Engineering and High Performance Plastics

Engineering and High Performance Plastics Market Report by David K. Platt Engineering and High Performance Pla...

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Engineering and High Performance Plastics

Market Report

by

David K. Platt

Engineering and High Performance Plastics Market Report

A Rapra Market Report

by

David K Platt

June 2003

Rapra Technology Limited Shawbury, Shrewsbury, Shropshire, SY4 4NR, UK Tel: +44 (0)1939 250383 Fax: +44 (0)1939 251118 http://www.rapra.net

The right of D.K. Platt to be identified as the author of this work has been asserted by him in accordance with Sections 77 and 78 of the Copyright, Designs and Patents Act 1988.

© 2003, Rapra Technology Limited ISBN: 1-85957-380-0 All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means—electronic, mechanical, photocopying, recording or otherwise—without the prior permission of the publisher, Rapra Technology Limited, Shawbury, Shrewsbury, Shropshire, SY4 4NR, UK. Typeset, printed and bound by Rapra Technology Limited. Cover printed by LG Davis Design and Print Solutions, Birmingham.

Contents

1 Introduction..............................................................................................................................1 1.1 Background ........................................................................................................................1 1.2 The Report..........................................................................................................................1 1.3 Methodology .......................................................................................................................2 1.4 About the Author.................................................................................................................2 2 Executive Summary ................................................................................................................3 2.1 Global Market Forecasts ....................................................................................................3 2.2 Material Trends...................................................................................................................4 2.3 Regional Trends .................................................................................................................5 2.4 Technology Tends..............................................................................................................5 2.5 Market Trends ....................................................................................................................6 2.6 Competitive Tends..............................................................................................................6 3 Overview of Engineering and High Performance Plastics .................................................9 3.1 Introduction.........................................................................................................................9 3.2 Polyamide (PA).................................................................................................................11 3.2.1 Properties ..................................................................................................................11 3.2.2 Applications ...............................................................................................................13 3.2.3 Processing .................................................................................................................13 3.2.4 Pricing Trends............................................................................................................14 3.3 Polybutylene Terephthalate (PBT) ...................................................................................14 3.3.1 Properties ..................................................................................................................14 3.3.2 Applications ...............................................................................................................15 3.3.3 Pricing Trends............................................................................................................15 3.4 Acrylonitrile-Butadiene-Styrene (ABS).............................................................................15 3.4.1 Properties ..................................................................................................................15 3.4.2 Applications ...............................................................................................................16 3.4.3 Pricing Trends............................................................................................................17 3.5 Polycarbonate (PC) ..........................................................................................................17 3.5.1 Properties ..................................................................................................................17 3.5.2 Applications ...............................................................................................................18 3.5.3 Pricing Trends............................................................................................................18 3.6 Polyoxymethylene (POM).................................................................................................19 3.6.1 Properties ..................................................................................................................19 3.6.2 Applications ...............................................................................................................20 3.6.3 Pricing Trends............................................................................................................20 3.7 Polymethylmethacrylate (PMMA).....................................................................................20 3.7.1 Properties ..................................................................................................................20 3.7.2 Applications ...............................................................................................................21 3.7.3 Pricing Trends............................................................................................................21 3.8 Polyphenylene Oxide (Ether) Blends (PPO and PPE).....................................................21 3.8.1 Properties ..................................................................................................................21 3.8.2 Applications ...............................................................................................................22 3.8.3 Pricing Trends............................................................................................................23 3.9 Polyphenylene Sulfide (PPS) ...........................................................................................23 3.9.1 Properties ..................................................................................................................23 3.9.2 Applications ...............................................................................................................24 3.9.3 Pricing Trends............................................................................................................24 3.10 Polyetherimide (PEI) ......................................................................................................24 3.10.1 Properties ................................................................................................................24 3.10.2 Applications .............................................................................................................25 3.10.3 Pricing Trends..........................................................................................................25 3.11 Polysulfone (PSU), Polyethersulfone (PES) ..................................................................25 3.11.1 Properties ................................................................................................................25

3.11.2 Applications .............................................................................................................26 3.11.3 Pricing Trends .........................................................................................................26 3.12 Polyphenylene Sulfone (PPSU) .....................................................................................26 3.12.1 Properties ................................................................................................................26 3.12.2 Applications .............................................................................................................26 3.13 Liquid Crystal Polymers (LCP) .......................................................................................27 3.13.1 Properties ................................................................................................................27 3.13.2 Applications .............................................................................................................28 3.13.3 Pricing Trends .........................................................................................................28 3.14 Polyetheretherketone (PEEK)........................................................................................28 3.14.1 Properties ................................................................................................................28 3.14.2 Applications .............................................................................................................29 3.14.3 Pricing Trends .........................................................................................................29 3.15 Polyphthalamide (PPA) ..................................................................................................30 3.15.1 Properties ................................................................................................................30 3.15.2 Applications .............................................................................................................30 3.16 Polyarylamide.................................................................................................................31 3.16.1 Properties ................................................................................................................31 3.16.2 Applications .............................................................................................................31 3.17 Polyamide-imide (PAI)....................................................................................................32 3.17.1 Properties ................................................................................................................32 3.17.2 Applications .............................................................................................................32 3.18 Developing Materials......................................................................................................32 3.18.1 Cyclic Olefin Copolymers ........................................................................................32 3.18.2 Syndiotactic Polystyrene .........................................................................................33 3.18.3 Cyclic Butylene Terephthalate (CBT)......................................................................33 3.18.4 Copolycarbonate .....................................................................................................33 4 Global Demand for Engineering and High Performance Plastics ...................................35 4.1 Total World Demand ........................................................................................................35 4.1.1 Economic Background...............................................................................................35 4.1.2 The Total World Market.............................................................................................35 4.2 Demand Trends by Polymer Type, 1999-2002................................................................38 4.2.1 Polyamide (PA)..........................................................................................................38 4.2.2 Polybutylene Terephthalate (PBT) ............................................................................39 4.2.3 Acrylonitrile-Butadiene-Styrene (ABS) ......................................................................41 4.2.4 Polycarbonate (PC) ...................................................................................................42 4.2.5 Polyoxymethylene (POM)..........................................................................................43 4.2.6 Polymethyl Methacrylate (PMMA).............................................................................45 4.2.7 Polyphenylene Oxide (Ether) Blends (PPO and PPE)..............................................46 4.2.8 Polyphenylene Sulfide (PPS) ....................................................................................47 4.2.9 Polyetherimide (PEI)..................................................................................................49 4.2.10 Polysulfone (PSU), Polyethersulfone (PES) ...........................................................50 4.2.11 Liquid Crystal Polymer (LCP) ..................................................................................51 4.2.12 Polyetheretherketone (PEEK) .................................................................................52 5 Automotive Applications for Engineering and High Performance Plastics ...................55 5.1 Introduction.......................................................................................................................55 5.2 Future Prospects for the World Automotive Industry .......................................................55 5.3 Future Trends for Engineering Polymers in Automotive Markets....................................56 5.3.1 Recycling of End-of-Life-Vehicles EU Directive ........................................................56 5.3.2 Proposed EU Legislation to Reduce Fuel Emissions ...............................................58 5.3.3 Development of ‘Mono-Material Systems’.................................................................58 5.4 Polyamide.........................................................................................................................58 5.4.1 Consumption Trends .................................................................................................58 5.4.2 Current Applications ..................................................................................................59 5.4.3 Market Trends ...........................................................................................................60 5.4.3.1 Inter-Polymer Substitution ..................................................................................60 5.4.3.2 Competition from Metal ......................................................................................60

5.4.3.3 Developments in Processing Technology ..........................................................61 5.4.3.4 Development of Hybrid Technology ...................................................................61 5.4.3.5 Development of In-Mould Painting Systems ......................................................61 5.4.3.6 Development of the 42-Volt Electrical System ...................................................61 5.4.3.7 New Applications Development..........................................................................62 5.5 Acrylonitrile-Butadiene-Styrene (ABS).............................................................................62 5.5.1 Consumption Trends .................................................................................................62 5.5.2 Current Applications ..................................................................................................63 5.5.3 Market Trends............................................................................................................63 5.5.3.1 Replacement of Traditional Materials.................................................................63 5.5.3.2 Inter-Polymer Substitution ..................................................................................63 5.6 Polybutylene Terephthalate (PBT) ...................................................................................64 5.6.1 Consumption Trends .................................................................................................64 5.6.2 Current Applications ..................................................................................................65 5.6.3 Market Trends............................................................................................................65 5.6.3.1 Growth in Electrical Applications ........................................................................65 5.6.3.2 Replacement of Metal Parts ...............................................................................65 5.6.3.3 Inter-Polymer Substitution ..................................................................................66 5.6.3.4 New Product Development.................................................................................66 5.7 Polycarbonate (PC) ..........................................................................................................66 5.7.1 Consumption Trends .................................................................................................66 5.7.2 Current Applications ..................................................................................................67 5.7.3 Market Trends............................................................................................................67 5.7.3.1 Development of Automotive Glazing ..................................................................67 5.7.3.2 Replacement of Glass Lenses............................................................................68 5.7.3.3 Inter-Polymer Substitution ..................................................................................68 5.8 Polyoxymethylene (POM).................................................................................................68 5.8.1 Consumption Trends .................................................................................................68 5.8.2 Current Applications ..................................................................................................69 5.8.3 Market Trends............................................................................................................70 5.8.3.1 Inter-Polymer Substitution ..................................................................................70 5.8.3.2 Product Developments .......................................................................................70 5.8.3.3 Technology Development...................................................................................70 5.8.3.4 Growth in Electrical Systems..............................................................................70 5.8.3.5 Replacement of Metal.........................................................................................70 5.9 Polymethyl Methacrylate (PMMA)....................................................................................70 5.9.1 Consumption Trends .................................................................................................70 5.9.2 Current Applications ..................................................................................................71 5.9.3 Market Trends............................................................................................................72 5.9.3.1 Replacement of Glass Car Headlamp Lenses ...................................................72 5.9.3.2 New Applications Development..........................................................................72 5.9.3.3 Inter-Polymer Substitution ..................................................................................72 5.10 Polyphenylene Oxide (Ether) Blends (PPO and PPE)...................................................72 5.10.1 Consumption Trends ...............................................................................................72 5.10.2 Current Applications ................................................................................................73 5.10.3 Market Trends..........................................................................................................73 5.10.3.1 Inter-Polymer Substitution ................................................................................74 5.10.3.2 Development of New Applications....................................................................74 5.10.3.3 New Product Development...............................................................................74 5.11 Polyphenylene Sulfide (PPS) .........................................................................................74 5.11.1 Consumption Trends ...............................................................................................74 5.11.2 Current Applications ................................................................................................75 5.11.3 Market Trends..........................................................................................................75 5.11.3.1 Replacement of Traditional Materials...............................................................76 5.11.3.2 Inter-Polymer Substitution ................................................................................76 5.11.3.3 New Applications Development........................................................................76 5.11.3.4 New Product Developments .............................................................................76

5.12 Polyetherimide (PEI) ......................................................................................................76 5.12.1 Consumption Trends ...............................................................................................76 5.12.2 Current Applications ................................................................................................77 5.12.3 Market Trends .........................................................................................................77 5.12.3.1 Replacement of Traditional Materials...............................................................78 5.12.3.2 Growth in Electrical Systems............................................................................78 5.12.3.3 Inter-Polymer Substitution ................................................................................78 5.12.3.4 Product Development .......................................................................................78 5.13 Polysulfone (PSU), Polyethersulfone (PES) ..................................................................78 5.13.1 Consumption Trends ...............................................................................................78 5.13.2 Current Applications ................................................................................................79 5.13.3 Market Trends .........................................................................................................79 5.13.3.1 Replacement of Thermosets ............................................................................79 5.14 Liquid Crystal Polymers (LCP) .......................................................................................80 5.14.1 Consumption Trends ...............................................................................................80 5.14.2 Current Applications ................................................................................................80 5.14.3 Market Trends .........................................................................................................81 5.14.3.1 Lead-Free Soldering Methods..........................................................................81 5.14.3.2 Material Replacement.......................................................................................81 5.15 Polyetheretherketone (PEEK)........................................................................................81 5.15.1 Consumption Trends ...............................................................................................81 5.15.2 Current Applications ................................................................................................82 5.15.3 Market Trends .........................................................................................................82 5.15.3.1 New Applications ..............................................................................................82 5.16 Polyphthalamide (PPA) ..................................................................................................82 5.16.1 Consumption Trends ...............................................................................................82 5.16.2 Current Applications ................................................................................................83 5.16.3 Market Trends .........................................................................................................83 5.16.3.1 New Applications ..............................................................................................83 6 Electrical and Electronics Applications for Engineering and High Performance Plastics ..................................................................................................85 6.1 Introduction.......................................................................................................................85 6.2 Trends and Market Drivers...............................................................................................85 6.3 Future Prospects for the World E&E Industry..................................................................87 6.4 Developments in Industry Regulations and Standards....................................................88 6.4.1 The EU Directive on Electrical & Electronics Waste .................................................88 6.4.2 EU Directive (IEC-60335-1) on Unattended Domestic Appliances...........................89 6.5 Polyamide.........................................................................................................................89 6.5.1 Consumption Trends .................................................................................................89 6.5.2 Current Applications ..................................................................................................90 6.5.3 Market Trends ...........................................................................................................90 6.5.3.1 Product Developments .......................................................................................90 6.5.3.2 Inter-Polymer Substitution ..................................................................................91 6.6 Acrylonitrile-Butadiene-Styrene (ABS).............................................................................91 6.6.1 Consumption Trends .................................................................................................91 6.6.2 Current Applications ..................................................................................................92 6.6.3 Market Trends ...........................................................................................................92 6.7 Polybutylene Terephthalate (PBT)...................................................................................92 6.7.1 Consumption Trends .................................................................................................92 6.7.2 Current Applications ..................................................................................................93 6.7.3 Market Trends ...........................................................................................................93 6.7.3.1 New Products .....................................................................................................93 6.7.3.2 Development of PBT Polymer Blends ................................................................94 6.7.3.3 Lead-Free Soldering Methods............................................................................94 6.8 Polycarbonate (PC) ..........................................................................................................94 6.8.1 Consumption Trends .................................................................................................94 6.8.2 Current Applications ..................................................................................................95

