stems฀from฀the฀fact฀that฀the฀car฀can฀be฀seen฀from฀all฀angles,฀not฀just฀
headlights฀and฀taillights,฀making฀it฀very฀visible฀at฀night.฀The฀rear฀panel฀doubles฀as฀a฀
brake฀light,฀and฀the฀side฀panels฀as฀blinkers.฀When฀somebody฀comes฀too฀close,฀the฀
panels฀increase฀in฀intensity,฀signaling฀the฀driver฀to฀keep฀a฀distance.
The฀GloCar฀lighting฀combined฀with฀injection฀molding฀can฀potentially฀eliminate฀
the฀ need฀ for฀ vehicle฀ paint,฀ reducing฀ manufacturing฀ complexity.฀ The฀ concept฀ car฀
projects฀an฀image฀of฀concern,฀safety,฀intelligence,฀and฀lightness.฀Built฀as฀a฀design฀
exercise฀it฀focuses฀on฀the฀prospective฀needs฀of฀drivers฀and฀shows฀a฀future฀where฀cars฀
are฀more฀optimistic฀and฀intelligent.฀The฀vehicle,฀powered฀by฀fuel฀cell฀technology,฀is฀
built฀ around฀ a฀ lightweight฀ aluminum฀ space฀ frame฀ with฀ aluminum฀ extrusions฀ and฀
castings.฀There฀are฀no฀plans฀to฀produce฀the฀car.
5.2 Aerospace Applications
5.2.1 Aerospace Applications Introduction
During฀the฀past฀50฀years,฀aeronautics฀technology฀has฀soared,฀with฀plastics฀playing฀a฀
major฀ role฀ in฀ aircraft,฀ missile,฀ satellite,฀ and฀ shuttle฀ development฀ for฀ civilian฀ air฀
travel,฀military฀air฀power,฀and฀space฀exploration.฀Plastic฀materials฀can฀be฀lexible฀
enough฀ to฀ withstand฀ helicopter฀ vibration฀ but฀ rigid฀ enough฀ to฀ ensure฀ safe฀ cargo.฀
They฀ can฀ be฀ transparent฀ for฀ easy฀ observation,฀ shatter฀ resistant฀ and฀ offer฀ ballistic฀
protection,฀ and,฀ most฀ signiicantly,฀ they฀ can฀ be฀ both฀ lightweight฀ and฀ strong.฀
Aerodynamic฀requirements฀of฀aerospace฀products฀demand฀maximum฀design฀lexi-
bility฀ and฀ minimal฀ weight.฀ Plastics฀ can฀ be฀ formulated฀ to฀ meet฀ a฀ wide฀ variety฀ of฀
speciications฀and฀are฀ideal฀for฀components฀incorporating฀smooth฀curves.฀Composites฀
are฀widely฀used฀in฀the฀panels฀of฀military฀jets฀and฀helicopters฀as฀well฀as฀for฀wing฀
skins,฀nacelles,฀fairings,฀laps฀and฀helicopter฀rotor-blades฀in฀commercial฀applications.฀
Plastics฀are฀also฀found฀throughout฀aircraft฀interiors฀in฀bulkheads,฀galleys,฀stair฀units,฀
seating,฀and฀looring.
5.2.2 Unmanned Aerial Vehicles
As฀in฀conventional฀aircraft,฀minimizing฀weight฀is฀important฀in฀the฀new฀unmanned฀
air฀vehicles฀(UAVs).฀Some,฀such฀as฀Northrop฀Grumman’s฀Global฀Hawk,฀are฀designed฀
for฀prolonged฀lights฀at฀high฀altitude.฀Cruising฀at฀extremely฀high฀altitudes,฀Global฀
5.2฀ Aerospace฀Applications 57
Hawk฀can฀survey฀large฀geographic฀areas฀with฀pinpoint฀accuracy,฀to฀give฀military฀
decision-makers฀the฀most฀current฀information฀about฀enemy฀location,฀resources,฀and฀
personnel.฀Although฀Global฀Hawk’s฀fuselage฀is฀aluminum,฀most฀of฀its฀other฀structures,฀
including฀certain฀fuselage฀components,฀are฀composite.฀Low฀airframe฀weight฀means฀
that฀half฀the฀25,600฀lb฀maximum฀takeoff฀weight฀is฀fuel,฀providing฀34฀h฀of฀light.฀The฀
UAV’s฀wing,฀longer฀than฀that฀of฀a฀Boeing฀737,฀comprises฀four฀I-beam฀spars฀and฀
prepreg฀face฀sheets,฀with฀carbon/epoxy฀spars฀and฀envelope฀bonded฀together.฀Leading฀
and฀trailing฀wing฀edges฀are฀Nomex฀aramid฀honeycomb฀cored฀sandwich฀laminates.
5.2.3 A380 Composite Floor Panels
M.C.฀ Gill฀ Corp฀ delivered฀ to฀ aircraft฀ manufacturer฀ Airbus฀ Industrie฀ in฀ Toulouse,฀
France,฀the฀irst฀set฀of฀a฀new฀type฀of฀composite฀high-performance฀loor฀panels฀for฀
the฀A380฀cockpit฀and฀two฀electronic฀equipment฀bays.฀The฀complete฀set฀consists฀of฀
67฀parts฀fabricated฀from฀Gillfab฀5509฀panels,฀which฀were฀speciically฀designed฀for฀
this฀application.฀These฀high-performance฀composite฀products฀are฀low฀smoke฀฀aircraft฀
sandwich฀panels฀of฀a฀Kevlar฀honeycomb฀core,฀with฀facings฀made฀of฀phenolic฀resin฀
reinforced฀ with฀ cross-plied฀ unidirectional฀ carbon฀ and฀ a฀ thin฀ iberglass฀ overlay฀ to฀
protect฀against฀galvanic฀corrosion.
The฀raw฀stock฀panels฀were฀developed฀and฀manufactured฀at฀the฀M.C.฀Gill฀Corporation฀
headquarters฀facility฀in฀El฀Monte,฀CA,฀then฀detailed฀at฀the฀M.C.฀Gill฀Europe฀plant,฀
which฀has฀extensive฀knowledge฀and฀expertise฀in฀detailing฀complex฀loor฀panels฀for฀a฀
range฀ of฀ aircraft฀ and฀ customers.฀ Detailing฀ activities฀ included฀ drilling,฀ machining,฀
folding,฀ and฀ fabricating฀ the฀ panels฀ into฀ precise฀ conigurations฀ to฀ meet฀ engineering฀
speciications.฀The฀equipment฀bay฀panels฀were฀treated฀with฀a฀non-slip฀surface.
5.2.4 Ultra Lightweight Global Flyer
Virgin฀Atlantic฀has฀unveiled฀the฀GlobalFlyer฀V.฀The฀pioneering฀aircraft,฀said฀to฀be฀the฀
world’s฀most฀eficient฀jet฀plane,฀achieved฀the฀irst฀solo,฀non-stop฀around฀the฀world฀
light.฀If฀successful,฀the฀aircraft฀will฀complete฀the฀80฀h฀voyage฀on฀one฀tank฀of฀fuel.฀
Virgin฀Atlantic฀is฀the฀sponsor฀the฀38.7฀foot฀long,฀single฀engine฀jet,฀with฀a฀114-foot฀
wingspan.฀Scaled฀Composites฀spent฀more฀than฀4฀years฀designing฀and฀building฀the฀
aircraft.฀The฀company฀used฀computer฀aided฀aerodynamic฀studies฀and฀built฀the฀struc-
ture฀entirely฀from฀ultra-light฀carbon,฀Kevlar,฀glass,฀and฀a฀combination฀of฀฀reinforced฀
epoxy฀and฀polyester฀composite฀materials.
On฀ takeoff,฀ the฀ plane฀ will฀ weigh฀ 22,000฀ lbs,฀ with฀ over฀ 84%฀ of฀ that฀ weight฀
being฀fuel฀and฀less฀than฀80฀h฀and฀23,000฀miles฀later,฀it฀will฀have฀shed฀18,000฀lbs฀
to฀ land฀ at฀ its฀ dry฀ weight฀ of฀ a฀ little฀ under฀ 4000฀ lbs.฀ The฀ GlobalFlyer’s฀ 3-body฀
฀coniguration฀ (twin-boom฀ fuselage,฀ and฀ seven฀ foot฀ cockpit฀ pod)฀ spreads฀ the฀
฀aircraft’s฀ weight฀ across฀ the฀ wing฀ reducing฀ the฀ peak฀ bending฀ load฀ and฀ aircraft฀
weight.฀The฀light฀will฀take฀off฀from฀the฀US,฀in฀early฀2005,฀lying฀at฀45,000฀ft฀and฀
traveling฀ 21,300฀ miles฀ (with฀ jet฀ stream)฀ at฀ speeds฀ in฀ excess฀ of฀ 985฀ mph.฀ On฀
฀completion฀of฀the฀trip,฀GlobalFlyer฀will฀have฀traveled฀75%฀further฀than฀the฀range฀
record฀set฀for฀jet฀powered฀planes.
5.2.5 Mars Tested Circuit Materials
Since฀the฀start฀of฀manned฀space฀light,฀DuPont฀has฀been฀providing฀high฀tech฀materials,฀
essential฀ for฀ lighter฀ weight,฀ reduced฀ volume,฀ durability,฀ and฀ environmental฀ resis-
tance.฀ Dupont฀ Electronic฀ Technologies฀ have฀ a฀ broad฀ range฀ of฀ advanced฀ circuit฀
materials,฀many฀Mars฀tested฀on฀the฀recent฀rovers,฀Spirit฀and฀Opportunity.
Seventy฀yards฀of฀lexible฀cable฀circuits฀made฀of฀thin฀DuPont฀Pyralux฀laminates/
composites฀replaced฀bulky฀round฀cables฀to฀save฀60–70%฀volume฀in฀each฀Mars฀rover.฀
The฀ Pyralux฀ lexible฀ circuits฀ connected฀ each฀ rover฀ ‘brain’฀ to฀ their฀ robotic฀ arm,฀
฀cameras,฀high฀gain฀antenna,฀wheels,฀and฀sensors.฀Pressure฀sensitive฀tape฀made฀from฀
DuPont฀Kapton฀polyimide฀ilm฀was฀used฀throughout฀to฀control฀vibration.฀Pyralux฀
lexible฀cables฀secured฀with฀Kapton฀tape฀offered฀durable,฀lightweight฀environmental฀
resistance฀ at฀ Mars฀ temperatures฀ of฀ –120°C฀ to฀ 22°C.฀ Hundreds฀ of฀ Kapton฀ strip฀
฀heaters฀were฀used฀to฀maintain฀minimum฀temperatures฀in฀the฀extremely฀cold฀martian฀
atmosphere฀and฀allow฀the฀rovers฀to฀use฀smaller฀solar฀panels฀and฀batteries.฀Kapton฀
ilm฀worked฀with฀layers฀of฀DuPont฀Telon฀luoropolymer฀resin฀and฀Pyralux฀lexible฀
cables฀ to฀ provide฀ power฀ from฀ the฀ Rover฀ electronics฀ module฀ to฀ hardware฀ compo-
nents.฀The฀lexible฀joints฀of฀the฀robotic฀arm,฀which฀had฀to฀withstand฀repeated฀bending฀
in฀extreme฀environments,฀used฀Kapton฀and฀Pyralux.฀Kapton฀strip฀heaters฀were฀also฀
wrapped฀ around฀ motors฀ on฀ the฀ robotic฀ arm฀ to฀ keep฀ them฀ running฀ at฀ optimum฀
฀temperature฀ and฀ eficiency.฀ Metallized฀ Kapton฀ was฀ used฀ in฀ thermal฀ shielding฀ for฀
heat-sensitive฀components.฀The฀airbags฀used฀for฀the฀rovers฀landings฀were฀threaded฀
and฀reinforced฀with฀DuPont฀Kevlar฀iber.
5.2.6 Robotic Jet Bombers
The฀same฀plastic฀foam฀technology฀designed฀for฀manufacturing฀surfboards฀is฀being฀
applied฀to฀the฀structural฀core฀material฀for฀wings฀of฀the฀X-45A฀unmanned฀combat฀
aerial฀vehicle฀(UCAV).฀Central฀to฀the฀Foam฀Matrix’฀technology฀is฀a฀unique,฀฀patented฀
process฀for฀producing฀net฀molded฀structures฀without฀the฀need฀for฀multi-piece฀assemblies.฀
Foam฀Matrix’฀highly฀integrated฀structures฀replace฀the฀large฀number฀of฀individual฀
parts฀used฀in฀‘traditional’฀aircraft฀manufacturing฀with฀a฀single฀component฀that฀satisies฀
the฀ requirements.฀ Using฀ the฀ irm’s฀ ‘Foam฀ Matrix฀ Core’฀ (FMC)฀ system฀ for฀ the฀
X-45A,฀the฀ribs,฀stringers,฀electrical฀conduit.฀and฀other฀wing฀parts฀are฀machined฀into฀
a฀single฀mold฀tool.฀The฀entire฀wing฀is฀molded฀as฀a฀one-piece฀foam฀core.฀On฀curing,฀
the฀foam฀core฀is฀wrapped฀in฀composite฀ibers฀and฀returned฀to฀the฀FMC฀mold฀tool฀for฀
resin฀injection฀and฀inal฀cure.
5.2฀ Aerospace฀Applications 59
The฀FMC฀system฀reduces฀parts฀count,฀provides฀seamless฀construction,฀reproduc-
ibility,฀shorter฀production฀cycle฀time.฀and฀lower฀cost.฀Use฀of฀the฀foam฀also฀eliminates฀
structure฀ hollow฀ cavities,฀ improves฀ damage฀ resistance฀ in฀ handling/assembly,฀ and฀
reduces฀the฀possibility฀of฀delamination.฀As฀the฀skins฀are฀backed฀by฀the฀foam,฀ield฀
repairs฀are฀easier.฀Boeing฀found฀the฀high-strength฀lightweight฀concept฀provided฀an฀
attractive฀alternative฀to฀conventional฀wing฀designs.฀Phantom฀Works,฀Boeing’s฀R&D฀
unit,฀ has฀ built฀ several฀ X-45A฀ UCAVs฀ under฀ a฀ $191฀ million฀ agreement฀ with฀ the฀
Defense฀Advanced฀Research฀Projects฀Agency฀and฀the฀US฀Air฀Force.฀The฀wings฀are฀
designed฀ to฀ be฀ removed฀ from฀ the฀ fuselage,฀ and฀ the฀ disassembled฀ aircraft฀ can฀ be฀
stored฀for฀up฀to฀10฀years.
5.2.7 Parachute Safe Air Transport
Eclipse฀Aviation’s฀new฀six-seater฀air฀taxis฀may฀boast฀a฀safety฀feature฀no฀jetliner฀can฀
match:฀a฀parachute฀large฀enough฀to฀loat฀the฀plane฀to฀the฀ground฀in฀the฀event฀of฀an฀
in-air฀emergency.฀Eclipse฀is฀creating฀the฀six-seater฀low฀cost/luxury฀air฀taxis฀to฀trans-
form฀ business฀ travel.฀ Ballistic฀ Recovery฀ Systems฀ (BRS)฀ has฀ a฀ $600,000฀ SBIR฀
(Small฀Business฀Innovative฀Research)฀award฀from฀NASA฀to฀develop฀a฀parachute฀for฀
six-seat฀jet฀air฀taxis.
Originally฀designed฀for฀lighter฀weight฀ultralights฀and฀experimental฀aircraft,฀BRS฀
has฀achieved฀the฀technological฀ability฀to฀develop฀parachute฀systems฀for฀conventional฀
aircraft.฀The฀jet฀taxi฀parachute฀will฀be฀a฀scaled฀up฀version฀of฀the฀chute฀BRS฀already฀
supplies฀to฀Cirrus฀Design฀for฀its฀four-seater฀propeller฀planes.฀BRS’฀unique฀proprie-
tary฀emergency฀ballistic฀parachute฀system฀is฀deployed฀with฀a฀solid฀fuel฀rocket฀motor.฀
The฀system,฀which฀makes฀use฀of฀extremely฀lightweight฀nylon/polyester฀fabric฀and฀
components,฀ is฀ pressure฀ packed฀ under฀ 40,000฀ pounds฀ of฀ pressure.฀ The฀ resulting฀
package฀can฀weigh฀as฀little฀as฀15฀pounds฀(ultralight),฀45฀pounds฀(Cessna฀150),฀or฀
67฀pounds฀(Cessna฀172).฀Chute฀system฀attaches฀to฀the฀airframe฀at฀three฀locations,฀
two฀at฀the฀leading฀edge฀where฀the฀leading฀edge฀meets฀the฀fuselage฀and฀one฀aft฀of฀the฀
baggage฀area.฀Cost฀of฀a฀typical฀system฀is฀generally฀5–10%฀of฀the฀value฀of฀the฀aircraft.฀
Avemco,฀the฀leading฀aviation฀insurance฀underwriter,฀grants฀a฀discount฀on฀insurance฀
premiums฀for฀those฀pilots฀choosing฀to฀ly฀with฀the฀BRS฀system.
5.2.8 7E7 Dreamliner Composites
Boeing฀is฀introducing฀a฀series฀of฀innovative฀features฀with฀its฀new฀7E7฀‘Dreamliner’฀
airplane,฀from฀initial฀concept฀and฀name฀to฀design,฀interiors,฀materials฀of฀construction,฀
and฀ inal฀ assembly฀ processes.฀ The฀ plane,฀ recently฀ introduced฀ to฀ customers,฀ is฀
expected฀to฀be฀available฀for฀service฀in฀2008.฀The฀new฀super฀eficient฀jetliner฀will฀be฀
the฀irst฀commercial฀jetliner฀to฀have฀the฀majority฀of฀its฀primary฀structure,฀including฀
wing฀and฀fuselage,฀to฀be฀made฀of฀composites฀rather฀than฀aluminum.฀The฀redesigned฀
interior฀will฀feature฀dynamic฀lighting,฀larger฀lavatories,฀more฀spacious฀luggage฀bins,฀
and฀electronic฀window฀shades฀with฀adjustable฀transparency.
The฀ company฀ conducted฀ extensive฀ analysis฀ before฀ choosing,฀ a฀ carbon/epoxy฀
composite฀for฀the฀primary฀structure฀and฀a฀titanium/graphite฀composite฀for฀the฀wings.฀
Composites฀offered฀numerous฀advantages฀including฀better฀durability,฀reduced฀main-
tenance฀ requirements,฀ and฀ increased฀ potential฀ for฀ future฀ developments.฀ Boeing฀
believes฀the฀choice฀will฀help฀them฀to฀take฀advantage฀of฀the฀most฀modern฀materials฀
technologies฀as฀it฀starts฀into฀the฀second฀century฀of฀light.฀Toray฀Industries’฀Torayca฀
prepreg฀ composites฀ will฀ be฀ used฀ in฀ the฀ primary฀ structural฀ areas.฀ This฀ material,฀ a฀
combination฀of฀high-strength฀carbon฀iber฀and฀toughened฀epoxy฀resin,฀has฀been฀used฀
on฀the฀Boeing฀777฀in฀structural฀applications฀such฀as฀the฀empennage฀and฀loor฀beams.฀
Projected฀to฀be฀20%฀more฀fuel฀eficient฀than฀current฀jets,฀the฀7E7฀and฀7E7฀Stretch฀
will฀carry฀200–250฀passengers฀on฀routes฀of฀up฀to฀6,600–8,000฀nautical฀miles.
5.3 Marine and Boat Applications
5.3.1 Marine and Boat Applications Introduction
Because฀they฀provide฀superior฀weight฀to฀strength฀ratios฀and฀resist฀weather฀and฀salt-
water฀much฀better฀than฀metal฀or฀wood,฀plastics฀have฀found฀numerous฀applications฀
in฀ the฀ marine฀ industry.฀ The฀ real฀ plastics฀ revolution฀ in฀ boatbuilding฀ began฀ in฀ the฀
1940s,฀when฀iberglass฀hulls฀made฀their฀debut.฀Boats฀were฀sleeker,฀better฀looking,฀
more฀fuel฀eficient,฀more฀maneuverable,฀and฀easier฀to฀maintain.฀Today,฀boatbuilders฀
looking฀ for฀ strength฀ and฀ lighter฀ weight฀ turn฀ to฀ plastics฀ for฀ sails,฀ rudders,฀ dagger฀
boards,฀centerboards,฀slats,฀spars฀and฀wings,฀as฀well฀as฀hulls.฀Composite฀use฀in฀the฀
nautical฀world฀gained฀considerable฀notice฀when฀America’s฀Cup฀entries฀began฀using฀
advanced฀composites฀in฀futuristic฀designs฀for฀both฀hulls฀and฀masts.฀Today,฀compos-
ites฀and฀other฀plastics฀ind฀wide฀application฀both฀on฀and฀below฀the฀sea฀in฀applica-
tions฀such฀as฀personal฀watercraft,฀jet฀boats,฀sail฀boats,฀stern฀drive฀boats,฀outboard฀
boats฀and฀inboard฀boats,฀diving฀equipment,฀off฀shore฀platforms,฀as฀well฀as฀commer-
cial฀and฀military฀vessels.
5.3.2 State-of-the-Art Outboard Engines
After฀investing฀5฀years฀and฀$100฀million฀in฀its฀new฀line฀of฀large,฀4-stroke฀outboard฀
engines,฀ Mercury฀ Marine’s฀ sleek฀ new฀ ‘Verado’฀ outboard฀ engine฀ cover฀ is฀ a฀ real฀
฀winner.฀Besides฀visual฀appeal,฀the฀engine฀includes฀some฀technical฀innovations.฀In฀
comparing฀compression฀molded฀SMC,฀thermoforming,฀RIM฀and฀injection฀molding,฀
the฀design฀team฀found฀that฀injection฀molding฀would฀afford฀greater฀design฀lexibility,฀
parts฀ integration,฀ lower฀ costs฀ for฀ assembly฀ and฀ paint,฀ lower฀ overall฀ weight,฀ and฀
higher฀yields.
5.3฀ Marine฀and฀Boat฀Applications 61
The฀upper฀cowl฀is฀the฀largest฀injection฀molded,฀glass฀reinforced฀nylon฀part฀ever฀
made.฀It฀weighs฀11฀lbs,฀20%฀less฀than฀if฀made฀from฀Mercury’s฀traditional฀material,฀
compression฀molded฀SMC.฀The฀combined฀upper/lower฀nylon฀cowls฀weigh฀30%฀less฀
than฀with฀SMC฀and฀cost฀46%฀less฀than฀SMC฀models.฀The฀engine฀cover฀has฀to฀be฀
structurally฀sound,฀able฀to฀withstand฀hitting฀a฀loating฀log฀while฀traveling฀at฀40฀mph.฀
The฀design฀team฀spent฀18฀months฀to฀come฀up฀with฀an฀aggressive,฀powerful฀design฀
for฀the฀Verado.฀Injection฀molding฀allowed฀additional฀design฀freedom,฀giving฀crisper฀
edges฀and฀a฀high฀gloss฀look฀on฀some฀of฀the฀parts฀out฀of฀the฀mold฀so฀they฀would฀not฀
have฀to฀be฀painted.฀The฀inal฀cowling฀design฀consists฀of฀four฀primary฀parts,฀the฀top฀
cowl,฀rear฀cowl,฀a฀structural฀rib,฀and฀front฀cowl,฀along฀with฀two฀mating฀parts฀that฀
comprise฀ the฀ lower฀ cowl.฀ Glass฀ illed฀ nylon฀ 6/6฀ is฀ used฀ for฀ the฀ top,฀ rear,฀ and฀ rib฀
members,฀whilst฀the฀front฀is฀molded฀from฀mineral/glass฀illed฀nylon.฀The฀massive฀
635฀lb,฀4-stroke,฀275฀horsepower฀(200,฀225,฀250฀hp฀also฀available)฀engine,฀Mercury’s฀
irst฀supercharged฀outboard฀for฀the฀consumer฀market,฀will฀retail฀for฀about฀$18,000.
5.3.3 High Tech Pontoon Boats
Genmar฀Holdings,฀Inc.฀introduced฀its฀latest฀technological฀innovation,฀the฀Windsor฀
Craft฀ pontoon,฀ at฀ the฀ Minneapolis฀ Boat฀ Show.฀ The฀ pontoon฀ market฀ segment฀ has฀
grown฀more฀than฀50%฀during฀the฀past฀5฀years.฀Genmar,฀the฀world’s฀largest฀builder฀
of฀recreational฀boats,฀is฀producing฀the฀mostly฀rotational฀molded฀24฀ft฀tri-hull฀pon-
toon฀ from฀ more฀ than฀ 2,600฀ lbs฀ of฀ polyethylene.฀ Unlike฀ a฀ traditional฀ pontoon’s฀
฀aluminum฀ hull,฀ the฀ PE฀ withstands฀ saltwater,฀ alleviating฀ concerns฀ about฀ saltwater฀
corrosion.฀ The฀ tri-hull฀ pontoon฀ boat,฀ constructed฀ using฀ the฀ company’s฀ patented฀
Roplene฀construction฀process,฀features฀a฀lifetime,฀limited฀warranty฀on฀the฀hull฀and฀
enhanced฀performance฀characteristics฀providing฀big-water฀handling฀while฀offering฀
a฀level฀of฀comfort฀and฀style฀previously฀unavailable฀in฀a฀pontoon฀boat.
Roplene฀is฀a฀patented฀dual-wall฀construction฀system฀made฀by฀rotomolding฀marine-
grade฀PE.฀This฀advanced฀technology฀was฀developed฀by฀Genmar฀subsidiary฀Triumph฀
Boats฀and฀allows฀Genmar฀to฀build฀higher฀quality,฀stronger฀boats฀with฀฀limited฀lifetime฀
warranties฀at฀a฀lower฀cost฀to฀the฀boating฀consumer.฀LLDPE฀is฀used฀for฀the฀three฀hulls,฀
fold-up฀cabana/changing฀station,฀console฀and฀base฀structure;฀high-density฀PE฀is฀used฀
for฀the฀loor฀and฀sides;฀and฀cross-linked฀PE฀for฀the฀fuel฀tank.
5.3.4 Subsea High-Strength Moorings
Single฀Buoy฀Moorings฀of฀Monaco฀is฀using฀PTFE฀illed฀Victrex฀PEEK฀polymer฀to฀
overcome฀corrosion฀problems฀with฀bronze฀bearing฀and฀thrust฀washer฀components฀
used฀in฀the฀company’s฀subsea฀mooring฀systems.฀The฀company฀is฀a฀major฀supplier฀of฀
loating฀production,฀storage,฀and฀ofloading฀systems฀(FPSOs).฀Designed฀and฀molded฀
by฀3P/EGC฀of฀Texas,฀the฀polymer฀bearings฀and฀thrust฀washers฀in฀the฀mooring฀and฀
driving฀chain฀systems฀have฀an฀extended฀service฀life,฀signiicantly฀less฀weight,฀and฀
excellent฀load฀bearing฀capabilities฀compared฀to฀those฀of฀the฀bronze฀parts.
Corrosion฀ resistance฀ in฀ subsea฀ environments฀ is฀ of฀ particular฀ importance฀ since฀
these฀platforms฀are฀constructed฀in฀open฀or฀unprotected฀water฀to฀facilitate฀the฀mooring฀
of฀tankers฀at฀offshore฀oil/gas฀exploration฀stations฀that฀have฀no฀jetties฀and฀breakwaters.฀
Unlike฀ bronze฀ components,฀ which฀ can฀ develop฀ severe฀ galvanic฀ corrosion,฀ PEEK฀
bearings฀ and฀ thrust฀ washers฀ provide฀ long-term฀ corrosion฀ resistance฀ and฀ superior฀
wear฀resistance.฀The฀bronze฀parts฀are฀subject฀to฀premature฀wear฀and฀reduced฀service฀
life฀should฀they฀run฀dry฀unlike฀PEEK฀parts,฀which฀require฀no฀external฀lubrication.฀
The฀PEEK฀material฀also฀provides฀signiicant฀weight฀savings,฀important฀as฀the฀mooring฀
bearings฀and฀thrust฀washers฀can฀be฀up฀to฀50฀cm฀in฀diameter,฀with฀wall฀thicknesses฀
of฀up฀to฀5฀cm,฀and฀are฀extremely฀heavy฀and฀dificult฀to฀handle฀when฀they฀are฀made฀
of฀bronze.฀3P/EGC฀has฀developed฀a฀tailor-made฀process฀to฀mold฀the฀large฀PEEK฀
polymer฀cylinders฀without฀defects.
5.3.5 Small Craft Rotomolding
Ideally฀suited฀to฀the฀rotational฀molding฀process,฀rotationally฀molded฀kayaks,฀essen-
tially฀hollow฀parts฀(with฀a฀hole฀cut฀for฀the฀person฀to฀enter),฀have฀a฀strong฀position฀in฀
the฀small฀marine฀craft฀market.฀However,฀iber฀reinforced฀plastic฀kayaks฀also฀maintain฀
a฀good฀market฀position.฀Competition฀is฀similarly฀vigorous฀between฀rotomolded฀and฀
FRP฀canoes฀as฀well฀as฀other฀small฀boats฀up฀to฀about฀20฀feet฀long.฀Rotomolded฀boats฀
are฀able฀to฀challenge฀FRP฀primarily฀through฀price฀with฀a฀rotational฀molded฀kayak฀
selling฀for฀roughly฀60%฀of฀the฀price฀of฀an฀FRP฀kayak.
Rotomolding฀ is฀ easier฀ to฀ automate฀ and,฀ while฀ cycle฀ times฀ are฀ long,฀ they฀ are฀
measurably฀less฀than฀FRP฀cure฀times.฀Polyethylene฀raw฀material฀costs฀are฀also฀less฀
than฀those฀of฀FRP,฀and฀PE฀parts฀have฀higher฀impact฀toughness,฀a฀strong฀selling฀point฀
for฀small฀rotomolded฀watercraft฀often฀used฀in฀rugged฀environments.฀On฀the฀other฀
hand,฀ small฀ FRP฀ watercraft฀ have฀ a฀ better฀ surface฀ inish/color฀ and฀ are฀ capable฀ of฀
more฀innovative฀designs.฀Repair฀is฀also฀problematic฀for฀the฀rotomolded฀PE฀boats,฀
requiring฀non-aesthetic฀thermally฀welded฀patches.฀Additionally,฀FRP฀parts฀can฀be฀
made฀ stiffer฀ allowing฀ lower฀ wall฀ thickness฀ and฀ all฀ important฀ lower฀ weight.฀ To฀
increase฀stiffness,฀PE฀watercraft฀have฀recently฀been฀successfully฀rotomolded฀with฀a฀
double฀hull฀and฀foamed฀interlayer.
5.3.6 Corrosion-Resistant Pier Sleeves
Many฀of฀New฀York’s฀Hudson฀River฀piers,฀built฀with฀wooden฀piles,฀are฀more฀than฀
50฀ years฀ old,฀ have฀ become฀ corroded,฀ and฀ are฀ losing฀ their฀ structural฀ integrity.฀
Additionally,฀ with฀ signiicant฀ improvements฀ in฀ the฀ river’s฀ water฀ quality,฀ wood฀
boring฀worms,฀which฀eat฀through฀the฀wooden฀piles,฀are฀thriving฀in฀the฀river.
5.3฀ Marine฀and฀Boat฀Applications 63
These฀corroded฀wooden฀pier฀supports฀are฀being฀restored฀using฀more฀than฀1½฀miles฀
of฀iber฀reinforced฀plastic฀(FRP)฀sleeving.฀MFG฀Construction฀Products฀Co.,฀a฀leading฀
supplier฀of฀composite฀products฀to฀the฀construction฀industry,฀produced฀the฀sleeves฀
needed฀for฀the฀restoration฀using฀a฀general฀purpose฀polyester฀resin,฀฀reinforced฀with฀
30%฀ glass฀ iber฀ chopped฀ strand฀ mat.฀ The฀ sleeves฀ it฀ around฀ each฀ pile฀ to฀ form฀ a฀
jacket,฀and฀epoxy฀grout฀is฀then฀pumped฀into฀the฀space฀between฀the฀jacket฀and฀the฀
pile.฀Made฀without฀a฀gel฀coat,฀the฀sleeves฀are฀translucent,฀allowing฀grout฀levels฀to฀be฀
monitored฀during฀installation.฀The฀pile฀repair฀sleeves฀are฀manufactured฀individually฀
according฀to฀pile฀length฀and฀diameter.฀A฀diver฀wraps฀the฀sleeve฀around฀each฀pile฀
then฀fastens฀it฀in฀place฀with฀a฀tongue฀and฀groove฀joint.฀Nylon฀straps฀are฀added฀to฀
provide฀extra฀support฀and฀the฀grout฀is฀then฀pumped฀in.฀One฀diver฀can฀install฀6–10฀
sleevesper฀day.฀Repairing฀the฀piles฀using฀the฀iber฀reinforced฀plastic฀sleeves฀is฀much฀
more฀economical฀than฀replacing฀the฀pilings฀or฀rebuilding฀the฀pier.
5.3.7 Lightweight Engineered Dock Pilings
Startup฀company฀ArmorDock฀Systems฀Inc.,฀is฀using฀PVC฀to฀make฀pilings,฀boatlifts,฀
ish฀cleaning฀stations,฀and฀other฀similar฀marine฀products.฀The฀new฀company฀is฀out-
sourcing฀production฀to฀pipe฀extruder฀Hawk฀Plastics฀Corp.฀and฀Macon฀Plastics฀Inc.฀
of฀Macon,฀GA,฀which฀handles฀the฀fabrication.฀ArmorDock฀chose฀PVC฀for฀its฀long฀
50฀year฀service฀life,฀compared฀with฀timber’s฀projected฀15-year฀life฀in฀marine฀service.฀
The฀ PVC฀ products฀ are฀ also฀ light฀ and฀ easy฀ to฀ handle.฀ ArmorDock฀ was฀ created฀ in฀
response฀to฀the฀need฀to฀ind฀alternatives฀to฀timber฀treated฀with฀chromated฀copper฀
arsenate฀(CCA).฀It฀is฀expected฀that฀the฀Environmental฀Protection฀Agency฀will฀phase฀
out฀CCA-treated฀timber฀for฀marine฀and฀water฀applications,฀following฀the฀phase฀out฀
of฀ wood฀ treatment฀ in฀ land฀ applications.฀ The฀ PVC฀ pilings,฀ available฀ in฀ 8–12฀ in.฀
diameter,฀do฀not฀require฀reinforcement,฀but฀can฀be฀illed฀with฀a฀substance฀such฀as฀
crushed฀stone.฀The฀irm฀has฀four฀patents฀and฀is฀working฀on฀other฀products฀including฀
sea฀ walls฀ and฀ bulkheads.฀ In฀ pile฀ accessories฀ are฀ also฀ produced,฀ including฀ in-pile฀
dock฀lights,฀in-pile฀water฀stations,฀in-pile฀electrical฀receptacles,฀and฀in-pile฀charging฀
stations.฀ ArmorDock฀ PVC฀ is฀ impact฀ modiied,฀ so฀ it฀ can฀ withstand฀ abuse฀ applied฀
when฀it฀is฀driven฀into฀the฀ground฀and฀can฀also฀withstand฀the฀impact฀of฀boats.
Chapter 6
Consumer Products End Use Applications
Keywords฀ Consumer฀products฀•฀Polycarbonate฀•฀Blu-ray฀•฀High฀temperature฀•฀Toy฀
•฀Recreation฀•฀Leisure฀•฀Furniture฀•฀Lawn฀•฀Garden
6.1 Consumer Products Applications
6.1.1 Consumer Products and the Consumer
Consumer฀products฀cover฀a฀lot฀of฀territory฀–฀everything฀from฀cosmetics฀and฀tooth-
brushes฀to฀housewares,฀toys,฀recreational฀goods,฀furniture,฀lawn฀and฀garden฀equipment,฀
etc.฀Considering฀the฀diversiication฀of฀this฀category,฀it฀is฀extremely฀dificult฀to฀assign฀
overall฀growth฀igures฀though฀there฀are฀a฀number฀of฀very฀proitable฀niche฀opportuni-
ties.฀Trends฀in฀disposable฀personal฀income฀play฀a฀major฀role฀in฀the฀purchase฀of฀these฀
products฀with฀any฀growth฀in฀real฀wages฀boosting฀consumer฀spending฀in฀this฀sector.฀
The฀downside฀of฀business฀in฀consumer฀goods฀is฀that฀the฀product฀life฀cycles฀are฀often฀
short,฀and฀most฀applications฀are฀price฀sensitive.฀Also,฀many฀of฀the฀end฀uses฀have฀
seasonal patterns.
6.1.2 A New Wine Cork Twist
Solvay฀Advanced฀Polymers’฀Amodel฀Polyphthalamide฀(PPA)฀has฀broken฀into฀the฀
wine฀ industry.฀ Typically฀ found฀ in฀ automotive,฀ electrical,฀ and฀ industrial฀ product฀
applications,฀ Solvay฀ Advanced฀ Polymers฀ LLC’s฀ high-performance฀ polymer฀ has฀
found฀a฀new฀use฀as฀a฀threaded฀anchor฀for฀the฀patented฀twist-to-uncork฀wine฀packaging฀
designed฀by฀Gardner฀Technologies,฀Inc.,฀a฀Napa,฀CA-based฀manufacturer.฀The฀new฀
product฀carries฀the฀MetaCork฀trade฀name฀and฀was฀on฀display฀at฀the฀recent฀K฀Fair฀in฀
Düsseldorf.฀MetaCork™฀consists฀of฀a฀hard฀plastic฀capsule฀with฀a฀threaded฀interior฀

