Plastic Material News

Foster's New Radiopaque Filler Delivers Improved Performance at Lower Cost for the Medical Device Industry

PUTNAM, CT, USA - (September 29, 2009) - Foster Corporation, part of the PolyMedex Discovery Group, has introduced a new radiopaque polymer enhancement technology that offers a superior value option for the medical device industry. Marketed under the name Foster Bismuth Subcarbonate, this new radiopaque filler offers superior quality that translates to improved performance at the extrusion step of the supply chain. According to Brian LaBrec, Director of Engineering at Foster, “This is the next generation filler that will allow improved yields and thinner wall thicknesses, thereby pushing the limits of product design.  Not only does it improve performance, it costs less than standard bismuth subcarbonate radiopaque fillers.”

Radiopaque fillers are added to polymers to make catheters and other medical devices visible under fluoroscopy or X-ray imaging. The filler affects the degree of contrast and the sharpness of the image to the extent that it influences the attenuation of X-rays passing through the body and the device. Standard bismuth subcarbonate radiopaque fillers, however, have historically caused problems for OEM and small extrusion operations due to rough surfaces and unstable extrusion processes.  “Dispersion of fillers into plastics in the medical industry has been an ongoing challenge,” explained LaBrec. “Poor dispersion is the result of agglomeration of fillers in the extruded plastics and this makes for bumpy areas on the surface of catheters.  These bumps are unacceptable to the industry because this results in discomfort to the patient or mechanical stress points that may cause premature failure of the device.”

Foster listened to its customers, said LaBrec, and began working with bismuth subcarbonate manufacturers to optimize the new filler for medical devices.  “We focused on the morphology, density, crystallinity, surface area and particle size,” he said. “Our Bismuth Subcarbonate allows for a much smoother surface, which means improved yields to the OEMs and happier customers throughout the supply chain.  We’ve had input from customers that this new filler is actually more stable in the extrusion process.  This is believed to be related to the particle morphology and dispersion characteristics.”

Foster Bismuth Subcarbonate compounds are the newest addition to Foster’s family of Lo-Pro™ radiopaque compounds designed to meet the increasing challenges of the medical device market.  They can be used in several different polymer families, such as TPE, TPU, PVC, EVA and polyolefins. Medical markets include cardiology, radiology, oncology, neurology, urology and gastroenterology. Applications include catheter tubes, balloons, stents, catheter tips and injection molded parts.

For more information, please call 860-928-4102 or visit the Foster website at www.fostercorporation.com

Expert insights will help drive interior design engineering innovations

Pittsburgh, September 28, 2009 — Visteon Corporation is the newest addition to the growing list of automotive suppliers coming onboard in collaboration with Velozzi as the automotive industry races to bring a new generation of alternative energy vehicles (AEVs) to market. With this announcement, Visteon joins a growing number of organizations – including Bayer MaterialScience – that are supporting Velozzi’s groundbreaking AEV project.

Visteon and Bayer MaterialScience have successfully collaborated on other material innovations for the automotive industry. In this initiative, Visteon will provide design and engineering expertise for the interiors of the Velozzi Solo Crossover and Supercar Sports Car, both competing in the Automotive X Prize. Visteon will leverage its global reach, understanding of consumer preferences and design expertise using the latest technologies to engineer the interiors of the Velozzi vehicles for a winning combination of comfort and style. 


Visteon will serve as a one-stop collaborator for global supply and development outreach, while offering a suite of technology solutions for interior systems such as instrument panels; door trim and floor consoles; and electronic controls, layout and component development. This centralized approach, beginning at the concept-design stage, will help ensure that the Velozzi AEV designs are technically viable for mass production and will help support Velozzi’s goal to move rapidly from concept to production.
 
Bayer MaterialScience will provide materials based upon emerging and newer technologies to meet the

 interior design and engineering parameters. Highlighting the value Visteon brings, Paul Platte, innovation manager, New Business, Bayer MaterialScience LLC, said, “Visteon plays a key role in the development of interiors that are environmentally compatible and convey a great sense of uncompromising, luxurious style. Visteon’s insights are critical to producing a Velozzi interior that satisfies the high expectations of today’s savvy consumers.”