6.8.3 Market Trends............................................................................................................95 6.9 Polyoxymethylene (POM).................................................................................................95 6.9.1 Consumption Trends .................................................................................................95 6.9.2 Current Applications ..................................................................................................96 6.9.3 Market Trends............................................................................................................96 6.10 Polymethyl Methacrylate (PMMA)..................................................................................97 6.10.1 Consumption Trends ...............................................................................................97 6.10.2 Current Applications ................................................................................................97 6.10.3 Market Trends..........................................................................................................97 6.11 Polyphenylene Oxide (Ether) Blends (PPO and PPE)...................................................98 6.11.1 Consumption Trends ...............................................................................................98 6.11.2 Current Applications ................................................................................................98 6.11.3 Market Trends..........................................................................................................99 6.12 Polyphenylene Sulfide (PPS) .........................................................................................99 6.12.1 Consumption Trends ...............................................................................................99 6.12.2 Current Applications ................................................................................................99 6.12.3 Market Trends....................................................................................................... 100 6.13 Polyetherimide (PEI) ................................................................................................... 100 6.13.1 Consumption Trends ............................................................................................ 100 6.13.2 Current Applications ............................................................................................. 101 6.13.3 Market Trends....................................................................................................... 101 6.14 Polysulfone (PSU), Polyethersulfone (PES) ............................................................... 101 6.14.1 Consumption Trends ............................................................................................ 101 6.14.2 Current Applications ............................................................................................. 102 6.14.3 Market Trends....................................................................................................... 102 6.14.3.1 Inter-Polymer Substitution ............................................................................. 102 6.14.3.2 New Applications ........................................................................................... 102 6.15 Liquid Crystal Polymers (LCP) .................................................................................... 103 6.15.1 Consumption Trends ............................................................................................ 103 6.15.2 Current Applications ............................................................................................. 103 6.15.3 Market Trends....................................................................................................... 104 6.15.3.1 Inter-Polymer Substitution ............................................................................. 104 6.15.3.2 New Applications ........................................................................................... 104 6.15.3.3 Lead-Free Soldering Methods....................................................................... 104 6.16 Polyetheretherketone (PEEK) ..................................................................................... 104 6.16.1 Consumption Trends ............................................................................................ 104 6.16.2 Current Applications ............................................................................................. 105 6.16.3 Market Trends....................................................................................................... 105 6.17 Polyphthalamide (PPA) ............................................................................................... 106 6.17.1 Current Applications ............................................................................................. 106 6.17.2 Market Trends....................................................................................................... 106 7 Industrial Applications for Engineering and High Performance Plastics.................... 107 7.1 Introduction.................................................................................................................... 107 7.2 Future Prospects for Industrial Markets ........................................................................ 107 7.3 Polyamide...................................................................................................................... 107 7.3.1 Consumption Trends .............................................................................................. 107 7.3.2 Current Applications ............................................................................................... 108 7.4 Acrylonitrile-Butadiene-Styrene (ABS).......................................................................... 108 7.4.1 Consumption Trends .............................................................................................. 108 7.4.2 Current Applications ............................................................................................... 109 7.5 Polybutylene Terephthalate (PBT) ................................................................................ 109 7.5.1 Consumption Trends .............................................................................................. 109 7.5.2 Current Applications ............................................................................................... 110 7.6 Polyoxymethylene (POM).............................................................................................. 110 7.6.1 Consumption Trends .............................................................................................. 110 7.6.2 Current Applications ............................................................................................... 111 7.7 Polycarbonate (PC) ....................................................................................................... 111

7.7.1 Consumption Trends ...............................................................................................111 7.7.2 Current Applications ................................................................................................112 7.8 Polymethyl methacrylate (PMMA)..................................................................................112 7.8.1 Consumption Trends ...............................................................................................112 7.8.2 Current Applications ................................................................................................113 7.9 Polyphenylene Oxide (Ether) Blends (PPO and PPE)...................................................113 7.9.1 Consumption Trends ...............................................................................................113 7.9.2 Current Applications ................................................................................................114 7.10 Polyphenylene Sulfide (PPS) .......................................................................................114 7.10.1 Consumption Trends .............................................................................................114 7.10.2 Current Applications ..............................................................................................115 7.11 Polyetherimide (PEI) ....................................................................................................115 7.11.1 Consumption Trends .............................................................................................115 7.11.2 Current Applications ..............................................................................................116 7.12 Polysulfone (PSU), Polyethersulfone (PES) ................................................................116 7.12.1 Consumption Trends .............................................................................................116 7.12.2 Current Applications ..............................................................................................117 7.13 Liquid Crystal Polymers (LCP) .....................................................................................117 7.13.1 Consumption Trends .............................................................................................117 7.13.2 Current Applications ..............................................................................................118 7.14 Polyetheretherketone (PEEK)......................................................................................118 7.14.1 Consumption Trends .............................................................................................118 7.14.2 Current Applications ..............................................................................................119 8 Consumer Product Markets for Engineering and High Performance Plastics ............121 8.1 Introduction.....................................................................................................................121 8.1.1 Washing Machines ..................................................................................................121 8.1.2 Vacuum Cleaners ....................................................................................................121 8.1.3 Cookers ...................................................................................................................122 8.1.4 Fridges.....................................................................................................................122 8.1.5 Microwave Ovens ....................................................................................................122 8.1.6 Food Containers ......................................................................................................123 8.1.7 Lawnmowers............................................................................................................123 8.1.8 Electric Irons............................................................................................................123 8.1.9 Shavers....................................................................................................................123 8.1.10 Fryers.....................................................................................................................124 8.1.11 Personal Hygiene ..................................................................................................124 8.1.12 Food Mixers...........................................................................................................124 8.2 Future Prospects for the Consumer Products Market ...................................................124 8.3 Market Trends ................................................................................................................125 8.3.1 Growing Use of Special Effects Resins...................................................................125 8.4 Polyamide.......................................................................................................................125 8.4.1 Consumption Trends ...............................................................................................125 8.4.2 Current Applications ................................................................................................126 8.5 Acrylonitrile-Butadiene-Styrene (ABS)...........................................................................126 8.5.1 Consumption Trends ...............................................................................................126 8.5.2 Current Applications ................................................................................................127 8.6 Polybutylene Terephthalate (PBT).................................................................................127 8.6.1 Consumption Trends ...............................................................................................127 8.6.2 Current Applications ................................................................................................128 8.7 Polycarbonate (PC) ........................................................................................................128 8.7.1 Consumption Trends ...............................................................................................128 8.7.2 Current Applications ................................................................................................129 8.8 Polyoxymethylene (POM) ..............................................................................................130 8.8.1 Consumption Trends ...............................................................................................130 8.8.2 Current Applications ................................................................................................131 8.9 Polymethyl Methacrylate (PMMA)..................................................................................131 8.9.1 Consumption Trends ...............................................................................................131

8.9.2 Current Applications ............................................................................................... 132 8.10 Polyphenylene Oxide (Ether) Blends (PPO and PPE)................................................ 132 8.10.1 Consumption Trends ............................................................................................ 132 8.10.2 Current Applications ............................................................................................. 133 8.11 Polyphenylene Sulfide (PPS) ...................................................................................... 133 8.11.1 Consumption Trends ............................................................................................ 133 8.11.2 Current Applications ............................................................................................. 134 8.12 Polyetherimide (PEI) ................................................................................................... 134 8.12.1 Consumption Trends ............................................................................................ 134 8.12.2 Current Applications ............................................................................................. 135 8.13 Polysulfone (PSU), Polyethersulfone (PES) ............................................................... 135 8.13.1 Consumption Trends ............................................................................................ 135 8.13.2 Current Applications ............................................................................................. 136 8.14 Liquid Crystal Polymers (LCP) .................................................................................... 136 8.14.1 Consumption Trends ............................................................................................ 136 8.14.2 Current Applications ............................................................................................. 137 9 Other Markets for Engineering and High Performance Plastics................................... 139 9.1 Introduction.................................................................................................................... 139 9.2 Future Prospects for the Medical Devices Market ........................................................ 139 9.3 Polyamide...................................................................................................................... 140 9.3.1 Consumption Trends .............................................................................................. 140 9.3.2 Current Applications ............................................................................................... 141 9.3.2.1 Film and Sheet................................................................................................. 141 9.3.2.2 Stock Shapes................................................................................................... 141 9.3.2.3 Other Markets .................................................................................................. 141 9.4 Acrylonitrile-Butadiene-Styrene (ABS).......................................................................... 141 9.4.1 Consumption Trends .............................................................................................. 141 9.4.2 Current Applications ............................................................................................... 142 9.5 Polybutylene Terephthalate (PBT) ................................................................................ 142 9.5.1 Consumption Trends .............................................................................................. 142 9.5.2 Current Applications ............................................................................................... 143 9.6 Polycarbonate (PC) ....................................................................................................... 143 9.6.1 Consumption Trends .............................................................................................. 143 9.6.2 Current Applications ............................................................................................... 144 9.7 Polyoxymethylene (POM).............................................................................................. 145 9.7.1 Consumption Trends .............................................................................................. 145 9.7.2 Current Applications ............................................................................................... 145 9.8 Polymethyl Methacrylate (PMMA)................................................................................. 146 9.8.1 Consumption Trends .............................................................................................. 146 9.8.2 Current Applications ............................................................................................... 146 9.8.2.1 Optical Media................................................................................................... 146 9.8.2.2 Medical Devices............................................................................................... 147 9.8.2.3 Packaging ........................................................................................................ 147 9.9 Polyphenylene Oxide (Ether) Blends (PPO and PPE).................................................. 147 9.9.1 Consumption Trends .............................................................................................. 147 9.9.2 Current Applications ............................................................................................... 148 9.10 Polyphenylene Sulfide (PPS) ...................................................................................... 148 9.10.1 Consumption Trends ............................................................................................ 148 9.10.2 Current Applications ............................................................................................. 149 9.11 Polyetherimide (PEI) ................................................................................................... 149 9.11.1 Consumption Trends ............................................................................................ 149 9.11.2 Current Applications ............................................................................................. 150 9.12 Polysulfone (PSU), Polyethersulfone (PES) ............................................................... 150 9.12.1 Consumption Trends ............................................................................................ 150 9.12.2 Current Applications ............................................................................................. 150 9.13 Liquid Crystal Polymers (LCP) .................................................................................... 151 9.13.1 Consumption Trends ............................................................................................ 151

9.13.2 Current Applications ..............................................................................................151 9.14 Polyetheretherketone (PEEK)......................................................................................152 9.14.1 Consumption Trends .............................................................................................152 9.14.2 Current Applications ..............................................................................................152 10 Leading World Suppliers of Engineering and High Performance Plastics.................153 10.1 Overview.......................................................................................................................153 10.2 Polyamide (PA) ............................................................................................................156 10.2.1 Major Suppliers......................................................................................................156 10.2.2 Products.................................................................................................................157 10.3 Polybutylene Terephthalate (PBT)...............................................................................159 10.3.1 Major Suppliers......................................................................................................159 10.3.2 Products.................................................................................................................160 10.4 Acrylonitrile-Butadiene-Styrene (ABS).........................................................................161 10.4.1 Major Suppliers......................................................................................................161 10.4.2 Products.................................................................................................................163 10.5 Polycarbonate (PC) ......................................................................................................164 10.5.1 Major Suppliers......................................................................................................164 10.5.2 Products.................................................................................................................165 10.6 Polyoxymethylene (POM) ............................................................................................166 10.6.1 Major Suppliers......................................................................................................166 10.6.2 Products.................................................................................................................168 10.7 Polymethyl Methacrylate (PMMA)................................................................................169 10.7.1 Major Suppliers......................................................................................................169 10.7.2 Products.................................................................................................................170 10.8 Polyphenylene Oxide (Ether) Blends (PPO and PPE) ................................................171 10.8.1 Major Suppliers......................................................................................................171 10.8.2 Products.................................................................................................................172 10.9 Polyphenylene Sulfide (PPS) .......................................................................................173 10.9.1 Major Suppliers......................................................................................................173 10.9.2 Products.................................................................................................................174 10.10 Polyetherimide (PEI) ..................................................................................................174 10.10.1 Major Suppliers....................................................................................................174 10.10.2 Products...............................................................................................................174 10.11 Polysulfone (PSU), Polyethersulfone (PES) ..............................................................175 10.11.1 Major Suppliers....................................................................................................175 10.11.2 Products...............................................................................................................175 10.12 Liquid Crystal Polymers (LCP)...................................................................................176 10.12.1 Major Suppliers....................................................................................................176 10.12.2 Products...............................................................................................................177 10.13 Polyetheretherketone (PEEK)....................................................................................178 10.13.1 Major Suppliers....................................................................................................178 10.13.2 Products...............................................................................................................178 10.14 Polyphthalamide (PPA) ..............................................................................................179 10.14.1 Major Suppliers....................................................................................................179 10.14.2 Products...............................................................................................................179 Directory of Major Suppliers .................................................................................................181 Abbreviations and Acronyms ...............................................................................................187


1 Introduction 1.1 Background Engineering polymers have been commercially available for many decades and a number of new high performance materials have also been introduced onto the marketplace during the last twenty years or so. Polymer scientists continue to develop higher performance thermoplastics that can challenge traditional materials such as metal and thermosets. Indeed, the last five years have seen substantial growth in top of the range materials such as liquid crystal polymers and polyketones. There is no widely accepted industry definition of an engineering or high performance polymer. However, these materials typically possess a range of desirable performance properties such as strength, temperature resistance and dimensional stability that are far superior to standard thermoplastics. There is inevitably an overlap between high-end engineering plastics and the lowend performance materials in terms of their property profile. As a general rule of thumb however, high performance plastics are considered to have a short-term heat resistance of 250 °C and longterm heat resistance of 160 °C. Engineering and high performance polymers have shown considerable growth during the latter half of the 1990s. Demand was fuelled primarily by product development, material substitution and strong growth in key market sectors such IT/telecom and automotive. The worldwide downturn in economic activity after 2000 has however meant a sharp reduction in demand for engineering thermoplastics. It was therefore felt timely to examine the world market for performance plastics to determine how suppliers are responding to lower consumption and to consider future growth prospects for the industry. A number of other interesting developments are also taking place that will have an important impact on future market trends. In the automotive sector for example, the European Union (EU) has introduced a Directive on material recycling of end-of-life vehicles, which will have significant implications for material selection. The EU has also introduced a Directive concerning Electrical & Electronics (E&E) waste, which will have similar implications for manufacturers of electrical goods. Standards and regulations concerning many aspects of the key automotive and E&E sectors are also being tightened. The pace of product and applications development has been unrelenting in recent years. New and improved grades continue to be introduced to meet more demanding specifications. Suppliers are also working ever more closely with converters and original equipment manufacturers (OEM) to develop new and innovative technologies and applications. The global structure of the industry is also changing. A growing share of engineering polymer production is now taking place in China and other Pacific Rim countries as OEMs relocate their manufacturing plants to lower cost economies. At the same time, North America, Japan and Western Europe are becoming more mature and lower growth markets. 1.2 The Report The report starts with an overview of the whole spectrum of engineering and high performance polymers, including their chemical structure, properties, processing and an outline of key applications. Chapter 4 examines the global market for each polymer type, showing consumption by major world region and market sector for the period 1999-2002, and forecasts for 2007.