66 6฀ Consumer฀Products฀End฀Use฀Applications
surface,฀a฀matching฀plastic฀threaded฀cap,฀and฀a฀natural฀or฀synthetic฀cork฀itted฀with฀
a฀threaded฀anchor,฀made฀from฀Amodel฀PPA,฀that฀is฀screwed฀into฀the฀cork฀during฀the฀
bottling฀process.
Twisting฀ the฀ plastic฀ capsule฀ eases฀ the฀ cork฀ out฀ of฀ the฀ bottle,฀ thanks฀ to฀ mated฀
threads฀inside฀the฀capsule฀and฀on฀the฀neck฀of฀the฀bottle.฀Once฀removed,฀the฀cork฀
along฀with฀the฀anchor฀and฀the฀top฀cap฀can฀be฀pushed฀out฀of฀the฀capsule฀unit.฀The฀
plastic฀capsule฀can฀be฀returned฀to฀the฀bottle฀for฀drip-resistant฀pouring,฀and฀the฀cap฀
can฀be฀screwed฀back฀on฀for฀a฀leak-proof฀seal.฀The฀design฀of฀the฀anchor฀is฀critical฀to฀
the฀design฀of฀MetaCork฀since฀the฀average฀breakaway฀torque฀required฀between฀the฀
anchor฀ and฀ capsule฀ to฀ extract฀ a฀ natural฀ cork฀ is฀ about฀ 14.5฀ inch-pounds.฀ Gardner฀
Technologies฀selected฀Amodel฀PPA฀because฀it฀can฀withstand฀more฀than฀twice฀that฀
level฀of฀torque.฀The฀Amodel฀material฀used฀in฀the฀MetaCork฀is฀a฀45%฀glass-reinforced฀
grade฀of฀PPA฀resin.฀The฀material฀has฀very฀good฀low฀characteristics,฀making฀it฀easy฀
to฀mold฀the฀threaded฀anchor฀or฀other฀parts฀with฀complicated฀geometries.
6.1.3 High Tech Gloves
Ergodyne,฀a฀pioneer฀in฀the฀development฀of฀products฀for฀worker฀comfort฀and฀safety,฀
has฀introduced฀ProFlex฀X-Factor฀gloves,฀designed฀to฀offer฀a฀new฀standard฀in฀protection฀
for฀ extreme฀ work฀ environments฀ such฀ as฀ those฀ encountered฀ by฀ emergency,฀ rescue฀
and฀construction฀workers.฀The฀specialized฀gloves฀offer฀unique฀design฀elements฀to฀
deliver฀the฀required฀combination฀of฀protection฀and฀dexterity.฀Features฀and฀beneits฀
of฀the฀ProFlex฀X-Factor฀gloves฀include฀Keprotec,฀which฀employs฀DuPont’s฀Kevlar฀
(730/732)฀ or฀ Armortex,฀ which฀ employs฀ DuPont’s฀ Kevlar/Nomex฀ (726/728)฀ over฀
Amara฀synthetic฀leather฀on฀ingers,฀thumb,฀and฀palm฀to฀reinforce฀against฀abrasions.฀
Double-needle฀ Kevlar฀ (730/732)฀ or฀ double-needle฀ 3-ply฀ 280D฀ nylon฀ (726/728)฀
stitching฀provides฀added฀durability.฀EVA฀padding฀protects฀knuckles฀against฀scrapes,฀
cuts,฀and฀bruises฀and฀also฀dampens฀shock,฀impact,฀and฀vibration.฀The฀use฀of฀relective฀
nylon฀on฀the฀glove฀backs฀improves฀worker฀visibility.฀The฀elastic฀cuff฀prevents฀the฀
introduction฀of฀dangerous฀or฀uncomfortable฀debris.฀PVC฀ingertips฀prevent฀slipping฀
and฀improve฀grip.฀A฀stretch฀spandex฀shell฀ensures฀maximum฀comfort฀and฀it.
6.1.4 Consumer Durable Cushioning
Rogers฀Corp.฀offers฀a฀collection฀of฀high-performance฀foams฀for฀use฀in฀the฀commu-
nications,฀ transportation,฀ and฀ consumer฀ markets.฀ The฀ company’s฀ Poron฀ urethane฀
and฀ Rogers฀ polyolein฀ foams฀ offer฀ a฀ broad฀ range฀ of฀ design฀ solutions฀ for฀ energy฀
absorption฀in฀applications฀from฀insoles฀and฀sock฀liners฀to฀life฀jacket฀cushioning฀and฀
back฀packs,฀where฀performance฀and฀comfort฀are฀essential.
Poron฀urethanes฀are฀a฀family฀of฀high-performance฀cellular฀foams฀that฀are฀ideally฀
suited฀to฀footwear฀applications.฀Poron฀comes฀in฀a฀wide฀variety฀of฀colors,฀thicknesses,฀
6.1฀ Consumer฀Products฀Applications 67
densities,฀ and฀ surface฀ textures฀ to฀ accommodate฀ footwear฀ for฀ any฀ type฀ of฀ activity,฀
from฀high-impact฀sports฀to฀elegant฀or฀formal฀occasions.฀A฀lightweight฀cellular฀mate-
rial,฀Poron฀urethane฀provides฀insoles฀with฀greater฀shock฀absorption฀than฀many฀other฀
materials.฀It฀also฀provides฀breathability,฀forming฀permeable฀layers฀that฀draw฀water฀
vapor฀and฀perspiration฀away฀from฀the฀foot฀to฀help฀keep฀shoes฀and฀feet฀dry.฀Depending฀
on฀the฀application,฀Poron฀urethanes฀combine฀readily฀with฀other฀materials,฀including฀
fabrics,฀typical฀EVAs,฀and฀molded฀urethanes.฀It฀is฀also฀easily฀die฀cut.฀In฀all฀applica-
tions,฀it฀promotes฀durability,฀abrasion฀resistance,฀friction,฀tension,฀and฀stitch฀stress.฀
Since฀Poron฀materials฀are฀made฀without฀plasticizers,฀the฀shoe฀insoles฀do฀not฀shrink฀
or฀become฀brittle฀and฀crack฀with฀age.฀Rogers฀polyolein฀foams฀are฀cross-linked฀elas-
tomeric฀ and฀ plastomeric฀ polyethylene-based฀ foam฀ materials฀ offered฀ in฀ roll฀ or฀ bun฀
form฀in฀a฀wide฀range฀of฀thicknesses,฀densities,฀and฀colors.฀The฀lightweight฀foams฀are฀
thermoformable฀and฀easily฀heat฀laminated฀to฀other฀materials.฀They฀possess฀excellent฀
tensile/elongation฀properties฀and฀are฀used฀in฀many฀sports฀and฀leisure฀applications.
6.1.5 High-Capacity Blu-Ray DVDs
Sony฀and฀arch฀rival฀Toshiba฀were฀on฀a฀collision฀course฀to฀work฀with฀ilm฀producers฀
to฀make฀the฀next฀generation฀of฀high฀deinition฀DVDs.฀Warner฀Bros.,฀Paramount,฀and฀
Universal฀have฀signed฀nonexclusive฀agreements฀with฀the฀HD฀Group,฀a฀consortium฀
headed฀by฀Toshiba,฀to฀make฀the฀new฀HD-DVD฀format฀which฀was฀discontinued฀in฀
2008.฀Meanwhile,฀Disney฀signed฀a฀nonexclusive฀agreement฀with฀Sony฀to฀produce฀
its฀videos฀as฀Blu-rays.฀Equipment฀makers฀and฀replicators฀monitored฀the฀situation฀
closely฀ in฀ order฀ to฀ eficiently฀ adapt฀ the฀ format฀ the฀ marketplace฀ would฀ ultimately฀
choose.฀The฀battle฀was฀reminiscent฀of฀the฀1980s฀ight฀between฀Sony฀and฀JVC฀over฀
the฀ creation฀ of฀ the฀ irst-generation฀ of฀ video฀ cassettes.฀ Sony฀ opted฀ for฀ Betamax฀
though฀the฀industry฀eventually฀adopted฀the฀rival฀VHS฀standard.
The฀Blu-ray฀disk,฀which฀Sony฀developed฀with฀Matsushita,฀holds฀up฀to฀ive฀times฀
the฀content฀possible฀with฀current฀DVDs,฀25฀GB฀for฀a฀single-layer฀BD฀and฀50฀GB฀for฀
a฀dual฀layer,฀while฀a฀standard฀DVD฀can฀hold฀4.7฀GB฀of฀content.฀This฀technology฀is฀
being฀pushed฀by฀Sony฀and฀a฀large฀coalition฀that฀includes฀most฀of฀the฀industry’s฀larg-
est฀consumer฀electronics฀and฀computer฀makers.฀The฀rival฀HD-DVD฀format,฀which฀
was฀developed฀by฀Toshiba฀and฀was฀marketed฀along฀with฀NEC฀and฀Samsung,฀was฀
expected฀to฀be฀on฀the฀market฀more฀quickly฀because฀it฀required฀fewer฀modiications฀to฀
existing฀DVD฀technology.฀It฀had฀three฀times฀the฀current฀space฀on฀a฀DVD฀but฀was฀
cheaper฀to฀produce฀than฀Blu-ray.฀The฀three฀studios฀that฀signed฀with฀Toshiba฀said฀
they฀expecedt฀to฀begin฀selling฀some฀DVDs฀on฀the฀Toshiba-backed฀format.฀HD-DVD฀
machines฀ would฀ be฀ able฀ to฀ play฀ older฀ discs฀ and฀ also฀ would฀ enable฀ replicators฀ to฀
retool฀without฀major฀equipment฀changes฀for฀the฀HD฀capability.฀Replicators฀of฀the฀
revolutionary฀ Blu-ray฀ format฀ require฀ mostly฀ new฀ equipment.฀ Sony’s฀ new฀ device฀
records฀and฀plays฀back฀Blu-ray฀discs฀but฀can฀also฀play฀back฀DVD,฀DVD-RW,฀DVD-R,฀
CD,฀and฀CD-RW฀discs.฀However,฀the฀recorder฀will฀not฀be฀able฀to฀read฀DVD-RAM฀
or฀DVD+RW฀discs.
Resin฀supplier฀Sabic฀Innovative฀Plastics฀had฀a฀stake฀in฀the฀contest.฀The฀company฀
explored฀qualiications฀of฀possible฀Blu-ray฀materials฀over฀2฀years.฀Noryl฀EXLN0090฀
has฀proven฀itself฀in฀Blu-ray฀trials฀vs.฀optical-grade฀Lexan฀polycarbonate.฀The฀Noryl฀
product฀“shows฀better฀dimensional฀stability฀than฀standard฀PC.”฀BD฀materials฀will฀be฀
more฀expensive฀but฀a฀BD฀system฀requires฀one฀molding฀machine฀instead฀of฀two฀and฀
one฀sputtering฀machine฀instead฀of฀two.
6.1.6 Electronic Book Binding
Sagoma฀ Plastics฀ invests฀ in฀ its฀ own฀ ideas,฀ investing฀ 10%฀ of฀ sales฀ in฀ product฀ and฀
฀production฀development.฀One฀of฀Sagoma฀Plastics’฀latest,฀patent฀pending,฀proprie-
tary฀products฀is฀an฀attractive,฀high-quality฀package฀for฀optical฀disks฀that฀combines฀
the฀familiar฀look฀and฀feel฀of฀a฀traditional฀book฀with฀the฀versatility,฀durability,฀and฀
high฀quality฀of฀injection฀molded฀plastic฀pages.฀Sagoma฀calls฀it฀DigitalBook.฀Disks฀
are฀placed฀in฀either฀a฀single-฀or฀double-sided฀tray฀that฀can฀be฀leafed฀through฀like฀
pages฀in฀a฀book.฀A฀single฀DigitalBook฀can฀hold฀up฀to฀34฀CD฀or฀DVD฀discs.฀It฀uses฀
custom-colored฀ disk-holding฀ ‘pages’฀ molded฀ from฀ ABS,฀ PC,฀ or฀ HIPS,฀ materials฀
that฀ are฀ stronger฀ than฀ the฀ crystal฀ PS฀ used฀ in฀ conventional฀ jewel฀ boxes.฀ The฀
DigitalBook฀design฀provides฀ample฀room฀to฀package฀promotional฀products,฀premiums,฀
and฀literature฀along฀with฀the฀disks.฀Its฀multiple฀cover฀options฀include฀a฀classic฀hard฀
book฀cover฀or฀soft฀cover฀treatment฀done฀in฀linen,฀leather,฀or฀paper,฀or฀a฀plastic฀pocket฀
cover฀treatment฀where฀graphics฀are฀slid฀behind฀a฀clear฀plastic฀sleeve.
The฀market฀for฀the฀DVD/CD฀book฀packaging฀is฀potentially฀very฀large.฀Sagoma฀
has฀patents฀on฀the฀high-speed฀automation฀to฀produce฀these฀products.฀They฀are฀investing฀
$1฀million฀for฀equipment฀and฀are฀looking฀for฀a฀larger฀manufacturing฀facility.฀ The฀
company฀expects฀to฀double฀their฀TCBS฀business฀over฀the฀next฀2฀years.
6.1.7 EU Food Compliant Containers
Rubbermaid฀has฀adopted฀a฀new฀EU฀food฀compliant฀grade฀of฀Santoprene฀thermo-
plastic฀vulcanizate฀(TPV)฀from฀Advanced฀Elastomer฀Systems฀(AES)฀for฀the฀seal฀in฀
its฀ food฀ container฀ lids.฀ Following฀ European฀ food฀ contact฀ legislation,฀ AES฀ devel-
oped฀a฀new฀TPV฀that฀meets฀the฀latest฀legislation฀and฀is฀ideal฀for฀applications฀in฀food฀
and฀beverage฀markets.฀AES฀collaborated฀with฀Rubbermaid฀to฀ensure฀that฀the฀new฀
EU฀ food฀ compliant฀ TPV฀ grades฀ would฀ match฀ Rubbermaid’s฀ part฀ design฀ and฀
processing฀ requirements.฀ Complying฀ with฀ the฀ latest฀ requirements฀ of฀ the฀ Plastics฀
Directive฀2010/72/EC฀for฀aqueous-based฀food,฀the฀new฀grades฀exhibit฀good฀chemical฀
resistance,฀outstanding฀compression฀set฀and฀temperature฀resistance฀with฀excellent฀
sealing฀properties฀across฀a฀wide฀range฀of฀temperatures.฀As฀a฀result,฀they฀are฀micro-
wave,฀freezer,฀and฀dishwasher฀safe.฀The฀new฀Santoprene฀TPV฀in฀grades฀are฀available฀
6.1฀ Consumer฀Products฀Applications 69
in฀three฀hardnesses:฀Shore฀55A,฀64A,฀and฀73A.฀Typical฀applications฀for฀these฀grades฀
include฀ food฀ and฀ beverage฀ closure฀ cap฀ liners,฀ beverage฀ packaging฀ applications,฀
other฀food฀packaging฀applications฀requiring฀high฀performance฀such฀as฀sealability฀
and฀high-temperature฀resistance.
6.1.8 High-Temperature Cookware
Tupperware,฀one฀of฀the฀world’s฀leading฀manufacturers฀of฀plastic฀household฀products,฀
has฀ developed฀ a฀ range฀ of฀ new฀ tableware,฀ in฀ cooperation฀ with฀ BASF.฀ The฀ new฀
attractively฀designed฀tableware฀is฀lightweight,฀durable,฀and฀also฀capable฀of฀with-
standing฀ temperature฀ extremes.฀ To฀ meet฀ Tupperware฀ needs,฀ BASF฀ researchers฀
developed฀a฀novel฀modiied฀Ultrason฀product.฀The฀new฀material,฀designed฀for฀the฀
Tupperware฀product,฀is฀specially฀formulated฀polyethersulfone฀(Ultrason฀E,฀PES),฀
to฀which฀BASF฀added฀UV฀stabilizers.฀The฀material฀is฀break฀and฀impact฀resistant฀
and฀particularly฀tough.฀This฀thermally฀stable฀thermoplastic฀can฀withstand฀tempera-
tures฀ from฀ −50°C฀ to฀ 220°C฀ without฀ effect.฀ The฀ innovative฀ plastic฀ tableware฀ can฀
therefore฀be฀transferred฀directly฀from฀deep฀freezer฀to฀microwave฀and฀then฀placed฀
on฀the฀table฀as฀attractively฀designed฀serving฀dishes.฀The฀material,฀suitable฀for฀food฀
contact฀ applications,฀ has฀ excellent฀ resistance฀ to฀ food฀ staining฀ and฀ dishwasher฀
detergents.฀Because฀of฀its฀excellent฀performance,฀Tupperware฀is฀giving฀a฀30-year฀
guarantee฀on฀the฀new฀tableware.฀The฀transparent฀containers฀that฀reveal฀the฀contents฀
at฀a฀glance฀are฀available฀in฀a฀variety฀of฀colors.฀Other฀possible฀applications฀are฀baby฀
bottles฀and฀food฀service฀applications฀for฀airlines,฀restaurants,฀and฀large-scale฀catering฀
kitchens.
6.1.9 High Tech Power Shavers
Gillette’s฀next฀generation฀triple-blade฀shaving฀system฀the฀Gillette฀M3Power฀is฀the฀
world’s฀most฀technologically฀advanced฀and฀expensive฀mass-market฀wet฀razor.฀The฀
battery฀powered฀plastic฀laden฀upgrade฀to฀the฀Gillette฀lagship฀Mach3฀line฀is฀a฀unique฀
razor.฀ Users฀ press฀ a฀ button฀ on฀ the฀ handle฀ to฀ activate฀ a฀ small฀ motor฀ to฀ produce฀ a฀
gentle฀ pulsing฀ action฀ said฀ to฀ stimulate฀ hair฀ upward฀ and฀ away฀ from฀ the฀ skin฀ to฀
produce฀a฀closer฀shave.฀The฀M3Power,฀which฀is฀said฀to฀outperform฀all฀men’s฀shaving฀
systems,฀including฀Gillette’s฀Mach3Turbo,฀operates฀under฀62฀patents.฀Other฀innova-
tions฀ in฀ the฀ shaver฀ include฀ proprietary฀ blades฀ enhanced฀ by฀ a฀ new฀ coating,฀ called฀
‘thin฀uniform฀telomer,’฀which฀provides฀a฀perceptible฀improvement฀in฀shaving฀comfort฀
throughout฀the฀life฀of฀the฀blade.฀The฀blade฀cartridge฀features฀an฀Indicator฀Lubrastrip฀
infused฀with฀Vitamin฀E฀and฀Aloe฀for฀added฀moisture,฀and฀an฀ergonomically฀engi-
neered฀ handle฀ with฀ strategically฀ placed฀ gripping฀ surfaces฀ to฀ enable฀ one฀ to฀ shave฀
safely฀ at฀ any฀ angle.฀ M3Power฀ also฀ is฀ shower-safe,฀ allowing฀ convenient฀ shower฀
shaving.฀ The฀ shaving฀ system฀ includes฀ the฀ reillable฀ razor,฀ two฀ cartridges,฀ and฀ an฀
AAA฀Duracell฀battery.
6.1.10 Blow Molded Standup Tubes
Graham฀ Packaging,฀ a฀ worldwide฀ leader฀ in฀ the฀ design,฀ manufacture,฀ and฀ sale฀ of฀
customized฀blow-molded฀plastic฀containers฀for฀the฀branded฀food/beverage,฀house-
hold/personal฀care,฀and฀automotive฀lubricants฀markets,฀has฀developed฀a฀new฀pack-
aging฀ phenomenon.฀ The฀ unique฀ design฀ is฀ a฀ blow-molded฀ stand-up฀ plastic฀ tube,฀
which฀when฀squeezed฀exposes฀a฀pop฀up฀dome฀revealing฀a฀small,฀13฀mm฀diameter฀
threaded฀ cap฀ from฀ a฀ recess฀ in฀ the฀ tubes฀ base.฀ The฀ small฀ resealable฀ closure฀ and฀
dome฀can฀be฀retracted฀back฀into฀the฀tube฀base฀when฀not฀in฀use฀so฀that฀the฀container฀
can฀ stand฀ on฀ end.฀ In฀ order฀ for฀ conventional฀ tubes฀ to฀ stand฀ upright,฀ a฀ large฀ and฀
costly฀cap฀is฀required฀to฀serve฀as฀a฀base฀on฀which฀to฀stand.
The฀ patent-pending฀ Graham฀ Flexa฀ Tube฀ is฀ constructed฀ in฀ one฀ piece฀ with฀ no฀
welds.฀Simple฀and฀sturdy,฀the฀new฀tube฀design฀is฀easier฀and฀less฀expensive฀to฀manu-
facture฀than฀are฀conventional฀tubes.฀The฀pop฀up฀dome฀has฀a฀living฀hinge฀that฀allows฀
the฀ dome฀ to฀ pop฀ in฀ and฀ out฀ of฀ the฀ tube฀ base.฀ The฀ sealed฀ end฀ of฀ the฀ tube฀ can฀ be฀
formed฀with฀a฀hook฀or฀eyelet,฀so฀that฀it฀can฀be฀hung฀from฀a฀display฀rack.฀The฀tube฀is฀
available฀in฀40,฀50,฀and฀58฀mm฀diameter฀sizes.฀Made฀with฀LDPE,฀the฀packaging฀was฀
initially฀introduced฀as฀a฀hair฀care฀product฀container.฀The฀package฀is฀being฀consid-
ered฀as฀a฀container฀for฀a฀range฀of฀products฀from฀creams฀and฀lotions฀to฀spreadable฀
foods,฀sauces,฀condiments,฀and฀household/chemical฀products.
6.1.11 Do-It-Yourself Faucets
Moen฀Inc.,฀one฀of฀the฀world’s฀largest฀residential฀and฀commercial฀plumbing฀products฀
producers,฀is฀manufacturing฀new฀kitchen฀faucet฀deck฀plates฀to฀make฀it฀simpler฀for฀
plumbers฀and฀‘do-it-yourself’฀consumers฀to฀install.฀The฀plates฀have฀a฀built-in฀ther-
moplastic฀vulcanizate฀(TPV)฀lip฀seal฀of฀Santoprene฀TPV฀from฀Advanced฀Elastomer฀
Systems,฀LP฀that฀creates฀the฀watertight฀barrier฀between฀the฀faucet฀and฀the฀counter-
top,฀eliminating฀the฀need฀to฀apply฀plumber’s฀caulk฀during฀installation฀to฀achieve฀the฀
seal.฀The฀pre-installed฀TPV฀gasket฀makes฀installation฀faster,฀and฀reduces฀tools฀and฀
materials฀necessary฀for฀faucet฀installation.฀Installing฀a฀Moen฀kitchen฀faucet฀with฀the฀
redesigned฀TPV฀deck฀plate฀seals฀simply฀requires฀inserting฀the฀faucet฀through฀the฀
sink฀top,฀tightening฀the฀nuts,฀and฀attaching฀the฀watertight฀supply฀lines.฀The฀innova-
tive฀new฀deck฀plates฀will฀be฀included฀in฀all฀of฀the฀company’s฀kitchen฀faucets.
During฀a฀two-shot฀injection฀molding฀process,฀a฀narrow฀groove฀around฀the฀perim-
eter฀of฀the฀oval฀deck฀plate฀is฀injected฀with฀a฀nylon฀bondable฀grade฀of฀Santoprene฀
TPV฀ to฀ create฀ the฀ lip฀ seal.฀ The฀ TPV฀ forms฀ a฀ virtually฀ unbreakable฀ bond฀ to฀ the฀
6.2฀ Toy฀Applications 71
durable฀ nylon฀ deck฀ plate฀ to฀ produce฀ a฀ watertight฀ surface.฀ This฀ process฀ enabled฀
Moen฀ to฀ reduce฀ cycle฀ times฀ versus฀ a฀ previously฀ used฀ procedure฀ that฀ injected฀ an฀
EPDM/nitrogen-illed฀foam฀into฀a฀groove฀to฀create฀the฀gasket.
6.1.12 Time Expired DVDs
Sabic฀ Innovative฀ Plastics,฀ in฀ a฀ 2-year฀ development฀ program฀ with฀ Flexplay฀