“Visteon is a key addition to our project,” said Roberto Velozzi, Velozzi CEO. “Visteon has a long track record of innovation, and their expertise and global reach will be critical in translating our interior designs into commercial reality. It’s one of the greatest challenges in our entire development process.”

To Visteon, Velozzi and the other companies participating in this project are heading in the right direction. “Velozzi has a keen understanding of what AEVs must deliver and has a novel approach to the challenge,” said Shannon Quinn, Program and Commercial Director, Visteon. “Visteon's expertise and automotive intellect can help Velozzi succeed in its quest to meet or exceed customer expectations in the features that matter most in a purchase decision.”

Bayer MaterialScience supports both traditional and non-traditional OEMs, including Velozzi, with high-performance materials including plastics, polyurethanes, coatings, adhesives and technology specialties to create low-weight, high-efficiency AEVs.
 
Visteon Corporation is a leading global automotive supplier that designs, engineers and manufactures innovative climate, interior, electronic and lighting products for vehicle manufacturers, and also provides a range of products and services to aftermarket customers. With corporate offices in Van Buren Township, Mich., (U.S.); Shanghai, China; and Chelmsford, UK; the company has facilities in 26 countries and employs approximately 30,000 people.

Bayer MaterialScience LLC is one of the leading producers of polymers and high-performance plastics in North America and is part of the global Bayer MaterialScience business with nearly 15,100 employees at 30 sites around the world and 2008 sales of 9.7 billion euros. Business activities are focused on the manufacture of high-tech polymer materials and the development of innovative solutions for products used in many areas of daily life. The main segments served are the automotive, electrical and electronics, construction, medical, and sports and leisure industries.

For more information about BMS materials, call 1-800-662-2927, e-mail naftainfo@bayerbms.com or visit www.bayermaterialsciencenafta.com.

For more information about Velozzi, visit www.velozzi.org or e-mail velozzi@velozzi.org.

For more information about Visteon, visit www.visteon.com.

This news release may contain forward-looking statements based on current assumptions and forecasts made by Bayer Group or subgroup management. Various known and unknown risks, uncertainties and other factors could lead to material differences between the actual future results, financial situation, development or performance of the company and the estimates given here. These factors include those discussed in Bayer’s public reports which are available on the Bayer website at www.bayer.com. The company assumes no liability whatsoever to update these forward-looking statements or to conform them to future events or developments. 

W. Amsler's New Reheat Stretch-Blow Molder Satisfies Widemouth Container Demands

RICHMOND HILL, Ontario, Sept. 25, 2009 – W. Amsler Equipment Inc. recently sold its newest model, the L15 all-electric reheat stretch-blow molder with hot-fill capability, to Diversified Ltd., based in Trinidad & Tobago, a PET bottle manufacturer for the food and household detergent industries. Diversified will use the machine to produce widemouth food jars ranging from 8-oz to 32-oz, along with 5-L detergent containers for the local market.

Upon winning new production work for widemouth containers, Diversified did an extensive examination of the blow molding machine supply base. “Based on our research, the W. Amsler machine is one of the few that can produce widemouth containers automatically,” explained Warren Scott, Diversified’s owner. “All of the advantages of an all-electric in terms of efficiency and economics also played a key role in our selection.”

W. Amsler’s new L15 custom blow molder is a single-cavity unit that produces containers from 20-mm to 70-mm at up to 1700 bottles/hr. It is targeted for small- to medium-size volumes and produces larger containers (up to 5-L) than the company’s L12 model (up to 2-L). The machine for Diversified is specially equipped for automatic loading of 89-mm diam. preforms and has a larger track for preform spigots. Diversified buys preforms and manufactures 13 different bottles for ketchup, peanut butter, mayonnaise, sauces, and other products. The company is also pursuing local opportunities for hot-fill containers.
Compared to hydraulics, the all-electric machine delivers an energy savings of 50%, along with greater precision, smaller footprint (170-in by 80-in), faster speed, reduced maintenance, and quicker mold changeovers, according to W. Amsler.

The new reheat blow molder is part of a turnkey operation sold to Diversified which also includes specially designed blow molds from W. Amsler.