1


The main body of the study is divided into five core sections based on key end user markets: • • • • •

Automotive Electrical & electronics Industrial, including building and construction Consumer products Other markets, including medical

Each section contains an overview of key end user market trends, plus analysis of world consumption by geographic region for the period 1999-2002, applications and market developments for the following polymer types: • • • • • • • • • • • •

Polyamide (PA) Polybutylene terephthalate (PBT) Acrylonitrile-butadiene-styrene (ABS) Polycarbonate (PC) Polyoxymethylene (POM) Polymethyl methacrylate (PMMA) Polyphenylene oxide (ether) blends (PPO and PPE) Polyphenylene sulfide (PPS) Polyetherimide (PEI) Polysulfone (PSU), polyethersulfone (PES) Liquid crystal polymers (LCP) Polyetheretherketone (PEEK)

Finally, there is also a section containing a detailed description of the world’s leading suppliers: including their products, production capacities, geographic coverage and corporate developments, for each polymer type. 1.3 Methodology The research for the report is based on various information sources including: the Rapra Polymer Library, trade press, Internet/company web sites, and interviews with some of the leading suppliers. The opinions expressed and the data presented are those of the author. 1.4 About the Author David Platt graduated from the University of Nottingham with an Economics degree before completing an MBA at the University of Bradford. He joined a leading international market consultancy where he specialized in plastics sector research. He conducted a wide range of multiclient and single-client studies covering a wide range of materials, from standard thermoplastics, engineering and high performance polymers to conductive polymers and thermoplastic elastomers. He also completed market studies on plastics in automotive, packaging, wire & cable, pipe and medical devices. Now operating as a freelance consultant, he makes regular contributions to the European plastics trade press, and also works with several major industry consultancies.

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2 Executive Summary 2.1 Global Market Forecasts In 2002, total world consumption of engineering and high performance plastics is estimated at 10.9 million tonnes, which represents approximately 7% of total world plastics consumption. Demand for engineering and high performance plastics has outperformed the plastics sector as a whole in recent years. During the period 1995-2000, the average growth in consumption of engineering and high performance plastics was between 8-10% per annum compared to 5-6% per annum for standard thermoplastics. The principal drivers of demand for engineering and high performance thermoplastics are: • • • •

Replacement of traditional materials such as metal and thermosets because of their lighter weight, ease of processing, design flexibility and lower total cost. Development of new applications. Product improvement and development. High growth in key end user markets such as electronics, telecommunications and automotive.

The downturn in world economic activity and the collapse of the IT/telecom sectors led to a reduction in demand for engineering and high performance plastics in 2001. World consumption fell by 6% from just over 11.0 million tonnes in 2000 to 10.4 million tonnes in 2001. Last year, world demand increased by an estimated 4.5%, but still remains below the level of 2000. Table 2.1 shows growth forecasts for engineering and high performance polymers for 2007. Table 2.1 World consumption of engineering and high performance plastics, 2000, 2002 and forecast for 2007, (000 tonnes) Compound annual growth 2000 2002 2007 rate (CAGR) 2002-2007 (%) Polyamide 2,002 1,950 2,430 4.5 ABS 4,736 4,667 5,280 2.5 PBT 484 477 623 5.5 POM 609 604 717 3.5 PMMA 986 989 1,174 3.5 Polycarbonate 1,726 1,714 2,637 9.0 PPS 53 50 77 9.0 Polyetherimide 15 15 24 10.5 PPO/PPE 368 353 461 5.5 PSU/PES 23 23 37 10.5 LCP 18 18 34 13.5 PEEK 1.4 1.3 2.4 13.5 TOTAL 11,022 10,860 13,497 4.5

The growth forecasts for all polymer types over the next five years are much more pessimistic than would have been envisaged only two years ago. In 2007, world consumption of engineering and high performance plastic is projected at 13.5 million tonnes. This represents a compound annual growth rate of 4.5% for the period 2002-2007. The main reasons for downgrading polymer growth projections are:

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The sharp downturn in world economic activity that has occurred since 2001, and the uncertain prospects for any substantial recovery in demand for at least another couple of years.

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Lower growth expectations from key market sectors such as IT, telecommunications and automotive.

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Major application areas for engineering plastics in particular, are maturing, which will restrict opportunities for further material substitution.

High performance plastics such as PEEK, LCP and the sulfone based polymers, will grow at double-digit rates during the period 2002-2007, as the potential for applications development and material substitution is much greater for these developing polymers. In contrast, the more mature engineering plastics such as polyamide, ABS, polyacetal and acrylics, will show the lowest rates of growth during the next five years. 2.2 Material Trends Product improvement and new product development are important features of the market. Polymer suppliers are continuously seeking to enhance the performance properties of their products to meet ever more demanding regulatory and customer requirements. A number of new high performance materials have also recently been developed. These include cyclic olefin copolymers (COC), syndiotactic polystyrene, cyclic butylene terephthalate (CBT) and copolycarbonate. The most important product development trends include improvements to the following properties: • • • • • • • • • • • • •

‘Easy-flow’ grades with reduced cycle times particularly aimed at thin wall electrical parts. Halogen-free flame retardant materials. High heat grades for electrical and automotive under-the-bonnet applications. High toughness grades for E&E applications. Improved static dissipating properties. Higher conductivity products, which make parts painting easier in automotive applications. Fibre-reinforced and mineral-filled grades. Low odour emission grades Ceramic-filled grades of polyetherimide for E&E applications. Hydrolysis-resistant grades of PBT specifically for connectors used in automotive production. UV-stabilised POM for automotive applications. ‘Odour-free’ polyacetals for car interior applications. PPS grades that resist aggressive media such as gasoline, diesel or liquefied natural gas.

Another important product trend is interpolymer substitution. In the automotive sector, engineering polymers such as polyamide and ABS for example, are being challenged by reinforced polypropylene in a number of application areas. PBT has also been replacing polyamide in some car electrical applications because of its better dimensional stability. PPO/PPE blends have replaced other polymers in bumper systems because of their better heat resistance and conductivity. Also, given the increasing temperature requirements under-the-bonnet, higher performance plastics such as PPS have been replacing plastics such as polyamide. In the electrical & electronics sector, higher cost and high performance materials such as PES/PSU and polyetherimide are subject to growing competition from other less expensive amorphous high temperature plastics due to rising cost pressures. At the same time, because of rising performance requirements, LCP and PPS are taking share from less expensive materials such as polyamide.

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Finally, consumers are demanding products that reflect their individuality and new styles in terms of design and colour are emerging much more quickly. In response to these trends plastics producers such as Dow and GE Plastics, have introduced lines of special effect resins. These can be used to create coloured moulded parts at a lower cost with special effects such as metallic, glitter, fluorescent, marble and pastel. 2.3 Regional Trends Table 2.2 shows percentage share of engineering and high performance polymer consumption by world region for 1999 and 2002. Table 2.2 Percentage share of engineering and high performance plastic consumption by world region 1999 2002 Western Europe 23.1% 23.5% North America 35.6% 33.3% Japan 11.1% 10.5% Rest of Asia Pacific 28.5% 31.0% Rest of World 1.7% 1.8%

North America remains the largest market for engineering and high performance polymers, followed by ‘Rest of Asia Pacific’ and Western Europe. The ‘Rest of Asia Pacific’ region excludes Japan, and is increasing its share of consumption faster than any other world region. Between 1999 and 2002, China and other Pacific Rim countries, raised their share of total consumption from 28.5% to 31.0%. This is due mainly to the growing trend for automotive and electrical and electronics companies to shift manufacturing facilities to lower cost economies. During the same period the shares of both Japan and North America declined. This is largely explained by the economic downturn and growing market maturity for many key applications, as well as the relocation of production by end users. The share of Western Europe increased slightly during the last three years to reach 23.5% in 2002. Other world regions such as Latin America account for a very small percentage of total world consumption, although their market share is growing slightly. 2.4 Technology Tends A number of new processing technologies are being developed to bolster growth in use of engineering and high performance polymers, particularly for automotive applications. These include: • • • • • • •

Fusible core technology, which has made rapid progress, with major investment by leading moulders throughout Europe. Friction welding of separately moulded individual components and blow moulding of high molecular weight natural and glass-reinforced polymers are also opening up new opportunities. Blow moulding developments, also includes process variants such as suction blow moulding. ‘Hybrid technology’, that binds plastics and steel to reduce weight and lowers module costs to create a high load-bearing capacity while allowing high energy absorption. ‘In-mould painting systems which can reduce capital costs and avoids the component handling necessary prior to painting. ‘Outsert’ technology’ (metal-plastic composites) offers good growth potential for engineering polymers in automotive applications. Combination of engineering polymers with injection moulded ‘soft’ components, including NBR rubber and polyester elastomers. 5


2.5 Market Trends Table 2.3 shows the percentage share of world engineering and high performance plastic consumption by market sector for 1999 and 2002. Table 2.3 Percentage share of engineering and high performance plastic consumption by market sector, 1999-2002 1999 2002 Automotive 26.4% 26.3% Electrical & Electronics 23.9% 23.4% Consumer products 18.4% 19.8% Industrial 15.7% 15.1% Other 15.6% 15.5%

The automotive sector is the largest consumer of engineering and high performance polymers followed by electrical & electronics. The E&E sector was the principal driver of market demand during the second half of the 1990s. However, the slowdown in the electronics and telecom sectors resulted in lower demand for engineering plastics, and hence a declining share of the total market since 1999. The market share of automotive has declined only slightly during the last three years. Growth in automotive plastics was bolstered by continued substitution of traditional materials, despite the sharp downturn in automotive production. The share of the industrial sector has also declined because of lower investment and a decline in the construction industry. The fastest growing sector has been consumer products with an increase in share from 18.4% to 19.8% between 1999 and 2002. The main reason for the better performance of consumer products has been the greater resilience of consumer spending in the face of an economic downturn. The medical devices market also presents some interesting growth opportunities for plastic. 2.6 Competitive Tends There are over fifty producers of engineering and high performance plastics worldwide in 2002. The world’s largest suppliers are global and multi-product companies with production facilities in all three major world regions. In terms of production capacity, the leading suppliers are GE Plastics, Bayer, BASF and DuPont. Several other companies also offer a broad range of engineering and high performance plastics. These include Dow, Ticona and Solvay Advanced Polymers, which specialises in high performance materials. Several Asian companies are developing their engineering plastics businesses through investment and joint ventures. The most broadly based operations in terms of product range include LG Chem of South Korea, Mitsubishi (Japan), Asahi Kasei (Japan), Sumitomo (Japan), Teijin and Toray, both of Japan. Engineering and high performance plastics markets are characterised by a high degree of concentration. The top three world suppliers of polycarbonate (GE Plastics, Bayer and Teijin), for example, control around 70% of total supply. The three leading polyamide suppliers control 55% of world supply and the largest three ABS producers account for 57% of world production. The most extreme cases are polyetherimide, polyphthalamide and PSU, where there are only one or two world suppliers of each type of plastic. The most notable competitive trends in engineering and high performance plastic markets are: 6


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China and other Pacific Rim countries have been increasing their share of world polymer production since 1999, largely at the expense of North America and Japan. A growing proportion of the new capacity building that has taken place in the last three years has been in the Far East. At the same time, several engineering polymer producers have closed plants in the USA and Europe due to over-capacity and negative returns. Asia’s share of world engineering polymer production is expected to grow much further in the coming years.

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A number of major western engineering plastic suppliers have established joint venture businesses with local suppliers in the Far East to capitalise on the growth opportunities.

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Globalisation in key end user markets such as automotive, electrical & electronics and domestic appliances, are encouraging the process of market concentration and globalisation in engineering plastic supply. The trend toward globalisation in end user markets means that customers are becoming more powerful and demanding of their suppliers.

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Customers are also demanding more customised grades to differentiate themselves in the marketplace. Engineering polymer producers are responding to this growing trend by working more closely with key customers and developing new grades, colours and special effect polymers with one customer in mind.

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Some engineering polymer producers are even moving further downstream by offering customers greater access to their knowledge and technology to create higher value services.

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Merger and acquisition activity between engineering polymer suppliers has slowed considerably since the period 1999-2000, when a large number of deals took place. This is due mainly to lower returns and uncertain demand trends facing suppliers.

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New entrants have been attracted into the fastest growing sectors such as LCP and PEEK, during the last two years.

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Engineering polymer prices, while being less volatile than standard thermoplastics, have experienced a long-term decline due to growing competition and the ‘experience curve’ effects of rising volumes (the decline in unit costs as cumulative volumes increase). This partly explains why most producers are currently facing either low or negative returns on their investment.