Technologies,฀has฀helped฀develop฀a฀new฀patented฀Lexan฀polycarbonate฀copolymer฀
that฀sets฀a฀precise฀limit฀on฀the฀service฀life฀of฀DVDs฀once฀they฀have฀been฀removed฀
from฀their฀package฀and฀exposed฀to฀air.฀A฀Flexplay฀enabled฀DVD฀is฀similar฀to฀a฀con-
ventional฀DVD,฀except฀that฀it฀has฀a฀48-h฀viewing฀window฀that฀begins฀when฀the฀disc฀
is฀removed฀from฀its฀packaging.฀Consumers฀will฀then฀be฀able฀to฀enjoy฀the฀movie฀or฀
other฀product฀as฀many฀times฀as฀they฀wish฀during฀this฀time฀frame.฀After฀48฀h,฀the฀
DVD฀will฀no฀longer฀be฀readable฀by฀the฀DVD฀player฀and฀can฀then฀be฀recycled.฀
A฀ Flexplay฀ enabled฀ DVD฀ works฀ in฀ all฀ players฀ that฀ accept฀ a฀ standard฀ DVD.฀ The฀
secret฀to฀Flexplay฀discs฀lies฀in฀the฀extra฀polymer฀layer฀added฀to฀a฀standard฀DVD฀
structure.฀This฀specialized฀layer฀includes฀a฀chemical฀compound฀that฀readily฀combines฀
with฀ oxygen.฀ While฀ the฀ orginal฀ chemical฀ compound฀ is฀ transparent,฀ the฀ oxidized฀
compound฀is฀opaque.฀When฀the฀layer฀is฀transparent,฀the฀laser฀passes฀through฀to฀the฀
relective฀ layers฀ to฀ read฀ the฀ DVD฀ data฀ as฀ normal.฀ When฀ the฀ extra฀ layer฀ becomes฀
opaque,฀ data฀ on฀ the฀ DVD฀ can฀ no฀ longer฀ be฀ read.฀ The฀ polycarbonate฀ disk฀ also฀
changes฀color฀from฀red฀to฀black฀to฀indicate฀that฀the฀disk฀service฀life฀has฀expired.
6.2 Toy Applications
6.2.1 Toy Applications Market
Retailers฀are฀devoting฀less฀shelf฀space฀to฀traditional฀toys฀and฀more฀to฀highly฀proit-
able฀video฀games.฀Larger,฀higher-priced฀toys฀such฀as฀ride-on฀toys฀and฀playground฀
equipment฀ (typically฀ rotomolded)฀ that฀ offer฀ lower฀ sales฀ for฀ the฀ amount฀ of฀ aisle฀
space฀they฀consume฀as฀a฀result฀are฀feeling฀the฀crunch.฀Many฀small฀companies฀par-
ticipate฀ in฀ the฀ toy฀ market,฀ but฀ four฀ major฀ injection฀ molders฀ dominate.฀ They฀ are฀
Fisher-Price฀ (part฀ of฀ Mattel),฀ Mega฀ Bloks,฀ Little฀ Tikes฀ Co.฀ (part฀ of฀ Newell฀
Rubbermaid),฀and฀American฀Plastic฀Toys.฀Together฀they฀represent฀77%฀of฀the฀injec-
tion฀ molded฀ toy฀ business฀ in฀ North฀ America.฀ Polypropylene฀ is฀ the฀ most฀ common฀
material฀utilized฀in฀this฀market,฀representing฀approximately฀38%฀of฀injection฀molded฀
toys.฀Second฀biggest฀is฀HDPE฀at฀25%฀of฀the฀market.฀Polystyrene,฀ABS,฀polycarbon-
ate,฀and฀LDPE฀resins฀are฀also฀utilized฀in฀considerable฀amounts,฀but฀each฀constitutes฀
less฀than฀10%฀of฀the฀business.฀Fastest฀growth฀(3.8%/year)฀is฀forecast฀for฀PS;฀next฀are฀
PP฀at฀3.2%/year฀and฀HDPE฀at฀2.3%/year.฀All฀the฀other฀resins฀are฀expected฀to฀decline฀
in poundage from 2010 to 2012.
6.2.2 Rotomolded Toys
Step2฀Co.,฀a฀multinational฀manufacturer฀and฀marketer฀of฀high-quality฀plastic฀pro-
ducts฀for฀children,฀makes฀extensive฀use฀of฀rotational฀molding,฀a฀process฀that฀Step2฀
founder฀ and฀ former฀ president฀ of฀ The฀ Little฀ Tikes฀ Company฀ Tom฀ Murdough฀ pio-
neered฀for฀use฀in฀the฀consumer฀products฀market.
While฀manufacturing฀toys฀using฀rotational฀molding฀allows฀for฀tremendous฀creativity,฀
to฀successfully฀push฀the฀envelope฀and฀get฀the฀most฀out฀of฀the฀rotational฀molding฀process,฀
it฀is฀important฀to฀understand฀how฀the฀molds฀are฀made.฀For฀example,฀designers฀can฀pre-
vent฀warping฀on฀large฀surface฀areas,฀such฀as฀the฀sides฀of฀a฀children’s฀climber,฀by฀adding฀
subtle฀ features฀ like฀ crowning,฀ contours,฀ textures,฀ and฀ a฀ slight฀ ‘pillowed฀ look.’฀ Mass฀
retailer฀concerns฀add฀another฀design฀dimension฀for฀rotomolding฀designers.฀At฀Step2,฀
many฀of฀the฀products฀are฀big฀and฀bulky.฀The฀company฀expends฀a฀lot฀of฀effort฀designing฀
for฀packaging฀and฀assembly฀to฀minimize฀product฀package฀size.฀One฀of฀Step2’s฀latest฀
toys,฀its฀‘Naturally฀Playful’฀picnic฀table,฀has฀fold฀out฀legs฀that฀the฀customer฀snaps฀into฀
place฀for฀a฀permanent฀it฀–฀a฀design฀that฀saves฀considerable฀space฀in฀the฀box.
6.2.3 Large-Scale Building Toy
Sagoma฀ Inc.฀ is฀ one฀ of฀ the฀ few฀ toy฀ producing฀ companies฀ located฀ in฀ the฀ US.฀ The฀
company฀produces฀popular,฀competitively฀priced฀toys฀bearing฀its฀trademark฀that฀are฀
marketed฀and฀sold฀by฀its฀strategic฀ally฀and฀customer,฀Taurus฀Toy฀Co.฀of฀Portland,฀
ME.฀One฀successful฀toy฀is฀its฀‘No฀Ends,’฀a฀large-scale฀building฀toy฀that฀allows฀chil-
dren฀to฀build฀large-scale฀forts,฀doll฀houses,฀puppet฀theaters,฀helicopters,฀airplanes,฀
animals/dinosaurs,฀and฀more฀from฀basic฀building฀components.฀The฀toys฀encourage฀
children฀to฀learn฀to฀build,฀create,฀work฀in฀groups,฀develop฀three-dimensional฀rela-
tionship฀skills,฀and฀have฀a฀lot฀of฀fun.฀Though฀children฀can฀build฀things฀to฀large฀scale,฀
the฀parts฀are฀in฀relatively฀small฀boxes,฀less฀than฀24" × 24" × 24".
The฀company฀also฀does฀proprietary฀product฀development฀for฀other฀toy฀compa-
nies,฀ and฀ helps฀ design,฀ develop,฀ build฀ Stereolithography฀ model/prototype,฀ and฀
assists฀in฀the฀tool฀building฀for฀such฀products฀to฀make฀for฀optimum฀eficiencies฀in฀
molding.฀The฀company,฀a฀state-of-the-art฀injection฀molder฀and฀assembler,฀provides฀
both฀ product฀ design฀ and/or฀ injection฀ molding฀ services.฀ The฀ designers฀ and฀ engi-
neers฀at฀Sagoma฀are฀responsible฀for฀both฀new฀product฀design฀and฀daily฀manufactur-
ing.฀The฀company฀enjoys฀several฀alliances฀with฀local฀companies,฀rapid฀prototypers,฀
machine฀shops,฀and฀tool฀shops,฀which฀have฀lasted฀more฀than฀30฀years.
6.2.4 Highly Precise Game Joy Sticks
Logitech’s฀latest฀controller฀for฀the฀PlayStation2฀is฀the฀Logitech฀Flight฀Force฀joystick.฀
Joysticks฀are฀all฀about฀precise฀and฀natural฀control฀of฀light฀and฀space฀combat฀games.฀
6.2฀ Toy฀Applications 73
In฀addition฀to฀excellent฀control,฀Flight฀Force฀provides฀the฀exciting฀immersiveness฀of฀
Logitech’s฀ force฀ feedback฀ technology.฀ This฀ force฀ feedback฀ joystick฀ lets฀ gamers฀
experience฀ the฀ sensations฀ of฀ light฀ combat,฀ including฀ weapon฀ recoil,฀ missile฀
launches,฀explosions,฀and฀other฀effects,฀in฀compatible฀games฀for฀PlayStation2.฀Soft฀
touch฀TPV,฀ABS,฀and฀polycarbonate฀plastics฀are฀used฀throughout฀the฀application.฀
Logitech฀Flight฀Force฀features฀a฀twist฀handle฀with฀versatile฀handgrip฀positions฀for฀
easy฀ rudder฀ control฀ and฀ improved฀ hand฀ comfort฀ in฀ tense฀ game฀ situations.฀ Seven฀
action฀buttons,฀four฀on฀the฀handle,฀two฀on฀the฀base,฀and฀a฀trigger,฀provide฀a฀broad฀
range฀of฀control฀options฀to฀deliver฀easy฀access฀to฀ire฀weapons,฀select฀targets,฀and฀
perform฀other฀functions฀using฀both฀hands.฀The฀handle฀buttons฀and฀an฀eight-way฀hat฀
switch฀are฀designed฀for฀quick฀access.฀A฀high฀precision฀throttle฀provides฀accurate฀
power฀modulation,฀while฀the฀substantial฀base,฀which฀contains฀steel฀weights,฀ensures฀
stability฀when฀the฀going฀gets฀exciting.
6.2.5 High Tech Learning Toys
Electronic฀learning฀aids฀are฀one฀of฀the฀few฀growth฀categories฀in฀the฀$25฀billion฀US฀
toy฀industry.฀Parents฀spent฀more฀than฀$820฀million฀on฀electronic฀learning฀toys฀for฀
preschoolers฀in฀2010฀alone,฀despite฀a฀lack฀of฀proof฀that฀they฀will฀jump฀start฀toddlers฀
on฀the฀path฀to฀perfect฀SAT฀scores.฀A฀sizzling฀hot฀product฀is฀LeapFrog’s฀LeapPad,฀a฀
learning฀aid฀that฀emits฀sounds฀and฀music฀when฀kids฀touch฀a฀stylus฀to฀a฀picture฀or฀
letter.฀In฀what฀is฀shaping฀into฀a฀blistering฀toy฀battle,฀Mattel’s฀Fisher-Price฀responded฀
with฀its฀similar฀smash฀hit,฀introducing฀its฀PowerTouch.฀LeapFrog฀countered฀with฀
three฀new฀products฀and฀slapped฀its฀rival฀with฀a฀patent฀infringement฀lawsuit.
In฀trying฀to฀beat฀LeapFrog,฀Mattel฀endeavored฀to฀make฀its฀PowerTouch฀unique.฀
While฀kids฀use฀a฀stylus฀pen฀to฀interact฀with฀a฀LeapPad,฀they฀only฀need฀to฀use฀their฀
ingers฀to฀operate฀PowerTouch.฀In฀addition,฀the฀PowerTouch฀console฀automatically฀
recognizes฀when฀a฀page฀is฀turned.฀LeapPad฀users฀must฀push฀a฀button฀to฀continue,฀
something฀ that฀ can฀ confuse฀ small฀ children.฀ LeapFrog฀ has฀ since฀ come฀ out฀ with฀
Littletouch฀LeapPad,฀basically฀a฀touch-sensitive฀plastic฀slab.฀By฀placing฀a฀specially฀
designed฀book฀in฀a฀holder฀on฀the฀slab,฀and฀inserting฀a฀program฀cartridge,฀the฀pic-
tures฀on฀the฀book฀pages฀become฀touch-sensitive฀buttons.฀The฀products฀are฀possible฀
as฀a฀result฀of฀high-speed฀chips฀and฀compact฀memory.฀The฀same฀capabilities฀a฀few฀
years฀ago฀would฀have฀required฀a฀CD-ROM฀and฀a฀$2000฀computer.
6.2.6 Import Proof Seasonal Toys
Unlike฀many฀plastics฀processing฀markets,฀foreign฀competition฀is฀not฀a฀big฀concern฀
at฀seasonal฀products฀blow฀molder฀Grand฀Venture.฀Seasonal฀blow-molded฀products฀
are฀big,฀bulky,฀and฀do฀not฀ship฀well,฀as฀they฀cannot฀be฀stacked฀and฀they฀contain฀a฀lot฀
of฀ air.฀ The฀ irm’s฀ top฀ Christmas฀ product฀ was฀ 38฀ in.฀ light-up฀ Santa.฀ The฀ seasonal฀
products฀company฀also฀offers฀a฀range฀of฀blow-molded฀nativity฀scenes,฀stars,฀lambs฀
reindeer,฀snowmen,฀and฀other฀Christmas฀subjects.฀The฀company’s฀largest฀Christmas฀
themed฀blow-molded฀product฀is฀a฀68฀in.฀light-up฀Santa฀in฀a฀reindeer-drawn฀sleigh฀
that฀the฀company฀recently฀introduced.
All฀ of฀ Grand฀ Venture’s฀ products฀ are฀ made฀ of฀ HDPE฀ and฀ are฀ molded฀ by฀ its฀
sister฀irm,฀Falcon฀Plastics฀Inc.,฀which฀shares฀its฀Washington฀location.฀Falcon฀
had฀sales฀of฀$12฀million฀last฀year฀and฀also฀blow฀molds฀trash฀pails,฀and฀lawn฀and฀
garden฀ products฀ for฀ Grand฀ Venture.฀ Grand฀ Venture฀ typically฀ takes฀ seasonal฀
orders฀for฀Halloween฀and฀Christmas฀in฀Q1฀of฀the฀year.฀It฀began฀molding฀Santas฀
and฀other฀Christmas฀products฀in฀July,฀to฀ship฀to฀its฀biggest฀customer฀Wal-Mart฀
Stores฀ Inc.฀ Christmas฀ is฀ still฀ the฀ top฀ market฀ for฀ seasonal฀ plastic฀ products฀
marketer.
6.3 Recreation and Leisure Applications
6.3.1 Recreation and Leisure Applications Introduction
In฀the฀US,฀the฀wholesale฀value฀of฀manufacturers’฀shipments฀of฀sports฀equipment฀and฀
recreation-related฀products฀climbed฀to฀$120฀million฀and฀$334฀million,฀respectively,฀
in฀ 2010.฀ Similar฀ to฀ toy฀ manufacturing,฀ production฀ of฀ many฀ sport฀ and฀ recreation฀
products฀have฀moved฀off-shore฀to฀Asian฀molders.฀Also฀like฀many฀other฀market฀sec-
tors,฀traditional฀materials฀such฀as฀canvas,฀leather,฀wood,฀and฀metal฀used฀in฀the฀manu-
facture฀ of฀ sports฀ and฀ recreational฀ products฀ are฀ increasingly฀ displaced฀ by฀ a฀ wide฀
range฀of฀plastic฀materials.฀Products฀such฀as฀hiking฀equipment,฀camping฀gear,฀climb-
ing฀boots,฀backpacks,฀snowshoes,฀skates฀archery฀equipment,฀and฀many฀others,฀even฀
kayaks,฀are฀increasingly฀made฀of฀high฀tech฀composites฀and฀other฀plastic฀materials฀
primarily฀ for฀ their฀ excellent฀ strength฀ to฀ weight฀ ratios,฀ water฀ resistance,฀ abrasion฀
resistance, etc.
6.3.2 Ultralight Foldable Kayak
Firstlight฀Foldable฀Kayaks฀of฀New฀Zealand฀have฀launched฀a฀new฀range฀of฀foldable,฀
strong฀and฀exceptionally฀lightweight฀kayaks.฀These฀dismantable฀kayaks฀are฀made฀
up฀of฀a฀lexible฀outer฀skin฀in฀Desmopan฀TPU฀and฀a฀frame฀in฀carbon฀iber/Kevlar฀
iber.฀The฀skin฀for฀the฀kayak฀is฀produced฀by฀Epurex,฀a฀Bayer฀MaterialScience฀sub-
sidiary,฀specializing฀in฀extruded฀Desmopan฀TPU฀ilm.฀The฀entire฀hull฀is฀made฀from฀
a฀single฀piece฀of฀material,฀meaning฀there฀are฀no฀seams฀under฀the฀waterline.฀Desmopan฀
(TPU)฀was฀chosen฀for฀its฀high฀abrasion฀resistance,฀lexibility฀over฀a฀wide฀tempera-
ture฀range,฀good฀resistance฀to฀weather฀exposure,฀transparency฀if฀necessary,฀freedom฀
from฀plasticizers,฀so฀it฀does฀not฀shrink฀and฀its฀excellent฀chemical฀resistance.฀These฀
6.3฀ Recreation฀and฀Leisure฀Applications 75
advantages฀permit฀a฀dimensionally฀stable,฀3D฀outer฀skin฀which฀is฀tear-resistant฀yet฀
still฀lightweight.
The฀kayaks,฀weighing฀8–10฀kg,฀fold฀down฀into฀a฀backpack-sized฀pack.฀Assembling฀
the฀kayak฀takes฀about฀20฀min.฀Use฀of฀composite฀carbon฀iber฀and฀Kevlar฀rods฀is฀the฀
key฀to฀providing฀the฀ultimate฀in฀lightweight฀folding฀kayaks.฀Not฀only฀are฀these฀rods฀
light฀and฀strong,฀but฀they฀provide฀excellent฀torsional฀rigidity.฀The฀cross฀ribs฀made฀
from฀Dupont’s฀Zytel฀high-performance฀polyamide฀are฀exceptionally฀strong,฀yet฀will฀
lex฀to฀allow฀the฀rods฀to฀conform฀to฀the฀shape฀of฀the฀kayak.฀The฀three-dimensional฀
shape฀of฀the฀bow฀and฀stern฀is฀formed฀using฀lightweight฀molded฀foam฀end฀units฀that฀
cushion฀and฀protect฀the฀inside฀of฀the฀skin฀from฀damage฀caused฀by฀chafing฀from฀the฀
frame฀and฀reinforce฀the฀bow฀shape.
6.3.3 Clear Corrosion-Resistant Pool Cleaners
Sabic฀ Innovative฀ Plastics฀ polycarbonate/polyester฀ alloys฀ are฀ increasingly฀ being฀