About  Diversified Ltd.
Diversified Ltd., based in Trinidad and Tobago, is a 10-year-old company specializing in blow molded PET and HDPE bottles for food, detergent, water, and other industries. The company uses state-of-the-art production equipment to make a range of container sizes for the local market. More information is available by calling (868) 672-6720 or e-mail fourscotts@tstt.net.tt.

About W. Amsler Equipment Inc.
W. Amsler Equipment Inc. is a privately-held Canadian company founded in 1994 by Werner Amsler. The company manufactures state-of-the-art, highly-efficient reheat stretch-blow molding machines and auxiliary equipment for manufacturers of plastic containers for the carbonated soft drink, water, and food industries. The product line includes linear machines with output up to10,000 bottles/hr and rotary equipment for up to 24,000 bottles/hr. The company was one of the first to develop all-electric machines which provide users with highly-repeatable processing, energy savings up to 50% vs. hydraulics, and a 75% reduction in maintenance costs.    

W. Amsler also supplies auxiliary equipment for complete blow bolding plants, water treatment, and filling lines. These products include bottle-inspection units, air compressors, process chillers, mold temperature-control units, blow-dome spin-off trimmers, gaylord dumpers, vacuum conveyors, and blow molds. The company has also partnered with companies to provide turnkey liquid filling equipment. More details are available at www.amslerequipment.net

DuPont Performance Elastomers to Demonstrate Turbo Charger Hose Extrusion Process and Present Technical Paper on Peroxide Cured AEM Compounds at the 176th Annual ACS Technical Meeting and Rubber Expo

WILMINGTON, Del., Sept. 28, 2009 - DuPont Performance Elastomers (DPE) will be participating with DuPont Advanced Fibers Systems, (Booth 1523) showcasing Viton® fluoroelastomers, and DuPont™ Vamac® ethylene acrylic elastomers.  DPE will also be showing a video in the booth, demonstrating the turbo charger hose extrusion process that makes this duo a winning combination. 

Neoprene polychloroprene will also be highlighted for its outstanding physical toughness, wide operating temperature range and resistance to ozone, sun and weather.

In a paper entitled, “Improved Flex Properties for Peroxide Cured AEM Compounds,” DuPont Performance Elastomers Technical Associate, Edward McBride, reports test results demonstrating the improvement of dynamic properties of peroxide cured AEM compounds.  A combination of factors has produced a step change in performance, so these compounds have dynamic properties that are similar to those of diamine-cured AEM compounds.  Studies indicate there are several potential advantages for these peroxide-cured compounds, including the possible elimination of the post-cure step in hose production, less scorch during the extrusion step and the option to use lower cost polyester fibers for reinforcement. 

Vamac® ethylene acrylic elastomers (AEM) and Viton® fluoroelastomers (FKM) are a winning combination in the manufacture of turbo charger hoses.  Together, their unique properties of temperature performance up to 200°C, low cost, an extrusion process that eliminates silicone (VMQ) wrapping, and better interlayer adhesion than FKM/VMQ, allows turbo charger hoses made with Vamac® and Viton® meet today’s tough requirements. A video demonstration of the turbo charger hose extrusion process will be available in DuPont’s Booth 1523.

DuPont Performance Elastomers, a global supplier of specialty elastomers with headquarters in Wilmington, Del., USA, is a wholly owned subsidiary of DuPont. The company is an industry leader in chloroelastomers and fluorinated elastomers, serving the automotive, chemical, petrochemical, semiconductor, food and pharmaceutical processing, construction, general rubber and wire and cable industries.

Bumpy Road Conditions are No Match for BASF’s Oil Pan Test Challenge

Collaboration with Dana Holding Corporation validates results

September 25, 2009 - Wyandotte, MI - The Sealing Products Group of Dana Holding Corporation and BASF conducted an oil pan module study to demonstrate and validate that Ultramid® PA (polyamide) can perform not only as an oil pan, but also as an oil pan that integrates and combines multiple components and functions.  Benefits compared to conventional design in metal include weight and cost reduction, as well as consolidation of parts and functions allowing for a simplified installation and assembly process. End-consumers can also benefit from a quieter drive by noise reduction and increased sump capacity that can lead to longer service intervals.

