Taking TPEs to the Next Level – New Developments Round-up

Application-engineered TEH Materials - The Powerful Synergy of Two Worlds

KRAIBURG TPE has developed an application-engineered TEH materials which combine different mixtures of various elastomers and thermoplastics with respective crosslinked systems to form materials with unprecedented properties. Their properties include:
 

• High media and temperature resistances, which are adjusted to the requirements of each application
• The flexibility to tailor the material's property profile to the requirements of specific application
• Hardness from 55 to 80 Shore A
• Permanent operating temperatures of up to 150 °C (302 °F), and
• Chemical stability against materials such as oils, lubricants, fuels and coolants 
   

Thus, they are particularly suitable for use in the environment of combustion engines, in heat management of drives and batteries for electric vehicles, as well as in lubrication and cooling systems of machines, process technology and buildings. Direct applications include seals and gaskets, plugs and connectors, lids and covers.

The resulting compounds can be used as an alternative to common crosslinked rubber solutions that is economically convincing and processable like thermoplastics. They also offer appealing options for multi-component applications when bonded with technical plastics such as polyamides and thermoplastic polyesters. They can be processed with common injection molding machines and extrusion lines, do not require any finishing and are completely recyclable.
 

Trend-Setting Thermoplastic Elastomers Hybrids
 

 

Nylon-based 'Hybrid' Engineering TPEs

At NPE 2018, Nylon Corporation of America, Inc. (NYCOA) highlighted its NY-FLEX® elastomer range - a class of nylon (polyamide) based engineering thermoplastic elastomers (E-TPE). These materials are block copolymers of nylon (polyamide) segments and polyether segments. The nylon (polyamide) block is the hard segment and the polyether block is the soft, flexible segment. 

These hybrid materials offering a unique combination of rubber-like elastomeric properties and thermoplastic-like processing capabilities and hence claimed to deliver on performance and cost.
 

• Excellent flexibility at low temperature
• Superior retention of properties to elevated temperature
• Exceptional toughness and resilience
• High creep resistance
• Strong resistance to flex fatigue
• Good abrasion resistance, and
• Superior resistance to greases, oils, and solvents
  
   

Custom-engineered Bio-based TPE Using Modular System

Climate change, finite oil resources and customers who are increasingly environmentally aware are leading more and more materials manufacturers and users to turn to 'renewable' and 'bio-based' solutions. By developing customer-specific and application-specific compounds using renewable raw materials, KRAIBURG TPE is aiming to meet the growing demand for environmentally friendly and sustainable thermoplastic elastomers.

The company sees tremendous potential for custom-engineered thermoplastic elastomers with adjustable proportions of renewable raw materials of up to 90%, both in the consumer market and also in the industrial and automotive markets.

In classical approaches, it is technically possible to produce bio-based materials with very high proportions of renewable raw materials. However, materials of this kind usually suffer from very high raw materials costs, while providing only very limited mechanical properties. But the modular system has now enabled KRAIBURG TPE to resolve this contradiction almost completely by following a new, innovative approach beside the classical one. The initial pilot projects based on the classical approach are showing a trend towards bio-based, certifiable proportions of 20% and more.

 

Sustainable TPVs Made from Bio-based EPDM Rubber

ARLANXEO has introduced its new thermoplastic vulcanizates (TPVs) based on sustainable ingredients with the specific aim of maximizing sustainable content without compromising technical performance. The new TPVs combine Keltan Eco ethylene propylene diene monomer rubber (EPDM) with green fillers, plasticizers and thermoplastics.

Keltan Eco is the world's first EPDM rubber manufactured using bio-based ethylene extracted from sugarcane. Depending on the ethylene content of each rubber grade, the proportion of bio-based material ranges between 50% and 70%. According to the company, the bio-based TPVs can make a significant contribution to the circular economy, scoring well in a cradle-to-cradle approach and helping to lower the carbon footprint.

 

Heat- and Chemical-resistant TPEs for Food-contact Applications

Recently Teknor Apex has launched a new series of styrenic thermoplastic elastomers (TPEs) suitable for food-contact, cosmetics, and regulated applications. Monprene® RG-15100 Series TPEs meet U.S. and EU regulations for single- and repeated-use applications with dry, acidic, aqueous, and alcoholic food type. They offer:
 

• Surface appearance and haptics like silicone rubber
• Lower compression set than standard TPS compounds
• Heat- (withstands temperatures in excess of 100 °C) and chemical resistance
   

The compounds are suitable for injection molding and extrusion applications such as:
 

1. Utensil grips
2. Kitchen appliance seals
3. Gaskets, and tubing
4. Food-saver container seals
5. Dropper bulbs
6. Cosmetics applications

Stain-resistant TPE for White-colored Phone Cases

Resisting blue jean staining for white and light-colored phone cases now a reality! And PolyOne made is possible with its Versaflex™ CE 3320-70 TPE. Brands using silicone or TPU materials have been seeking an alternative for a number of reasons, including:
 

• Long sourcing lead times and manufacturing challenges for silicone and
• The inability of TPU to endure blue jeans contact without staining 
   

According to the company, its new stain-resistant TPEs not only help boost design capabilities, but also offer the supply chain flexibility and ease of processing that brands require bringing their white and light-colored phone cases to market both quickly and costing effectively. Further, the new Versaflex CE material stands up to sunscreen, hand sanitizer and isopropyl alcohol while enduring UV light. This recyclable thermoplastic also processes faster than silicones and adheres well to polycarbonate when overmolded.
 