used฀for฀a฀variety฀of฀pool฀and฀spa฀applications.฀Xylex฀X8210฀and฀X8300฀are฀trans-
parent,฀ have฀ good฀ impact฀ strength,฀ weathering฀ performance,฀ and฀ resistance฀ to฀
chemicals฀like฀spa฀water฀conditioners,฀bromine,฀and฀chlorine฀making฀these฀alloys฀
suitable฀for฀cleaner฀housings,฀light฀lenses,฀spa฀remote฀controls,฀pump฀covers,฀designer฀
caps,฀ilter฀parts,฀control฀panels,฀and฀other฀pool฀and฀spa฀accessories.
Xylex฀ alloys฀ combine฀ an฀ aliphatic฀ polyester฀ with฀ polycarbonate฀ to฀ offer฀ an฀
outstanding฀balance฀of฀chemical฀resistance,฀clarity,฀and฀mechanical฀strength.฀The฀
materials’฀strong฀resistance฀to฀chemicals฀used฀in฀pool/spa฀care฀and฀other฀aqueous฀
environments฀helps฀reduce฀cracking/crazing฀and฀their฀good฀UV฀performance,฀and฀
temperature฀resistance฀provide฀weatherability฀that฀is฀as฀good฀or฀better฀than฀many฀
competing฀ resins.฀ Both฀ Xylex฀ X8210฀ and฀ X8300฀ combine฀ clarity฀ and฀ ductility฀
with฀ chemical฀ resistance,฀ high฀ in฀ mold฀ low,฀ hot฀ and฀ cold฀ ambient฀ temperature฀
impact฀ strength,฀ gloss฀ retention,฀ and฀ UV฀ resistance.฀ X8210฀ resin฀ is฀ used฀ for฀ a฀
variety฀ of฀ applications฀ demanding฀ impact฀ strength,฀ ductility,฀ and฀ aesthetics฀
฀differentiation฀using฀GE฀Plastic’s฀Visualfx฀special฀color฀and฀effect฀resins,฀while฀
X8300฀ is฀ better฀ suited฀ for฀ applications฀ requiring฀ the฀ highest฀ level฀ of฀ chemical฀
resistance.
6.3.4 Cross Country Skiing/Skating
All-terrain฀skates฀from฀GateSkate,฀Inc.฀are฀designed฀to฀go฀over฀any฀type฀of฀฀surface฀
including฀asphalt,฀dirt,฀gravel,฀grass,฀and฀mountain฀trails.฀Thanks฀to฀an฀innovative฀
design฀with฀a฀rugged฀chassis฀molded฀from฀a฀new฀super฀strong฀DuPont฀Zytel฀HTN฀
high฀performance฀polyamide฀resin,฀and฀pneumatic฀tires,฀TrailSkate฀rolls฀easily฀over฀
bumps,฀cracks,฀and฀debris,฀while฀hand-operated฀hydraulic฀brakes฀allow฀skaters฀to฀
easily฀control฀speed฀and฀stop฀quickly฀while฀remaining฀comfortably฀balanced.
The฀chassis,฀essentially฀a฀ski฀on฀wheels,฀must฀withstand฀repeated฀dynamic฀loading฀
under฀ the฀ rider’s฀ full฀ weight.฀ Long฀ glass฀ ibers฀ in฀ the฀ 50%฀ glass-illed฀ Zytel฀
HTN51LG50HSL฀resin฀are฀crucial฀to฀the฀chassis’฀performance฀providing฀improved฀
fatigue฀ performance,฀ impact฀ resistance,฀ and฀ surface฀ appearance.฀ The฀ design฀ is฀ a฀
challenging฀one.฀The฀21฀in.฀long฀chassis฀has฀wall฀section฀thicknesses฀of฀0.04–0.79฀in.฀
Load-bearing฀ requirements฀ make฀ avoidance฀ of฀ stress฀ concentration฀ essential฀ and฀
therefore฀mold฀design฀proved฀critical.฀DuPont฀US฀specialists฀using฀mold฀low฀anal-
ysis฀recommended฀the฀gate฀location,฀and฀local฀specialists฀in฀China฀recommended฀
enlargement฀of฀the฀gate฀to฀enhance฀iber฀orientation฀and฀improvements฀in฀venting฀to฀
assure฀complete฀mold฀ill.
6.3.5 Snow Skates
Global฀sports฀equipment฀manufacturer฀Salomon฀is฀using฀DuPont฀Delrin฀acetal฀resin฀
for฀the฀ski฀section฀of฀its฀new฀concept,฀‘bombproof’฀PP3฀Kurb฀snow฀skate.฀PP3,฀the฀
codename฀ for฀ a฀ well-known,฀ ‘bombproof’฀ Russian฀ submarine,฀ was฀ selected฀ to฀
communicate฀that฀the฀PP3฀KURB฀resists฀shocks฀and฀damage฀from฀small฀stones.฀Snow฀
skating,฀a฀snowboard-type฀sport฀recently฀launched฀in฀the฀US,฀differs฀from฀snow฀board-
ing฀in฀that฀the฀user฀is฀not฀attached฀by฀bindings฀to฀the฀board,฀giving฀the฀snow฀skater฀a฀
greater feeling of freedom.
The฀acetal฀resin฀chosen฀for฀the฀ski฀section฀of฀PP3฀Kurb฀is฀ten฀times฀tougher฀than฀
HDPE,฀the฀standard฀material฀for฀ski฀running฀bases,฀providing฀signiicantly฀improved฀
mechanical฀resistance฀against฀small฀pebble฀damage.฀The฀acetal฀resin฀is฀also฀lexible฀
while฀remaining฀stiff฀and฀strong.฀Users฀can฀lex฀the฀ski฀by฀pushing฀down฀on฀the฀rear฀
of฀the฀maple฀wood฀deck฀to฀complete฀signiicantly฀more฀complex฀jumps฀and฀tricks฀
than฀with฀previous฀snow฀skate฀models.฀The฀design฀freedom฀given฀by฀the฀acetal฀also฀
means฀that฀Salomon฀could฀design฀side฀channels฀into฀the฀ski฀section฀for฀added฀stability฀
when฀the฀user฀wants฀to฀ride฀over฀soft,฀mountain฀snow.฀Meanwhile,฀in฀order฀for฀users฀
to฀use฀their฀snow฀skates฀in฀the฀evenings,฀down฀in฀the฀resorts,฀central฀‘grind฀channels’฀
are฀included฀in฀the฀design฀for฀extra฀stability฀when฀the฀user฀is฀‘grinding’฀along฀handrail฀
sections฀of฀skateboard฀parks.
6.3.6 Laserline Golf Tees
The฀Laserline฀tee,฀a฀goling฀innovation,฀was฀developed฀by฀Europe’s฀most฀successful฀
golf฀player,฀Nick฀Faldo,฀using฀Bayer’s฀Makrolon฀polycarbonate.฀The฀new฀tee฀prom-
ises฀ precise฀ ball฀ contact,฀ improved฀ light฀ path,฀ and฀ increased฀ hit฀ quota฀ which฀ all฀
translates฀into฀an฀improved฀game.฀Unlike฀traditional฀tees,฀the฀teepin฀has฀been฀moved฀
8฀mm฀towards฀the฀lag฀and฀ensures฀the฀direct฀contact฀with฀the฀ball฀without฀touching฀
the฀tee.฀The฀development฀improves฀ball฀contact฀at฀every฀tee฀off฀providing฀both฀ama-
teurs฀ and฀ professionals฀ with฀ a฀ more฀ precise฀ game.฀ When฀ developing฀ the฀ tee,฀ the฀
6.4฀ Furniture฀Applications 77
manufacturers,฀ ‘Spirit฀ of฀ Golf’฀ and฀ Nick฀ Faldo,฀ chose฀ polycarbonate฀ as฀ the฀ high฀
tech฀ material฀ has฀ exceptional฀ shock฀ resistance฀ and฀ is฀ unbreakable,฀ giving฀ the฀
Laserline฀tee฀a฀clear฀advantage฀compared฀to฀classical฀wooden฀and฀traditional฀plastic฀
tees.฀The฀Laserline฀tee฀is฀completely฀recyclable฀and฀complies฀with฀European฀envi-
ronmental฀requirements.฀The฀innovative฀tee฀is฀available฀in฀a฀range฀of฀colors฀and฀can฀
be฀obtained฀in฀golf฀sports฀shops.฀Spirit฀of฀Golf,฀the฀exclusive฀Bally฀Golf฀licensee,฀
recently฀introduced฀the฀Laserline฀tee฀to฀the฀United฀States฀market.
6.3.7 Light, Efficient Golf Club Merchandising Carts
Meese฀Orbitron฀Dunne฀(MOD)฀Co.’s฀American฀Rotational฀Molding฀(ARM)฀Group฀
redesigned฀and฀manufactured฀a฀custom฀golf฀club฀merchandising฀cart฀for฀Callaway฀
Golf฀Co.฀The฀merchandising฀cart,฀a฀key฀element฀in฀Callaway’s฀custom฀club฀itting฀
system,฀is฀a฀portable฀scooter฀that฀holds฀56฀woods฀and฀irons฀and฀an฀IBM฀ThinkPad฀
data฀ acquisition฀ system.฀ It฀ reportedly฀ enables฀ Callaway฀ teaching฀ professionals฀ to฀
gather฀data฀from฀each฀swing฀and฀recommend฀ideal฀club฀sizes฀with฀the฀aid฀of฀the฀
company’s฀proprietary฀itting฀software.
MOD/ARM฀ redesigned฀ the฀ cart฀ to฀ add฀ strength,฀ longevity,฀ and฀ visual฀ appeal฀
while฀guarding฀against฀the฀elements.฀A฀sleek,฀durable,฀rotationally฀molded฀polyeth-
ylene฀ structure฀ replaced฀ the฀ earlier฀ fabricated฀ metal฀ and฀ vacuum฀ formed฀ plastic฀
panel฀structure.฀The฀new฀design฀replaced฀hundreds฀of฀parts฀and฀fasteners฀and฀associ-
ated฀assembly฀requirements฀with฀nine฀rotationally฀molded฀panels,฀three฀injection฀
molded฀ wheels,฀ and฀ one฀ extruded฀ tube฀ to฀ protect฀ each฀ club.฀ The฀ simpliication฀
increased฀production฀rates,฀aided฀quality฀assurance,฀and฀contributed฀to฀an฀overall฀
cost฀reduction฀of฀75%฀versus฀the฀original฀metal฀cart.฀While฀cutting฀costs,฀MOD/
ARM฀engineers฀added฀numerous฀amenities฀and฀security฀precautions.฀The฀cart฀was฀
redesigned฀ to฀ it฀ through฀ standard-sized฀ doorways.฀ A฀ cumbersome฀ front฀ wheel฀
assembly฀was฀replaced฀with฀a฀single฀front฀wheel฀that฀swivels฀360°.฀A฀new฀brake฀
halts฀the฀cart฀when฀movement฀is฀not฀desired฀yet฀remains฀hidden฀from฀view฀for฀visual฀
appeal.฀A฀clever฀towing฀bar,฀which฀stows฀inside฀a฀compartment฀at฀the฀front฀of฀the฀
cart฀when฀not฀in฀use,฀was฀added฀to฀permit฀towing฀with฀a฀golf฀cart.
6.4 Furniture Applications
6.4.1 Furniture Applications Introduction
The฀furniture฀market฀consists฀of฀ive฀primary฀categories,฀home฀and฀ofice฀furniture,฀
juvenile฀or฀infant฀furniture,฀public฀seating฀(school,฀lecture฀hall,฀stadium,฀and฀arena),฀
outdoor฀and฀patio฀furniture,฀and฀miscellaneous฀furniture฀parts.฀Injection฀molded฀fur-
niture฀consumes฀the฀most฀plastic฀resin.฀In฀2010,฀the฀furniture฀market฀accounted฀for฀4%฀
of฀total฀thermoplastic฀sales.฀In฀the฀United฀States,฀domestic฀injection฀molded฀furniture฀
consumed฀ an฀ estimated฀ 409.9฀ million฀ lb฀ of฀ resin฀ in฀ 2010.฀ With฀ an฀ average฀ annual฀
growth฀rate฀around฀3%,฀this฀market฀could฀grow฀to฀475฀million฀lb฀by฀2012.฀Polypropylene฀
constitutes฀around฀80%฀of฀the฀resin฀consumed฀for฀injection฀molded฀furniture.฀HDPE฀
is฀a฀distant฀second฀place฀at฀around฀7%,฀and฀polystyrene฀is฀third฀at฀6%.
Within฀the฀injection฀molded฀furniture฀category,฀outdoor฀furniture฀is฀the฀largest฀
segment฀ (44%฀ of฀ the฀ total),฀ home฀ and฀ ofice฀ furniture฀ is฀ the฀ second฀ largest฀ area฀
(25%),฀juvenile฀and฀infant฀furniture฀represents฀22%฀of฀the฀market,฀public฀seating฀is฀
6%,฀and฀the฀miscellaneous฀furniture฀segment฀represents฀3%.฀Much฀of฀the฀injection฀
molded฀furniture฀market฀is฀directly฀related฀to฀the฀housing฀market.฀Changes฀in฀the฀
level฀of฀orders฀for฀housing-related฀furniture฀products฀arrive฀about฀6฀months฀after฀
any฀sharp฀changes฀in฀housing฀starts.
6.4.2 Polyurethane Foam Quilting Replacement
Bayer฀MaterialScience฀AG฀has฀recently฀developed฀an฀extremely฀light฀polyurethane฀
foam฀to฀replace฀the฀padded฀quilting฀that฀normally฀makes฀up฀about฀10–15%฀of฀the฀
volume฀of฀upholstered฀furniture.฀Known฀as฀HyperNova฀this฀highly฀elastic฀material,฀
thanks฀to฀the฀spatial฀crosslinking฀of฀its฀pores,฀is฀more฀dimensionally฀stable฀than฀the฀
polyester฀iber฀leece฀and฀other฀materials฀traditionally฀used฀in฀this฀service.฀Using฀
HyperNova,฀the฀seat฀surface฀of฀upholstered฀furniture฀remains฀largely฀unaffected฀by฀
frequent฀use,฀always฀recovering฀its฀shape฀when฀you฀stand฀up,฀leaving฀no฀wrinkles฀or฀
creases฀and฀the฀upholstery฀padding฀will฀retain฀its฀resilience฀over฀many฀years.฀An฀
additional฀beneit฀of฀this฀very฀soft฀polyurethane฀foam฀is฀its฀exceptional฀breathability:฀
it฀is฀extremely฀permeable฀to฀air฀and฀can฀absorb฀up฀to฀10%฀of฀its฀weight฀in฀moisture฀
and฀emit฀it฀again฀later.฀The฀breathable฀foam฀was฀manufactured฀in฀close฀cooperation฀
with฀Hennecke฀GmbH฀of฀Sankt฀Augustin,฀Germany.฀The฀environmentally฀friendly฀
foam฀ uses฀ only฀ carbon฀ dioxide฀ for฀ blowing฀ agent.฀ For฀ allergy฀ sufferers,฀ the฀ new฀
polyurethane฀foam฀is฀resistant฀to฀mite฀and฀microbe฀infestations.
6.4.3 Lightweight Composite Tables
Under฀ the฀ name฀ ‘Triple-E฀ luxe฀ tafels,’฀ Dutch฀ irm฀ Tinga฀ R&D฀ BV฀ is฀ marketing฀
lightweight,฀stackable฀tables฀that฀are฀far฀easier฀to฀handle฀than฀‘conventional’฀wooden฀
furniture,฀thanks฀to฀a฀sandwich฀composite฀using฀Baypreg,฀a฀polyurethane฀system฀
from฀Bayer.฀Sandwich฀composites฀were฀originally฀considered฀exotic฀materials฀pri-
marily฀used฀in฀aerospace฀and฀more฀recently฀automotive฀manufacturing.฀Now฀thanks฀
to฀a฀promising฀idea฀from฀Tinga฀R&D,฀they฀will฀soon฀be฀found฀in฀lecture฀or฀dining฀
halls฀and฀cafeterias.
Setting฀ up฀ and฀ taking฀ down฀ tables฀ in฀ a฀ multipurpose฀ room฀ is฀ usually฀ a฀ heavy฀
chore.฀ Tinga฀ recognized฀ the฀ potential฀ that฀ sandwich฀ composites฀ with฀ their฀ low฀
6.4฀ Furniture฀Applications 79
weight฀and฀high฀strength฀might฀offer฀the฀furniture฀industry.฀Using฀a฀sandwich฀design฀
the฀Triple-E฀tables฀weigh฀only฀12.5฀kg฀despite฀measuring฀80฀×฀200฀cm.฀The฀core฀of฀
these฀tables฀is฀made฀of฀a฀lightweight฀rigid฀PU฀foam,฀reinforced฀top฀and฀bottom฀with฀
lax฀mats฀to฀absorb฀tensile฀forces.฀The฀external฀surface฀is฀coated฀with฀an฀extremely฀
tough,฀washable฀plastic฀ilm฀available฀in฀imitation฀wood฀or฀colored฀inishes.฀The฀
table฀edges฀are฀reinforced฀with฀solid฀wood.฀To฀manufacture฀a฀sandwich฀composite,฀
the฀iber฀mats฀are฀thoroughly฀impregnated฀on฀both฀sides฀with฀PU฀in฀a฀spray฀process.฀
The฀ sandwich฀ components฀ are฀ then฀ placed฀ in฀ a฀ preheated฀ mold฀ and฀ pressed฀ into฀
inal฀shape฀at฀an฀elevated฀temperature฀(60–120°C)฀and฀pressure฀(6–8฀bar).฀The฀PU฀
cures฀in฀minutes.฀The฀sandwich฀composite฀requires฀no฀after฀treatment.฀This฀highly฀
economical,฀one-step฀process฀produces฀a฀durable,฀very฀tough฀and฀rigid฀composite฀
that฀can฀withstand฀even฀high฀mechanical฀loads.
6.4.4 Naturally Flexing Office Chairs
An฀ attractive฀ new฀ chair,฀ part฀ of฀ contract฀ furnishings฀ manufacturer฀ Allsteel฀ Inc.’s฀
‘Get฀Set’฀line฀of฀ofice฀chairs,฀tables,฀and฀accessories,฀is฀its฀Get฀Set฀multi-purpose฀
room฀seating/ofice฀side฀chair.฀The฀new฀chair,฀a฀comfortable,฀lexible฀solution฀for฀
learning฀environments,฀is฀designed฀for฀both฀horizontal฀nesting฀and฀vertical฀stacking฀
(up฀to฀four฀high)฀for฀versatile,฀easy฀transportation฀and฀storage.฀Though฀portability฀is฀
a฀plus,฀the฀beneit฀of฀Get฀Set฀chairs฀is฀the฀hours฀of฀comfortable฀seating฀they฀provide.฀
Unlike฀non-padded฀folding฀or฀stacking฀chairs฀often฀used฀in฀a฀learning฀setting,฀Get฀
Set฀chairs฀focus฀on฀comfort,฀featuring฀seat฀cushions฀and฀a฀unique฀‘lex฀back,’฀which฀
has฀a฀structure฀that฀lexes฀naturally,฀to฀counterbalance฀body฀weight฀and฀conform฀to฀
support฀users฀of฀different฀shapes฀and฀sizes.฀An฀ergonomic฀sloping฀arm฀option฀also฀
allows฀for฀natural฀movement฀of฀the฀body.฀Perforations฀in฀the฀chair฀back฀allow฀air฀
circulation,฀an฀important฀consideration,฀as฀well.฀Durable฀multi-surface฀casters฀make฀
movement฀easy.
Innovative฀ Injection฀ Technologies฀ Inc.฀ of฀ West฀ Des฀ Moines,฀ Iowa,฀ injection฀
molds฀several฀parts฀for฀the฀stacking฀ofice฀chair,฀from฀18%฀glass-illed฀nylon,฀using฀
gas-assisted molding.
6.4.5 Performance Enhanced Window Shades
DuPont฀Delrin฀acetal฀resin฀is฀used฀for฀the฀gears฀in฀an฀innovative฀new฀gearbox฀for฀
Hunter฀Douglas’s฀UltraGlide฀lifting฀system,฀which฀eases฀height฀adjustment฀of฀hon-
eycomb฀window฀shades.฀The฀low-friction฀gearbox฀allows฀Hunter฀Douglas฀to฀extend฀
their฀product฀offering฀to฀larger฀shades,฀by฀providing฀a฀mechanical฀advantage฀to฀lift฀
weights฀up฀to฀7฀lb,฀about฀double฀that฀without฀a฀gearbox.
Performance฀ Gear฀ Systems,฀ Inc.฀ (www.performance-gear.com)฀ designed฀ the฀
gearbox฀to฀meet฀Hunter฀Douglas’s฀needs฀for฀smooth฀operation฀and฀low฀wear฀in฀a฀
compact฀package฀that฀its฀in฀the฀space฀limited฀conines฀of฀the฀shade’s฀head฀rail.฀
The฀gearbox฀contains฀three฀gears,฀input,฀parallel-mounted฀cluster,฀and฀output฀gear.฀
Performance฀Gear฀Inc.฀injection฀molds฀all฀three฀gears฀from฀a฀specially฀formulated฀
ultra฀ low฀ friction฀ grade฀ of฀ Delrin฀ containing฀ 10%฀ by฀ weight฀ of฀ DuPont฀ Telon฀
PTFE฀luoropolymer฀in฀micropowder฀form.฀The฀connector฀is฀molded฀from฀general฀
purpose฀grade฀Delrin฀500P.฀Telon’s฀locked-in฀lubricating฀action฀ensures฀that฀there฀
is฀no฀risk฀of฀fabric฀staining,฀a฀potential฀problem฀with฀externally฀lubricated฀resins.฀
Other฀components฀of฀the฀gearbox฀are฀the฀housing,฀housing฀cap,฀and฀retainer.฀The฀
retainer฀holds฀the฀gears฀in฀the฀housing฀and฀has฀an฀integral฀bearing฀shaft฀for฀the฀
input฀and฀output฀gears.฀Performance฀Gear฀molds฀these฀parts฀from฀DuPont฀Zytel฀
132฀F฀nylon฀resin,฀an฀unreinforced,฀fast฀cycling฀PA66฀grade.
6.4.6 Renewable Resource Sleep Products
Pillows,฀comforters,฀mattress฀pads,฀and฀iberbeds฀illed฀with฀NatureWorks฀ibers฀are฀
beginning฀to฀appear฀on฀store฀shelves,฀offering฀consumers฀a฀new฀and฀natural-based฀
alternative฀to฀traditional฀synthetic฀ibers.฀The฀new฀ibers฀made฀from฀an฀entirely฀corn฀
derived฀product฀were฀developed฀by฀Paciic฀Coast฀Feather฀Co.,฀a฀leader฀in฀the฀US฀
and฀Canadian฀bedding฀industry.฀These฀new฀bedding฀products฀provide฀natural฀com-
fort฀ and฀ warmth฀ with฀ superior฀ performance฀ attributes฀ versus฀ polyester฀ iberill.฀
These฀ new฀ products฀ provide฀ a฀ natural฀ loft฀ and฀ resilience฀ to฀ give฀ greater฀ support฀
while฀sleeping,฀while฀the฀insulating฀warmth฀and฀wicking฀attributes฀make฀for฀a฀dryer฀
and฀more฀comfortable฀sleep฀experience.฀Overall,฀NatureWorks฀ibers฀combine฀the฀
best฀physical฀characteristics฀of฀natural฀ills฀and฀polyester฀synthetics฀but฀with฀supe-
rior฀performance฀that฀will฀not฀diminish฀after฀washings฀or฀through฀extended฀use.฀The฀
new฀ natural-based฀ ibers฀ deliver฀ great฀ comfort,฀ loft,฀ and฀ durability฀ without฀ the฀
‘environmental฀ shortcomings’฀ of฀ petroleum-based,฀ polyester฀ ibers.฀ NatureWorks฀
uses฀20–50%฀less฀fossil฀resources฀in฀the฀production฀process฀than฀conventional฀plas-
tics,฀resulting฀in฀signiicantly฀less฀CO2 emissions.
6.4.7 Environmentally Friendly Chairs
The฀Mirra฀midlevel฀executive฀chair฀is฀Herman฀Miller’s฀most฀advanced฀launch฀fol-
lowing฀their฀‘Design฀for฀the฀Environment’฀protocols,฀which฀provides฀guidelines฀that฀
engineers/designers฀must฀meet฀at฀every฀stage฀For฀the฀Mirra฀that฀meant฀considering฀
not฀just฀the฀types฀of฀resins฀used,฀but฀the฀breakdown฀of฀all฀materials฀including฀stabi-
lizer฀in฀the฀nylon฀and฀pigment฀for฀the฀polypropylene.฀Working฀under฀the฀guidelines฀
of฀the฀McDonough฀Braungart฀Design฀Chemistry฀system,฀HMI฀dropped฀the฀use฀of฀
PVC,฀replacing฀it฀with฀nylon฀or฀TPE.
The฀effort฀affected฀the฀chair’s฀overall฀design.฀In฀addition฀to฀comfort฀during฀its฀work฀
life,฀the฀chair฀is฀designed฀for฀easy฀disassembly฀for฀recycling.฀A฀typical฀chair฀back฀sup-
port฀has฀structural฀steel฀with฀an฀overmolded฀plastic฀skin,฀and฀adjustment฀mechanisms฀of฀
6.5฀ Lawn฀and฀Garden฀Applications 81
overmolded฀ screws฀ and฀ springs.฀ Nearly฀ impossible฀ to฀ recycle,฀ Mirra฀ designers฀ and฀
engineers฀decided฀to฀use฀an฀all฀polypropylene฀seat฀back฀supported฀by฀a฀glass฀illed฀
structural฀nylon฀spine,฀with฀a฀composite฀leaf฀spring.฀A฀nonilled฀nylon฀webbing฀provides฀
additional฀lumbar฀support.฀The฀chair฀can฀be฀disassembled฀for฀recycling฀within฀30฀s.
6.5 Lawn and Garden Applications
6.5.1 Lawn and Garden Introduction
The฀$30฀billion฀US฀lawn฀and฀garden฀market฀which฀consists฀of฀three฀primary฀catego-
ries฀–฀outdoor฀equipment,฀supplies,฀and฀professional฀lawn฀care฀services฀–฀is฀expected฀
to฀grow฀by฀5.5%฀annually฀through฀2012฀as฀American฀homeowners,฀now฀at฀a฀record฀
number,฀settle฀into฀their฀newly฀acquired฀properties฀and฀baby฀boomers฀enter฀the฀peak฀
years฀for฀gardening฀popularity.฀Driving฀this฀market฀are฀extremely฀favorable฀demo-
graphics,฀continued฀homeowner฀afluence,฀and฀a฀new฀focus฀on฀push-marketing฀by฀
the฀consolidating฀major฀players,฀a฀proliferation฀of฀lawn฀and฀garden฀retailers,฀and฀
numerous฀new฀products฀introduced฀to฀satisfy฀the฀needs฀of฀millions฀of฀homeowners.฀
Additionally,฀golf฀courses฀are฀big฀business฀for฀the฀lawn฀and฀garden฀market.
6.5.2 Novel Plastic Fencing
Kroy฀Building฀Products,฀Inc.,฀a฀leading฀manufacturer฀of฀vinyl฀fencing,฀decks,฀railing,฀
accessories,฀decorative฀structures,฀and฀specialty฀building฀products,฀has฀introduced฀a฀
novel฀new฀vinyl฀fence฀technology฀that฀offers฀superior฀strength฀and฀performance.฀The฀
new฀technology,฀named฀‘Fusion฀Fence,’฀uses฀sonic฀welding฀rather฀than฀glue฀during฀
the฀assembly฀process,฀to฀create฀a฀stronger,฀more฀durable฀fence.฀Fusion฀welding฀the฀
vinyl฀components฀to฀the฀main฀frame฀of฀the฀fence฀section฀produces฀a฀sturdier฀and฀
more solid fence.
Kroy’s฀ new฀ Fusion฀ Fence฀ also฀ simpliies฀ the฀ purchase/installation฀ of฀ compo-
nents,฀producing฀a฀single฀unit฀that฀is฀easy฀to฀purchase,฀transport,฀and฀install.฀Every฀
Fusion฀Fence฀vinyl฀section฀is฀custom฀manufactured฀to฀precisely฀it฀the฀customer’s฀
speciications.฀All฀Fusion฀Fence฀vinyl฀proiles฀are฀manufactured฀via฀an฀extrusion฀
process,฀fabricated฀with฀computerized฀machinery฀and฀assembled฀with฀fusion฀vinyl฀
welders฀for฀superior฀strength,฀durability,฀and฀aesthetics.฀The฀technology฀is฀available฀
in฀a฀wide฀range฀of฀traditional฀and฀classic฀fence฀designs฀for฀both฀the฀new฀construction฀
and฀remodeling฀markets.
6.5.3 Miracle-Gro Multipurpose Pails
Seeking฀to฀redesign฀its฀Miracle-Gro฀pail,฀Scotts฀Co.,฀the฀world’s฀largest฀marketer฀of฀
branded฀ consumer฀ and฀ garden฀ products฀ enlisted฀ the฀ aid฀ of฀ Unimark฀ Plastics.฀
Unimark,฀ a฀ leading฀ full-service฀ supplier฀ of฀ innovative฀ plastic฀ and฀ manufacturing฀

solutions,฀ specializes฀ in฀ high-volume,฀ precision฀ injection฀ molding.฀ Replacing฀ a฀
nondescript฀stock฀pail฀previously฀used฀to฀hold฀four฀different฀varieties฀of฀the฀water฀
soluble฀plant฀food฀formula฀with฀an฀updated฀design฀has฀helped฀sales฀of฀the฀fertilizer฀
to฀lourish.
Scotts฀ wanted฀ to฀ improve฀ its฀ miracle฀ gro฀ market฀ presentation฀ from฀ the฀ stock฀
container฀ and฀ involved฀ Unimark฀ right฀ from฀ the฀ beginning฀ of฀ the฀ redesign.฀ Other฀
Scotts฀goals฀for฀the฀new฀design฀were฀an฀easily฀removable฀lid฀and฀stackability.฀It฀also฀
wanted฀to฀eliminate฀secondary฀printing฀on฀the฀lid฀and฀replace฀it฀with฀a฀molded฀in฀
engraving฀of฀the฀Miracle-Gro฀logo฀and฀name.฀Unimark฀helped฀improve฀the฀polypro-
pylene฀ bucket฀ through฀ its฀ Greenville-based฀ Innovative฀ Solutions฀ design฀ house,฀
designing฀a฀domed฀lid฀that฀sheds฀water.฀To฀improve฀appearance,฀the฀edges฀of฀the฀
container฀are฀rounded.฀A฀Miracle-Gro฀logo฀is฀molded฀on฀the฀lid.฀Another฀design฀
change฀helps฀the฀buckets฀stack฀on฀top฀of฀each฀other฀like฀Legos,฀as฀each฀lid฀its฀into฀
the฀bottom฀of฀the฀pail฀on฀top฀of฀it.฀Unimark฀promotes฀pellet-to-pallet฀automation฀
capabilities,฀providing฀cost-eficient฀solutions฀so฀that฀their฀customers฀can฀put฀extra฀
money฀ into฀ the฀ design฀ and฀ marketing.฀ The฀ inished฀ Scotts฀ product฀ is฀ a฀ compact,฀
sturdy฀and฀bright,฀high฀gloss฀garden฀container฀in฀a฀bouquet฀of฀four฀vibrant฀colors฀
and฀a฀new฀packaging฀market฀for฀Unimark.
6.5.4 Non-Slip Garden Tools
Fiskars฀Corp.,฀a฀leading฀manufacturer฀of฀scissors฀and฀knives,฀has฀introduced฀non-slip฀
garden฀pruners.฀Fiskars฀requires฀any฀design฀to฀unify฀all฀the฀qualities฀of฀an฀ergonomic฀
product,฀including฀quality,฀viability,฀safety,฀and฀comfort.฀Starting฀from฀this฀design฀
philosophy,฀Fiskars฀looked฀to฀design฀three฀new฀garden฀ingerloop฀pruners.฀The฀com-
pany฀wanted฀to฀produce฀these฀tools฀with฀grips฀that฀were฀more฀comfortable,฀soft฀and฀
slip-resistant฀than฀previous฀designs,฀making฀the฀pruners฀much฀easier฀to฀use.฀Fiskars฀
initially฀considered฀using฀a฀modiied฀grade฀of฀polyamide,฀the฀traditional฀material฀for฀
grips฀in฀these฀applications,฀but฀this฀option฀proved฀to฀be฀too฀costly.฀Alternative฀mate-
rials฀were฀assessed,฀and฀it฀soon฀became฀clear฀that฀Santoprene฀thermoplastic฀vulcani-
zates฀(TPVs)฀would฀produce฀the฀desired฀level฀of฀comfort฀and฀softness.
The฀grips฀for฀the฀tools฀are฀produced฀using฀a฀two-shot฀injection฀molding฀process,฀
consisting฀of฀a฀shot฀of฀black฀nylon฀6฀with฀30%฀glass฀iber฀(Durethan฀BKV฀130)฀
followed฀by฀a฀shot฀of฀gray฀Santoprene฀TPV฀8291-70PA,฀eliminating฀the฀need฀for฀
adhesives฀or฀assembly฀procedures.
6.5.5 Functional Stylized Glazing
Conservatory฀ roof฀ manufacturer฀ Wendland฀ is฀ offering฀ Sabic฀ Innovative฀ Plastics’฀

new฀Lexan฀Thermoclear฀Easy฀Clean฀polycarbonate฀sheet฀in฀a฀product฀line฀to฀help฀
6.5฀ Lawn฀and฀Garden฀Applications 83
their฀ conservatory฀ roofs฀ to฀ stay฀ clean.฀ The฀ Sabic฀ Innovative฀ Plastics’฀ Lexan฀
Thermoclear฀ Easy฀ Clean฀ sheet฀ is฀ part฀ of฀ the฀ Lexan฀ Thermoclear฀ sheet฀ range฀ of฀
lightweight,฀weather-฀and฀impact-resistant฀sheets฀extruded฀from฀Lexan฀resin.฀Lexan฀
Thermoclear฀Easy฀Clean฀sheet฀features฀a฀special฀coating฀on฀the฀outside฀surface฀that฀
provides self-cleaning properties.
Suitable฀for฀all฀applications฀that฀are฀exposed฀to฀rain฀or฀water,฀this฀specially฀treated฀
Lexan฀ sheet฀ has฀ a฀ special฀ hydrophobic฀ coating฀ developed฀ by฀ Sabic฀ Innovative฀
Plastics฀that฀reduces฀the฀angle฀of฀water฀drops฀on฀the฀sheet฀from฀101°฀to฀66°.฀As฀a฀
result฀the฀drops฀of฀water฀get฀bigger฀and฀transport฀and฀drain฀off฀the฀dirt฀on฀the฀sheet.฀
The฀multi-wall฀sheet฀has฀UV฀protection฀on฀both฀sides฀and฀the฀unique฀Easy฀Clean฀
properties฀on฀the฀upper฀side.฀The฀sheet,฀which฀is฀produced฀in฀a฀range฀of฀thicknesses,฀
offers฀high฀light฀transmission,฀good฀insulation฀properties,฀and฀good฀impact฀resis-
tance.฀Sabic฀backs฀the฀self-cleaning฀properties฀of฀the฀product฀with฀a฀3-year฀warranty,฀
although฀tests฀indicate฀it฀will฀last฀signiicantly฀longer.
Chapter 7
Medical, Emerging, and Other End
Use Applications
Keywords฀ Medical฀•฀Catheter฀•฀Surgical฀•฀Emerging฀•฀PLA฀•฀Luminescent฀•฀Virtual฀
layering฀•฀Government฀•฀Pipe฀•฀Waste฀management
7.1 Medical Applications
7.1.1 Medical Applications Introduction
Medical฀is฀a฀strong฀and฀growing฀market,฀particularly฀as฀the฀baby฀boomer฀generation฀
enters฀old฀age.฀The฀industry฀projects฀demand฀for฀disposable฀medical฀supplies฀will฀
grow฀5.6%฀annually฀through฀2012.฀Gains฀will฀be฀led฀by฀drug-eluting฀stents,฀preilled฀
inhalers,฀and฀syringes,฀as฀well฀as฀cellular฀analysis,฀nucleic,฀and฀blood฀glucose฀diag-
nostic฀devices.฀US฀disposable฀medical฀supplies฀was฀a฀$60.3฀billion฀industry฀in฀2010,฀
with฀ the฀ largest฀ players฀ being฀ Johnson฀ &฀ Johnson,฀ Abbott฀ Laboratories,฀ Becton-
Dickinson,฀Kimberly-Clark,฀Baxter฀Healthcare,฀3M,฀Boston฀Scientiic,฀and฀Roche.
The฀US฀medical฀device฀industry฀produces฀one-half฀of฀the฀world’s฀medical฀devices฀
and฀consumes฀approximately฀40%฀of฀the฀world’s฀output.฀Most฀of฀the฀market฀is฀held฀
by฀ just฀ 17฀ companies฀ that฀ account฀ for฀ 65%฀ of฀ the฀ total฀ revenue฀ in฀ this฀ segment.฀
Although฀there฀are฀approximately฀6,000฀medical฀device฀manufacturers฀employing฀
about฀ 400,000฀ people,฀ roughly฀ 80%฀ of฀ those฀ companies฀ employ฀ fewer฀ than฀ 50.฀
Many฀are฀small,฀entrepreneurial฀irms฀that฀produce฀very฀speciic฀devices.฀The฀market฀
is฀projected฀to฀reach฀$68.9฀billion฀this฀year฀and฀$74.5฀billion฀in฀2011.
7.1.2 High Tech IV Catheters
Medical฀ device฀ contract฀ manufacturer฀ NDH฀ Medical,฀ Inc.฀ is฀ patenting฀ its฀ novel฀
extrusion฀ process฀ to฀ produce฀ unique฀ catheter฀ tubing฀ for฀ a฀ new฀ line฀ of฀ catheters.฀