Dana’s Victor Reinz® design coupled with BASF’s material and propriety CAE analysis and analytical tools all confirmed that Ultramid® PA is capable of meeting the material and functional requirements of this demanding application.   BASF optimized the oil pan design to meet various performance challenges ranging from noise, vibration, harshness (NVH), sealing and stone impact. BASF also validated the joint Dana/BASF design using the advanced ULTRASIM™ technology during the various development phases. BASF’s unique ULTRASIM™ technology was used to predict the stone impact resistance and static crash load simulations.  When measured on actual parts, the predicted critical panel breathing mode was within 1.8 percent of lab tests.  The sophisticated sealing analysis allowed for a high level of accuracy in predicting the long-term creep behavior of the oil pan produced in Ultramid® PA at 120 degrees Celsius for 10,000 hours to ensure that adequate gasket sealing pressure was maintained for the lifetime of the oil pan module.

“We quickly embraced the hands-on, practical test of our oil pan module by placing it on a Dodge Durango driven every day on Michigan freeways,” said David Nash, Engineering Director, Dana Sealing Products Group. “Several of Michigan’s highways are under construction and that really put the material and design to the test.”

“This type of real-life demonstration, conceived and implemented by BASF, is proof-positive that BASF is an innovative and pioneering company focused on bringing innovative applications to the consumer market,” said Michael Britt, Group Vice President for BASF’s Engineering Plastics business in North America.  “Customer satisfaction is what wins in today’s markets. Companies that are focused on the end result and consumer satisfaction are going to be successful today and in the future.”

Concurrently, in response to OEM concerns about stone impact, BASF developed a unique Ultramid PA grade optimized for stone impact, working in conjunction with Dana’s innovative rib design. Initial results show that oil pans can be designed in Ultramid PA to meet or exceed the stone impact performance of conventional metal based components.

BASF road tests Ultramid® PA6 to provide real results.

Stylepark Selects LyondellBasell’s Pristene Resins for its New Material Edition

ROTTERDAM, Netherlands, September 24, 2009 – Stylepark design network has selected metallocene-based Pristene resins from LyondellBasell Industries for its ninth Stylepark Material Edition, a selection of plastics and other materials recommended for use in applications historically the domain of polycarbonate. 

“LyondellBasell is the first polyolefins supplier we are cooperating with,” said Christian Gärtner, Chief Executive Officer of Stylepark, located in Frankfurt, Germany. “This is due to the outstanding mechanical properties of Pristene resins, making them highly suitable for a wide range of design-oriented applications in building and construction.”

With its Material Editions, Stylepark provides designers and material enthusiasts with a new way of accessing materials. The company acts as curator and intermediary for the creative industry by providing a platform for research and evaluation of contemporary design. Its service is aimed at architects and product, interior and other types of designers, as well as end users interested in design.

Potential to replace polycarbonate
Conceived by Stylepark and created with the support of LyondellBasell experts, the Material Edition features a variety of material samples that illustrate the translucency, colors and surfaces offered by Pristene resins. “Today, a large portion of metallocene-based resins are used in the packaging industry,” said Gärtner. “Only a very small portion of these resins is used in areas such as building and construction, which is of particular interest to us and to the creative industry. As we believe that Pristene resins offer significant potential, we are offering this edition to designers and architects who are interested in broadening the range of materials they use in interior design.”

Stylepark design experts are recommending Pristene resins for use in numerous design-orientated applications, such as bathrooms. “Due to their mechanical properties, Pristene resins can be considered for use in shower cubicles and other applications typically produced using polycarbonate and requiring improved flowability, transparency and chemical resistance in the bathroom,” said Bernd Schütz, LyondellBasell’s Marketing Manager for metallocene-based products. “In electronic devices, designers might consider transparent and amorphous polymers, as this area has been dominated by overdesigned solutions produced using polycarbonate.” The Material Edition is also targeting cosmetic packaging due to the resins’ outstanding brilliance and processability, enabling customers to create complex packaging designs.