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3 Overview of Engineering and High Performance Plastics 3.1 Introduction This section presents an overview of the main types of engineering and high performance thermoplastics, their key properties and applications. A more detailed analysis of applications and market trends are presented in subsequent chapters. Engineering polymers include polyamide (PA), polybutylene terephthalate (PBT), acrylonitrilebutadiene-styrene (ABS), polyacetal (POM), polymethyl methacrylate (PMMA) and polycarbonate (PC). These materials have significantly better mechanical properties than standard commodity thermoplastics including high heat resistance, dimensional stability, strength and resistance to a range of chemicals. These properties have enabled engineering plastics to replace traditional materials such as metal and thermosets in many demanding applications areas such as automotive, electrical & electronics, consumer products, industrial machinery and medical markets. It is difficult to agree on a precise definition of a high performance plastic. There is indeed a clear overlap across the entire classification spectrum of thermoplastic materials. Some commodity plastics can be modified through reinforcements to compete with traditional engineering resins. Glass fibre-reinforced polypropylene is a good example of a standard thermoplastic material that is challenging polyamide and ABS in many different fields of application. As a general rule of thumb, high performance plastics are considered to have a short-term heat resistance of 250 °C and can withstand long-term heat resistance of 160 °C. Other distinguishing features of high performance plastics include their high strength and stiffness, resistance to many chemicals and their outstanding electrical properties. Table 3.1 shows continuous use temperatures for engineering and high performance polymers. For comparative purposes, 30% glass fibre-reinforced grades have been selected. PEEK has the highest continuous use temperature of up to 260 ºC, followed closely by liquid crystal polymers. Other high performance polymers are polyphthalamide (PPA), polyamideimide (PAI), polyarylimide, polyphenylene sulfone (PPSU), polyphenylene sulfide (PPS), polyetherimide (PEI), polysulfone (PSU), polyethersulfone (PES). Table 3.1 Continuous use temperature (CUT) for engineering and high performance plastics CUT (ºC) PEEK 260 LCP 240 PAI 210 PPSU 205 PPS 200 PES 180 PEI 170 PSU 150 PBT 120 PC 115 POM 85 PA6 80 PA66 80 PPO 80 ABS 70 PMMA 50

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PBT has the highest continuous use temperature of the engineering polymers, followed by polycarbonate, POM, polyamide, ABS and acrylics. PPO/PPE alloys are often considered to be high performance materials due to their excellent combination of properties such as high impact strength and dimensional stability, although their continuous use temperature is lower than some engineering plastics. There are also a number of high performance materials that are relatively new to the market including: cyclic olefin copolymers (COC), syndiotactic polystyrene, cyclic butylene terephthalate (CBT) and copolycarbonate. These developing materials are described in Section 3.18. Engineering and high performance plastics can also be classified according to whether the polymers are semi-crystalline or amorphous. A crystalline polymer denotes a molecular structure in some resins, which denotes uniformity and compactness of the molecular chains forming the polymer. Normally this can be attributed to the formation of solid crystals having a definite geometric form. An amorphous polymer is devoid of crystallinity, with no definite order. Semi-crystalline thermoplastics are noted for very good electrical properties, as well as the ability to withstand both high heat and severe chemical environments. They include polyamide, PBT, polyphenylene sulfide (PPS), polyphthalamide, polyarylimide, liquid crystal polymers and polyketones. Amorphous materials are random entanglements of polymer chains, known for very good mechanical properties (strength, stiffness) and dimensional performance. Amorphous polymers include ABS, polycarbonate, PPO/PPE, polyphenylene sulfone, polyethersulfone, polysulfone and polyetherimide. Nowadays, there are many different types of engineering and high performance plastics to choose from. In contrast, back in 1980, the plastics design engineer had a much smaller number of materials from which to choose. Among the thermoplastics there were the fluoropolymers that were ideal for extrusion applications such as wire and cable insulation. These resins were not however easily adapted to produce complex injection moulded parts. There were also the sulfone-based resins such as polysulfone and polyphenylene sulfone, and polyamideimide, which had proven itself in small parts that had to operate in hostile environments. Among the thermosets, there were only a few commercial grades of bismaleimide on the market, requiring heavy glass or carbon fibre reinforcement to overcome this resin’s inherent brittleness. During the 1980s and 1990s, the pace of research and commercialisation of high-temperature plastics accelerated dramatically. The thermoplastic resin manufacturers introduced many new materials based on imide, sulfone, and ketone-based polymers. These include polyetherimide (1982) and polyphthalamide (1991). Polyketones and liquid crystal polymers were also commercialised in the 1990s. Competing materials at the high performance end of the market such as thermosets have also seen significant product development in recent decades. The thermoset manufacturers have brought out a whole range of polyimides with excellent mechanical performance at elevated (250-350 °C) temperature for use in applications including automotive, military and commercial aircraft engines. The thermal and mechanical performance of all the major thermosets such as epoxy, phenolics, vinyl ester and cyanate esters, have also been enhanced through compounding with hightemperature thermoplastics and modifying the basic thermoset formulations. In effect, the search for higher-temperature performance extends right through the whole contemporary resin classification system, and this is leading to increased competition among the suppliers and increased options among the end-users. Manufacturers of commodity resins such as

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polystyrene, polyamide and PVC have recently introduced ‘high-temperature’ grades of their resins. Formerly intractable resins such as polyphenylene oxide and maleic anhydride have been harnessed to high-temperature applications through the medium of alloying and blending with more processable resins. Alloying and blending has also been a route to synergistic combinations of thermal and mechanical performance in the field of polyimides and liquid crystal polymers. 3.2 Polyamide (PA)

3.2.1 Properties Polyamide or nylon is a semi-crystalline polymer and has been commercialised since the mid 1930s. This material offers an excellent combination of mechanical and electrical properties coupled with good resistance to heat and chemicals. It has high lubricity and moderate strength. It is tough, inexpensive, but has poor dimensional stability due to water absorption. A number of different types of polyamide are available covering a wide range of properties. The standard grades are PA6 and PA66. PA6 is made by hydrolytic polymerisation of caprolactam. PA66 is made by the polycondensation of hexamethylenediamine and adipic acid. Special copolyamide grades such as PA6/12 and PA6/66, partially aromatic grades and transparent grades are also produced. Polyamide 11 and polyamide 12 are high performance materials. Polyamide 11 is produced by polymerisation of amino-undecanoic acid from castor oil. PA12 is obtained from crude oil by polycondensation of lauryllactam. Polyamide is formed by two methods. Dual numbers arise from the first, a condensation reaction between diamines and dibasic acids produces a polyamide salt. The first number of the polyamide type refers to the number of carbon atoms in the diamine, the second number is the quantity in the acid (e.g., polyamide 612 or polyamide 66). The second process involves opening up a monomer containing both amine and acid groups known as a lactam ring. The polyamide identity is based on the number of atoms in the lactam monomer (e.g., polyamide 6 or polyamide 12, etc.). The key performance properties of polyamides are summarized below. PA6 and 66: • • • • • • • • • • •

Good rigidity and hardness Very high strength and toughness Good low-temperature impact strength High dynamic strength Abrasion and wear resistance High heat resistance (PA6 short-term to 200 °C, long-term from 80 to 150 °C, PA66 short-term to 250 °C, long-term from 80 to 150 °C) Resistant to many chemicals Excellent processing properties Tensile modulus: 450 to 15,000 MPa for PA6 and 900 to 15,000 MPa for PA66 Good mechanical and electrical properties Very good abrasion and wear resistance

Table 3.2 presents a comparison of the performance properties of PA6, PA66 and PA612.

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Table 3.2 Comparison of performance properties for PA6, PA66 and PA612 moulding compounds PA6 PA66 PA612 Elastic modulus (MPa) 2622-3202 1587-2795 1505-2001 (tensile with 0.2% water content) Flexural modulus (MPa) 2691-2829 2829-3243 1656-2305 Tensile strength (MPa) (at break) 42-166 56-83 41-58 Compression strength (at yield or break) 90-111 87-104 n.a. Hardness (Rockwell R state) 119 120 115 Coefficient of thermal expansion (10-6/ºC) 80-83 80 n.a. Deflection temperature (ºC) 175-191 219-246 155-166 Specific gravity 1.12-1.14 1.13-1.15 1.06-1.1 Water absorption 8.5-10 8.5 2.5-3 (% weight increase, saturated) Dielectric strength (V/mil) 400 600 400 Melting temperature (ºC) 210-220 255-265 195-219 Processing temperature (ºC) 227-288 260-327 233-288 Moulding pressure (MPa) 7-138 7-173 7-104 Compression ratio 3-4 3-4 3-4 Linear mould shrinkage (cm/cm) 0.003-0.015 0.007-0.018 0.011

The main advantage of polyamide 6 over 66 is that it is easier to process and produces lower mould shrinkage. The main disadvantage of polyamide 6 is that it has lower strength, stiffness and abrasion resistance than polyamide 66 and higher water absorption. The main advantages of polyamide 66 are its better low temperature toughness than acetal, PBT and polyamide 6, and its good fatigue resistance. It should however be noted that the choice between polyamide 6 and 66 is often made for reasons of availability, price or familiarity, rather than for technical reasons. The exception to this is ease of moulding, where polyamide 6 dominates. Properties of partially aromatic, transparent polyamides are: • • • • • • • •

Transparent in all thicknesses High-gloss or textured, depending on mould surface Mechanical and electrical properties largely unaffected by moisture Tensile modulus: 3,000 MPa Short-term heat resistance to 120 °C Good dimensional stability Good electrical insulating properties Good resistance to stress cracking and chemicals, although not as good as PA 6 and PA 66

PA11 and 12 offer outstanding physical and chemical properties. • • • • • • •

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Flexibility and resistance to pressure Rigidity and impact resistance Resistance to extreme temperatures Resistance to abrasion and low friction coefficient Light weight and tensile strength Impermeability and chemical resistance Good surface finish and resistance to weathering


The main advantages of PA11 are its lower water absorption and UV resistance compared to other polyamides. It also has higher strength and heat resistance than PA12. It is however more expensive than PA6 and PA66. PA12 is tougher than PA11 and has lower water absorption than standard polyamides. PA12 is however expensive and has the lowest strength and heat resistance of any unmodified polyamide. PA612 offers higher stiffness, hardness and thermal stability compared to PA12. It also has lower water absorption than PA6 and PA66. The main disadvantage is that it has a lower heat distortion temperature than PA66 and is more expensive.

3.2.2 Applications Polyamide resins and compounds are used in a wide range of applications, which reflects the very broad range of grades currently available. Products are sold either as unreinforced resin or in compound form with mineral or glass fibre reinforcements. The automotive sector is the biggest market for polyamide. Main applications are under-the-bonnet applications such as the air intake manifold, the air and cooling systems, peripherals, throttle body housing, the cylinder head cover, the water-glycol circuit and engine parts. High performance PA is also used to make tubing for under-the-bonnet applications such as fuel systems. In car electrical systems, polyamide is found in the peripherals, sensors, switches, relays and electronic housing. For exterior parts, PA is used to manufacture parts such as rear mirror housing, door handles and windscreen wiper parts. In car interiors, applications include door handles, key lock systems, push buttons and switch control panels. Electrical & electronics is the next most important market for polyamide. It is used to manufacture electrical components such as switches, connectors, contactors and various household appliance components. It is also used for wire and cable jacketing. PA compounds often include flame retardant grades. Film is the third largest market followed by consumer products. Key applications include parts for appliances and power tools, caster wheels for furniture, sports equipment such as ski and snowboard bindings and packaging parts such as lighters and aerosol valves. Industrial applications are also significant users of polyamide. Polyamide is used for manufacture of many different components for industrial machinery and equipment. Applications include bearing cages, pumps, pneumatic connectors and cable chains. PA is also used for fixation products such as fasteners, staples and drills. Other markets include sheet, rod and tubes, filaments, and various other injection moulding applications.

3.2.3 Processing Polyamide can be processed using the following technologies: • • • • • • •

Injection moulding Mono and multilayer injection Injection blow moulding Rotomoulding Mono- and bi-material moulding Pipe, profile, sheet, film, and filament extrusion Extrusion blow moulding of sheets and other parts

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• • •

Mono or multilayer extrusion Thermoforming Thermoretraction

3.2.4 Pricing Trends In December 2002, unreinforced grades of PA6 cost between €2,100-2,350 per tonne. Reinforced grades cost around €200 more. PA66 is more expensive than PA6, costing between €2,600-2,850 per tonne for unreinforced and €200 per tonne more for glass reinforced grades. Over the long term, the trend in polyamide prices is firmly downwards. In the early 1990s for example, PA6 prices reached €3,700 per tonne. Since then PA prices have moved in a cyclical manner, but the overall trend in prices is lower. 3.3 Polybutylene Terephthalate (PBT)

3.3.1 Properties Polybutylene terephthalate (PBT) is a semi-crystalline saturated polyester, which has been produced since 1942. PBT is made by the polycondensation of terephthalic acid or dimethyl terephthalate with 1,4-butanediol in the presence of a catalyst. Terephthalic acid, dimethyl terephthalate and 1,4-butanediol are derived from petrochemicals such as xylene and acetylene. The polymer is noted for high stiffness and strength, high resistance to heat, low water absorption and high dimensional stability. It has moderate chemical resistance and low resistance to strong acids and bases. There are a number of different grades and types of PBT resins and compounds available. The most widely used are unreinforced and reinforced injection moulding grades, followed by extrusion and coating grades. Injection moulding grades are available in a wide range of strengths and degrees of toughness. Reinforced PBT compounds contain glass or mineral filled reinforcements for added toughness, UV stabilisers or flame retardants for high heat electrical applications. PBT is also blended with polycarbonate to give special low warpage grades with high impact strength even at low temperatures. The volume of PC/PBT blends is included in the market definition of PBT. Table 3.3 presents a comparison of the performance properties of unfilled, 30% glass fibrereinforced and 30% long glass fibre-reinforced PBT grades. The main features of PBT performance properties are: • • • • • • • •

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Good chemical resistance High dielectric strength Outstanding electrical properties High heat resistance, up to 140 °C long term Low temperature performance down to –40 °C Strength and modulus at elevated temperatures Very good processability, long flow in thin sections Flame resistance


Table 3.3 Comparison of performance properties for PBT injection moulding compounds 30% long glass 30% glass Unfilled fibrefibrereinforced reinforced Elastic modulus (MPa) 1932-3002 8970-10005 9660 (tensile with 0.2% water content) Flexural modulus (MPa) 2277-2760 5865-8280 8970 Tensile strength (MPa) (at break) 57-61 97-135 138 Compression strength (at yield or break) 60-101 125-163 180 Hardness (Rockwell R state) 68-78 90 n.a. Coefficient of thermal expansion 60-95 15-25 n.a. (10-6/ºC) Deflection temperature (ºC) 116-191 217-260 208 Specific gravity 1.3-1.38 1.48-1.54 1.56 Water absorption 0.4-0.5 0.35 n.a. (% weight increase, saturated) Dielectric strength (V/mil) 420-550 460-560 n.a. Melting temperature (ºC) 228-267 220-267 235 Processing temperature (ºC) 224-274 227-277 249-283 Moulding pressure (MPa) 28-69 35-104 69-138 Compression ratio n.a. n.a. 3-4 Linear mould shrinkage (cm/cm) 0.009-0.022 0.002-0.008 0.001-0.003

3.3.2 Applications Automotive is the largest market for PBT. Electronic components and housings are the main applications area for PBT in the automotive sector. Exterior applications are the next most important market with main uses being bumper fascias, mudguards, door handles, mirror housings and wiper arms. Interior applications include parts of the instrument panels such as ashtrays and interior trim. Electrical and electronics is the next largest market for PBT with principal applications including connectors, smart network interface devices (SNIDs), power plugs and electrical components, switches and controls, circuit breaker enclosures and outdoor telecommunications enclosures. PBT can also be found in electrical appliance components requiring high surface gloss and fibre optic tubing. Other applications include industrial, consumer and recreation products.