86 7฀ Medical,฀Emerging,฀and฀Other฀End฀Use฀Applications฀
The฀ extrusion฀ process฀ produces฀ multi-lumen฀ catheter฀ tubing฀ with฀ varying฀ wall฀
thicknesses.฀NDH฀used฀the฀new฀process฀in฀developing฀the฀irst฀product฀utilizing฀the฀
FlatCath฀ Hemodialysis฀ Catheter฀ technology฀ under฀ an฀ agreement฀ with฀ FlatCath,฀
LLC฀of฀Georgia,฀a฀joint฀venture฀between฀Hatch฀Medical฀LLC฀and฀the฀tubing฀inventor,฀
Aubrey฀ Palestrant,฀ M.D.฀ Palestrant฀ holds฀ a฀ patent฀ on฀ the฀ tubing.฀ Large,฀ multi-
lumen฀catheters฀are฀regularly฀placed฀into฀the฀venous฀system฀to฀perform฀hemodialysis,฀
infusion฀or฀aspiration.฀Catheter฀placement฀often฀creates฀turbulence฀and฀sluggish฀
blood฀low฀resulting฀in฀a฀myriad฀of฀patient-related฀health฀concerns.฀The฀FlatCath฀
technology฀facilitates฀a฀signiicantly฀reduced฀cross-sectional฀catheter฀proile฀within฀
the฀blood฀vessel฀when฀the฀catheter฀is฀not฀in฀use฀reducing฀the฀risk฀of฀blood฀clots฀and฀
complications.฀ NDH฀ Medical฀ specializes฀ in฀ custom฀ extrusion฀ of฀ single-lumen,฀
paratubing,฀ multi-lumen,฀ and฀ co-extruded฀ tubing.฀ The฀ company฀ provides฀ insert฀
molding,฀injection฀molding,฀pad฀printing,฀assembly,฀and฀other฀services฀as฀well฀as฀
in-house฀tooling฀design฀and฀fabrication.
7.1.3 Life-Saving Items Safely Packaged
Storopack,฀a฀leading฀manufacturer฀of฀structural฀molded฀packaging,฀is฀using฀BASF’s฀
Neopor฀expandable฀PS฀for฀boxes฀used฀in฀the฀transport฀of฀blood฀products฀and฀organs.฀
Since฀these฀life-saving฀products฀must฀be฀maintained฀at฀constant฀temperature,฀good฀
thermal฀insulation฀is฀essential.฀Storopack฀molds฀Neopor,฀which฀comes฀in฀the฀form฀
of฀small฀black฀beads,฀into฀silver-grey฀foam฀blocks฀and฀shapes.฀Neopor฀has฀outstand-
ing฀heat฀insulation฀properties,฀high฀compressive฀strength,฀impact฀absorption,฀light-
ness฀ and฀ moisture฀ resistance.฀ It฀ also฀ contains฀ infrared฀ absorbers฀ and฀ relectors,฀
which฀lower฀the฀foam’s฀thermal฀conductivity฀and฀give฀it฀its฀silver฀grey฀color.
One฀ package฀ is฀ a฀ blood฀ product฀ foam฀ container฀ called฀ MonoTripleBox฀ that฀
Storopack฀ designed฀ with฀ medical฀ products฀ company฀ Delta฀ T฀ of฀ Germany.฀ The฀
MonoTripleBox฀ is฀ a฀ highly฀ insulating฀ Neopor฀ box฀ designed฀ for฀ shipping฀ blood฀
products฀ by฀ post฀ or฀ courier.฀ The฀ box,฀ comprising฀ two฀ foam฀ halves฀ with฀ walls฀
65–80฀mm฀thick,฀can฀hold฀up฀to฀three฀temperature฀control฀packs,฀containing฀bags฀of฀
blood฀ or฀ plasma.฀ The฀ temperature฀ control฀ packs฀ by฀ Delta฀ T฀ called฀ ‘x°-Control’฀
resemble฀domestic฀freezer฀packs฀and฀contain฀a฀special฀hydrocarbon฀cooling฀medium,฀
which฀is฀used฀to฀maintain฀the฀blood฀products฀at฀a฀stable฀temperature฀during฀transport.฀
Once฀encased฀in฀Neopor,฀red฀blood฀corpuscles฀can฀be฀maintained฀at฀2–8°C฀for฀over฀
24฀h฀at฀an฀ambient฀temperature฀of฀25°C.
7.1.4 Highly Maneuverable Surgical Microscope
Operating฀ microscopes฀ play฀ a฀ crucial฀ role฀ in฀ the฀ operating฀ room.฀ They฀ must฀
deliver฀ top฀ performance฀ in฀ a฀ highly฀ demanding฀ environment฀ and฀ they฀ must฀ be฀
lightweight,฀always฀accessible฀but฀never฀in฀the฀way฀during฀demanding฀and฀detailed฀
work.฀ Consequently,฀ these฀ instruments฀ are฀ equipped฀ with฀ highly฀ sophisticated฀
7.1฀ Medical฀Applications 87
balancing฀ systems฀ that฀ ensure฀ high-precision฀ movement฀ of฀ the฀ complex฀ optical฀
system฀without฀manual฀involvement฀on฀the฀part฀of฀the฀surgeon.฀The฀arm฀which฀the฀
microscope฀moves฀on฀must฀therefore฀be฀as฀light฀as฀possible.฀High-performance฀
plastics฀like฀the฀lightweight,฀robust,฀Baydur฀110฀polyurethane฀system฀from฀Bayer฀
MaterialScience฀AG฀are฀ideal฀for฀use฀in฀this฀application.
Leica฀utilizes฀Baydur฀110฀polyurethane฀for฀all฀six฀housing฀components฀in฀its฀new฀
M520F40฀operating฀microscope,฀manufactured฀by฀the฀Swiss฀polyurethane฀proces-
sor฀Puratech฀GmbH฀of฀Altendorf.฀The฀Baydur฀110฀molded฀parts฀have฀thin฀walls,฀
making฀them฀lightweight฀while฀still฀extremely฀stiff.฀These฀properties฀enabled฀the฀
Leica฀engineers฀to฀avoid฀using฀a฀sheet฀metal฀or฀aluminum฀framework,฀which฀would฀
have฀ made฀ the฀ arm฀ signiicantly฀ heavier.฀ The฀ Baydur฀ material฀ also฀ has฀ excellent฀
lowability฀so฀that฀even฀complex฀product฀geometries฀such฀as฀ribbing,฀apertures,฀or฀
undercuts฀can฀be฀realized฀easily฀in฀a฀single฀step.฀These฀thin-walled,฀high-strength฀
housings฀ allow฀ complete฀ and฀ reliable฀ protection฀ of฀ the฀ electronics฀ and฀ delicate฀
mechanical฀components.฀Also,฀as฀sharp฀corners฀and฀edges฀are฀avoided฀in฀the฀design,฀
the฀operating฀microscope฀is฀easy฀to฀clean฀and฀disinfect.฀This฀is฀facilitated฀by฀the฀
good฀coatability฀and฀excellent฀chemical฀resistance฀of฀the฀polyurethane.
7.1.5 Surgical Microtools
ERBE฀Elektromedizin฀GmbH฀has฀developed฀microtweezers฀for฀non-invasive฀surgery฀
(keyhole฀surgery),฀with฀handle฀and฀working฀parts฀molded฀of฀glass-reinforced฀DuPont฀
Zytel.฀This฀bipolar฀microtweezer฀is฀a฀multi-purpose฀instrument฀that฀can฀grasp,฀open,฀
and฀prepare฀the฀tissue฀and฀administer฀low-intensity฀electrical฀current฀to฀stop฀blood฀low.฀
The฀handle’s฀individual฀parts฀include฀the฀main฀housing,฀a฀cable฀channel฀at฀the฀back฀and฀
a฀holder฀at฀the฀front฀for฀a฀metal฀tube,฀which฀guides฀wires฀that฀operate฀the฀tweezer฀jaws.
ERBE฀and฀system฀supplier฀PEZET฀chose฀Dupont’s฀Zytel฀70G30HSL฀in฀place฀of฀
PEEK฀originally฀planned฀for฀the฀handle.฀The฀Zytel,฀a฀glass-reinforced,฀heat-stabilized,฀
hydrolysis฀resistant฀grade฀of฀nylon฀66,฀was฀modiied฀by฀incorporation฀of฀a฀master-
batch฀to฀accept฀laser-marking.฀Very฀precise฀parts฀can฀be฀molded฀from฀this฀high-per-
formance฀resin.฀Thanks฀to฀its฀dimensional฀stability,฀the฀parts฀retain฀their฀functionality,฀
even฀after฀multiple฀sterilizations฀in฀an฀autoclave฀with฀superheated฀steam฀at฀134°C.฀
Like฀ all฀ nylons,฀ it฀ also฀ offers฀ long-term฀ resistance฀ to฀ the฀ cleaning฀ agents฀ used฀ in฀
hospitals฀and฀medical฀facilities,฀such฀as฀those฀involved฀in฀lushing฀the฀metal฀tube.
7.1.6 Micro-sized Assay Disks
Tecan฀has฀developed฀a฀fast,฀low฀cost,฀easy฀to฀use฀microlab,฀LabCD.฀As฀the฀micro-
lab฀ Uses฀ less฀ than฀ 10฀ mL฀ for฀ analysis,฀ it฀ also฀ cuts฀ consumption฀ of฀ valuable฀ test฀
compounds฀by฀up฀to฀90%.฀The฀system฀moves฀test฀compounds฀and฀reactants฀through฀
tiny฀channels฀by฀spinning฀a฀CD-sized฀disk฀at฀precise฀speeds,฀to฀perform฀48฀simul-
taneous drug screening assays.
Scientists฀working฀in฀drug฀discovery,฀molecular฀biology,฀and฀related฀areas฀rely฀on฀
high-throughput฀assays฀to฀evaluate฀how฀compounds฀are฀absorbed,฀metabolized,฀and฀
excreted,฀and฀the฀toxic฀effects฀produced.฀The฀5฀mm฀thick,฀124฀mm฀diameter฀disk฀
consists฀of฀an฀upper฀half฀containing฀the฀systems฀channels฀bonded฀to฀a฀lower฀half฀with฀
the฀storage฀and฀measurement฀wells.฀Samples฀are฀transferred฀to฀the฀disk฀by฀Tecan’s฀
Genesis฀workstation฀and฀its฀Ultra฀system฀governs฀spinning฀and฀measures฀reaction฀
products฀using฀absorbance,฀luorescence,฀and฀luminescence.฀Tecan฀evaluated฀numer-
ous฀transparent฀polymers฀for฀the฀disk฀before฀Ticona’s฀Topas฀cyclic฀olein฀copolymer฀
(COC)฀ was฀ selected.฀ The฀ COC฀ provides฀ low฀ autoluorescence฀ and฀ excellent฀ UV฀
transmittance฀in฀molded฀parts,฀minimizing฀background฀noise.฀Weidmann฀Plastics฀of฀
Switzerland฀molds฀the฀disks.฀The฀irm’s฀micromolding฀experience฀and฀proprietary฀
technologies฀enabled฀it฀to฀meet฀the฀±2฀mm฀tolerances฀of฀the฀disk’s฀tiny฀50฀mm฀chan-
nels.฀COC฀has฀the฀inherent฀dimensional฀stability฀necessary฀to฀hold฀those฀tolerances,฀
and฀its฀surface฀energy฀allows฀the฀luids฀to฀low฀predictably฀into฀the฀microchannels.
7.1.7 Home Healthcare CPAP Systems
TAGA฀Medical฀Technologies฀is฀using฀a฀polycarbonate฀compound฀supplied฀by฀RTP฀
Company฀to฀produce฀a฀proprietary฀set฀of฀bafles฀in฀its฀humidiier฀system฀used฀to฀
help฀ obstructive฀ sleep฀ apnea฀ (OSA)฀ patients.฀ Known฀ as฀ the฀ Velocity฀ Passover฀
humidiier,฀ the฀ system฀ serves฀ to฀ counteract฀ the฀ dehydrating฀ effect฀ of฀ use฀ of฀
Continuous฀Positive฀Air฀Pressure฀(CPAP),฀in฀which฀air฀is฀pumped฀to฀the฀back฀of฀the฀
patient’s฀throat฀to฀prevent฀the฀tissue฀collapse฀that฀blocks฀respiration฀in฀OSA฀patients.฀
The฀humidiier฀provides฀cool,฀moist฀air฀to฀the฀patient฀during฀CPAP฀treatment฀mini-
mizing฀the฀dehydrating฀effect฀that฀can฀lead฀to฀sinus฀problems.
TAGA฀ Medical฀ worked฀ with฀ RTP฀ and฀ molder฀ Elyria฀ Plastics฀ to฀ fabricate฀ the฀
plastic฀bafle฀system฀from฀a฀customized฀RTP฀300฀Series฀polycarbonate฀supplied฀as฀
a฀ transparent฀ blue฀ compound.฀ As฀ the฀ humidiiers฀ must฀ be฀ portable,฀ strength฀ and฀
impact฀resistance฀are฀a฀must.฀Since฀walls฀are฀as฀thin฀as฀0.050฀in.,฀the฀compound฀use฀
required฀lubricity฀and฀superior฀low฀properties.฀As฀the฀housing฀functions฀as฀a฀water฀
reservoir,฀transparency฀allows฀the฀patient฀to฀see฀when฀a฀reill฀is฀required.฀The฀inal฀
product฀was฀formulated฀with฀FDA฀compliant฀resin฀and฀pigment,฀to฀meet฀Class฀2฀
FDA฀510K฀standards฀and฀incorporated฀high฀flow฀and฀lubrication฀additives.฀
A฀notched฀Izod฀impact฀strength฀to฀15฀ft฀lbs/in.฀and฀lexural฀modulus฀of฀0.34฀psi฀×฀106
provided฀required฀strength฀and฀rigidity.
7.2 Emerging Applications
7.2.1 Emerging Applications Introduction
One฀of฀the฀most฀exciting฀emerging฀market฀in฀recent฀years฀involves฀conductive฀and฀
light-emitting฀polymers฀which฀are฀changing฀the฀face฀of฀electronics.฀A฀movement฀is฀
7.2฀ Emerging฀Applications 89
currently฀ underway฀ that฀ will฀ transform฀ the฀ way฀ we฀ view฀ information,฀ especially฀
when฀we฀are฀on฀the฀move.฀Companies฀are฀now฀producing฀prototypes฀of฀ultra-thin,฀
large-area,฀rollable฀displays฀on฀a฀routine฀basis.฀The฀technology฀will฀also฀make฀pos-
sible฀the฀production฀of฀much฀larger,฀3-D฀high-deinition฀displays฀for฀both฀indoor฀
and฀outdoor฀applications.฀Engineers฀are฀also฀now฀capable฀of฀creating฀electrolumi-
nescent฀ilm฀that฀can฀be฀illuminated฀much฀like฀irelies,฀with฀the฀application฀of฀a฀
voltage.฀Elsewhere,฀many฀new฀applications฀are฀emerging฀in฀the฀medical฀area,฀with฀
plastic฀bone฀a฀possible฀new฀market.
One฀ strongest฀ indication฀ that฀ a฀ new฀ technology฀ has฀ bridged฀ the฀ gap฀ from฀ an฀
intriguing฀to฀emerging฀technology฀is฀when฀capital฀is฀being฀bet.฀One฀of฀the฀largest฀
wagers฀made฀on฀new฀plastic฀is฀that฀placed฀by฀NatureWorks฀LLC฀on฀polylactides฀
(PLA),฀ a฀ plastics฀ made฀ from฀ a฀ bio-based฀ monomer฀ created฀ by฀ fermenting฀ corn.฀
NatureWorks฀has฀invested฀$750฀million฀and฀10฀years฀of฀R&D฀on฀their฀NatureWorks฀
PLA฀plant,฀which฀recently฀began฀operation.
Another฀measure฀of฀an฀emerging฀market฀is฀high฀growth฀rate,฀typically฀at฀or฀above฀
10%.฀By฀this฀deinition,฀plastic฀pallets฀not฀thought฀of฀as฀new฀are฀an฀emerging฀mar-
ket.฀Global฀demand฀is฀still฀growing฀at฀better฀than฀10%/year,฀and฀no฀single฀produc-
tion฀process฀is฀yet฀predominant฀in฀their฀manufacture.฀Most฀applications฀on฀reaching฀
their฀apex฀will฀have฀one฀process฀dominate,฀or฀two฀compete฀to฀some฀degree.฀For฀pal-
let฀processing,฀there฀are฀at฀least฀four฀plastics฀processes฀extensively฀used:฀injection฀
molding,฀ rotational฀ molding,฀ single-฀ or฀ twin-sheet฀ thermoforming,฀ and฀ structural฀
foam฀ molding.฀ Elsewhere,฀ business฀ is฀ booming฀ in฀ blown฀ ilm฀ for฀ stretch–hood฀
applications.฀In฀Europe฀alone฀the฀stretch–hood฀web฀market฀is฀projected฀to฀grow฀by฀
more฀than฀22%/year฀through฀2012,฀compared฀to฀5.5%/year฀growth฀for฀stretch฀ilm.
7.2.2 Plastic Bone Wound Repair
Advanced฀Ceramics฀Research฀(ACR)฀Inc.฀has฀developed฀a฀new฀type฀of฀artiicial฀
bone฀strong฀enough฀to฀support฀new฀bone฀growth฀but฀porous฀enough฀to฀be฀absorbed฀
and฀replaced฀by฀the฀human฀body.฀The฀material฀developed,฀dubbed฀‘Plasti-Bone,’฀
is฀made฀from฀a฀biologically฀compatible฀plastic฀with฀a฀ceramic฀coating.฀The฀mate-
rial฀ which฀ the฀ company฀ expects฀ to฀ reach฀ market฀ within฀ 5฀ years฀ holds฀ promise฀
over฀metallic฀inserts,฀which฀cannot฀be฀absorbed฀by฀the฀body฀and฀must฀eventually฀
be฀replaced,฀and฀also฀biological฀materials฀that฀are฀too฀brittle฀to฀support฀any฀sig-
niicant฀force.
In฀ the฀ case฀ of฀ a฀ crushed฀ arm฀ bone฀ for฀ example,฀ doctors฀ could฀ convert฀ bone฀
scans฀of฀the฀good฀arm฀into฀code฀for฀the฀construction฀of฀a฀replacement฀part฀for฀the฀
injured฀ arm฀ bone.฀ The฀ code฀ would฀ be฀ used฀ by฀ rapid฀ prototyping฀ equipment฀ to฀
make฀the฀desired฀artiicial฀bone฀segment฀from฀a฀polymer฀coated฀with฀a฀thin฀layer฀
of฀porous฀calcium฀phosphate.฀Natural฀bone฀begins฀bonding฀to฀the฀Plasti-Bone฀in฀
8฀ weeks.฀ Eventually,฀ the฀ implant฀ is฀ ‘bioresorbed’฀ replaced฀ by฀ new฀ bone฀ tissue.฀
ACR฀ developed฀ the฀ material฀ under฀ a฀ grant฀ from฀ the฀ Ofice฀ of฀ Naval฀ Research,฀
which฀is฀seeking฀advanced฀bone฀treatments฀for฀the฀wounded.฀The฀ability฀to฀use฀
rapid฀prototyping฀technology฀to฀quickly฀create฀custom฀it฀artiicial฀bone฀material฀
is฀ a฀ major฀ beneit฀ of฀ the฀ product.฀ The฀ tissue฀ engineering฀ market฀ is฀ expected฀ to฀
reach฀$80฀billion฀in฀sales฀by฀2012.
7.2.3 Satellite TV Car Antennas
Sarnatech฀BNL,฀a฀specialist฀designer฀and฀manufacturer฀of฀innovative฀plastic฀bearing฀
solutions,฀has฀teamed฀with฀KVH฀Industries฀to฀produce฀two฀molded฀parts฀for฀KVH’s฀
new฀ TracVision฀ A5฀ for฀ cars.฀ The฀ system฀ allows฀ access฀ to฀ satellite฀ TV฀ while฀ the฀
vehicle฀ is฀ moving,฀ using฀ a฀ roof-mounted฀ pancake-shaped฀ satellite฀ TV฀ antenna฀
designed฀speciically฀for฀passenger฀vehicles.฀Motors฀rotate฀the฀antenna฀as฀the฀car฀
turns.฀ A฀ computer฀ control฀ device฀ keeps฀ track฀ of฀ signal฀ strength฀ and฀ rotates฀ the฀
antenna฀to฀keep฀it฀pointed฀at฀the฀satellite.
A฀bearing฀and฀a฀giant฀thrust฀race฀form฀the฀antenna’s฀mobile฀base.฀With฀height฀of฀
the฀low-proile฀antenna฀ixed฀at฀4.5฀in.,฀an฀ultra฀thin฀bearing฀was฀required.฀Sarnatech฀
designed฀a฀bearing฀3/8฀in.฀high฀using฀BASF’s฀Ultraform฀POM฀(polyoxymethylene)฀
copolymer,฀with฀the฀pitch฀circle฀of฀the฀raceway฀as฀large฀as฀possible฀to฀offer฀maxi-
mum฀support.฀Integrated฀features฀include฀belt฀drive฀teeth,฀brass฀inserts฀to฀afix฀it฀to฀
the฀antenna฀unit,฀and฀molded฀pads฀for฀stability.฀Using฀plastic฀instead฀of฀steel฀cut฀the฀
bearing฀weight฀by฀50%฀and฀costs฀by฀a฀third.฀A฀giant฀thrust฀race฀with฀a฀25฀in.฀outside฀
diameter฀was฀designed฀to฀support฀the฀perimeter฀of฀the฀30.5฀in.฀wide฀antenna.฀This฀
large฀POM฀part฀was฀formed฀in฀eight฀identical฀sections฀with฀each฀section฀molded฀in฀
one฀shot.฀The฀eight฀sections฀of฀the฀inished฀thrust฀race฀it฀together฀effortlessly฀by฀
means฀of฀an฀integral฀clip฀connection฀design.
7.2.4 Luminescent Handbags
Bree฀Collection฀GmbH,฀an฀international฀leather฀and฀bag฀specialist,฀has฀created฀an฀
illuminated฀business฀handbag฀using฀Smart฀Surface฀Technology฀(SST).฀Bree฀had฀
been฀toying฀with฀the฀idea฀of฀illuminating฀the฀dark฀insides฀of฀handbags฀for฀some฀
time,฀but฀lacked฀an฀elegant฀solution.฀The฀answer฀is฀now฀available฀as฀Smart฀Surface฀
Technology฀developed฀by฀Bayer฀Polymers,฀in฀partnership฀with฀Lumitec,฀a฀spe-
cialist฀in฀electroluminescence฀(EL)฀and฀precision฀electronic฀components.฀EL฀is฀a฀
method฀of฀generating฀light฀reminiscent฀of฀the฀chemical฀method฀employed฀by฀ire-
lies.฀ Engineers฀ are฀ using฀ a฀ ilm฀ that฀ lights฀ up฀ on฀ application฀ of฀ a฀ voltage฀ to฀
achieve฀electroluminescence.฀An฀advantage฀of฀EL฀is฀that฀it฀does฀not฀produce฀heat.฀
However฀ until฀ now,฀ only฀ lat฀ surfaces฀ of฀ limited฀ size฀ could฀ be฀ achieved.฀ Smart฀
Surface฀Technology฀makes฀it฀possible฀for฀the฀ilms฀to฀be฀shaped฀to฀illuminate฀any฀
conceivable฀geometry.฀Incorporated฀in฀a฀nonconductive฀layer,฀the฀ilm฀in฀Bree’s฀
handbag฀lights฀up฀at฀the฀press฀of฀a฀button.฀Bayer฀Polymers,฀sees฀the฀main฀applica-
tion฀ for฀ this฀ technology฀ in฀ the฀ auto฀ industry.฀ Incandescent฀ lamps฀ in฀ cars฀ will฀
7.3฀ Other฀Applications 91
become฀obsolete.฀Instrument฀panels฀will฀be฀designed฀to฀take฀up฀less฀room฀and฀a฀
car’s฀interior฀headliner฀will฀glow฀in฀a฀soft฀glare฀free฀light.
7.2.5 “Virtual Layering” Clothing Fabrics
Malden฀ Mills฀ Industry’s฀ Polartec฀ Heat฀ Technology฀ provides฀ warmth฀ on฀ demand฀
during฀stop฀and฀go฀activities.฀Battery฀powered฀“Polartec฀Heat”฀polyester฀iber฀cloth-
ing฀panels฀reduce฀the฀need฀to฀add฀or฀subtract฀layers฀of฀clothing฀as฀weather฀or฀activity฀
levels฀change.฀The฀thin,฀lexible,฀lightweight฀panels฀are฀durable,฀machine฀washable,฀
and฀designed฀not฀to฀interfere฀with฀a฀garment’s฀function.฀The฀heat฀controller฀with฀a฀
molded฀ PBT/ABS฀ alloy฀ housing฀ provides฀ temperature฀ adjustment฀ as฀ necessary฀
using฀three฀modes:฀full฀power,฀oscillate,฀or฀power฀off.฀The฀heat฀panels฀are฀powered฀
by฀ lightweight฀ lithium฀ ion฀ batteries,฀ rechargeable฀ without฀ removal฀ from฀ the฀ gar-
ment,฀using฀standard฀110฀V฀household฀current,฀a฀solar฀powered฀charger,฀or฀a฀vehi-
cle’s฀12฀V฀cigarette฀lighter฀port.฀Battery฀life฀is฀5฀h฀on฀oscillate฀and฀2.5฀h฀on฀full฀
power.
Thermal฀ Mannequin฀ Testing฀ at฀ the฀ US฀ Army฀ Natick฀ Soldier฀ Systems฀ Center฀
have฀demonstrated฀the฀increase฀in฀thermal฀insulation฀(clo).฀When฀set฀on฀low,฀Polartec฀
Heat฀Technology฀adds฀an฀additional฀.093฀clo฀to฀the฀body’s฀microclimate,฀the฀equiva-
lent฀of฀adding฀an฀additional฀layer฀of฀Polartec฀100฀Series฀leece.฀When฀set฀on฀high,฀
an฀additional฀1.51฀clo฀is฀added฀to฀the฀body’s฀microclimate,฀equivalent฀to฀adding฀an฀
additional฀ layer฀ of฀ Polartec฀ 300฀ Series฀ leece.฀ This฀ “virtual฀ layering”฀ allows฀ the฀
wearer฀to฀quickly฀add฀and฀subtract฀insulation฀at฀the฀touch฀of฀a฀button.
7.3 Other Applications
7.3.1 Government Applications Introduction
Numerous฀ US฀ plastics฀ injection฀ molders฀ have฀ discovered฀ that฀ the฀ best฀ offense฀
against฀global฀competition฀is฀a฀good฀defense฀–฀i.e.,฀manufacturing฀for฀the฀largest฀
purchaser฀of฀goods฀and฀services฀in฀the฀world,฀the฀US฀Dept.฀of฀Defense.฀The฀mili-
tary฀budget฀for฀FY2011฀is฀$600฀billion฀with฀more฀than฀half฀that฀spent฀on฀hardware.฀
Considering฀ the฀ homeland฀ security฀ implications,฀ the฀ military/defense฀ market฀ is฀