The Material Edition contains a wide variety of surface textures produced with Pristene resins, which can be used in back injection molding of textiles as well as in abrasion-proof surface finishes. “Pristene resins are easy to process, and the Material Edition demonstrates the innovative opportunities that the materials offer designers,” said Schütz. “Our cooperation with Stylepark will assist our customers in providing new design ideas for the creative market.”

The Material Edition can be ordered by contacting Janina.Isinger@lyondellbasell.com. Detailed information can be found at www.stylepark.com/en/material

Stylepark design network has selected Pristene resins from LyondellBasell Industries for its ninth Stylepark Material Edition, a selection of plastics recommended for use in applications historically the domain of polycarbonate. The Edition contains a variety of surface textures produced with Pristene resins, which can be used amongst others in back injection molding of textiles and in abrasion-proof surface finishes.
 

Borealis’ BorSafe™ PE100 pipes deliver disruption-free water supply to Sicilian airport

Produced by Borealis, a leading provider of innovative, value creating plastics solutions, BorSafe™ HE3490-LS was selected for the infrastructure redesign at Palermo International Airport on the island of
Sicily. As well as giving the required performance, the material was able to deliver significant savings on installation costs and time.

The ‘Falcone e Borsellino’ Airport is one of Italy’s busiest airports, currently handling in excess of 4.5 million passengers a year – and this number is projected to double by 2015. To prepare for this massive increase in throughput, the airport is undergoing extensive expansion and upgrading of services and facilities. However, the expansion had to be achieved through the redesigning of infrastructure within the pre-existing airport boundaries.

With the upscaling of facilities within the same limited space, maintenance becomes more difficult, more expensive and more disruptive to airport operations and therefore has to be minimized – so systems must perform better and last longer.

In addition to expanding the drinking water distribution system, there was also a need to replace the old pipes of the existing system. As this was installed more than 40 years ago, the steel water pipes had corroded and become increasingly unreliable through leakages which required constant maintenance. New pipes had to be corrosion resistant and able to provide for a long leak-free in-service life, to
avoid future disruptions to airport services.

To satisfy these criteria, Carini Plast supplied its TURBO PEAD PE100 material based on Borealis’ BorSafe HE3490-LS high density PE for the installation of 7,500 metres of OD (outside diameter) 200 mm, PN 25 pipe.

BorSafe HE3490-LS established a solid performance track record in water distribution projects, in a broad range of environments and types of sub-soil conditions across Europe. An important reason for this choice was the flexibility of BorSafe HE3490-LS. This made it possible to bend the pipe around obstacles and other buried utilities without needing to use mechanical joints, thereby significantly reducing a primary source of leaks.

“The use of Butt Fusion welded joints helped to avoid the need for anchorage blocks, which are often difficult to install in facilities such as airports, because of their services-crowded underground environment. Being able to eliminate them has saved both laying-time and costs.” says Clemente Gaspare from MA.DI. Costruzioni. “BorSafe LS PE100 pipes meet the needs of today’s stringent environmental policies and practices and will perform reliably over many years, with little or no maintenance. Borealis’ role in the development of a new drinking water delivery system is a foundation step in helping to prepare
Palermo International Airport to fulfill its potential as a high growth hub in European commercial aviation.”

AIJU-CETEMMSA-CIDETEC consortium are researching the introduction of ‘Plastic Electronics’ in Toys

The Technological Research Institute for Toys,–AIJU-, whose main objective is to boost the development of the toy sector, is coordinating the PLASeTOY project carried out in consortium with CIDETEC and CETEMMSA for the experimental development of Plastic Electronic devices and their incorporation in toys and other child products. This project, supported by the Science and Innovation Ministry in Spain, has the objective of their insertion in the medium term for the Toy Sector, which will allow the introduction of electronic and interactive functions in objects and products in a flexible and innovative way.

Plastic Electronics represents a new branch in the electronic field which is focused on the production of displays on plastic surfaces made from organic materials and hybrids. This new technology provides lighter and more flexible devices making their incorporation into certain articles easier or even allowing the development of big displays which roll up or fold on themselves. On the other side, it is a cheap technology both, for the type of materials used as well as the ease of the production technologies.