3.3.3 Pricing Trends PBT prices have fallen since the early 1990s. From a peak of just less than €4,000 per tonne, the long-term trend in PBT prices is downwards. In December 2002, PBT unreinforced cost around €2,850-3,300 per tonne with reinforced grades costing around €200 per tonne more. 3.4 Acrylonitrile-Butadiene-Styrene (ABS)

3.4.1 Properties Acrylonitrile-butadiene-styrene (ABS), an amorphous polymer, has been in mass production since the 1960s. It is a styrenic copolymer blend made out of elastomeric components and an amorphous thermoplastic component. The elastomeric component is usually polybutadiene or a butadiene copolymer. The thermoplastic component is SAN, a copolymer of styrene and acrylonitrile. SAN 15


can be either grafted to and/or blended with the elastomeric component. The three monomers (A, B and S) offer flexibility in tailoring the property profiles. Acrylonitrile provides chemical resistance, ageing resistance, hardness, rigidity, gloss and melt strength. Butadiene provides low temperature ductility, flexibility and melt strength. Styrene provides processing ease, gloss and hardness. Producers can vary the relative amount of the three components to optimise certain properties to meet the different requirements for various applications. The versatility of ABS can be further enhanced by substituting styrene with alpha-methylstyrene, or other high heat co-monomers, to obtain higher heat resistance. Probably the most notable property of ABS is its toughness and high impact strength at extreme temperatures which permit applications at temperatures of between –40 °C to +100 °C. ABS also offers good electrical insulation, low water absorption and good resistance to most chemicals. As far as processing is concerned, ABS has a good melt-flow, low shrinkage and produces excellent surface finish. The main disadvantages of ABS are its poor solvent and fatigue resistance, poor UV resistance, unless protected, and maximum continuous use temperature is only around 70 °C. ABS compounds are available in many forms including medium and high impact grades, high gloss, UV stabilized, flame retardant, heat resistant, low gloss, glass-fibre reinforced and transparent. Table 3.4 presents a comparison of the performance properties of medium impact, high impact and 30% glass fibre-reinforced ABS. Table 3.4 Comparison of performance properties for ABS injection moulding compounds 30% glass Medium impact High impact fibrereinforced Elastic modulus (MPa) 1380-3105 966-2070 690-8280 (tensile with 0.2% water content) Flexural modulus (MPa) 2139-2760 1236-2588 6900 Tensile strength (MPa) (at break) 38-52 31-44 90-111 Compression strength (at yield or break) 13-87 32-56 104-118 Hardness (Rockwell R state) 102-115 85-106 75-85 Coefficient of thermal expansion 80-100 95-110 n.a. (10-6/ºC) Deflection temperature (ºC) 89-108 99-108 110-116 Specific gravity 1.03-1.06 1.01-1.05 1.29 Water absorption 0.2-0.45 0.2-0.45 0.3 (% weight increase, saturated) Dielectric strength (V/mil) 350-500 350-500 n.a. Melt flow (gm/10 min) 1.1-34.3 1.1-18 n.a. Melting temperature (ºC) 102-115 91-110 100-110 Processing temperature (ºC) 199-274 194-274 205-238 Moulding pressure (MPa) 56-173 56-173 n.a. Compression ratio 1.1-2 1.1-2 n.a. Linear mould shrinkage (cm/cm) 0.004-0.009 0.004-0.009 0.002-0.003

3.4.2 Applications Impact ABS is used for helmets, pipes and fittings, and housings for items such as vacuum cleaners, telephone sets and cameras. High gloss grades are used for domestic appliances such as

16


washing machines and refrigerator housings. Low gloss grades are used in automotive interior and domestic appliance housings. Flame retardant grades are used in electrical appliances such as TV, VCR, PC and printer housings. Heat resistant products tend to be used mostly in automotive applications. Transparent ABS is used to make clear parts for home appliances and business equipment. Automotive is the most important market for ABS. Main applications include loudspeaker grilles, door handles, door trim, instrument panels and consoles. ABS is also used for exterior components, electrical parts such as navigation systems housing and a small amount is used under-the-bonnet. PC/ABS blends are used for interior and exterior applications. ABS is widely used for manufacture of housings for a wide range of consumer products. These include cameras, business equipment, TVs, vacuum cleaners, food mixers, telephone sets and audio equipment, and many more. Electrical and electronics applications include transformer housings and switches. Other applications for ABS include pipes, sports equipment, safety helmets, luggage, furniture, medical equipment, tubes and caps.

3.4.3 Pricing Trends ABS prices have drifted downwards since the early 1990s. In late 1991, ABS cost around €2,250 per tonne. Since then, prices have moved in a cyclical fashion but the long-term trend is lower. In December 2002, natural grade ABS cost €1,350-1,550 per tonne. Coloured grades cost €1,7502,100 per tonne, with UV stabilized grades around €100 per tonne more. 3.5 Polycarbonate (PC)

3.5.1 Properties Polycarbonate is an amorphous engineering thermoplastic, which was first commercialised in 1958. Polycarbonate has excellent strength and toughness. It possesses good dimensional stability, dielectric strength, flame retardancy, and impact resistance (highest among transparent rigid materials). It is susceptible to stress cracking with aromatic solvents, and is difficult to machine. The introduction of glass fibres raises its heat deflection temperature but its impact strength is reduced in contrast to most other glass filled plastics. Common to all polycarbonates is the carbonate group in the main chain. Polycarbonates are referred to as aliphatic or aromatic, depending on the dihydroxy used in their synthesis. Aliphatic polycarbonates are of much less economic importance than aromatic types. Common pathways to aliphatic polycarbonate are the transesterification of diols with dialkyl or diphenyl carbonates or dioxolanones, in the presence of a catalyst. Aromatic polycarbonates are prepared from various bisphenols, the most widely used being bisphenol A. The synthesis of aromatic polycarbonates is based on the reaction of bisphenol with carbonic acid derivatives such as phosgene, diphosgene, carbonic acid esters and chloroformic acid esters. The most important process for production of aromatic polycarbonate is the so-called ‘interfacial process’, first developed by Bayer. In this process, bisphenol A is phosgenated in the presence of methylene chloride in controlled conditions. Advances in melt processing technology are challenging traditional ways of producing polycarbonate. The growing use of these non-phosgene processes is being prompted by lower capital costs and the fact that these are more environmentally friendly processes. Melt processing also gives better product quality for the fast growing optical media applications.

17


There are a wide range of polycarbonate resins and compounds available on the market. Table 3.5 presents a comparison of the performance properties of unfilled, 30% glass fibrereinforced and 30% long glass fibre-reinforced grades of polycarbonate. Table 3.5 Comparison of performance properties for polycarbonate moulding compounds 30% long glass 30% glass fibreUnfilled fibrereinforced reinforced Elastic modulus (MPa) 2381 8625-9660 8280-10350 (tensile with 0.2% water content) Flexural modulus (MPa) 2277-2346 7590 5520-10350 Tensile strength (MPa) (at break) 63 132-138 125-159 Compression strength (at yield or break) 69-87 125-138 125-206 Hardness (Rockwell R state) 70-75 92 85-95 Coefficient of thermal expansion 68 22-23 n.a. (10-6/ºC) Deflection temperature (ºC) 138-142 149-152 152 Specific gravity 1.2 1.4-1.43 1.34-1.43 Water absorption 0.32-0.35 0.08-0.14 0.09-0.11 (% weight increase, saturated) Dielectric strength (V/mil) 380 470-475 Melting temperature (ºC) 150 150 150 Processing temperature (ºC) 294 288-344 310-344 Moulding pressure (MPa) 69-138 69-207 69-207 Compression ratio 1.74-5.5 n.a. n.a. Linear mould shrinkage (cm/cm) 0.005-0.007 0.001-0.002 0.001-0.003

3.5.2 Applications Polycarbonate resin is used in applications such as safety sheets and goggles, lenses, business machine housings, instrument casing, light fittings, safety helmets, electrical switchgear, bulletproof glazing, kitchenware and microwave cookware. UV stabilised grades are used for canopies, skylights and walkways. Flame retardant grades are used for electrical appliance enclosures, gas meters, firemen’s helmets and food service equipment. Glass fibre reinforced grades are used for electrical enclosures while carbon fibre reinforced grades are used mostly for high strength business machine components and casings. In terms of end markets for polycarbonate, optical media such as CDs and DVDs are the most important uses, followed by glazing applications. Transportation and electrical are also major markets.

3.5.3 Pricing Trends Polycarbonate prices have also been drifting lower over the last decade or so. At the end of 1991 for example, transparent PC cost around €4,000 per tonne. Since then, prices have fluctuated but the general trend is downward. In December 2002, transparent PC cost between €2,600-2,800 per tonne. Glass reinforced grades cost around €400 per tonne more.

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3.6 Polyoxymethylene (POM)

3.6.1 Properties Polyoxymethylene or polyacetal is a highly crystalline polymer. POM is most noted for its high stiffness, mechanical strength, abrasion resistance and good resistance to chemicals and solvents. It also displays good low temperature impact resistance, high dimensional stability, favourable frictional properties and low water absorption. The main disadvantages of the polymer are its poor resistance to acids and alkalis, and that it burns easily. It also has a restricted processing temperature range and poor UV resistance. Table 3.6 presents a comparison of the performance properties of polyacetal homopolymers, copolymers and 25% glass fibre-reinforced copolymers. Table 3.6 Comparison of performance properties for polyacetals Homopolymer Elastic modulus (MPa) (tensile with 0.2% water content) Flexural modulus (MPa) Tensile strength (MPa) (at break) Compression strength (at yield or break) Hardness (Rockwell R state) Coefficient of thermal expansion (10-6/ºC) Deflection temperature (ºC) Specific gravity Water absorption (% weight increase, saturated) Dielectric strength (V/mil) Melt flow (gm/10 min) Melting temperature (ºC) Processing temperature (ºC) Moulding pressure (MPa) Compression ratio Linear mould shrinkage (cm/cm)

Copolymer

Copolymer 25% glass fibrereinforced

4623

3105

8625-9660

828-932 67-69 108-125 92-94

2553-3105 58-72 111 75-90

7590 111-128 118 79-90

50-112

61-110

17-44

163-173 1.42

155-166 1.4

164-167 1.58-1.61

0.25-1

0.2-0.22

0.22-0.29

400-500 1-20 172-184 194-244 69-138 2-4.5 0.018-0.025

500 1-90 160-175 172-205 56-138 3-4.5 0.02

480-580 n.a. 160-180 185-249 56-138 3-4.5 0.004

The first polyacetal was introduced in 1960. A problem which beset the moulders of the early polyacetal resins was that the polymer chains have to be stabilised to prevent the resin breaking down during processing at elevated temperatures. More heat-stable versions appeared in the early 1990s, incorporating new stabiliser technology that reduces mould and screw deposits. There are two different methods for producing polyacetals. Anionic polymerisation of formaldehyde produces homopolymers that crystallize particularly well and therefore have high stiffness and strength. The other method is cationic polymerisation of trioxane. Here the addition of small amounts of comonomers lowers the crystallinity to increase toughness. The stiffness and strength are however somewhat lower than for homopolymers. Copolymers are by far the most widely used polyacetals with a share of around 75% of total POM sales. Copolymers have been growing faster than homopolymers in recent years mainly because

19


they are easier to process. Homopolymers, on the other hand, have better physical and mechanical properties than copolymers.

3.6.2 Applications There are distinct markets for both types of polymer. Homopolymers are best suited to applications in which good abrasion resistance and a low coefficient of friction is needed. Applications include bearings, gears, conveyer belt links and safety systems like seat belts. Copolymers are best suited to applications that require low coefficient of friction such as electric kettles and water jugs, components with snap fits, chemical pumps, bathroom scales, telephone keypads and housing for domestic appliances. Polyacetals can be extruded, injection moulded and blow moulded. Most of the material is injection moulded. Injection moulding grades come in various melt viscosities and can be processed rapidly and easily into moulded parts. There are also impact modified injection moulding grades for high toughness applications and glass fibre-reinforced grades.

3.6.3 Pricing Trends In common with other engineering plastics, POM prices have been moving downward since the early 1990s. At the end of 1991, natural grade POM cost just over €3,500 per tonne. Prices have since fluctuated in response to changes in industry supply and demand, but the overall trend is lower. In December 2002, natural POM prices were between €2,150-2,500 per tonne. Glass reinforced grades cost up to €300 per tonne more. 3.7 Polymethylmethacrylate (PMMA)

3.7.1 Properties Acrylics are derived from esters and are produced by polymerisation of methyl methacrylates (MMA) to give a range of properties from soft elastomers to stiff thermoplastics. The main features of polymethylmethacrylate (PMMA), or acrylics, are their excellent clarity and UV resistance, good abrasion resistance, stiffness and hardness. The main drawback of acrylics is their poor solvent resistance, low continuous use temperature (approximately 50 °C) and poor fatigue resistance. Table 3.7 presents a comparison of the performance properties for acrylic cast sheet, PMMA moulding and extrusion compounds and PMMA moulding and extrusion compounds, impact modified. Acrylics come in many different forms such as liquid emulsion for coatings, cast sheet, high impact and general purpose grades.

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Table 3.7 Comparison of performance properties for acrylics

Elastic modulus (MPa) (tensile with 0.2% water content) Flexural modulus (MPa) Tensile strength (MPa) (at break) Compression strength (at yield or break) Hardness (Rockwell R state) Coefficient of thermal expansion (10-6/ºC) Deflection temperature (ºC) Specific gravity Water absorption (% weight increase, saturated) Dielectric strength (V/mil) Melt flow (gm/10 min) Melting temperature (ºC) Processing temperature (ºC) Moulding pressure (MPa) Linear mould shrinkage (cm/cm)

Cast sheet

PMMA moulding and extrusion compound

PMMA moulding and extrusion compound Impact modified

2691-3278

2553-3174

1656-2553

2208-22149 46-76 76-132 80-102

2243-3174 49-73 73-125 68-105

1380-2967 35-63 28-97 35-78

50-90

50-90

48-80

74-113 1.17-1.2

74-108 1.17-1.2

83-97 1.11-1.18

0.2-0.4

0.1-0.4

0.19-0.8

450-550 n.a. 90-105 n.a. n.a. 0.0017

400-500 1.4-27 85-105 163-260 35-138 0.001-0.004

380-500 1-11 80-103 205-260 35-130 0.002-0.008

3.7.2 Applications Cast sheet grades are used for glazing, illuminated and non-illuminated signs, street lamp housing, coach roof lights, guards for machines and food displays, baths and washbasins, and covers on solar panels. High impact grades are used for glazing, signs and displays, and automotive rear light housings. General purpose acrylics are used for bath enclosures, tap tops and accessories, aircraft glazing, signs and displays, automotive rear light housings, car badges and fascia panels. Cast and extrusion sheet represents around two-thirds of total acrylics production, the remainder being injection moulding applications.