one฀marketplace฀that฀is฀deinitely฀not฀going฀offshore.฀Many฀new฀applications฀under฀
development฀ call฀ for฀ the฀ lightweight฀ functionality฀ that฀ plastic฀ parts฀ can฀ provide฀
and฀mirror฀many฀of฀the฀opportunities฀for฀plastics฀in฀the฀nonmilitary฀markets,฀such฀
as฀ aerospace,฀ vehicular฀ equipment฀ and฀ components,฀ building฀ and฀ construction,฀
E/E,฀telecom,฀medical/dental,฀appliances,฀packaging,฀and฀IT฀parts.฀In฀nonmilitary฀
government฀markets,฀there฀is฀signiicant฀opportunity฀for฀plastics฀and฀plastic฀parts฀
producers฀ as฀ much฀ of฀ the฀ North฀ American฀ and฀ European฀ infrastructure,฀ from฀
bridges฀ to฀ tunnels,฀ power฀ and฀ pipelines฀ to฀ telephone฀ poles฀ and฀ street฀ light฀ stan-
dards฀and฀lighting฀systems,฀built฀in฀the฀1950s฀and฀1960s฀needs฀to฀be฀renovated,฀
rebuilt,฀or฀replaced.
7.3.2 Driver Safe Lamp Posts
In฀response฀to฀European฀passive฀safety฀legislation฀(EN฀12767,฀introduced฀to฀reduce฀
deaths/serious฀injuries฀resulting฀from฀vehicles฀colliding฀with฀roadside฀structures)฀col-
lapsing฀plastic฀light฀posts,฀able฀to฀absorb฀much฀of฀the฀force฀in฀a฀collision,฀have฀been฀
developed฀as฀a฀Eureka฀project฀(a฀pan-European฀network฀for฀market-oriented,฀indus-
trial฀R&D).฀There฀are฀approximately฀165฀million฀utility฀poles,฀and฀similar฀structures฀
in฀use฀throughout฀Europe฀(16฀million฀in฀the฀UK)฀with฀200฀motorist฀deaths฀and฀3,000฀
injuries/year฀in฀the฀UK฀involving฀cars฀collisions฀with฀steel฀or฀concrete฀lighting฀col-
umns.฀These฀columns฀and฀poles,฀in฀steel,฀aluminum,฀wood,฀or฀reinforced฀concrete,฀are฀
prone฀to฀corrosion฀due฀to฀the฀combination฀of฀road฀salts,฀ground฀conditions,฀and฀dog’s฀
urine,฀limiting฀their฀life฀to฀20–25฀years฀and฀none฀behave฀in฀a฀passive฀safe฀manner.
‘Thermopole’฀ lamp฀ post,฀ a฀ iber฀ reinforced฀ plastics฀ post,฀ developed฀ by฀ Euro-
Projects฀Ltd.,฀is฀light฀weight,฀durable฀(40฀years฀life),฀maintenance฀free,฀and฀is฀made฀
of฀ the฀ only฀ material฀ to฀ demonstrate฀ passive฀ safety฀ performance฀ when฀ tested฀ in฀
accordance฀with฀the฀new฀European฀standard.฀FRP฀materials฀based฀on฀thermosetting฀
polyester฀resins,฀used฀widely฀in฀lagpole฀construction,฀not฀been฀used฀in฀columns฀and฀
signposts฀ due฀ to฀ high฀ cost,฀ and฀ lack฀ of฀ engineering฀ conidence.฀ Thermopole฀ can฀
withstand฀the฀elements,฀including฀high฀winds,฀but฀fails฀when฀a฀car฀hits฀it,฀crumbling฀
or฀ hinging฀ to฀ absorb฀ the฀ impact.฀ Prototypes฀ are฀ stronger฀ than฀ steel,฀ maintenance฀
free,฀and฀recyclable.฀Over฀400฀composite฀lighting฀columns฀have฀been฀installed฀in฀
the฀UK฀on฀a฀trial฀basis.฀To฀date฀there฀have฀been฀four฀major฀high-speed฀accidents฀
involving฀the฀composite฀columns฀resulting฀in฀no฀deaths.
7.3.3 Ageless Underground Pipe
Dow’s฀Continuum฀bimodal฀PE฀resins฀offer฀the฀opportunity฀to฀install฀a฀new,฀virtually฀
leak-free฀ pipe฀ system฀ or฀ to฀ cost-effectively฀ rehabilitate฀ an฀ existing฀ system฀ using฀
trenchless฀ technology.฀ The฀ Continuum฀ bimodal฀ PE฀ resins฀ made฀ by฀ proprietary฀
Unipol฀II฀process฀technology฀are฀a฀family฀of฀performance฀differentiated฀PE฀resins฀
developed฀for฀the฀underground฀construction฀market.฀These฀PE฀resins฀provide฀longer฀
life฀expectancy฀and฀outstanding฀strength฀for฀pressure฀pipe฀and฀ittings฀used฀in฀water฀
and฀ natural฀ gas฀ distribution,฀ mining,฀ and฀ oil/gas฀ processing.฀ The฀ resins฀ offer฀
improvements฀ in฀ long-term฀ strength,฀ temperature฀ performance,฀ and฀ resistance฀ to฀
slow฀ crack฀ growth฀ and฀ rapid฀ crack฀ propagation฀ compared฀ to฀ traditional฀ PE฀ pipe฀
materials.฀The฀performance฀advantages฀of฀Continuum฀Bimodal฀PE฀resins฀provide฀
an฀ideal฀solution฀for฀helping฀ix฀the฀nation’s฀aging฀water,฀wastewater,฀and฀natural฀
gas฀distribution฀infrastructure.
7.3.4 Super Strong Water Pipe
Sekisui฀Chemical฀has฀developed฀a฀new฀composite฀three-layer฀PE฀pipe฀that฀has฀supe-
rior฀strength฀to฀conventional฀PE฀water฀pipes,฀allowing฀signiicant฀reduction฀of฀wall฀
thicknesses฀and฀raw฀material฀costs฀that฀more฀than฀offsets฀higher฀production฀costs.฀
The฀company,฀which฀is฀exploring฀licensing฀the฀technology,฀supplies฀the฀pipes฀under฀
the฀brand฀name฀Eslon฀PE฀Ultra.฀One฀area฀of฀focus฀for฀Sekisui’s฀Urban฀Infrastructure฀
and฀Environmental฀Products฀subsidiary฀that฀produces฀the฀new฀pipe฀is฀on฀new฀instal-
lations฀for฀water฀supply฀and฀sewer฀pipelines฀as฀well฀as฀replacements฀of฀conventional฀
pipes฀with฀anti-corrosive฀piping.
The฀ pipes฀ consist฀ of฀ inner฀ and฀ outer฀ layers฀ of฀ HDPE฀ sandwiching฀ a฀ sheet฀ of฀
highly฀stretched฀(20–30฀fold),฀highly฀oriented,฀spiral-wound฀Ecosurf฀HDPE฀sheet.฀
The฀inner฀layer฀is฀irst฀extruded,฀and฀the฀sheet฀then฀is฀wound฀round฀this฀inner฀layer.฀
The฀semi-inished฀pipe฀is฀next฀fed฀through฀a฀special฀extrusion฀die฀to฀add฀the฀inal฀
layer.฀The฀sheet฀has฀a฀tensile฀modulus฀of฀15฀GPa,฀a฀tensile฀strength฀of฀500฀MPa,฀and฀
elongation฀ of฀ 10%.฀ The฀ complex฀ process฀ is฀ cost-effective฀ for฀ pipes฀ with฀ outside฀
diameters฀of฀200฀mm,฀while฀400฀mm฀pipes฀are฀30%฀lower฀in฀cost.฀A฀200฀mm฀Eslon฀
PE฀Ultra฀pipe฀has฀half฀the฀wall฀thickness฀of฀Sekisui’s฀single-layer฀PE฀pipes,฀allow-
ing฀a฀single฀worker฀to฀carry฀a฀5฀m฀long฀pipe,฀easing฀installation.฀The฀irst฀commer-
cial฀ application฀ of฀ the฀ product฀ was฀ in฀ high-pressure฀ piping฀ to฀ pump฀ water฀ up฀ a฀
mountainside฀in฀Nagano฀Prefecture.
7.3.5 Composite UCAVs
The฀UCAV-N,฀unmanned฀combat฀air฀vehicle฀for฀the฀Navy,฀is฀envisioned฀as฀a฀ship-
based,฀ ‘irst฀ day฀ of฀ the฀ war’฀ force฀ multiplier.฀ Designed฀ with฀ stealth฀ features฀ and฀
shaped฀ like฀ a฀ kite,฀ Pegasus฀ is฀ constructed฀ largely฀ with฀ composite฀ materials.฀ The฀
aircraft฀measures฀27.9฀feet฀long฀and฀has฀a฀nearly฀equal฀wingspan฀of฀27.8฀feet.฀The฀
goal฀of฀the฀joint฀DARPA/Navy฀project฀is฀to฀demonstrate฀the฀technical฀feasibility฀for฀
a฀UCAV฀system฀to฀effectively฀and฀affordably฀conduct฀sea-based฀twenty-irst฀century฀
surveillance,฀ suppression฀ of฀ enemy฀ air฀ defenses,฀ and฀ strike฀ missions฀ within฀ the฀
emerging฀global฀command฀and฀control฀architecture.฀Northrop฀Grumman’s฀X-47A฀
has฀successfully฀landed฀near฀a฀predesignated฀touchdown฀point฀to฀simulate฀the฀tail-
hook฀arrestment฀point฀on฀a฀carrier฀light฀deck.฀The฀shipboard-relative฀global฀posi-
tioning฀ satellite฀ system฀ is฀ used฀ as฀ the฀ primary฀ navigation฀ source฀ for฀ increased฀
landing precision.
7.3.6 Waste Management Applications Introduction
Since฀1990,฀the฀plastics฀industry,฀as฀individual฀companies฀and฀through฀organizations฀
such฀as฀the฀American฀Plastics฀Council,฀has฀invested฀more฀than฀$1฀billion฀to฀support฀
increased฀ recycling฀ and฀ educate฀ communities฀ in฀ the฀ United฀ States.฀ Conserving฀
resources฀means฀using฀less฀raw฀materials฀and฀energy฀throughout฀a฀product’s฀entire฀life฀
from฀ development฀ through฀ disposal.฀ Plastics฀ are฀ derived฀ from฀ natural฀ resources฀ –฀
typically฀oil฀and฀natural฀gas.฀And฀yet,฀because฀of฀plastics’฀unique฀characteristics฀–฀
lightweight,฀ durability,฀ formability฀ –฀ they฀ often฀ conserve฀ more฀ resources฀ during฀ a฀
product’s฀life฀when฀compared฀to฀other฀materials.฀While฀there฀has฀been฀much฀discus-
sion฀in฀the฀US฀regarding฀waste฀management,฀recycle,฀and฀resource฀conservation,฀both฀
Europe฀and฀Japan฀are฀global฀leaders฀in฀introducing฀legislation฀and฀implementing฀pro-
grams฀to฀control฀waste฀management฀and฀conserve฀resources.
7.3.7 Recycled PET Mine Shaft Reinforcement
Jennmar฀Corp.,฀together฀with฀Terrasimco฀Inc.,฀Napcor฀and฀the฀TOP฀Bottle฀Project฀
have฀ announced฀ a฀ major฀ new฀ technology฀ and฀ application฀ use฀ for฀ post-consumer฀
PET฀bottle฀material.฀The฀process฀developed฀by฀Terrasimco฀Inc.,฀a฀Martinsburg฀WV฀
technology฀ company,฀ has฀ been฀ licensed฀ by฀ Jennmar฀ and฀ will฀ be฀ used฀ to฀ produce฀
new฀ types฀ of฀ roof฀ bolt฀ products฀ used฀ to฀ reinforce฀ coal฀ and฀ other฀ shaft฀ mines.฀
Pittsburgh-based฀Jennmar฀is฀the฀world’s฀leading฀supplier฀of฀roof฀control฀products฀
for฀the฀mining฀and฀tunneling฀industries.฀Jennmar฀has฀six฀manufacturing฀facilities฀in฀
the฀US,฀two฀in฀Australia,฀and฀a฀new฀plant฀under฀construction฀in฀China.฀The฀new฀bolt฀
will฀eliminate฀the฀two-step฀system฀previously฀used฀to฀install฀the฀bolt฀into฀the฀mine฀
roof,฀by฀applying฀a฀polyester-based฀compound฀directly฀onto฀the฀bolt.฀The฀new฀prod-
uct฀is฀called฀the฀‘Buddy฀Bar’฀to฀highlight฀the฀buddy฀system฀that฀is฀used฀in฀the฀mines฀
during฀the฀installation฀of฀the฀reinforcing฀system.
Napcor฀ (National฀ Association฀ for฀ PET฀ Container฀ Resources)฀ provided฀ the฀
expertise฀ in฀ identifying,฀ developing,฀ and฀ sourcing฀ appropriate฀ post-consumer฀
materials.฀The฀assistance฀provided฀by฀Napcor฀was฀part฀of฀the฀TOP฀Bottle฀Project฀
initiated฀ by฀ Napcor฀ to฀ eliminate฀ the฀ barriers฀ that฀ prevent฀ all฀ PET฀ bottles฀ from฀
being฀recycled฀irrespective฀of฀color฀or฀construction.฀Jennmar฀expects฀to฀have฀the฀
irst฀of฀ive฀฀projected฀retroits฀operational฀by฀the฀fourth฀quarter฀2004.฀Demand฀for฀
the฀฀post-consumer฀materials฀is฀anticipated฀to฀be฀as฀much฀as฀15฀million฀lb฀by฀the฀
end of 2005.
7.3.8 Waste Carpet Fiber Products
Carpet฀recycling฀consortium฀CARE฀(Carpet฀America฀Recovery฀Effort)฀has฀estab-
lished฀ an฀ economic฀ way฀ to฀ pelletize฀ unwashed,฀ recycled฀ nylon฀ carpet.฀ CARE,฀ a฀
jointly฀ sponsored฀ industry฀ and฀ government฀ initiative,฀ was฀ established฀ to฀ increase฀
the฀recycle/reuse฀of฀post-consumer฀carpet฀and฀reduce฀the฀disposal฀of฀waste฀carpet฀in฀
landills.฀ More฀ than฀ 2.5฀ million฀ tons฀ of฀ carpet฀ are฀ discarded฀ each฀ year฀ and฀ with฀
landill฀capacity฀declining,฀there฀is฀an฀environmental฀need฀to฀recycle/reuse฀carpet.฀
As฀used฀carpet฀is฀heavy฀and฀bulky฀to฀handle,฀it฀is฀dificult฀and฀expensive฀to฀manage฀
posing฀a฀burden฀on฀waste฀processors฀and฀often฀results฀in฀the฀illegal฀disposal฀of฀car-
pet฀by฀the฀general฀public.
CARE฀worked฀on฀the฀problem฀of฀used฀carpet฀disposal฀for฀3฀years฀with฀two฀engi-
neering฀ irms,฀ Project฀ Consultants฀ &฀ Associates฀ Inc.฀ of฀ Florida,฀ and฀ Superior฀
Polymer฀Systems฀Inc.฀of฀ON,฀Canada.฀The฀melt฀compounding฀and฀densiication฀of฀
shredded฀carpet฀proved฀too฀expensive.฀CARE฀found฀that฀a฀more฀viable฀solution฀was฀
to฀‘cold’฀press฀the฀carpet฀waste฀in฀a฀pellet฀mill.฀The฀compressed฀pellets,฀0.25–0.50฀in.฀
in฀diameter฀and฀0.50–0.75฀in.฀long,฀contain฀46%฀nylon฀iber,฀35%฀calcium฀carbonate,฀
10%฀ polypropylene,฀ and฀ 9%฀ styrene-butadiene฀ rubber.฀ The฀ pellets฀ are฀ reused฀ by฀
melt฀blending฀at฀10–50%฀levels฀with฀a฀polyolein.฀The฀nylon฀ibers,฀which฀do฀not฀
melt฀in฀the฀polyolein฀matrix,฀provide฀85%฀of฀the฀properties฀of฀a฀comparable฀quan-
tity฀of฀glass฀iber฀of฀similar฀length.฀Carpet฀pellets฀have฀been฀tested฀as฀stiffeners฀for฀
polyolein฀railroad฀ties,฀marine฀pilings,฀and฀decking.฀Pellet฀test฀quantities฀are฀avail-
able฀from฀CARE.
7.3.9 Nylon Car Parts Recycling
DuPont฀Composite฀Recycle฀Technology,฀a฀closed-loop฀nylon฀recycling฀process,฀can฀
convert฀ parts฀ made฀ of฀ glass฀ or฀ mineral฀ illed฀ nylon฀ 6฀ or฀ 66฀ into฀ irst-use฀ quality฀
material฀in฀a฀way฀that฀is฀economically฀viable฀and฀environmentally฀responsible.฀The฀
new฀DuPont฀Composite฀Recycle฀Technology฀marks฀a฀giant฀step฀forward฀in฀helping฀
automakers฀ meet฀ the฀ European฀ Union’s฀ mandates฀ for฀ end-of-life฀ vehicle฀ (ELV)฀
closed-loop฀recycling.฀The฀EU฀directive฀requires฀that฀85%฀by฀weight฀of฀a฀vehicle฀be฀
capable฀of฀recovery฀and฀reuse฀by฀the฀end฀of฀2005฀(versus฀75%฀currently).฀Results฀of฀
‘in-use’฀ testing฀ of฀ recycle฀ content฀ material฀ generated฀ by฀ a฀ development฀ program฀
with฀Denso฀Corp.฀(www.globaldenso.com)฀show฀Composite฀Recycle฀Technology฀
(CRT)฀can฀be฀one฀of฀the฀most฀effective฀technologies.
The฀feedstock฀for฀the฀study฀consisted฀of฀500฀radiator฀end฀tanks฀collected฀from฀
scrapped฀end-of-life฀vehicles฀in฀Japan.฀All฀of฀the฀tanks฀were฀made฀of฀glass฀rein-
forced฀nylon฀66.฀The฀tanks฀were฀dirty,฀and฀the฀material฀had฀been฀degraded฀by฀years฀
of฀contact฀with฀hot฀engine฀coolant.฀CRT฀dissolves฀the฀used฀polyamide,฀then฀ilters฀
away฀contaminants฀and฀illers.฀The฀molecular฀weight฀of฀the฀recovered฀polyamide฀is฀
increased฀to฀whatever฀level฀is฀the฀desired฀for฀the฀inal฀application.฀The฀process฀gen-
erates฀resin฀equivalent฀to฀virgin฀nylon.฀The฀studies฀conirmed฀the฀process’s฀capabil-
ity฀to฀convert฀nylon฀auto฀parts฀from฀scrapped฀vehicles฀into฀glass฀reinforced฀nylon฀
resins฀and฀parts฀with฀properties฀equivalent฀to฀those฀of฀virgin฀nylons฀for฀a฀workable,฀
cradle-to-cradle฀solution฀of฀radiator฀end฀tanks.฀The฀process฀can฀likely฀be฀adapted฀to฀
recycle฀air฀intake฀manifolds฀and฀other฀nylon฀parts.
7.3.10 Eco-efficient Mechanical Recycling
A฀study฀recently฀released฀by฀PlasticsEurope฀(formerly฀the฀Association฀of฀Plastics฀
Manufacturers฀ in฀ Europe฀ –฀ APME)฀ showed฀ that฀ mechanical฀ recycling฀ of฀ plastic฀
parts฀from฀cars฀is฀favorable฀from฀an฀eco-eficiency฀point-of-view฀only฀where฀large,฀
easily฀ accessible,฀ monomaterial฀ parts฀ are฀ concerned.฀ Feedstock฀ recycling฀ and฀
energy฀recovery฀are฀the฀most฀effective฀methods฀for฀recovering฀plastics฀in฀end-of-life฀
cars฀in฀the฀majority฀of฀cases.฀The฀report฀provided฀the฀irst฀quantitative฀data฀for฀the฀
comparison฀of฀recycling฀and฀energy฀recovery฀options฀for฀plastics฀parts฀in฀end-of-life฀
vehicles฀(ELV)฀and฀will฀be฀an฀important฀consideration฀in฀determining฀the฀fate฀of฀
8฀million฀cars฀reaching฀the฀end฀of฀their฀useful฀lives฀each฀year฀in฀Europe.฀The฀use฀of฀
plastics฀in฀cars฀is฀steadily฀growing฀and฀by฀2015฀it฀is฀expected฀that฀1.3฀million฀tonnes฀
of฀plastics฀waste฀will฀come฀from฀12฀million฀end-of-life฀vehicles.
Six฀ plastics฀ waste฀ management฀ options฀ (mechanical฀ recycling,฀ blast฀ furnace,฀
cement฀kiln,฀syngas฀production,฀waste฀combustion,฀landill)฀were฀analyzed฀in฀the฀
study฀with฀a฀focus฀on฀seven฀vehicle฀components฀(bumper,฀seat฀cushion,฀intake฀mani-
fold,฀wash฀liquid฀tank,฀air฀duct,฀headlamp฀lens,฀mirror฀housing).฀Key฀indings฀of฀the฀
study฀were฀(1)฀mechanical฀recycling฀is฀the฀method฀of฀choice฀mainly฀for฀large,฀easily฀
accessible,฀mono฀material฀parts.฀(2)฀For฀most฀parts,฀feedstock฀recycling฀options฀and฀
energy฀recovery฀are฀the฀methods฀of฀choice.฀(3)฀Whole฀life-cycle฀analysis฀shows฀that฀
the฀use฀phase฀of฀plastics฀parts฀in฀cars฀that฀have฀the฀largest฀contribution฀to฀the฀envi-
ronmental฀ impacts.฀ (4)฀ Landill฀ shows฀ the฀ worst฀ eco-eficiency฀ of฀ all฀ the฀ options฀
studied.
7.3.11 Environmentally Marketed Irrigation Pipe
Polyethylene฀irrigation฀tubing฀is฀an฀inexpensive฀way฀to฀irrigate฀crops,฀but฀it฀is฀easily฀
contaminated฀with฀soil฀and฀vegetation฀during฀the฀growing฀season฀and฀is฀dificult฀to฀
reuse.฀The฀tubing,฀which฀can฀wind฀through฀miles฀of฀farmland,฀is฀typically฀used฀for฀
only฀one฀season฀before฀it฀is฀replaced฀and฀creates฀a฀major฀waste฀stream฀for฀farms.
Polyethylene฀irrigation฀tubing฀manufacturer,฀Delta฀Plastics,฀has฀created฀a฀recy-
cling฀system฀to฀collect฀the฀used฀material฀for฀recycle.฀Double฀G฀Farm฀of฀Arkansas฀is฀
one฀operation฀that฀recycles฀its฀pipe฀to฀rid฀the฀farm฀of฀a฀waste฀stream.฀The฀4,600฀acre฀
farm฀uses฀120฀rolls,฀or฀30฀miles฀of฀pipe฀a฀year.฀The฀PE฀tubing฀is฀easier฀to฀install,฀
easier฀ to฀ pick฀ back฀ up,฀ and฀ is฀ less฀ expensive฀ to฀ handle฀ than฀ aluminum฀ irrigation฀
systems.฀ Delta฀ Plastics฀ operates฀ 104฀ collection฀ sites฀ traveling฀ up฀ to฀ 300฀ miles฀ at฀
least฀twice฀a฀year฀to฀each฀site฀to฀pick฀up฀used฀pipe.฀Farmers฀who฀utilize฀the฀com-
pany’s฀recycling฀service฀must฀buy฀their฀new฀pipe฀from฀Delta.฀The฀pipe฀is฀returned฀to฀
the฀ Delta฀ Plastics฀ plant฀ in฀ Stuttgart,฀ AK,฀ where฀ it฀ is฀ cut,฀ washed,฀ and฀ pelletized.฀
Because฀of฀weathering’s฀negative฀effect฀on฀the฀plastic’s฀properties,฀the฀used฀material฀
is฀not฀recycled฀into฀new฀irrigation฀pipe.฀Makers฀of฀trash฀bags฀and฀parking฀stops฀are฀
the฀main฀consumers฀of฀the฀pellets.฀From฀1998฀through฀the฀end฀of฀2002,฀Delta฀Plastics฀
recycled฀70฀million฀lb฀of฀the฀irrigation฀tubing.
Chapter 8
Plastics End Use Applications
Company Source Guide
Keywords฀ Plastics฀•฀Metal฀•฀Rubber฀•฀Paper฀•฀Wood฀•฀Glass฀•฀Ceramic฀•฀Endusers฀
•฀Fabricators฀•฀Suppliers
8.1 Plastic and Related Materials Segments
8.1.1 Source Guide Introduction
This฀source฀material฀covers฀the฀ive฀primary฀competitive฀material฀areas฀and฀their฀inter-
acting฀20฀major฀plastic฀end฀use฀market฀segments.฀Featured฀are฀250฀key฀market฀leader฀
corporate฀sources,฀and฀375฀other฀major฀company฀sources.฀For฀organizational฀purposes฀
the฀25฀major฀areas฀are฀arranged฀into฀ive฀groups฀of฀ive฀related฀segments,฀consisting฀of฀
one฀group฀of฀competitive฀materials฀and฀four฀groups฀of฀end฀use฀markets.
Within฀each฀of฀the฀25฀segments฀there฀are฀two฀subdivisions฀which฀consist฀of฀ten฀
key฀market฀leading฀corporations฀and฀15฀other฀major฀companies,฀organized฀alpha-
betically฀in฀each฀category,฀for฀a฀total฀of฀625฀entities.
The฀irst฀subdivision,฀Primary,฀covers฀the฀top฀ten฀global฀starting฀points฀for฀com-
pany฀information฀in฀a฀given฀area฀of฀interest.฀The฀second฀subdivision,฀Other,฀paral-
lels฀the฀preceding฀key฀database฀source฀approach฀from฀an฀identically฀patterned฀but฀
more฀concise฀manner.฀Within฀each฀of฀the฀subdivisions,฀companies฀are฀qualiied฀on฀
the฀basis฀of฀speciic฀segment฀Sales฀size,฀technical฀marketing฀product฀line฀breadth,฀
global฀diversiication,฀specialty฀niche฀positioning,฀and฀overall฀net฀Sales.
To฀facilitate฀cross฀comparison฀and฀review฀of฀company฀sources,฀the฀ive฀tables฀(one฀
for฀each฀of฀the฀ive฀groups฀of฀ive฀segments)฀summarize฀primary฀key฀market฀leading฀
and฀ other฀ major฀ companies฀ across฀ the฀ twenty-ive฀ critical฀ areas฀ (ive฀ competitive฀
materials,฀followed฀by฀twenty฀largest฀to฀smallest฀end฀use฀markets).฀Also฀in฀the฀tables,฀
companies฀are฀identiied฀as฀suppliers฀(“S”),฀fabricators฀(“F”),฀Endusers฀(“E”),฀or฀com-
binations฀thereof.฀Sales฀dollar฀igures฀are฀in฀$US฀for฀ease฀of฀comparison฀(B฀=฀billion).฀
Company฀country฀of฀origin฀is฀indicated฀by฀two฀letter฀codes฀in฀parenthesis.