Shock & Vibration Absorbing Applications - TPE in Action!
 

Highlighting the enormous market potential use TPEs in demanding sports & leisure applications, another development includes a modular padding technology developed by French company Hexaflex. The company has developed a patented padding technology based on hexagonal-pyramidal shapes molded thermoplastic elastomer compound from KRAIBURG TPE. 

TPE provides the flexibility, light weight and full articulation characteristics of the modular system that lends itself to a myriad of shock and vibration absorbing applications, from sportswear and personal protection equipment to healthcare and other demanding industries.
 

In a first application, the creative technology is used for a dorsal protection product covered with high-strength aromatic polyamide stretch fabric for bikers and motorcyclists. The lightweight material combination acts like a second skin, and the Hexaflex padding with its interlocking shapes in THERMOLAST® K is fully articulated to follow body motion while ensuring maximum shock absorption.

 

From Eyeglasses Frames to Coffee Machine Handles...

Further, FC/AD/PA THERMOLAST® K series from KRAIBURG TPE provides a wide range of design options and cost-effective processing that are intended to meet sophisticated TPE/PA applications in the consumer industry. With hardness degrees ranging between 40 and 80 Shore A, they combine tactile properties such as soft-touch and non-slip grip even at low wall thicknesses.

Technology of the FC/AD/PA THERMOLAST K series is targeted specifically at manufacturers and processors in the consumer and food industries. Typical examples of applications are:
 

• Tool components that comply with food regulations as well as handles and surfaces of household appliances such as coffee machines and juicers.
• Health care aids from interdental brushes to eyeglasses frames to hearing aids, along with a wide array of cosmetics and sports articles.
  
   

Stylish & Comfortable - Soft-touch Feel in Smart Watch

Wearables demand high performance materials that have the look of stylishness, the feel of comfort, and are easy to design and process. And DSM made it possible for Zhongxing Telecommunication Equipment Corporation (ZTE) for its new smart watch ZTE Quartz featuring Arnitel® TPE.
 

• Arnitel is selected for the soft strap on this watch, providing comfort, flexibility, safety and design flexibility.
• Arnitel also feels cool and smooth on the skin, with a good balance of physical and chemical properties.

According to VP of ZTE Terminal Division, Luo Wei, Arnitel TPE has helped them make the cutting-edge ZTE Quartz a resounding success in the market. After its successful launch in China, ZTE Quartz is targeting global markets and the ZTE wearable is set to be a T-Mobile exclusive in the USA.

 

The healthcare market depends on the reliable and secure supply of controlled raw materials which must fulfill especially demanding standards w.r.t safety, biocompatibility, toxicity and more. Recent TPE developments include:
 

• Expansion of Cellene™ thermoplastic elastomer (TPE) compounds for healthcare by Colorite. Cellene™ TPE range includes both injection molding and extrusion grades suitable for IV therapy with high clarity, improved bonding and kink resistance, general purpose healthcare, gaskets/seals, syringe stoppers etc.

• Three new medical-grade thermoplastic elastomers (TPEs) by Teknor Apex for biopharmaceutical tubing provide performance superior to the industry standard TPE in this application, making them effective alternatives to widely used silicone. 
  
  The company developed these compounds (Medalist MD-12352, Medalist MD-50357, Medalist MD-10353) for challenging tubing applications in the biopharma industry for peristaltic pumps and extreme low temperature applications. The materials provide the elasticity required to keep pace with rapid pump action and the durability needed for the tubing to retain its shape and remain intact over time. 
   

• Borealis and Borouge have developed first controlled plastomers solution - Bormed™ PL8830-PH - for the global healthcare market. It is an ethylene-based, octene-1 plastomer. Because it is a reactor polymer, it boasts the very highest and most consistent quality. Overall, it exhibits excellent purity and cleanliness. It offers enhanced compatibility with PP, easy processing, clarity, and flexibility on an elastomers level. 

• Kraton's Cariflex™ IR2GL1 Latex is a clean and pure thermoplastic elastomer (TPE) latex offering strength, flexibility and softness. Originally developed for surgical glove applications and other dipped goods, Cariflex IR2GL1 was designed to match the strength, protection and comfort of Cariflex isoprene rubber latex while also reducing the risk of Type IV allergies.

Flexible polymer materials significantly expand the options for additive manufacturing because they allow us to realize new, demanding applications in attractive markets.

Hence, expanding TPE capabilities to 3D Printing, Evonik has worked closely with EOS (technology provider for industrial 3D Printing) to develop a new high-performance flexible plastic material based on PEBA (polyether block amide) suitable for a variety of powder-based 3D printing technologies (laser sintering (LS), high speed sintering (HSS) or binder jetting).
 

• 3D printed parts made from the new PEBA powder show:
  • A high degree of flexibility,
  • Excellent resistance to chemicals and
  • Outstanding durability over a wide temperature range from -40°C to 90°C. 

The powder is also ideally suited for the manufacture of functional 3D high-tech plastic parts – for prototypes as well as series products.