3.7.3 Pricing Trends Unlike other engineering plastics, PMMA prices have been fairly stable over the last decade or so. In late 1991, transparent PMMA cost around just over €2,500 per tonne. Prices have fluctuated since then in response to market conditions, but on average prices have been fairly stable. In December 2002, transparent PMMA cost between €2,500-2,750 per tonne. 3.8 Polyphenylene Oxide (Ether) Blends (PPO and PPE)

3.8.1 Properties Modified polyphenylene oxide (PPO) and polyphenylene ether (PPE) resins were first commercialised in the mid 1960s. PPO and PPE are similar in chemical composition and properties 21


and will be discussed as one class of resins. Polyphenylene ether (PPE) is obtained through oxidation-coupling polymerisation of its monomer, 2,6-xylenol, in the presence of oxygen. The modification of these resins involves blending with a second polymer usually polystyrene or polyamide. By varying the blend ratio and other additives, a variety of grades are produced. Unmodified, these polymers are characterised by regular closely spaced ring structures (phenyl groups) in the main molecular chain. This feature along with strong intermolecular attraction causes extreme stiffness and lack of mobility. Their low molecular polarity gives them very low water absorption. Melt processing of the unmodified polymer is extremely difficult. These features lead to high strength, high modulus, excellent dimensional stability, very good impact resistance, and high thermal distortion resistance. The modified polymers retain these properties to a significant degree. The main disadvantage of PPO and PPE blends is that they are easily attacked by some hydrocarbons. They are, however, resistant to many chemicals. Table 3.8 presents a comparison of the performance properties for PPO/polystyrene alloy and PPO/polystyrene alloy with 30% glass fibre-reinforcement. Table 3.8 Comparison of performance properties for PPO alloys PPO/PS alloy 30% PPO/PS alloy glass fibrereinforced Elastic modulus (MPa) 2139-2622 6900-8970 (tensile with 0.2% water content) Flexural modulus (MPa) 2243-2760 7590-7935 Tensile strength (MPa) (at break) 45-54 101 Compression strength (at yield or break) 9-114 124 Hardness (Rockwell R state) 115-116 115-116 Coefficient of thermal expansion (10-6/ºC) 38-70 14-25 Deflection temperature (ºC) 110 138-160 Specific gravity 1.04-1.1 1.27-1.36 Water absorption (% weight increase, saturated) 0.06-0.1 0.06 Dielectric strength (V/mil) 400-665 550-630 Melting temperature (ºC) 100-112 100-125 Processing temperature (ºC) 205-316 205-333 Moulding pressure (MPa) 83-138 69-276 Linear mould shrinkage (cm/cm) 0.005-0.008 0.001-0.004

Key properties of modified PPO/PPE are good electrical insulating properties and long-term dimensional stability due to low moisture absorption. It also has superior impact strength, is lightweight, and is hydrolytically stable. It may be used continuously at temperatures in excess of 80 °C. For enhanced mechanical and thermal performance, glass fibre reinforcement may be added. Because of its alloy matrix composition, PPO/PPE blends are also one of the few non-metallic materials that can be readily electroplated (after an electroless plating surface has been applied using a selective etching process).

3.8.2 Applications Modified PPO/PPE is used for its outstanding properties in a broad range of applications such as automotive, fluid handling (water softener valves, and water pump components), power tools and enclosures (VDU and computers), TV components, washing machine components, electrical insulation and telecommunications.

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3.8.3 Pricing Trends PPO/PPE blends cost around €4.05-4.50 per kg in December 2002. PPO/PPE prices tend to be more stable than most other engineering plastics. However, producers managed to push through price increases of about 5.0% in 2000. 3.9 Polyphenylene Sulfide (PPS)

3.9.1 Properties Polyphenylene sulfide (PPS) was first mass-produced by the Phillips Petroleum Company in 1972. PPS is a semi-crystalline polymer made up of alternating sulfur atoms and phenylene rings in a para-substitution pattern. The highly stable chemical bonds of its molecular structure impart a remarkable degree of molecular stability toward both thermal degradation and chemical reactivity. The molecular structure also readily packs into a very thermally stable crystalline lattice. PPS has a high crystalline melting point of about 285 °C (545 °F). Because of its molecular structure, PPS tends to char during combustion, making the material inherently flame retardant. PPS has not been found to dissolve in any solvent at temperatures below about 200 °C. Table 3.9 presents a comparison of the performance properties for PPS unfilled, 30% glass fibrereinforced and 30% long glass fibre-reinforced grades. Table 3.9 Comparison of performance properties for PPS 30% glass 30% long glass Unfilled fibrefibre-reinforced reinforced Elastic modulus (MPa) 3312 n.a. 12420 (tensile with 0.2% water content) Flexural modulus (MPa) 3795-4140 11730 11730 Tensile strength (MPa) (at break) 49-87 152 145 Compression strength (at yield or break) 111 n.a. 224 Hardness (Rockwell R state) 123-125 103 n.a. Coefficient of thermal expansion 27-49 n.a. n.a. (10-6/ºC) Deflection temperature (ºC) 199 279 255 Specific gravity 1.35 1.38-1.58 1.52-1.62 Water absorption 0.01-0.07 0-0.03 n.a. (% weight increase, saturated) Dielectric strength (V/mil) 380-450 n.a. n.a. Melting temperature (ºC) 285-290 275-285 310 Processing temperature (ºC) 310-338 310-338 305-327 Moulding pressure (MPa) 35-104 56-83 56-69 Compression ratio 2-3 3 3 Linear mould shrinkage (cm/cm) 0.006-0.014 0.003-0.005 0.001-0.007

When blended with glass fibres and other fillers, PPS has a unique combination of properties including: • • • • •

An excellent combination of both long-term and short-term thermal stability High temperature resistance with continuous use temperature of 230 °C Exceptionally high modulus and creep resistance Outstanding resistance to a wide variety of aggressive chemical environments Precision moulding to tight tolerances with high reproducibility 23


• •

Inherent non-flammability without flame retardant additives Dielectric and insulating properties stable over a wide range of conditions

3.9.2 Applications Automotive is the biggest market for PPS, accounting for over a half of total consumption. The main applications for PPS in automotive are electrical components such as connectors, housings and coil formers, chemical pumps, and car under-the-bonnet components such as brake systems, and electrical/electronic devices requiring high heat resistance, high dimensional stability, and corrosion resistance. Electrical & electronics and industrial applications are also major markets for PPS.

3.9.3 Pricing Trends In December 2002, the average price of PPS was around €7.70-8.50 per kg. Non-reinforced or pure linear grades are at the upper end of the price spectrum, costing around €15-20 per kg. Highly filled compounds with a glass fibre or mineral content are to the lower end of the price range, while high performance types are more expensive. Producers raised prices by 6% in October 2000 due to rising raw material prices. 3.10 Polyetherimide (PEI)

3.10.1 Properties Introduced by GE Plastics in 1982, polyetherimide (PEI) is an amorphous thermoplastic offering outstanding high heat resistance and strength. The high heat resistance and heat stability are attributable to its imide structure. PEI also has resistance to a broad range of chemicals, and is inherently flame resistant with low smoke emission. A major component of PEI is bisphenol A, which is also produced by GE Plastics, mainly for use in polycarbonates. Polyetherimide is a hybrid between polyarylethers and polyimides. The imides impart high temperature performance and the inclusion of ether groups allows melt processing. The properties of PEI are in fact closer to PES than to non-melting polyimides. PES and PEI therefore compete directly in many applications. The main advantages of PEI are its high tensile strength at 20 °C more than either PES or polysulfone. It also has lower water absorption than PES. Continuous use temperature is around 170 °C compared to PES of 180 °C. The main disadvantage is that stress cracking occurs when in contact with chlorinated solvents. Table 3.10 presents a comparison of the performance properties for unfilled polyetherimide and 30% glass fibre-reinforced grades.

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Table 3.10 Comparison of performance properties for polyetherimide (PEI) 30% glass fibreUnfilled reinforced Elastic modulus (MPa) 2967 8970-11040 (tensile with 0.2% water content) Flexural modulus (MPa) 3312 8280-8970 Tensile strength (MPa) (at break) 105 170 Compression strength (at yield or break) 152 163-212 Hardness (Rockwell R state) 109-110 114-125 Coefficient of thermal expansion (10-6/ºC) 47-56 20-21 Deflection temperature (ºC) 208-210 212-213 Specific gravity 1.27 1.50 Water absorption (% weight increase, saturated) 1.25 0.9 Dielectric strength (V/mil) 500 495-630 Melting temperature (ºC) 215-217 215 Processing temperature (ºC) 338-427 327-427 Moulding pressure (MPa) 69-138 69-138 Compression ratio 1.5-3 1.5-3 Linear mould shrinkage (cm/cm) 0.005-0.007 0.001-0.004

3.10.2 Applications A wide range of high performance applications have been developed for polyetherimide resins. The main markets for PEI resin and compounds are electrical/electronic applications, aircraft/aerospace interiors, food service (ovenable), high temperature lighting bezels and reflectors, medical instrument trays, institutional kitchenware and under-hood automotive applications. Automotive applications account for around a half of PEI market volume.

3.10.3 Pricing Trends Polyetherimide is one of the most expensive high performance polymers. At the end of 2000, the average price of PEI was around €9.50-10.5 per kg. PEI prices have been fairly stable in the last two years. 3.11 Polysulfone (PSU), Polyethersulfone (PES)

3.11.1 Properties PES and PSU were first commercialised by BASF in 1965. They are semi-transparent, very high temperature resistant amorphous thermoplastics that are used where the performance requirements exceed the capabilities of other engineering plastics such as polyamide, PBT and polyacetals. PES and PSU can also replace thermosets, metals and ceramics. The main features of these polymers are their high stiffness, high continuous operating temperatures, high mechanical strength, good electrical insulation properties and good dimensional stability. The continuous operating temperature of PES at 204 °C is much higher than for PSU at 174 °C. PSU and PES are hydrolysis resistant in hot water and steam at temperatures of up to 149 °C (300 °F). They also offer high chemical resistance to acidic and salt solutions, and good resistance to detergents. The main drawbacks of PSU and PES are their susceptibility to stress cracking in certain solvents and poor weathering properties.

25


PES and PSU resins are often reinforced with glass or carbon fibre for additional strength. Table 3.11 presents a comparison of the performance properties for 30% glass fibre-reinforced grades of PSU and PES. Table 3.11 Comparison of performance properties for PSU and PES PSU 20% glass PES 20% glass fibre-reinforced fibre-reinforced Elastic modulus (MPa) 7038 5693-7797 (tensile with 0.2% water content) Flexural modulus (MPa) 5865 5175-6762 Tensile strength (MPa) (at break) 116 105-138 Compression strength (at yield or break) n.a. 135-166 Hardness (Rockwell R state) 83 96-99 -6 Coefficient of thermal expansion (10 /ºC) 25 23-32 Deflection temperature (ºC) 188 210-222 Specific gravity 1.4 1.51-1.53 Water absorption (% weight increase, saturated) 0.6 1.65-2.1 Dielectric strength (V/mil) n.a. 375-500 Melting temperature (ºC) 190 200-225 Processing temperature (ºC) 349-380 333-391 Moulding pressure (MPa) Compression ratio 2-3.5 Linear mould shrinkage (cm/cm) 0.0028 0.002-0.005

3.11.2 Applications The main areas of application for these polymers are electrical and electronic engineering, chemical engineering and automotive.

3.11.3 Pricing Trends In December 2002, the price range for PSU/PES compounds was €5-8 per kg for large orders. Highly filled compounds were at the lower end of the price spectrum. PSU/PES prices have been fairly stable in recent years. 3.12 Polyphenylene Sulfone (PPSU)

3.12.1 Properties PPSU is the highest performance amorphous polymer and made by the reaction of 4,4´dichlorodiphenylsulfone (DCDPS) with bisphenol. The material is used in very demanding, high temperature applications. Heat deflection temperature is 207 °C (405 °F), it can withstand continuous exposure to heat and still absorb extremely high impact without deflecting or breaking. Its chemical resistance is higher than most other amorphous polymers.

3.12.2 Applications PPSU is most widely used in the medical market. Medical devices require high strength materials to sustain repeated sterilization, while maintaining their performance. PPSU resin offers extremely high impact strength plus excellent chemical resistance, which allows it to successfully withstand

26


repeated steam sterilization and harsh boiler additives. PPSU is also extremely resistant to stains caused by disinfecting solutions. Medical applications for PPSU include medical trays and containers, surgical instruments, a binocular ophthalmoscope and a bellow housing for anaesthetics. Other applications for PPSU are institutional food service trays and aircraft interiors. Solvay Advanced Polymers is the world’s only producer of PPSU under the Radel R trade name. Radel R resin can be injection moulded, vacuum formed or machined. 3.13 Liquid Crystal Polymers (LCP)

3.13.1 Properties Liquid crystal polymers are wholly aromatic polyester polymers that were first launched in the late 1980s. However the advance in liquid crystal polymers has taken longer than anticipated because of their high cost relative to competing materials such as PPS. A characteristic feature of LCP is the molecular structure. These polymers consist of rigid rod-like macromolecules, which align in the melt to produce liquid crystal structures. If a liquid crystal polymer melt is subjected to shear or stretching flow, as in the case of all thermoplastic processing operations, then the rigid macromolecules order themselves into fibres and fibrils, which are frozen when the melt cools. This is how the specific morphology of LCP is formed in the solid state. Table 3.12 presents a comparison of the performance properties for unfilled, 30% mineral filled and 30% glass fibre-reinforced grades of liquid crystal polymers. Table 3.12 Comparison of performance properties for LCP 30% mineral 30% glass fibreUnfilled filled reinforced Elastic modulus (MPa) 9660-19320 4071 4830-20700 (tensile with 0.2% water content) Flexural modulus (MPa) 2760-6210 9660 11454-14490 Tensile strength (MPa) (at break) 110-187 111 117-207 Compression strength (at yield or 43-132 n.a. 69-145 break) Hardness (Rockwell R state) 76 n.a. 77-87 Coefficient of thermal expansion 5-7 8-22 5-78 (10-6/ºC) Deflection temperature (ºC) 180-355 235 205-277 Specific gravity 1.35-1.84 1.63 1.6-1.67 Water absorption 0-0.01 n.a. 0.05 (% weight increase, saturated) Dielectric strength (V/mil) 800-890 n.a. 640-1000 Melting temperature (ºC) 280-421 n.a. 280-680 Processing temperature (ºC) 283-410 349-366 291-410 Moulding pressure (MPa) 7-111 28-56 7-97 Compression ratio 2.5-4 2.5-3 2.5-4 Linear mould shrinkage (cm/cm) 0.001-0.006 n.a. 0.001-0.09

LCPs have excellent dimensional stability and creep resistance, especially at very high temperatures. Continuous use temperature is about 240 °C. LCPs are highly resistant to many

27


chemicals, including concentrated acids, bases and hydrocarbons. They also display outstanding fatigue resistance and high dielectric strength performance over a very wide temperature range. In addition, LCP has substantial processing advantages over other types of high performance thermoplastics with very short cycle times. Tests have shown cycle times of < 1 second and for a production batch of 1 million components, the lower production costs of LCP far outweighed the lower material costs of for example, PA46. On the downside, LCP requires drying and careful attention to part design. LCP has low weld line strength and low toughness with fracture behaviour resembling that of wood.