98 8฀ Plastics฀End฀Use฀Applications฀Company฀Source฀Guide
8.1.2 Plastic, Metal, Paper & Wood, Rubber, Glass & Ceramic
Companies
Table 8.1฀ Major฀endusers,฀fabicators฀and฀suppliers—Group฀One

Plastic
Primary Other
Asahi฀Kasei฀Corporation฀(JP);฀S Ashland฀Inc฀(US);฀S
www.asahi-kasei.co.jp www.ashland.com
Sales:฀$4.53฀billion
Chevron฀Phillips฀Chem.฀(US);฀S
Basell฀N.V.฀(NL);฀S www.cpchem.com
www.basell.com
Sales:฀$5.7฀billion Daicel฀Chemical฀Ind.฀(JP);฀S
www.daicel.co.jp/indexe.html
BASF฀AG฀(DE);฀S DSM฀N.V.฀(NL);฀S/F
www.basf.com www.dsm.com
Ferro฀Corporation฀(US);฀S
Bayer฀AG฀(DE);฀S www.ferro.com
www.bayer.com
Sales:฀$11.6฀billion Mannesmann฀Plastics฀M฀(DE);฀S
www.mannesmann-plastics.com
Dow฀Chemical฀Co.฀(US);฀S/F Milicron฀Inc.฀(US);฀S
www.dow.com www.milacron.com
Polyone฀Corporation฀(US);฀S
Dupont฀Company฀(US);฀S/F www.polyone.com
www.dupont.com
Sales:฀$18.4฀billion Rohm฀&฀Haas฀Co.฀(US);฀S
www.rohmhaas.com
Eastman฀Chemical฀Co฀(US);฀S Sinochem฀Corporation฀(CN);฀S
www.eastman.com www.sinochem.com
SMS฀Plastics฀Tech.฀(DE);฀S
Equistar฀Chem.฀LP฀(US);฀S www.sms-k.com
www.equistarchem.com
Sales:฀$5.54฀billion Solvay฀S.A.฀(BE);฀S
www.solvay.com
Exxon฀Mobil฀Chemical฀(US);฀S Ticona฀Inc.฀(US);฀S
www.exxonmobil.com/chemical www.ticona-us.com
Total฀Fina฀Elf-Atoina฀(FR);฀S/F
G.E.฀Plastics฀(US);฀S/F www.atoina.com
www.geplastics.com
Wellman฀Inc.฀(US);฀S/F
www.wellmaninc.com
8.1฀ Plastic฀and฀Related฀Materials฀Segments 99
Metal Paper฀and฀wood
Primary Other Primary
Alcan฀Inc.฀(US);฀S/F AK฀Steel฀Corporation฀(US);฀S/F Georgia฀Paciic฀(US);฀S/F
www.alcan.com. www.aksteel.com www.gp.com.
Sales:฀$11.72฀billion Sales:฀$18.95฀billion
ASARCO฀Inc.฀(MX);฀S/F
Alcoa฀Inc.฀(US);฀S/F www.asarco.com International฀Paper฀(US);฀S/F
www.alcoa.com www.internationalpaper.com
Sales:฀$17.5฀billion Bethlehem฀Steel฀(US);฀S/F Sales:฀$16.70฀billion
www.bethsteel.com
Arcelor฀(ES,฀LU,฀FR);฀S Commercial฀Metals฀(US);฀F Kimberly-Clark฀(US);฀F
www.arcelor.com www.commercialmetals.com www.kimberly-clark.com
Sales:฀28.6฀billion Sales:฀$14.5฀billion
INCO฀Ltd.฀(CA);฀S
Corus฀Group฀plc฀(UK);฀S/F www.inco.com MeadWestvaco฀Corp.฀(US);฀F
www.corusgroup.com www.meadwestvaco.com
Sales:฀$11.4฀billion International฀Steel฀Grp.฀(US);฀S/F Sales฀est.:฀$6.86฀billion
www.ltvsteel.com
Kobe฀Steel,฀Ltd.฀(JP);฀S/F ISPAT฀Int’l฀N.V.฀(NL);฀S/F Nippon฀Paper฀Ind.฀Co.฀(JP);฀F
www.kobelco.co.jp www.ispat.com www.npaper.co.jp
Kawasaki฀Steel฀Corp.฀(JP);฀S/F
Nippon฀Steel฀Corp.฀(JP);฀S/F www.kawasaki-steel.co.jp OJI฀Paper฀Co.฀Ltd.฀(JP);฀S/F
www.nsc.co.jp www.ojipaper.co.jp
Sales:฀$13.88฀billion Maxxam฀Inc.฀(US);฀S/F Sales:฀$7.90฀billion
www.kaiseral.com
NKK฀Corporation฀(JP);฀S/F Nucor฀Corporation฀(US);฀S/F SAPPI฀Ltd.,฀(ZA);฀S/F
www.nkk.co.jp www.nucor.com www.sappi.com
Phelps฀Dodge฀Corp.฀(US);฀S/F
POSCO฀Ltd.฀(KR);฀S/F www.phelpsdodge.com Stora฀Enso฀OYJ฀(FI);฀S/F.
www.posco.co.kr www.storaenso.com
Sales:฀$9.45฀billion Ryerson฀Tull,฀Inc.฀(US);฀S/F Sales:฀$13.76฀billion
www.ryersontull.com
Rio฀Tinto฀plc฀(UK);฀S Sandvik฀AB฀(SE);฀S/F UPM-Kymmmene.฀(FI);฀F
www.riotinto.com www.sandvik.com www.upm-kymmene.com
Teck฀Cominco฀Ltd.฀(CA);฀S
US฀Steel฀Corporation฀(US);฀S/F www.teckcominco.com Weyerhaeuser฀Co.฀(US);฀S/F.
www.ussteel.com www.weyerhaeuser.com
Thyssen฀Krupp฀(DE);฀S/F
www.thyssenkrupp.com
(continued)
Table 8.1฀ (continued)

Paper฀and฀wood Rubber
Other Primary Other
Abitibi฀Consolidated฀(CA);฀S/F Bridgestone฀Corporation฀(JP);฀F Bandag฀Inc฀(US);฀S
www.abicon.com www.bridgestone.co.jp www.bandag.com
Aracruz฀Cellulose฀S.A.฀(BR);฀S/F Bayer฀AG฀(DE);฀S
www.aracruz.com.br Michelin฀(FR);฀F www.bayerrubberone.com
www.michelin.com
Arjo฀Wiggins฀Appleton฀(UK);฀S/F Sales:฀$11.62฀billion Carlisle฀Co.฀Inc.฀(US);฀F
www.awusa.com www.carlisle.com
Boise฀Cascade฀Corp.฀(US);฀S/F Continental฀AG฀(DE);฀F Dayco฀Products.฀Inc.฀(US);฀F
www.bc.com www.conti.de www.dayco.com
Bowater฀Inc.฀(US);฀F Dow฀Corning฀Corp.฀(US);฀S
www.bowater.com Cooper฀Tire฀&฀Rubber฀(US);฀F www.dowcorning.com
www.coopertire.com
Domtar฀Inc.฀(CA);฀S/F Sales:฀$1.8฀billion DSM฀N.V.฀(US);฀S
www.domtar.com www.dsmelastomers.com
Fletcher฀Challenge฀(NZ);฀S/F Freudenberg฀&฀Company฀(DE);฀F Dupont฀Dow฀Elastomers฀(US);฀S
www.fcf.co.nz www.freudenberg.com www.dupont-dow.com
Holmen฀AB฀(SE);฀S/F Exxon฀Mobil฀Chemical฀(US);฀S
www.modogroup.com Goodyear฀(US);฀S/F www.exxon.mobil.com
www.goodyear.com
Louisiana-Paciic฀(US);฀S/F Sales:฀$13.0฀billion The฀Gates฀Corp.฀(UK);฀F
www.lpcorp.com www.gates.com
Nexfor฀Inc.฀(CA);฀S/F Pirelli฀SpA฀(IT);฀F Gencorp฀Inc.฀(US);฀F
www.nexfor.com www.pirelli.com www.gencorp.com/vs.html
Norske฀Skog.฀ASA฀(NO);฀S/F Manuli฀Rubber฀Industries฀SpA
www.norske-skog.com Sumitomo฀Rubber฀Ind.฀(JP);฀F www.manulirubber.com
www.sumitomorubber.co.jp
Potlatch฀Corporation฀(US);฀S/F Sales:฀$3.79฀billion Sabanci฀Holding฀A.S.฀(TR);฀F
www.potlatchcorp.com www.sabanci.com.tr
Rayonier฀Inc.฀(US)฀S/F Toyo฀Tire฀&฀Rubber฀(JP);฀S/F Sime฀Darby฀Berhad฀(MY);฀S/F
www.rayonier.com www.toyo-rubber.co.jp www.simenet.com
Svenska฀Cellulosa฀(SE);฀F Vredestein฀N.V.฀(NL);฀S/F
www.sca.se Yokohama฀Rubber฀Co.฀(JP);฀F www.vredestein.com
www.yrc.co.jp/home.html
Tembec฀Inc.฀(CA);฀S/F Sales:฀$3.01฀billion Waterville฀TG฀Inc.฀(JP);฀F
www.tembec.com www.wtg.ca
8.1฀ Plastic฀and฀Related฀Materials฀Segments 101
Glass฀and฀ceramic
Primary Other
Asahi฀Glass฀Company฀(JP);฀S/F Cemex,฀S.A.฀de฀C.V.฀(MX);฀S
www.agc.co.jp. www.cemex.com
Cookson฀Group฀plc.฀(UK);฀S
Carl-Zess-Stiftung฀(DE);฀F www.cooksongroup.co.uk
www.zeiss.com
Sales:฀$2.43฀billion Donnelly฀Corporation฀(US);฀F
www.donnelly.com
Corning฀Inc.฀(US);฀S/F Engelhard฀Corporation฀(US);฀S
www.corning.com www.engelhard.com
Fisher฀Scientiic฀Int’l฀Inc.฀(US);฀F
Elkem฀ASA฀(NO);฀S www.isherscientiic.com
www.elkem.com
Sales:฀$0.70฀billion Guardian฀Ind.฀Corp.฀(US);฀F
www.guardian.com
Kyocera฀Corporation฀(JP);฀S/F Harbison-Walker฀Refract.฀(US)฀S
www.kyocera.co.jp www.hwr.com
Johns฀Manville฀Corp.฀(US);฀F
LaFarge฀S.A.฀(FR);฀S www.jm.com
www.lafarge.fr
Sales:฀$15.73฀billion Lancaster฀Colony฀Corp.฀(US);฀F
www.glassonline.com
Owens฀Corning฀(US);฀S/F Morgan฀Crucible฀Co.฀(UK);฀S
www.owenscorning.com www.morgancrucible.com
N.A.฀Refractories฀Co.฀(US);฀S/F
Pilkington฀plc฀(UK);฀F www.hwr.com
www.pilkington.com
Sales:฀$4.56฀billion Seiko฀Epson฀Corporation฀(JP);฀F
www.epson.co.jp
PPG฀Industries,฀Inc฀(US);฀S/F Taiheiyo฀Cement฀Corp.฀(JP);฀S
www.ppg.com www.taiheiyo-cement.co.jp
Tosoh฀Corporation฀(JP);฀F
Saint฀Gobain฀Group฀(FR);฀S/F www.tosoh.com
www.saint-gobain.fr
Sales:฀$20.48฀billion Waterford฀Wedgewood฀(IE);฀F
tel: +353-147-8155
8.2 Major and Intermediate Plastic End Use Market Segments
8.2.1 Major Packaging, Building & Construction, Automotive,

Electrical & Electronic, and Appliance Companies
Table 8.2฀ Major฀endusers,฀fabricators฀and฀suppliers—Group฀Two

Packaging
Primary Other
Ball฀Corporation฀(US);฀F Amcor฀Ltd.฀(AU);฀F
www.ball.com www.amcor.com.au
Bemis฀Company,฀Inc.฀(US);฀F
Crown฀Cork฀&฀Seal฀Co.฀(US);฀F www.bemis.com
www.crowncork.com
Sales:฀$6.8฀billion Dart฀Container฀Corp.฀(US);฀F
www.dartcontainer.com
Groupo฀Vitro฀(MX);฀F Gerresheimer฀Group฀(DE);฀F
www.vto.com www.gerresheimer.com
Greif฀Brothers฀Corp.฀(US);฀F
Owens-Illinois,฀Inc.฀(US);฀F www.greif.com
www.o-i.com
Sales:฀$5.64฀billion Huhtamaki฀OYJ฀(FI);฀S/F
www.huhtamaki.com
Pactiv฀Corporation฀(US);฀F Menasha฀Corp.฀(US);฀S/F
www.pactiv.com www.menasha.com
Packaging฀Corp.฀(US);฀F
Pechiney฀S.A.฀(FR);฀S/F www.packagingcorp.com
www.pechiney.com
Sales:฀$2.52฀billion Plastipak฀Packaging฀Inc.฀(US);฀F
www.plastipak.com
Smurit-Stone฀Container฀(US);฀F Printpack,฀Inc.฀(US);฀F
www.smurit-stone.com www.printpack.com
Rexam฀plc฀(UK);฀F
Sonoco฀Products฀Co฀(US);฀S/F www.rexam.co.uk
www.sonoco.com
Sales:฀$2.81฀billion Sealed฀Air฀Corp.฀(US);฀F
www.sealedaircorp.com
Temple฀Inland฀Inc.฀(US);฀S/F Silgan฀Holdings,฀Inc.฀(US);฀F
www.temple-inland.com www.silgan.com
Solo฀Cup฀Company฀(US);฀F
Toyo฀Seikan฀Kaisha฀(JP);฀S/F www.solocup.com
www.toyo-seikan.co.jp
Sweetheart฀Cup฀Co.฀(US);฀F
www.sweetheart.com
8.2฀ Major฀and฀Intermediate฀Plastic฀End฀Use฀Market฀Segments 103
Building and construction Automotive

American฀Standard฀Inc.฀(US);฀F Andersen฀Corporation฀(US);฀F DaimlerChrysler฀AG฀(DE);฀F/E
www.americanstandard.com. www.andersencorp.com www1.daimlerchrysler.com
AOKI฀Corporation฀(JP);฀F/E
Daiwa฀House฀Industry฀(JP);฀F/E www.aoki.co.jp Fiat฀Auto฀SPA฀(IT);฀F/E
www.daiwahouse.co.jp www.iatgroup.com
Sales:฀$9.03฀billion Armstrong฀World฀Ind.฀(US);฀F Sales:฀$34.98฀billion
www.armstrong.com
Kumagai฀Gumi฀Co.฀(JP);฀F/E Centex฀Corporation฀(US);฀F/E Ford฀Motor฀Company฀(US);฀F/E
www.kumagai.co.jp www.centex.com www.ford.com
Fujita฀Corporation฀(JP);฀F/E
Masco฀Corporation฀(US);฀F www.fujita.co.jp General฀Motors฀Corp.฀(US);฀F/E
www.masco.com www.gm.com
Sales:฀$9.4฀billion Haseko฀Corporation฀(JP);฀F/E Sales:฀$148.0฀billion
www.haseko.co.jp
Mitsui฀Fudosan฀Co.฀(JP);฀F/E D.R.฀Horton,฀Inc.฀(US);฀F/E Honda฀Motor฀Co.฀(JP);฀F/E
www.mitsuifudosan.co.jp www.drhorton.com www.honda.com
KB฀Home฀(US);฀F/E
Obayashi฀Corporation฀(JP);฀F/E www.kbhomes.com Nissan฀Motor฀Co.฀(JP);฀F/E
www.obayashi.co.jp www.nissan-global.com
Sales:฀$11.32฀billion Kohler฀Company.฀(US);฀F Sales:฀$52.42฀billion
www.kohlerco.com
Sekisui฀House,฀Ltd.(JP);฀F/E Lennar฀Corporation฀(US);฀F/E Peugeot฀Citroen฀S.A.฀(FR);฀F/E
www.sekisuihouse.co.jp www.lennar.com www.psa.fr
Lennox฀International฀Inc.฀(US);฀F
Shimizu฀Corporation฀(JP);฀F/E www.lennoxinternational.com Renault฀S.A.฀(FR);฀F/E.
www.shimz.co.jp www.renault.com
Sales:฀$10.75฀billion Pulte฀Homes฀Inc.฀(US);฀F/E Sales:฀$37.09฀billion
www.pulte.com
Skanska฀AB฀(SE);฀F/E Sherwin฀Williams฀Co.฀(US);฀S Toyota฀Motor฀Corp.฀(JP);฀F/E
www.skanska.com www.sherwin-williams.com www.toyota.co.jp
USG฀Corporation฀(US);฀S/F
Taisei฀Corporation฀(JP);฀F/E www.usgcorp.com Volkswagen฀AG฀(DE);฀F/E
www.taisei.co.jp www.volkswagen.de
U.S.฀Industries,฀Inc.฀(US);฀F
www.usindustries.com
(continued)

Automotive Electrical฀and฀electronic
Other Primary Other
ArvinMeritor,฀Inc.฀(US);฀F Fujitsu฀Ltd..฀(JP);฀F/E ABB฀Ltd.฀(CH);
www.arvinmeritor.com www.fujitsu.com www.abb.com
BMW฀(DE);฀F/E Alcatel฀SA฀(FR);฀F/E
www.bmw.com Hewlett-Packard฀Co฀(US);฀F/E www.alcatel.com
www.hp.com
Robert฀Bosch฀GmbH฀(DE);฀F Sales:฀$45.96฀billion Apple฀Computer฀Inc฀(US);฀F/E
www.bosch.de www.apple.com
Daihatsu฀Motor฀Corp.฀(JP);฀F/E Hitachi,฀Ltd.฀(JP);฀F/E Cisco฀Systems฀Inc.฀(US);฀F/E

www.daihatsu.com www.hitachi.co.jp www.cisco.com
Delphi฀Auto฀Systems฀(US);฀F Dell฀Computer฀Corp฀(US);฀F/E
www.delphiauto.com IBM฀Corporation฀(US);฀F/E www.dell.com
www.ibm.com
Hyundai฀Motor฀Com.฀(KR);฀F/E Sales:฀$27.5฀billion Emerson฀Electric฀Co฀(US);฀F/E
www.hmc.co.kr www.gotoemerson.com
Isuzu฀Motors฀Ltd.฀(JP);฀F/E Lucent฀Technologies฀(US);F/E General฀Electric฀Co.฀(US);฀F/E

www.isuzu.co.jp www.lucent.com www.ge.com
Johnson฀Controls฀Inc.฀(US);฀F Murata฀Mfg.฀Co.฀(JP);฀F/E
www.johnsoncontrols.com Motorola,฀Inc.฀(US);฀F/E www.murata.co.jp
www.motorola.com
Lear฀Corporation฀(US);฀F $26.68฀billion Nokia฀Corporation฀(FI);฀F/E
www.lear.com www.nokia.com
Magna฀International฀Inc.฀(CA);฀F NEC฀Corporation.฀(JP);฀F/E Nortel฀Networks฀Corp.฀(CA);฀F/E

www.magnaint.com www.nec.com www.nortel.com
Sales:฀$US฀38.45฀billion
Mazda฀Motor฀Corp.฀(US);฀F/E Sharp฀Corporation฀(JP)฀F/E
www.mazda.co.jp Royal฀Philips฀Elect.฀NV฀(NL);฀F/E www.sharp-world.com
www.philips.com
Mitsubishi฀Motors฀Corp.฀(US)฀F/E Sales:฀$31.12฀billion Sun฀Microsystems฀Inc.฀(US);฀F/E
www.mitsubishi-motors.co.jp www.sun.com
Paccar฀Inc.฀(US);฀F/E Siemens฀AG฀(DE);฀F/E Telefonaktiebolaget฀(SE);฀F/E

www.paccar.com www.siemens.de www.ericsson.com
Visteon฀Corporation.฀(US);฀F Tyco฀International฀Ltd.฀(BM);฀F/E
www.visteon.com Toshiba฀Corporation฀(JP);฀F/E www.tycoint.com
www.toshiba.co.jp
AB฀Volvo฀(SE);฀F/E Sales:฀$30.68฀billion Vishay฀Intertechnology฀(US);฀F/E
www.volvo.com www.vishay.com
Appliance
Primary Other
Bosch-Siemens฀(DE);฀F/E Applica฀Inc.฀(US);฀F/E
www.bsh-group.com www.applicainc.com
Elco฀Brandt฀S.A.฀(FR);฀F/E
Carrier฀Corporation฀(US);฀F/E www.elcopourbrandt.com
www.global.carrier.com
Sales:฀$8.77฀billion Fedders฀Corporation฀(US);฀F/E
www.fedders.com
Electrolux,฀AB฀(SE);฀F/E Goodman฀Mfg.฀Co.฀(US);฀F/E
www.electrolux.com www.goodmanmfg.com
Groupe฀SEB฀(FR);฀F/E
G.E.฀Consumer฀Prod.฀(US);฀F/E www.฀groupeseb.com
www.geappliances.com
Sales:฀$6.07฀billion NACCO฀Housewares,฀(US);฀F/E
www.hambeach.com
Maytag฀Corporation฀(US);฀F/E Juki฀Corporation฀(JP);฀F/E
www.maytagcorp.com www.juki.co.jp
Lennox฀International฀(US);฀F/E
Miele฀&฀CIE,฀GmbH.฀(DE);฀F/E www.lennoxinternational.com
www.miele.de
Sales:฀$2.42฀billion Melitta฀(DE);฀F/E
www.melitta.de
Sunbeam฀Corp.฀(US);฀F/E Merloni฀Elettrodomestici฀(IT);฀F/E
www.sunbeam.com www.merloni.com
Nortek฀Holdings฀Inc.฀(US);฀F/E
The฀Trane฀Company฀(US);฀F/E www.nortek-inc.com
www.trane.com
Sales:฀$4.74฀billion The฀Rival฀Company฀(US);฀F/E
www.rivco.com
Whirlpool฀Corporation฀(US);฀F/E Salton฀Inc.฀(US);฀F/E
www.whirlpoolcorp.com www.saltoninc.com
Singer฀NV฀(CN);฀F/E
York฀Int’l฀Corporation฀(US);฀F/E www.singerco.com
www.york.com
Sales:฀$3.84฀b฀illion Vorwerk฀and฀Company฀(DE);฀F/E
www.vorwerk.de
8.2.2 Intermediate Medical, Consumer Products, Toy, Recreation &

Leisure, and Furniture Companies
Table 8.3฀ Major฀endusers,฀fabricators฀and฀suppliers—Group฀Three

Medical
Primary Other
Abbott฀Laboratories฀(US);฀F/E Bausch฀&฀Lomb฀Inc.฀(US);฀F/E
www.abbott.com www.bausch.com
Biomet,฀Inc฀(US);฀F/E
Baxter฀Int’l฀Inc.฀(US);฀F/E www.biomet.com
www.baxter.com
Sales:฀$5.01฀billion CAPSUGEL฀(US);฀F
www.capsugel.com
Becton฀Dickinson฀(US);฀F/E C.R.฀Bard,฀Inc.฀(US);฀F/E
www.bd.com www.crbard.com
Gambro฀AB฀(SE);฀F/E
Boston฀Scientiic฀(US);฀F/E www.gambro.com
www.bsci.com
Sales:฀$2.92฀billion Hill-Rom฀Co.฀(US);฀F/E
www.hillenbrand.com
GE฀Medical฀Systems฀(US);F/E Kendall฀Company,฀The฀(US);฀F/E
www.gemedicalsystems.com www.kendallhq.com
Medline฀Industries฀(US);฀F/E
Guidant฀Corporation฀(US);฀F/E www.medline.com
www.guidant.com
Sales:฀$3.24฀billion Omron฀Corporation฀(JP);฀F/E
www.omronhealthcare.com
Hoffmann-La฀Roche฀(CH);฀F/E St฀Jude฀Medical฀(US);฀F/E
www.roche.com www.sjm.com
Smith฀&฀Nephew฀plc฀(UK);฀F/E
Johnson฀&฀Johnson฀(US);฀F/E www.smith-nephew.com
www.jnj.com
Sales:฀$19.15฀billion Stryker฀Corporation฀(US);฀F/E
www.strykercorp.com
Medtronic,฀Inc.฀(US);฀F/E Sybron฀Dental฀(US);฀F/E
www.medtronic.com www.sybrondental.com
Wyeth฀(US);฀F/E
Siemens฀Medical฀(DE);฀F/E www.wyeth.com
www.siemensmedical.com
Sales:฀$8.20฀billion Zimmer฀Holdings,฀Inc.฀(US);F/E
www.zimmer.com
Consumer฀products Toy
Eastman฀Kodak฀Co.฀(US);฀F/E Bose฀Corporation฀(US);฀F/E Bandai฀Co.,฀Ltd.฀(JP);฀F/E
www.kodak.com www.bose.com www.bandai.com
Carrefour฀SA฀(FR);฀E
Gillette฀Co.,฀The฀(US);฀F/E www.carrefour.com Hasbro,฀Inc.฀(US);฀F/E
www.gillette.com www.hasbro.com
Sales:฀$8.453฀billion Conair฀Corporation฀(US);฀F/E Sales:฀$2.86฀billion
www.conair.com/corporate
LG฀Electronics฀(KR);฀F/E Daewoo฀Electronics฀(KR);฀F/E K-B฀Toys฀(US);฀E
www.lge.co.kr www.dwe.co.kr www.kbtoys.com
Fuji฀Photo฀Film฀Co.฀(JP);฀F/E
Matsushita฀Electric฀(JP);฀F/E www.fujiilm.co.jp Lego฀Company฀(DK);฀F/E
www.panasonic.co.jp/global www.lego.com
Sales:฀$11.88฀billion Ito-Yokado฀Co.,฀Ltd.฀(JP);฀E Sales:฀$1.1฀billion
www.itoyokado.iyg.co.jp
Newell฀Rubbermaid฀(US);฀F/E Luxottica฀Group.฀SpA฀(IT);฀F/E Little฀Tikes฀Co.,฀The฀(US);฀F/E
www.newell-rubbermaid.com www.luxottica.it/english www.littletikes.com
Polaroid฀Corporation฀(US);฀F/E
Pioneer฀Corporation฀(JP);฀F/E www.polaroid.com Mattel,฀Inc.฀(US);฀F/E
www.pioneer.co.jp www.mattel.com
Sales:฀$3.53฀billion Samsung฀Electronics฀(KR);฀F/E Sales:฀$4.8฀billion
www.samsungelectronics.com
Sanyo฀Electric฀Co.฀(JP);฀F/E Seiko฀Corporation฀(JP);฀F/E Nintendo฀Co.฀Ltd.฀(JP);฀F/E
www.sanyo.co.jp www.seiko-corp.co.jp www.nintendo.com
Snap-On฀Inc.฀(US);฀F/E
Sony฀Corporation฀(JP);฀F/E www.snapon.com SEGA฀Corporation.฀(JP);฀F/E
www.sony.co.jp/en/sonyInfo www.sega.co.jp
Sales:฀$17.16฀billion TDK฀Corporation฀(JP);฀F/E Sales:฀$1.82฀billion
www.tdk.com
Stanley฀Works,฀The฀(US);฀F/E Tupperware฀Corp.฀(US);฀F/E Toys฀“R”฀Us,฀Inc.฀(US);฀E
www.stanleyworks.com www.tupperware.com www.tru.com
Wal-Mart฀Stores฀Inc.฀(US);฀E
3M฀Company฀(US);฀F/E www.walmartstores.com Ty฀Inc.฀(US);฀F/E
www.mmm.com www.ty.com
Sales:฀$2.792฀billion YKK฀Group฀(JP);฀F/E Sales:฀$0.85฀billion
www.ykk.co.jp
(continued)