The “Plastic Electronic” displays which are going to be developed within the project are:

• Electrooptics. Three types of these are going to be developed: electrochromic, PDLC (Polymer Dispersed Liquid Crystals) and electroluminescent (EL). All of them use an electric field to provoke a different optical effect; Electrochromic change colour, PDLC’s allow a range between transparent and translucent and electroluminescent emit light.
• The incorporation of these devices will allow us to give added value to the final product, in accordance with the standards applicable to electric toys.
• Flexible Tactile Switches. They will be developed with the objective of replacing all kind of keys and buttons by contact areas within the same piece, allowing the homogenizing of the toy, making its design easy and avoiding additional moulds. Moreover, this provides wider safety guarantees for the toy as they avoid small pieces that could come off.
• Flexible Plastic Electronic Circuits. The development of these kinds of circuits will avoid the use of cables and welding, making the product design easier, reducing the generation of electrical and electronic waste thus complying with directive RoHS, which is difficult to achieve using current techniques.

Starting Point for these Technologies on an International and National Scope.
According to the book titled “How the Toy and Game Industry will be Transformed  by Printed Electronics” , the lastest developments undertaken in this field will notably increase innovation, competitiveness and the sustainability of the sector. Among other developments it mentions the use of inkjet in board games, the incorporation of e-books, tales and greeting cards, the insertion of smart plastic foils which will improve interactivity with the toy or the article, displays which simulate dolls or ionic robots, and devices which give off aromas and flavours or even edible displays.

According to another study undertaken by IDTechEX (Figure 1), an exceptional income increase in the “plastic electronics” sector is being forecast, which will rise from $1.92 billion in 2009 to $57.16 billion in 2019 . The investment destined to the research and development of these displays exceeds $2 billion only in Europe and USA. The amount of researchers and developers of these ‘plastic electronic’ products has doubled in a two year period, with 510 organisations dedicated to the research of the specific devices studied within the project framework .
 

Figure 1. Projection of the Market for Plastic Electronics
This data is an indicator of the vast potential that plastic electronics have for companies which invest in this field, it does not matter if they are raw material suppliers, equipment manufacturers, or system manufacturers or integrators.

Read full article (pdf)

We would like to acknowledge the Science and Innovation Ministry for the financial support it has granted to this Project Developed under Consortium, through the Experimental Programme of National Development, a sub-programme for Supporting Technological Centres DEX-560540-2008-3 and the co-financing of FEDER funds.

AdDent's Composite Dispenser Gun Made of Radel® R PPSU is One of the First Autoclavable Plastic Units

ALPHARETTA, Ga., - Sept. 23, 2009 – AdDent, Inc., Danbury, Conn., a leading manufacturer of dental instruments and devices, has introduced its first composite dispenser gun – an ergonomic and easy-to use device that features Solvay Advanced Polymers, LLC’s Radel® R polyphenylsulfone (PPSU) resin for autoclavability, strong chemical resistance, and high strength. The new CoMax™ composite dispenser gun is a dedicated device that is compatible with the company’s Calset™ composite warmer and is one of the first autoclavable plastic dispensing guns, according to Dr. Joshua Friedman, founder and president of AdDent Inc.

The CoMax™ dispensing unit has a patented ergonomic mechanism and an easy-to-hold trigger and handle that minimize the force to dispense heavily-filled composite dental fillings. It consists of a stainless steel barrel along with a handle, trigger, and flange all injection molded of Radel® R-5100 NT 15 resin. The high-performance thermoplastic offers a high heat deflection temperature (HDT) of 405°F (207°C) and can withstand more than 1,000 cycles of steam sterilization without any significant loss of properties. This performance accounts for its use in other demanding healthcare applications such as sterilization cases and trays, surgical instrument handles, and provisional trials used during implant surgery. The material also has exceptional resistance to a broad range of commonly used cleaning agents and disinfectants.

The innovative spring-loaded design incorporates several snap-fits, creating a highly dimensionally stable device with just two fasteners. The composite dispensing gun is available globally and has received CE certification in Europe, signifying conformance with certain EU health and safety requirements.