3.13.2 Applications These properties make them especially suitable for precision electrical and electronic components, connecting parts in fibre optic cables, telecommunications devices, chemical processing machines, medical devices, automotive under-the-bonnet components, aerospace and machinery components. A variety of filled and reinforced products are available, including carbon, glass fibre, mineral and graphite, which allows the basic polymer to be adapted to the requirements of many areas of application. A key driver of LCP growth has been their replacement of moulded parts previously made from metal, thermosets and other advanced thermoplastics in the electronics and telecommunication industries. The trend in these markets to miniaturization and greater precision as well as demand for more heat resistant materials has also boosted demand for LCPs.

3.13.3 Pricing Trends Producers raised prices by €1.28 per kg at the end of 1999 due to cost pressure. At the end of 2002, LCP prices ranged from €20-30 per kg, depending on the grade and application. While LCP is more expensive than most other engineering plastics, the total systems cost of applying LCP is extremely favourable. LCP has very short cycle times for example, that are unmatched by any other material. 3.14 Polyetheretherketone (PEEK)

3.14.1 Properties Polyetheretherketones are high performance, semi-crystalline, melt processable materials with a unique combination of properties. PEEKs can be made by two general routes. In both cases the main difficulty is to keep the crystallisable polymer in solution. Formation of the carboxyl link by polyaroylation can be carried out in liquid HF by catalysts such as BF3. The reaction is also possible in solvents such as dichlorobenzene with an excess of AlC13 both to catalyse the reaction and to solubilise the polymer by complexing with the carbonyl group in the backbone. AlC13 must then be neutralized and extracted from the polymer. The waste stream contains organic compounds, aluminium salts and hydrochloric acid. The alternative is to form the ether link via displacement of activated halogen atoms by phenoxide anions. Hence PEEK can be manufactured from 4,4´-difluorobenzophenone and hydroquinone. The polymer is then isolated by removal of the alkali metal fluoride and the polymerisation solvent.

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A comparison of key performance properties for three different grades of PEEK polymers is summarised in Table 3.13. Table 3.13 Comparison of performance properties for PEEK Standard viscosity 30% glass fibregrade for injection reinforced moulding Relative density (crystalline) 1.32 1.49 Continuous use temperature (ºC) 260 260 Melting point (ºC) 343 343 Flexural strength at 23 ºC (MPa) 170 250 Tensile strength (MPa) (at 23 ºC) 97-100 156-157 Hardness (Rockwell R state) 126 124 -5 Coefficient of thermal expansion (10 /ºC) 4.7 2.2 Water absorption (% weight increase, saturated) 0.5 0.11 Dielectric strength (V/mil) 190 n.a.

The main features are: • • • • • • • •

High temperature performance – a continuous service temperature of up to 260 °C (500 °F) with excellent electrical and mechanical properties retained Melt temperature of 343 °C High strength and toughness over a wide range of temperatures Excellent resistance to a very wide range of organic and inorganic liquids at elevated temperatures Excellent friction and wear properties Low flammability Hydrolysis resistance Electrical properties – remains stable over a wide range of temperatures and frequencies.

PEEK can be processed on all conventional processing technologies with modification made for higher processing temperature of 350 to 400 °C. The plastification units require high temperature steel thus ensuring the components have a long lifespan. Special wear layers are only advisable for filled grades, as with all other high temperature materials. The mould temperature for injection moulding of PEEK should be in the range 180-200 °C for thin-walled, complex parts, and also filled PEEK parts. This is essential to achieve optimum crystallisation.

3.14.2 Applications PEEK, produced by Victrex plc, is the market leading polyketone. PEEK can be used in very demanding applications as a replacement for metal. Key markets are aerospace, transportation, industrial, electronics, medical and the food processing industry.

3.14.3 Pricing Trends PEEK is the most expensive of the high performance plastics. In December 2002, PEEK cost between €75-80 per kg. Prices are however more stable than most other engineering resins.

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3.15 Polyphthalamide (PPA)

3.15.1 Properties Polyphthalamide (PPA) is a semi-crystalline engineering polymer that bridges the costperformance gap between traditional engineering thermoplastics such as polycarbonate (PC), polyamides (PA), polyester (PET, PBT), acetals (POM) and higher-cost speciality polymers such as liquid crystal polymers (LCP), polyphenylene sulfide (PPS) and polyetherimide (PEI). Table 3.14 presents a comparison of the performance properties for unfilled, 15% glass fibrereinforced and 40% glass fibre-reinforced grades of PPA. Table 3.14 Comparison of performance properties for grades of PPA 15% glass 45% glass Unfilled reinforced reinforced Elastic modulus (MPa) 2415 n.a. 17250 (tensile with 0.2% water content) Flexural modulus (MPa) 2540 7521 14490-14904 Tensile strength (MPa) (at break) 73 132 263-272 Compression strength (at yield or break) n.a. 207 314 Hardness (Rockwell R state) 120 127 125 Coefficient of thermal expansion n.a. 4 8 (10-6/ºC) Deflection temperature (ºC) 118 278 275-288 Specific gravity 1.15 1.26 1.56-1.6 Water absorption 0.68 0.3 0.12 (% weight increase, saturated) Dielectric strength (V/mil) n.a. 480 560 Melt flow (gm/10 min) n.a. n.a. n.a. Melting temperature (ºC) 310 n.a. 310 Processing temperature (ºC) 302-349 302-338 302-349 Moulding pressure (MPa) 35-104 n.a. 35-104 Compression ratio 2.5-3 n.a. 1.5-3 Linear mould shrinkage (cm/cm) 0.015-0.02 0.006-0.007 0.002-0.006

PPA resin has excellent mechanical properties (e.g., strength, stiffness, fatigue, creep resistance) over a broad temperature range. Compounded grades are available in a wide range of unreinforced and reinforced formulations. Unreinforced grades are designed for general-purpose injection moulding and extrusion applications that require high surface gloss, lubricity, low warpage and toughness, along with a high level of mechanical performance at elevated temperature.

3.15.2 Applications Key market sectors for PPA are: •

Automotive: sensors and solenoids, halogen lamp sockets and fog lamp assemblies, motor end caps and housings, fuel system components, anti-lock braking system components, cooling and heating system components.

•

Electrical & electronics: high brightness LEDs, SMT electronic components, capacitor and chip carriers, heat sinks and switches

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•

Consumer and industrial markets: vacuum cleaner impellers, lawn and garden machine components, oil well drilling components, valve stems and handles (plumbing). PPA resin has a wide range of features that are beneficial in numerous consumer applications. PPA offers low thermal conductivity and good heat resistance, along with retention of strength and rigidity at elevated temperatures, to provide long-lasting service in lawn and garden tool components. The outstanding impact resistance, rigidity, and strength at elevated temperatures are key reasons for PPA being used for vacuum cleaner impellers.

•

Industrial markets: PPA resin has a wide range of features that make it useful for various industrial applications. For example, its superior impact resistance, especially at sub-zero temperatures, combined with its good chemical resistance in down-hole environments, makes it an excellent choice for oil well drilling components.

3.16 Polyarylamide

3.16.1 Properties Polyarylamide is a semi-crystalline polymer that offers very high rigidity for a polymeric material due to its glass transition temperature of approximately 85 °C (185 °F). Other key properties are its high strength (flexural strength as high as 400 MPa), very low creep (deformation of less than 1% after 1000 hours under 50 MPa), excellent surface finish, ease of processing and slow rate of water absorption. Polyarylamide has good resistance to most common solvents, aqueous solutions and engine oils. However, it is degraded by strong and concentrated mineral acids, powerful oxidants and strong bases. It is sensitive to certain organic acids and to some solutions of metallic salts. Also, it is recommended that their use should be carefully considered where the product is continuously in contact with water.

3.16.2 Applications Polyarylamide has replaced metal in many fields of application. •

Automotive and transportation: fuel pumps, cam covers, vandal-proof seats, rear-view mirror housings, clutch parts, wiper controls, oil filter bodies, headlamp control pivots, door handles, seat adjustment mechanisms, headlamp surrounds.

•

Electrical & electronics: connectors, chassis and housings for electrical and electronic equipment, sliding parts in video recorders, safety switches, disk supports in CD players, induction motor supports, telecommunications parts.

•

Domestic appliances: electric razor heads, electric iron parts, vacuum cleaner motor supports, sewing machine parts.

•

Other markets: leisure industry applications, machine tools, furniture, medical.

Solvay Advanced Polymers is the world’s only producer of polyarylamide. The Ixef resins are produced in the USA and compounded at Oodenarde, Belgium, in a 10,000 tpa compounding plant

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3.17 Polyamide-imide (PAI)

3.17.1 Properties Solvay Advanced Polymers is also the world’s only producer of polyamide-imide with its Torlon product range. Polyamide-imide is produced from a reaction between trimellitic, anhydride, and various diamines. It has a high melt viscosity and is reactive in the melt state. Accordingly, it is not possible to reduce viscosity by raising temperature. Injection moulding requires heavy duty, high rate machines, preferably using hydraulic accumulators. It is also possible to compression mould and extrude into stock shapes.

3.17.2 Applications PAI offers similar outstanding performance in extreme environments to thermosets. These resins have exceptional strength at high temperature with excellent resistance to creep, wear and chemicals, including organic solvents. PAI is also used in coating applications, due to its outstanding surface adhesion to many different materials including metals and polytetrafluoroethylene. PAI is mainly used in injection moulding applications and has been replacing metal in a range of automotive and electrical & electronics applications in recent years. Examples include: •

Precision components for demanding electronic handling operations such as test sockets that are used to protect delicate devices during robotic handling and high-speed, high-force compression into electrical test sockets.

•

Parts for military aircraft, automotive transmissions and off-highway equipment, including hydraulic parts, seal rings, washers and bushings.

•

Test sockets that are used to protect delicate devices during robotic handling.

•

Seal adapters on testing units for printed IC boards. These must be sealed to maintain test temperatures from –50 °C to 150 °C (–58 °F to 302 °F), and PAI can provide better dimensional stability for a tighter seal fit and offer longer part life than traditional materials.

3.18 Developing Materials Several new types of resin have been developed in recent years.

3.18.1 Cyclic Olefin Copolymers Cyclic olefin copolymers (COC) are an amorphous glass clear copolymer of ethylene and norbornene, made via proprietary metallocene catalysts. The material was developed by Ticona GmbH and is now being marketed under the Topas trade name. The principal performance properties of COC polymers are: • • • • 32

low density high transparency extremely low water absorption very high water vapour barrier properties


• • • • •

graded heat distortion temperature (HDT/B) up to 170 °C high rigidity, strength and hardness good resistance to acids and alkalis very good electrical insulating properties very good processability/flow properties

Topas is mainly suitable for the production of transparent parts. Main areas of application development include: • • • • • • •

medical devices and diagnostic disposables (prefillable syringes, cuvettes, bottles, microplates, microstructured parts) lighting sector (lenses, components) optics (lenses, sensors, displays, light guides) optical data storage speciality films primary packaging of pharmaceuticals, blister packs, shrink caps, sleeves and stand-up pouches blends of Topas COC with a variety of polyolefins for packaging films, etc.

Ticona is initially developing injection moulding and film packaging applications for COC. Production of COC is located at a 30,000 tpa plant at Oberhausen, Germany.

3.18.2 Syndiotactic Polystyrene Dow Chemicals Questra syndiotactic polystyrene is a new semi-crystalline engineering polymer. The main performance properties of Questra include high heat resistance, lightweight, electrical properties, chemical resistance and processability. These polymers are impact, chemical and glycol resistant as well as ideal for medium and high heat environments. Grades include mineral and glass fibre-reinforced, medium heat, impact resistance, high heat and chemical resistance. Questra resins are used predominantly in automotive applications such as chassis/powertrain, electrical and coolant systems. Syndiotactic PS competes mainly with PBT, polycarbonate and ABS.

3.18.3 Cyclic Butylene Terephthalate (CBT) Dow Automotive entered an alliance with Cyclics to develop cyclic butylene terephthalate (CBT) resins for automotive applications. Research will focus on a number of automotive structural composites, including vertical and horizontal body panels and truck boxes. The companies expect that components will be able to be formed using a number of techniques, including compression and injection moulding. CBT resins will contribute to lighter weight vehicle design and be recyclable.

3.18.4 Copolycarbonate In 1996, Dow Plastics introduced a new family of advanced copolycarbonate resins, which provide a cost-effective alternative to existing high-performance amorphous polymers. The ‘Inspire’ advanced copolycarbonate resins offer equivalent or better high-heat performance than other highheat amorphous polymers at a cost advantage. Generally, manufacturers and moulders are forced to choose between lower-cost engineering thermoplastics, which, in some cases, do not provide acceptable heat performance, and advanced polymers, which provide acceptable high-heat performance, but at a significant price premium. ‘Inspire’ resins provide an alternative for manufacturers who require the heat performance associated with advanced polymers (e.g.,

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polysulfone, polyetherimide and polyethersulfone), but who are looking for a more cost-effective solution. The new advanced copolycarbonate resins are a copolymer of bisphenol A and bishydroxyphenol fluorene (BHPF), a fluorenyl derivate. Among the primary features of Inspire resins are equivalent or better heat and inherent ignition resistance without the use of halogens, improved processability, and superior transparency and optical properties when compared to advanced polymers.

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4 Global Demand for Engineering and High Performance Plastics 4.1 Total World Demand

4.1.1 Economic Background Table 4.1 shows real GDP growth rates for the period 2000-2004 for major world regions. Table 4.1 Actual and forecast growth in real GDP by major world region (% change) 2000 2001 2002 2003 2004 USA 3.8 0.3 2.3 2.6 3.6 Japan 2.6 -0.3 -0.7 0.8 0.9 European Union 3.4 1.6 0.9 1.9 2.7 Source: OECD The world economy experienced a sharp downturn in 2001 with the main markets for engineering and high performance plastics such as electronics, telecommunications and automotive suffering more than other sectors. Total GDP of the European Union countries increased by only 1.6% in 2001 against 3.4% in the previous year. US economic growth fell from 3.8% in 2000 to just 0.3% in 2001, while the Japanese economy contracted by 0.3%. The US economy recovered in 2002 to register growth of 2.3% but the European Union and Japan experienced a further deterioration in their economic growth. GDP in the EU rose by only 0.9% in 2002 and Japan experienced a further reduction of 0.7%. The latest OECD projections indicate a slow and modest recovery in economic growth during the next two years. The US economy is forecast to grow by 2.6% in 2003 and 3.6% in 2004. The European Union is expected to grow by 1.9% in 2003 and then by 2.7% in 2004. Japan will continue to show the lowest growth rates of the world’s major economic region with growth forecasts of just 0.8-0.9% during the next two years. However, even these forecasts may be optimistic given the dampening effect that the war in Iraq is having on world economic growth.