Toy Recreation and leisure
Other Primary Other
Acclaim฀Entertainment฀(US);฀F/E Adidas-Salomon฀AG฀(DE);฀F/E AMF฀Bowling฀Inc.฀(US);฀F/E
www.acclaim.com www.adidas-salomon.com www.amf.com
Action฀Performance฀(US);฀F/E Callaway฀Golf฀Co.฀(US);฀F/E
www.goracing.com Bombardier฀Recreation฀(CA);฀F/E www.callawaygolf.com
www.products.bombardier.com
Applause฀LLC฀(US);฀F/E Sales:฀$1.70฀billion Coleman฀Co.,฀The฀(US);฀F/E
www.applause.com www.coleman.com
Capcom฀Co.,฀Ltd.฀(JP);฀F/E Brunswick฀Corporation฀(US);฀F/E Head฀NV;฀F/E

www.capcom.co.jp www.brunswickcorp.com www.head.com
DSI฀Toys,฀Inc.฀(US);฀F/E Huffy฀Corporation฀(US);฀F/E
www.dsitoys.com Fleetwood฀Enterprises฀(US);฀F/E www.huffy.com
www.leetwood.com
Empire฀of฀Carolina฀Inc.฀(US);฀F/E Sales:฀$1.213฀billion Icon฀Health฀&฀Fitness฀(US);฀F/E
www.empiretoys.com www.iconitness.com
First฀Years฀Inc.,฀The฀(US);฀F/E Fortune฀Brands฀(US);฀F/E Johnson฀Outdoors฀(US);฀F/E

www.theirstyears.com www.fortunebrands.com www.jwa.com
Flexible฀Flyer฀(US);฀F/E K2฀Inc.฀(US);฀F/E
www.lexible-lyer.com Harley-Davidson,฀Inc.฀(US);฀F/E www.k2sport.com
www.harley-davidson.com
Jakks฀Paciic,฀Inc.฀(US);฀F/E Sales:฀$4.091฀billion Mizuno฀Corporation฀(JP);฀F/E
www.jakkspaciic.com www.mizuno.com
Marvel฀Enterprises฀Inc.฀(US);฀F/E Michaels฀Stores,฀Inc.฀(US);฀E Recreational฀Equipment฀US);฀F/E

www.marvel.com www.michaels.com www.rei.com
Midway฀Games฀Inc.฀(US);฀F/E SCP฀Pool฀Corporation฀(US);฀F/E
www.midway.com NIKE,฀Inc.฀(US);฀F/E www.scppool.com
www.nikebiz.com
Playmates฀Toys฀Holding฀(CN);฀E Sales:฀$9.893฀billion Shimano฀Inc.฀(JP)฀F/E
www.playmatestoys.com www.shimano.com
RC2฀Corporation฀(US)฀F/E Reebok฀Int’l฀Ltd.฀(US);฀F/E Skis฀Rossignol฀S.A.฀(FR);฀F/E

www.rcertl.com www.reebok.com www.skirossignol.com
Toy฀Quest฀(US)฀F/E Spaulding฀Sports฀(US);฀F/E
www.manleytoyquest.com Yamaha฀Corporation฀(JP);฀F/E www.spalding.com
www.yamaha.co.jp
Wham-o,฀Inc.฀(US)฀F/E Sales:฀$3.79฀billion Wilson฀Sport.฀Goods฀(US)฀F/E
www.wham-o.com www.wilsonsports.com
Furniture
Primary Other
Furniture฀Brands฀Int’l฀(US);฀F/E Ashley฀Furniture฀(US);฀F/E
www.furniturebrands.com. www.ashleyfurniture.com
Bassett฀Furniture฀Ind.฀(US);฀F/E
Haworth฀Inc.฀(US);฀F/E www.bassettfurniture.com
www.haworth.com
Sales:฀$1.66฀billion Bush฀Industries฀Inc.฀(US);฀F/E
www.bushfurniture.com
Herman฀Miller฀Inc.฀(US);฀F/E Chromcraft฀Revington฀(US);฀F/E
www.hermanmiller.com Tel:฀(765)฀564-3500
Craftmatic฀Ind.฀(US);฀F/E
HON฀Industries฀Inc฀(US);฀F/E Tel:฀(215)฀639-1310
www.honi.com
Sales:฀$1.692฀billion Dorel฀Industries,฀Inc.฀(CA);฀F/E
www.dorel.com
IKEA฀International฀A/S฀(DK);฀E Ethan฀Allen฀Inc.฀(US);฀F/E
www.ikea.com www.ethanallen.com
Hunter฀Douglas฀NV฀(NL);฀F/E
Kimball฀Int’l,฀Inc.฀(US);฀F/E www.hunterdouglas.com
www.kimball.com
Sales:฀$฀0.736฀billion Klaussner฀Furniture฀(US);฀F/E
www.klaussner.com
Knoll,฀Inc.฀(US);฀F/E Leggett฀&฀Platt,฀Inc.฀(US);฀F/E
www.knoll.com www.leggett.com
O’Sullivan฀Industries฀(US);฀F/E
LA-Z-Boy฀Inc.฀(US);฀F/E www.osullivan.com
www.lazboy.com
Sales:฀$2.154฀billion Pillowtex฀Corporation฀(US);฀F/E
www.pillowtex.com
MFI฀Furniture฀Group฀(UK);฀F/E Sauder฀Woodworking฀(US);฀F/E
www.migroup.co.uk www.sauder.com
Serta฀Inc.฀(US);฀F/E
Steelcase฀Inc.฀(US);฀F/E www.serta.com
www.steelcase.com
Sales:฀$฀2.600฀billion Silentnight฀(UK);฀F/E
www.silentnight-holdings.co.uk
8.3 Specialty and Niche Plastic Enduse Market Segments
8.3.1 Specialty Office Products, Lawn & Garden, Marine & Boat,
Aerospace, and Industrial Companies
Table 8.4฀ Major฀endusers,฀fabricators฀and฀suppliers—Group฀Four

Ofice฀products
Primary Other
AVERY฀Dennison฀(US);฀F/E ACCO฀World฀Corp.฀(US);฀F/E
www.averydennison.com www.acco.com
Brother฀Industries฀Ltd.฀(JP);฀F/E
Canon,฀Inc.฀(JP);฀F/E www.brother.com
www.canon.com
Sales:฀$18.552฀billion Co.฀Machines฀Bull฀(FR);฀F/E
www.bull.com
Lexmark฀Int’l฀Grp.฀(US);฀F/E Datacard฀Corporation฀(US)฀F/E
www.lexmark.com www.datacard.com
A.B.฀Dick฀Company฀(US);฀F/E
Minolta฀Co.,฀Ltd฀(JP);฀F/E www.abdick.com
www.minolta.com
Sales:฀$2.88฀billion Diebold,฀Inc.฀(US);฀F/E
www.dibold.com
NCR฀Corporation.฀(US);฀F/E Esselte฀AB฀(SE);฀F/E
www.ncr.com www.esselte.com
Fellowes฀Manuf.฀Co฀(US);฀F/E
Pitney฀Bowes฀Inc.฀(US);฀F/E www.fellowes.com
www.pitneybowes.com
Sales:฀$2.32฀billion IKON฀Ofice฀Sol’ns฀(US);฀E
www.ikon.com
Ricoh฀Company฀Ltd.฀(JP);฀F/E Konica฀Corporation฀(JP);฀F/E
www.ricoh.com www.konica.co.jp
Moore฀Corporation฀Ltd.฀(CA);฀F/E
Sharpie฀Group฀(US);฀F/E www.moore.com
www.sanfordcorp.com
Sales:฀$1.8฀billion Océ฀N.V.฀(NL);฀F/E
www.oce.com
Staples฀Inc.฀(US);฀E Palm฀Inc.฀(US);฀F/E
www.staples.com www.palm.com
Societe฀BIC฀S.A.฀(FR);฀F/E
Xerox฀Corporation฀(US);฀F/E www.bic.fr
www.xerox.com
Sales:฀$7.95฀billion United฀Stationers฀Inc.฀(US);฀E
www.unitedstationers.com
8.3฀ Specialty฀and฀Niche฀Plastic฀Enduse฀Market฀Segments 111
Lawn฀and฀garden Marine฀and฀boat
Ames฀True฀Temper฀(US);฀F/E Acorn฀Products฀(US);฀F/E Alstom฀S.A.฀(FR);฀F/E
www.ames-truetemper.com www.uniontools.com www.alstom.com
Sales:฀$0.58฀billion Sales:฀$1.081฀billiom
Agrium฀Inc.฀(CA);฀F/E
Black/Decker฀Corp.฀(US);฀F/E www.agrium.com Brunswick฀Corporation฀(US);฀F/E
www.bdk.com www.brunswickcorp.com
Sales:฀$0.98฀billion Blount฀Int’l,฀Inc.฀(US);฀F/E Sales:฀$3.111฀billion
www.blount.com
The฀Home฀Depot,฀(US);฀E Central฀Garden฀&฀Pet฀(US);฀E DCN฀(FR);฀F/E
www.homedepot.com www.centralgardenandpet.com www.dcnintl.com
Davey฀Tree฀Expert,฀The฀(US);฀E
Husqvarna฀AB฀(SE);฀F/E www.davey.com General฀Dynamics฀(US);฀F/E
www.international.husqvarna.com www.generaldynamics.com
Sales:฀$1.98฀billion Gilmour฀Manuf.฀Co฀(US);฀F/E Sales:฀$3.650฀billion
www.gilmour.com
LESCO,฀Ltd฀(US);฀F/E Homebase฀Ltd.฀(UK);฀E Genmar฀Holdings฀Inc.฀(US);฀F/E
www.lesco.com www.homebase.co.uk www.genmar.com
Honda฀Power฀Equip.฀(JP);฀F/E
MTD฀Products,฀Inc.฀(US);฀F/E www.hondapowerequipment.com Hyundai฀Heavy฀Ind.฀(KR);฀F/E
www.mtdproducts.com www.hhi.co.kr
Sales:฀$0.810฀billion Lawnware฀Products฀(US);฀F/E Sales:฀$3.208฀billion
tel:฀(847)฀966-3400
Murray฀Inc.฀(US);฀F/E Makita฀Corporation฀(JP);฀F/E Mitsubishi฀Heavy฀Ind.฀(JP);฀F/E
www.murrayinc.com www.makita.co.jp www.mhi.co.jp
Sakata฀Seed฀Corp.฀(JP);฀F/E
Orkin฀Exterminating฀Co.฀(US);฀E www..sakataseed.co.jp Mitsui฀Eng.฀&฀Shipbuild.฀(JP);฀F/E
www.orkin.com www.mes.co.jp
Sales:฀$0.665฀billion Snapper฀Power฀Equip.฀(US);฀F/E Sales:฀$1.008฀billion
www.snapper.com
Scotts฀Company,฀The฀(US);฀F/E Textron฀Golf฀and฀Turf฀(US);฀F/E Northrop฀Grumman฀(US);฀F/E
www.scottscompany.com www.ttcsp.com www.nns.com
US฀Home฀&฀Garden฀Inc.฀(US);฀F
Toro฀Company,฀The฀(US);฀F/E www.ushg.com Samsung฀Heavy฀Ind.฀(KR);฀F/E
www.toro.com www.shi.samsung.co.kr
Sales:฀$1.399฀billion Woodstream฀Corporation฀(US);฀F Sales:฀$1.54฀billion
www.woodstreamcorp.com
(continued)

Marine฀and฀boat Aerospace
Other Primary Other
Aker฀Kværner฀Yards฀(NO);฀F/E Airbus฀S.A.S.฀(FR);฀F/E Alcoa฀Aerospace.฀(US);฀F/E
www.kvaerner.com www.airbus.com www.cordanttech.com
Boat฀America฀Corp.฀(US);฀E Arianespace฀SA฀(FR);฀F/E
Tel:฀(703)฀370-4202 Boeing฀Co.,฀The฀(US);฀F/E www.arianespace.com
www.boeing.com
Daewoo฀Shipbuilding.฀(KR);฀F/E Sales:฀$28.387฀billion Banner฀Aerospace฀Inc.฀(US);฀F/E
www.daewooshipbuilding.com www.banners.com
Davie฀Industries฀Inc.฀(CA);฀F/E Bombardier฀Aerospace฀(CA);฀F/E Dassault฀Aviation฀Grp.฀(FR);฀F/E

www.davie.ca www.aero.bombardier.com www.dassault-aviation.com
Dorbyl฀Marine฀Co.฀(ZA);฀F/E Doncasters฀plc฀(UK);฀F/E
www.dorbylmarine.co.za EADS฀(NL);฀F/E www.doncasters.com
www.eads-nv.com
Fountain฀Powerboat฀(US);฀F/E Sales:฀$25.61฀billion Embraer-Empresa฀(BR);฀F/E
www.fountainpowerboats.com www.embraer.com
Greenway฀Partners,฀(US);฀F/E G.E.฀Aircraft฀Eng.฀(US);฀F/E Fuji฀Heavy฀Industries฀(JP);฀F/E

Tel:฀(212)฀350-5100 www.geae.com www.fhi.co.jp
Hobie฀Cat฀Company฀(US);฀F/E Goodrich฀Corp.฀(US);฀F/E
www.hobiecat.com NASA฀(US);฀E www.goodrich.com
www.nasa.gov
Hunter฀Marine฀Corp฀(US);฀F/E Sales:฀$14.035฀billion Hexel฀Corporation฀(US);฀F/E
www.huntermarine.com www.hexcel.com
J.฀Ray฀McDermott฀(US)฀F/E Pratt฀&฀Whitney฀(US);฀F/E Israel฀Aircraft฀Industries฀(IL);฀F/E

www.jraymcdermott.com www.pratt-whitney.com www.iai.co.il
Kawasaki฀Heavy฀Ind.฀(JP);F/E Kaman฀Corporation฀(US)฀F/E
www.khi.co.jp Rolls-Royce฀plc฀(UK);฀F/E www.kaman.com
www.rolls-royce.com
Oceaneering฀Int’l.฀(US);฀F/E Sales:฀$6.525฀billion Loral฀Space฀&฀Com.฀(US);฀F/E
www.oceaneering.com www.loral.com
Oshima฀Shipbuilding฀(JP);F/E SNECMA฀(FR);฀F/E Magellan฀Aerospace฀(CA);F/E

www.osy.co.jp www.snecma.com www.malaero.com
Universal฀Shipbuilding฀(JP);฀F/E Orbital฀Sciences฀(US);฀F/E
www.hitachizosen.co.jp Textron฀Inc.฀(US);฀F/E www.orbital.com
www.textron.com
Viking฀Yacht฀Co.฀(SE);฀F/E Sales:฀$4.922฀billion Smiths฀Group฀plc฀(UK);฀F/E
www.vikingyachts.com www.smiths-ind-aerospace.com
Industrial
Primary Other
ABB฀Ltd.฀(CH);฀F/E Briggs฀&฀Stratton฀Corp.฀(US);฀F/E
www.abb.com. www.briggsandstratton.com
Eaton฀Corporation฀(US);฀F/E
Caterpillar,฀Inc.฀(US);฀F/E www.eaton.com
www.cat.com
Sales:฀$18.602฀billion Fanuc฀Ltd.฀(JP);฀F/E
www.fanuc.com
G.E.฀Industrial฀(US);฀F/E Halliburton฀Co.฀(US);฀F/E
www.ge.com www.halliburton.com
ITT฀Industries,฀Inc.฀(US);฀F/E
Illinois฀Tool฀Works฀(US);฀F/E www.ittind.com
www.itwinc.com
Sales:฀$9.22฀billion Kawasaki฀Heavy.฀Ind.฀(JP);฀F/E
www.khi.co.jp
Ingersoll-Rand฀Co.฀(US);฀F/E Komatsu฀Ltd.฀(JP);฀F/E
www.irco.com www.komatsu.com
NACCO฀Materials฀Hd฀(US);฀F/E
Kubota฀Corporation฀(JP);฀F/E www.nacco.com
www.kubota.co.jp
Sales:฀$6.51฀billion NSK฀Ltd.฀(JP);฀F/E
www.nsk.com
Man฀AG฀(DE);฀F/E Parker฀Hanniin฀Corp.฀(US);฀F/E
www.man.de www.parker.com
Pentair,฀Inc.฀(US);฀F/E
Mitsubishi฀Electric฀(JP);฀F/E www.pentair.com
www.mitsubishielectric.com
Sales:฀$17.74฀billion Rockwell฀Automation.฀(US);฀F/E
www.rockwellautomation.com
Mitsubishi฀Heavy.฀Ind.฀(JP);฀F/E Schlumberger฀Ltd.฀(FR);฀F/E
www.mhi.co.jp www.slb.com
Sulzer฀Ltd.฀(CH);฀F/E
Schneider฀Electric฀S.A฀(FR);฀F/E www.sulzer.com
www.schneiderelectric.com
Sales:฀$฀9.754฀billion Timken฀Company,฀The฀(US);฀F/E
www.timken.com
8.3.2 Niche Agriculture, Waste Management, Government,

Export, and Other & Emerging Companies
Table 8.5฀ Major฀endusers,฀fabricators฀and฀suppliers—Group฀Five

Agriculture
Primary Other
Archer฀Daniels฀Midland฀(US);฀E AGCO฀Corporation฀(US);฀F/E
www.admworld.com www.agway.com
Agway,฀Inc.฀(US);฀E
Cargill฀Inc.฀(US);฀E www.agway.com
www.cargill.com
Sales:฀$41.1฀billion Campbell฀Soup฀Co.฀(US);฀E
www.campbellsoups.com
Conagra,฀Inc.฀(US);฀E Chiquita฀Brands฀Int’l฀(US);฀E
www.conagra.com www.chiquita.com
CNH฀Global฀N.V.฀(US);฀F/E
Danone฀Group฀(FR);฀E www.cnh.com
www.danonegroup.com
Sales:฀$14.237฀billion Deere฀&฀Company.฀(US);฀F/E
www.deere.com
General฀Mills,฀Inc.฀(US);฀E Dole฀Food฀Company฀(US);฀E
www.generalmills.com www.dole.com
Farmland฀Industries.฀(US);฀E
Kraft฀Foods,฀Inc.฀(US);฀E www.farmland.com
www.kraft.com
Sales:฀$29.723฀billion Frito-Lay฀Company.฀(US);฀E
www.fritolay.com
McDonald’s฀Corp.฀(US);฀E H.J.฀Heinz฀Company฀(US);฀E
www.mcdonalds.com/corporate www.heinz.com
Hormel฀Foods฀Corp.฀(US);฀E
Nestlé฀S.A.฀(CH);฀E www.hormel.com
www.nestle.com
Sales:฀$60.559฀billion Kellogg฀Company฀(US);฀E
www.kelloggs.com
Sysco฀Corporation฀(US);฀E McCormick฀&฀Company฀(US);฀E
www.sysco.com www.mccormick.com
Sara฀Lee฀Corporation฀(US);฀E
Unilever฀plc฀(UK);฀E www.saralee.com
www.unilever.com
Sales:฀$28.48฀billion Tyson฀Foods,฀Inc.฀(US);฀E
www.tyson.com
Waste฀management Government
Allied฀Waste฀Ind.฀(US);฀E Brambles฀Industries฀Ltd.฀(AU);฀E BAE฀Systems฀plc฀(UK);฀F/E
www.alliedwaste.com www.brambles.com www.baesystems.com
Calgon฀Carbon฀Corp.฀(US);฀F/E
Danaher฀Corporation฀(US);฀F/E www.calgoncarbon.com Bechtel฀Group,฀Inc฀(US);฀F/E
www.danaher.com www.bechtel.com
Sales:฀$3.385฀billion Casella฀Waste฀Systems฀(US);฀E Sales:฀$8.52฀billion
www.casella.com
Dover฀Industries฀(US);฀F/E Clean฀Harbors,฀Inc.฀(US);฀E Boeing฀Integ.฀Defense฀(US);฀F/E
www.dovercorporation.com www.cleanharbors.com www.boeing.com/ids
Compaction฀America฀(US);฀F/E
Ebara฀Corporation฀(JP);฀F/E www.uniteddominion.com Bouygues฀SA฀(FR);฀F/E
www.ebara.co.jp www.bouygues.fr
Sales:฀$2.21฀billion Crane฀Environmental฀(US);฀F/E Sales:฀$15.186฀billion
www.cranenv.com
Philip฀Services฀Corp.฀(CA);฀E ELG฀Haniel฀GmbH฀(DE);฀E Fluor฀Corporation฀(US);฀F/E
www.contactpsc.com www.haniel.de, www.elg.de www.luor.com
GE฀Osmonics,฀Inc.฀(US);฀F/E
Republic฀Services฀(US);฀E www.osmonics.com General฀Dynamics฀(US);฀F/E
www.republicservices.com www.generaldynamics.com
Sales:฀$2.365฀billion Ionics฀Inc.฀(US);฀F/E Sales:฀$12.45฀billion
www.ionics.com
Safety-Kleen฀Corp.฀(US);฀E Kelda฀Group฀plc฀(UK);฀E Kajima฀Corporation฀(JP);฀F/E
www.safety-kleen.com www.keldagroup.com www.kajima.com
Norcal฀Waste฀Systems฀(US);฀E
Suez฀SA฀(FR);฀F/E www.norcalwaste.com Lockheed฀Martin฀Corp.฀(US);฀F/E
www.suez.fr www.lockheedmartin.com
Sales:฀$4.64฀billion Shaw฀E฀&฀I฀Inc.฀(US);฀E Sales:฀$23.92฀billion
www.shaw.grp.com
Veolia฀Environment฀(FR);฀F/E Sumitomo฀Heavy฀Ind.฀(JP);฀F/E Northrop฀Grumman฀(US);฀F/E
www.vivendienvironnement.com www.shi.co.jp www.northgrum.com
Tetra฀Tech,฀Inc.฀(US);฀E
Waste฀Management฀(US);฀E www.tetratech.com Raytheon฀Company฀(US);฀F/E.
www.wm.com www.raytheon.com
Sales:฀$11.142฀billion Waste฀Industries฀Inc.฀(US);฀E Sales:฀$11.73฀billion
www.waste-ind.com
(continued)

Government Export
Other Primary Other
Alliant฀Techsystems฀(US);฀F/E ABB฀Ltd.฀(CH);฀F/E Alcoa฀Inc.฀(US);฀S/F
www.atk.com www.abb.com. www.alcoa.com
EADS฀D&SS฀(DE);฀F/E Bridgestone฀Corporation฀(JP);฀F
www.eads-nv.com Boeing฀Co.,฀The฀(US);฀F/E www.bridgestone.co.jp
www.boeing.com
Foster฀Wheeler฀(US);฀F/E Sales:฀$54.069฀billion Brunswick฀Corporation฀(US);฀F/E
www.fwc.com www.brunswickcorp.com
GKN฀plc฀(UK);฀E Du฀Pont฀Company฀(US);฀S/F Canon,฀Inc.฀(JP);฀F/E

www.gknplc.com www.dupont.com www.canon.com
HBG฀NV฀(NL);฀F/E Crown฀Cork฀and฀Seal฀(US);฀F
www.hbg.nl General฀Electric฀(US);฀S/F/E www.crowncork.com
www.ge.com
Hochtief฀AG฀(DE);฀F/E Sales:฀$130.685฀billion Electrolux,฀AB฀(SE);฀F/E
www.hochtief.de www.electrolux.com
Peter฀Kiewit฀Sons฀Inc.฀(US);฀F/E General฀Motors฀(US);฀F/E Johnson฀&฀Johnson฀(US);฀F/E

www.kiewit.com www.gm.com www.jnj.com
Philipp฀Holzmann฀AG฀(DE);฀F/E Lockheed฀Martin฀Corp.฀(US);฀F/E
www.philipp-holzmann.de International฀Paper฀(US);฀S/F www.lockheedmartin.com
www.internationalpaper.com
Rosoboronexport฀(RU);฀E Sales:฀$16.70฀billion Mattel,฀Inc.฀(US);฀F/E
www.rusarm.ru www.mattel.com
SAIC฀(US)฀F/E Mitsui฀&฀Co.,฀Ltd.฀(IT);฀S/F/E NIKE,฀Inc.฀(US);฀F/E

www.saic.com www.mitsui.co.jp www.nikebiz.com
Thales฀SA฀(FR);฀F/E Saint฀Gobain฀Group฀(FR)฀S/F
www.thalesgroup.com Nestlé฀S.A.฀(CH);฀E www.saint-gobain.fr
www.nestle.com
TRW,฀Inc.฀(US);฀F/E Sales:฀$60.559฀billion Steelcase฀Inc.฀(US);฀F/E
www.trw.com www.steelcase.com
United฀Defense฀Ind.฀(US);฀F/E Siemens฀AG฀(DE);฀F/E Taisei฀Corporation฀(JP);฀F/E

www.uniteddefense.com www.siemens.de www.taisei.co.jp
Vinci฀SA฀(FR);฀F/E Toro฀Company,฀The฀(US);฀F/E
www.groupe-vinci.com Sony฀Corporation฀(JP);฀F/E www.toro.com
www.sony.co.jp
Washington฀Group฀Int’l฀(US);฀F/E Sales:฀$17.16฀billion Waste฀Management฀Inc.฀(US);฀E
www.wgint.com www.wm.com
Other฀and฀emerging
Primary Other
Armor฀Holdings,฀Inc.฀(US);฀F/E Caliper฀Technologies฀(US);F/E
www.armorholdings.com www.calipertech.com
Cree,฀Inc.฀(US);฀F/E
Friede฀Goldman฀H.฀(US);฀F/E www.cree.com
www.fgh.com
Sales:฀$0.246฀billion Digital฀Lightwave฀Inc.฀(US);฀F/E
www.lightwave.com
Hain฀Celestial฀Grp.,฀The฀(US);฀E Fiskars฀Corporation฀(FI);฀F/E
www.hain-celestial.com www.iskars.i
Hi-Rise฀Recycling฀Inc.฀(US);฀F/E
Industrial฀Distribution฀(US);฀E www.hiriserecycling.com
www.idglink.com
Sales:฀$0.493฀billion Interiors,฀Inc.฀(US);฀F/E
www.interiors.com
Kellstrom฀Industries฀(US);฀F/E Jakks฀Paciic,฀Inc.฀(US);฀F/E
www.kellstrom.com www.jakkspaciic.com
K-Swiss฀Inc.฀US);฀F/E
NCI฀Building฀Systems฀(US);฀F/E www.kswiss.com
www.ncilp.com
Sales:฀$0.953฀billion Landec฀Corporation฀(US);฀F/E
www.landec.com
Salton฀Inc.฀(US);฀F/E Matrixx฀Initiatives฀Inc.,฀(US);฀F/E
www.saltoninc.com www.gum-tech.com
Polymedica฀Corp.฀(US);฀E
Scansource,฀Inc.฀(US);฀E www.polymedica.com
www.scansource.com
Sales:฀$0.842฀billion Standard฀Auto.฀Corp.฀(US);฀F/E
www.standardauto.com
SLI,฀Inc.฀(US);฀F/E Summa฀Industries฀(US);฀F/E
www.sli-lighting.com www.summaindustries.com
Thermoview฀Industries฀(US);฀F/E
Solectron,฀Inc.฀(US);฀F/E www.thermoviewinc.com
www.solectron.com
Sales:฀$12.27฀billion US฀Plastic฀Lumber฀(US);฀F/E
www.usplasticlumber.com
About the Author
Dr. Donald V. Rosato, President of PlastiSource, Inc. a prototype manufacturing,

technology development, and marketing advisory firm in Massachusetts, USA is
internationally recognized as a leader in plastics technology, business, and market-
ing. He has extensive technical and marketing, plastic industry business experience
from laboratory testing, through production to marketing, having worked for
Northrop Grumman, Owens-Illinois, DuPont/Conoco, Hoechst Celanese/Ticona,
and Borg Warner/G.E. Plastics. He has developed numerous polymer related patents
and is a participating member of many trade and industry groups. Relying on
his unrivaled knowledge of the industry plus high level international contacts,
Dr. Rosato is also uniquely positioned to provide an expert, inside view of a range
of advanced plastics materials, processes and applications through a series of semi-
nars and webinars. Among his many accolades, Dr. Rosato has been named Engineer
of the Year by the Society of Plastics Engineers. Dr. Rosato has written exten-
sively, authoring or editing numerous papers, including articles published in the
Encyclopedia of Polymer Science and Engineering, and major books, including the
Concise Encyclopedia of Plastics, Injection Molding Handbook 3rd Ed., Plastic
Product Material and Process Selection Handbook, Designing with Plastics and
Advanced Composites, and Plastics Institute of America Plastics Engineering,
Manufacturing and Data Handbook. Dr. Rosato holds a BS in Chemistry from
Boston College, MBA at Northeastern University, M.S. Plastics Engineering from
University of Massachusetts Lowell, and Ph.D. Business Administration at
University of California, Berkeley.

DOI 10.1007/978-1-4614-0245-9, © Springer Science+Business Media, LLC 2011

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SpringerBriefs in Materials

For further volumes:

Plastics End Use Applications

ISSN 2192-1091 eISSN 2192-1105

Library of Congress Control Number: 2011931281

© Springer Science+Business Media, LLC 2011

Printed on acid-free paper

Springer is part of Springer Science+Business Media (www.springer.com)

This SpringerBrief is designed to keep professionals in the global plastics industry

1 Executive Summary ................................................................................. 1

3.1.3 PLED Flat Panel Displays .................................................. 20

4.3.6 Aerodynamic Truck Brackets ............................................. 44

6.1.4 Consumer Durable Cushioning........................................... 66

7.1.5 Surgical Microtools............................................................. 87

1.1.2 Global Technology Highlights (North America,

1.1.3 Electrical and Electronic Applications

D.V. Rosato, Plastics End Use Applications, SpringerBriefs in Materials, 1

1.1.4 Industrial Applications

1.1.5 Transportation Applications

1.1.6 Consumer Products Applications

1.1.7 Medical, Emerging, and Other Applications

1.2 Scope and Methodology

Electrical and electronic applications Agricultural applications

1.2.3 Plastics End Use Applications Webwatch Directory

3.฀Electrical and electronics end use applications

Keywords฀ Polypropylene฀ •฀ Polyethylene฀ •฀ Polystyrene฀ •฀ Polyvinyl฀ chloride฀

2.1.1 Markets Overview

D.V. Rosato, Plastics End Use Applications, SpringerBriefs in Materials, 11

2.1.2 Packaging Market

2.2 Other Major Markets

2.2.1 Building and Construction Market

2.2.2 Automotive Market

2.2.3 Electrical and Electronic Market

2.3 Key Crossover Markets

2.3.1 Consumer Goods Market

2.3.2 Industrial and Stock Shapes Markets

2.3.3 Other Markets

3.1 Electrical and Electronic Applications

3.1.1 Electrical and Electronic Applications Introduction

3.1.2 Fuel Cell Plates

D.V. Rosato, Plastics End Use Applications, SpringerBriefs in Materials, 19

3.1.3 PLED Flat Panel Displays

3.1.4 Flexible Printed Transistors

3.1.5 High-Performance Ignition Coil Bobbins

3.1.6 Smart Wallplates

3.1.7 Electronic Cloth

3.1.8 Intrinsic EMI Shielded Products

3.1.9 Miniaturized DSL Transformers

3.1.10 Electrodynamic Loudspeakers

3.1.11 Visual/Tactile Electronic Enclosures

3.1.12 High-Performance Outdoor Cable

3.2 Office Products Applications

3.2.1 Office Products Applications Introduction

3.2.2 Miniaturized Fuel Cells

3.2.3 Rollable Reading Displays

readability฀ and฀ extremely฀ low฀ power฀ consumption.฀ Currently,฀ PolymerVision฀ is฀

3.2.4 Digital Pens

3.2.5 Orbital Web Cameras

3.2.6 Removable Data Storage Media

3.3 Appliance Applications