 About AdDent Inc.
AdDent, Inc., based in Danbury, Conn., is a leading manufacturer of advanced dental instruments and devices. The company operates a 6,500-sq-ft manufacturing and R&D facility in Danbury and is a supplier to major dental dealers via an extensive sales network throughout the U.S. and overseas. Learn more at www.addent.com

About Solvay Advanced Polymers
Solvay Advanced Polymers, LLC, produces more plastics with more performance than any other company in the world. This gives design engineers worldwide more ways to solve top design challenges in automotive, healthcare, electronics, aerospace, and other demanding industries. Learn more at www.solvayadvancedpolymers.com.

Solvay is an international chemical and pharmaceutical Group with headquarters in Brussels. Its companies employ more than 28,000 people in 50 countries. In 2008, its consolidated sales amounted to EUR 9.5 billion, generated by its three sectors of activity: Plastics, Chemicals and Pharmaceuticals. Solvay (NYSE Euronext: SOLB.BE - Bloomberg: SOLB.BB - Reuters: SOLB.BR) is listed on the NYSE Euronext stock exchange in Brussels. Details are available at www.solvay.com

LyondellBasell Selected by Opel as Key Supplier of PP Compounds for Its New Insignia European Car of the Year

September 22, 2009 – Rotterdam, The Netherlands - Hostacom compounded polypropylene (PP) resins produced by LyondellBasell Industries are being used to manufacture the interior components of Opel’s new Insignia model, which received the 2009 European Car of the Year award.

“To be selected as one of the key suppliers of PP Compounds for the interior applications of the new Opel reflects not only our continuous innovation capabilities, but also the ongoing ability of PP compounded solutions to outperform other material concepts,” said Wolfgang Jonischkeit, LyondellBasell’s Customer Project Manager for Opel.

Several Hostacom compounded PP grades are being used to produce the instrument panel, door panel and pillar trim. “Opel required materials that address their needs for mechanical and safety properties, long service life, cost/performance balance and a superior, low-gloss surface finish,” added Jonischkeit.

Key to this extraordinary performance is a new additive package used in the Hostacom PP compounds, which surpasses conventional PP compounds in terms of scratch resistance and surface properties. According to Opel’s scratch and mar resistance tests, parts produced using the Hostacom grades with 15 percent filler demonstrated a much better surface appearance compared to other Polypropylene compounds on the market which contain nearly 20 percent filler. “The lower talc content also improves the density performance, enabling the production of lighter-weight parts while retaining all of the desired properties,” said Jonischkeit. “The Hostacom grades also provide a good impact/stiffness balance and outstanding processability.”

Meeting customer’s requirements
Opel experts placed special emphasis on improving the aesthetics of the Insignia’s visible parts. For the glove box and door panels, LyondellBasell provided a Hostacom TRC 160T grade, which features outstanding paint-bonding properties and allows the production of finished parts without the need for priming. “We helped Opel achieve a surface quality consistent with traditional coating solutions, while significantly reducing manufacturing chain complexity,” said Rainer Köhler, Product Development Engineer at LyondellBasell.

Surface aesthetics also played a major role in the design of the upper pillar trim, as Opel required a material that displayed the same look and feel of the surface as traditional textile-laminated parts. Based on LyondellBasell’s patented, customized Hostacom EKC 133N Multispot grade that includes carbon fibers, Opel was able to attain a surface quality comparable to conventional parts laminated with a textile layer.

Opel also use LyondellBasell’s new soft-touch Catalloy resins, marketed under the trade name Softell, for a side cover (two-component application). Opel engineers required a flexible polymer that met the mechanical stress requirements for automotive seating. Softell grades also provide the necessary suppleness without sacrificing crash-relevant properties such as impact resistance.

Global specifications
As the Insignia has been launched globally, Opel required supply from LyondellBasell locations worldwide to ensure material consistency across all regions. “With 16 compounding production plants in 13 countries on five continents and all in close proximity to the OEM’s manufacturing plants  we provide the material consistency that global producers need,” said Alain Gourjault, Automotive Marketing Manager at LyondellBasell.

The 2009 European Car of the Year has been acclaimed as the most outstanding new vehicle to enter the market in the last 12 months. The Insignia also received the coveted Red Dot Design Award for its innovative, trendsetting design.