4.1.2 The Total World Market Table 4.2 shows world consumption of engineering and high performance plastics for the years 2000, 2002 and forecasts for 2007. Table 4.2 World consumption of engineering and high performance plastics, 2000, 2002 and forecast for 2007 (000 tonnes) CAGR 2000 2002 2007 2002-2007 % Polyamide 2,002 1,950 2,430 4.5 ABS 4,736 4,667 5,280 2.5 PBT 484 477 623 5.5 POM 609 604 717 3.5 PMMA 986 989 1,174 3.5 Polycarbonate 1,726 1,714 2,637 9.0 PPS 53 50 77 9.0 Polyetherimide 15 15 24 10.5 PPO/PPE 368 353 461 5.5 PSU/PES 23 23 37 10.5 LCP 18 18 34 13.5 PEEK 1.4 1.3 2.4 13.5 TOTAL 11,022 10,860 13,497 4.5 35


In 2002, total world consumption of engineering and high performance plastics is estimated at 10,860,000 tonnes. This represents approximately 7% of total world plastics consumption. Demand for engineering and high performance plastics has outperformed most other plastic types in recent years. During the period 1995-2000, the average growth in consumption of engineering and high performance plastics was around 8.5% per annum compared to 6.5% per annum growth in standard thermoplastics. The principal drivers of demand for engineering and high performance plastics are replacement of traditional materials such as metal and thermosets, development of new applications and strong growth in key end user markets such as electronics, telecommunications and automotive. The downturn in world economic growth and collapse of the IT/telecom sectors led to a reduction in demand for engineering and high performance plastics in 2001. World consumption fell by 6% from just over 11,000,000 tonnes in 2000 to 10,400,000 tonnes in 2001. Demand recovered slightly in 2002, although total world consumption remains below the 2000 level. In 2007, world consumption of engineering and high performance plastic is projected at 13,497,000 tonnes. This represents a compound annual growth rate of 4.5% for the period 2003-2007. The projected growth rates for all polymer types are lower than were experienced during the boom time of the late 1990s. This is because of the sharp downturn in world economic activity that has occurred since 2001, and the uncertain prospects for any substantial recovery in demand for at least another couple of years. Furthermore, major application areas for engineering plastics in particular, are becoming mature, and therefore the opportunities for further material substitution are more restricted. High performance plastics such as PEEK, LCP and the sulfone-based polymers will grow at double-digit rates during the next five years, as the potential for material substitution is much greater for these polymers. In contrast, the more mature engineering plastics such as ABS, polyacetal and acrylics, will show the lowest rates of growth during the next five years. The most widely used engineering plastic is ABS with total world consumption of 4,667,000 tonnes in 2002. Polyamide is the second largest category with total consumption of 1,950,000 tonnes, followed by polycarbonate with 1,714,000 tonnes. Acrylics, polyacetal and PBT are also well-established and high volume engineering plastics. PPO/PPE blends are the most widely used of the high performance plastics with market tonnage of 353,000 tonnes in 2002. It should be noted however that this figure represents PPO/PPE compounds with other polymers such as polystyrene and polyamide, which vastly overstates the actual PPO/PPE resin content. PPS is the most widely used of the sulfone polymer types with total world consumption of 50,000 tonnes in 2002. PSU/PES market tonnage is 23,000 tonnes. Liquid crystal polymers and polyetherketones are the smallest groups in terms of market volume, but are the most costly polymers and are growing at the fastest rate. Table 4.3 shows consumption of engineering and high performance plastics by world region for the period 1999-2002. North America is the largest consumer of engineering and high performance plastics with total demand of 3,540,000 tonnes in 2002. Asia Pacific, excluding Japan, is the next most important user with consumption of 3,459,000 tonnes. The market share of Asia Pacific can be explained by the high concentration of ABS production and consumption in the region, and particularly in China. Western Europe with 2,548,000 tonnes is the third largest consuming region, followed by Japan with 1,116,000 tonnes.

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Table 4.3 Consumption of engineering and high performance plastics by world region, 1999-2002 (000 tonnes) 1999 2000 2001 2002 Western Europe 2,373 2,624 2,440 2,548 North America 3,653 3,743 3,463 3,540 Japan 1,144 1,194 1,093 1,116 Rest of Asia Pacific 2,932 3,265 3,223 3,459 Rest of World 172 196 184 196 TOTAL 10,274 11,022 10,403 10,860

Table 4.4 shows the percentage share of engineering and high performance plastic consumption by world region for the period 1999-2002. Table 4.4 Percentage share of engineering and high performance plastic consumption by world region, 1999-2002 1999 2000 2001 2002 Western Europe 23.1% 23.8% 23.5% 23.5% North America 35.6% 34.0% 33.3% 33.3% Japan 11.1% 10.8% 10.5% 10.5% Rest of Asia Pacific 28.5% 29.6% 31.0% 31.0% Rest of World 1.7% 1.8% 1.8% 1.8%

Asia Pacific, excluding Japan, is increasing its share of engineering and high performance plastics consumption faster than any other region. Between 1999 and 2002, China and other Pacific Rim countries, raised their share of total consumption from 28.5% to 31.0%. This is due mainly to the growing trend for automotive and electrical and electronics companies to shift manufacturing facilities to lower cost economies. During the same period the shares of both Japan and North America declined. This is largely explained by the economic downturn and growing market maturity for many key applications. The share of Western Europe has also increased slightly during the last three years to reach 23.5% in 2002. Other world regions such as Latin America account for a very small percentage of total world consumption, although their share is growing. Table 4.5 presents world engineering and high performance plastics volumes by market sector, 1999-2002. Table 4.5 World engineering and high performance plastics by market sector, 1999-2002 (000 tonnes) 1999 2000 2001 2002 Automotive 2,711 2,929 2,739 2,851 Electrical & Electronics 2,457 2,621 2,438 2,538 Consumer products 1,889 2,108 2,046 2,153 Industrial 1,612 1,661 1,562 1,636 Other 1,605 1,701 1,618 1,681 TOTAL 10,274 11,022 10,403 10,860

Automotive, electrical & electronics and telecommunications together account for around a half of total consumption of engineering and high performance plastics in 2002. Consumer products,

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which include domestic and electrical appliances and power tools, are the next most important market, followed by industrial and ‘other markets’. Table 4.6 shows the percentage share of world engineering and high performance plastic consumption by market sector for the period 1999-2002. Table 4.6 Percentage share of engineering and high performance plastic consumption by market sector, 1999-2002 1999 2000 2001 2002 Automotive 26.4% 26.6% 26.3% 26.3% Electrical & Electronics 23.9% 23.8% 23.4% 23.4% Consumer products 18.4% 19.1% 19.7% 19.8% Industrial 15.7% 15.1% 15.0% 15.1% Other 15.6% 15.4% 15.5% 15.5%

Growth in the E&E sector was the principal driver of plastics demand during the latter part of the 1990s. However, the slowdown in the electronics and telecom sectors has resulted in lower demand for engineering plastics, and hence a declining share of the total market since 1999. The share of the automotive industry has remained steady during the last three years, but industrial markets have declined. The fastest growing sector has been consumer products with an increase in share from 18.4% to 19.8% between 1999 and 2002. The main reason for the better performance of consumer products has been the greater resilience of consumer spending in the face of an economic downturn. 4.2 Demand Trends by Polymer Type, 1999-2002

4.2.1 Polyamide (PA) Table 4.7 shows world consumption of polyamide by sector for the period 1999-2002. Table 4.7 World consumption of polyamide by sector for the period, 1999-2002 (000 tonnes) 1999 2000 2001 2002 Automotive 638 686 634 660 Electrical & Electronics 441 474 442 465 Consumer products 201 216 200 215 Industrial 140 149 137 146 Other 461 477 446 464 TOTAL 1881 2002 1859 1950

In 2002, total world consumption of polyamide was 1.95 million tonnes. About 90% of total consumption is PA6 and PA66, with roughly two-thirds PA6, and one-third PA66. The remaining 10% comprises PA11, PA12 and various copolymers. Between 1998 and 2000, the average annual growth in world polyamide resin consumption was 8.5%. In 2001, world demand was down by just over 7% due to the downturn in major markets such as automotive and E&E. Demand recovered by an estimated 4.9% in 2002 with the Asia Pacific region registering the fastest growth. Western Europe grew in line with the world market, while consumption in the USA and Japan grew more slowly. For the period 2002-2007, world polyamide consumption is projected to increase at a compound annual growth rate of between 4-5%, which is somewhat lower than recent historical growth trends. Lower world economic growth and maturing markets are the main factors restraining future growth

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projections. Market growth will however be sustained by continuous product improvement, new applications development and new technologies, with the automotive sector in particular, expected to be a major driver. Table 4.8 shows percentage share of total world polyamide consumption by region for the period 1999-2002. Table 4.8 Percentage share of world polyamide consumption by region, 1999-2002 1999 2000 2001 2001 Western Europe 36.9% 37.5% 38.0% 37.9% North America 32.4% 31.0% 30.1% 29.6% Japan 8.7% 8.6% 8.4% 8.2% Rest of Asia Pacific 14.8% 15.5% 16.1% 16.8% Rest of World 7.2% 7.5% 7.4% 7.4%

Europe is the largest consumer of polyamide with 37.9% of total world consumption in 2002. North America consumes 29.6%, followed by the ‘Rest of Asia Pacific’ (16.8%), Japan (8.2%) with the rest of the world accounting for the remaining 7.4%. Asia, except for Japan, is growing its share of world consumption, while Japan and the USA have witnessed a small reduction in their shares since 1999. Table 4.9 shows percentage share of total world polyamide consumption by market sector for the period 1999-2002. Table 4.9 Percentage share of world polyamide consumption by market sector, 1999-2002 1999 2000 2001 2002 Automotive 33.9% 34.3% 34.1% 33.8% Electrical & Electronics 23.4% 23.7% 23.8% 23.8% Consumer Products 10.7% 10.8% 10.8% 11.0% Industrial 7.4% 7.4% 7.4% 7.5% Other 24.5% 23.8% 24.0% 23.8%

In terms of end user markets, the automotive sector is the major user of polyamide with 33.8% of total world consumption, followed by electrical and electronics with 23.8%, consumer products 11% and industrial products 7.5%. ‘Other markets’ with 23.8% of total consumption are quite significant users of polyamide. The main markets included are film and sheet, plus stock shapes.

4.2.2 Polybutylene Terephthalate (PBT) Table 4.10 shows world consumption of PBT by sector for the period 1999-2002. Table 4.10 World consumption of PBT by sector for the period, 1999-2002 (000 tonnes) 1999 2000 2001 2002 Automotive 181 200 188 195.5 Electrical & Electronics 140 159 147 154 Consumer/Recreation 59 64 64 68 Industrial 36 39 34 37 Other 19 22 21 22 TOTAL 435 484 454 476.5

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In 2002, total world consumption of PBT resin was 476,000 tonnes. Assuming a filler content of approximately 45%, this equates to around 700,000 tonnes of PBT compounds. Between 1995 and 2000, the average annual growth in world PBT resin consumption was just over 5.0%. In 2000, demand for PBT increased considerably worldwide with growth at 11.3%, due in particular to strong growth in key end user markets such as automotive, telecommunications and electrical goods. World demand fell however by 6-7% in 2001 due to the downturn in automotive and the E&E sector. Consumption of PBT recovered in 2002 by 5.0% with the Asia Pacific region registering the fastest growth. Growth rates in Western Europe and North America were between 45% in 2002, while demand in Japan increased by just over 3.0%. For the period 2002-2007, world PBT consumption is projected to increase at a compound annual growth rate of between 5-6%, which is about in line with recent historical growth trends. Market growth will be bolstered by further product improvement, new applications development and new technologies, with the automotive sector in particular, continuing to be a key driver. Table 4.11 shows percentage share of total world PBT consumption by region for the period 19992002. Table 4.11 Percentage share of world PBT consumption by region, 1999-2002 1999 2000 2001 2001 Western Europe 24.4% 24.4% 25.6% 25.6% North America 34.3% 33.1% 32.4% 32.1% Japan 20.0% 19.8% 19.8% 19.5% Rest of Asia Pacific 19.5% 20.7% 20.5% 21.0% Rest of World 1.8% 2.1% 1.8% 1.8%

North America is the largest consumer of PBT with 32.1% of total world consumption in 2002. Europe consumes 25.6%, Asia, excluding Japan, 21.0% and Japan 19.5%. The rest of the world consumes the remaining 1.8%. Asia and Europe are growing their share of total world PBT consumption, while Japan and the USA have witnessed a small reduction in share since 1999. Table 4.12 shows percentage share of total world PBT consumption by market sector for the period 1999-2002. Table 4.12 Percentage share of world PBT consumption by market sector, 1999-2002 1999 2000 2001 2002 Automotive 41.6% 41.3% 41.4% 41.0% Electrical & Electronics 32.2% 32.9% 32.4% 32.3% Consumer/Recreation 13.6% 13.2% 14.1% 14.3% Industrial 8.3% 8.1% 7.5% 7.8% Other 4.4% 4.5% 4.6% 4.6%

In terms of end user markets, the automotive sector is the major user of PBT accounting for 41.0% of total world consumption, followed by electrical and electronics with 32.3%, consumer/recreation products 14.3% and industrial products 7.8%. ‘Other markets’ account for the remaining 4.6% of demand. Consumer and recreation products have increased their share of total demand in the last two years because these markets have been more resilient in the face of the global economic downturn.

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4.2.3 Acrylonitrile-Butadiene-Styrene (ABS) Table 4.13 shows world consumption of ABS by sector for the period 1999-2002. Table 4.13 World consumption of ABS by sector for the period 1999-2002 (000 tonnes) 1999 2000 2001 2002 Automotive 1066 1157 1105 1153 Electrical & Electronics 1160 1219 1132 1167 Consumer Products 1083 1170 1115 1169 Industrial 462 436 416 425 Other 721 754 728 753 TOTAL 4492 4736 4496 4667

In 2002, total world consumption of ABS was 4.67 million tonnes. Between 1990 and 2000, the average annual growth in world ABS resin consumption was 7.0%. In 2001, demand fell by 5.1% due to the downturn in major markets such as automotive, consumer products and E&E. World demand recovered by 3.8% in 2002 with the Asia Pacific region, excluding Japan, showing the fastest growth. Demand in Western Europe and North America grew by around 1% in 2002. For the period 2002-2007, world ABS consumption is projected to increase at a compound annual growth rate of around 2-3%, which is somewhat lower than recent historical growth trends. The European and North American markets are very mature users of ABS and consumption will grow in line with real GDP. China on the other hand, is a fast developing market and will increase consumption at an annual rate of around 5-6%. Table 4.14 shows percentage share of total world ABS consumption by region for the period 19992002. Table 4.14 Percentage share of world ABS consumption by region, 1999-2002 1999 2000 2001 2002 Western Europe 14.3% 14.8% 14.0% 13.6% North America 37.3% 35.2% 35.2% 34.3% Japan 9.2% 8.9% 8.7% 8.6% Rest of Asia Pacific 39.2% 41.2% 42.1% 43.5%

Asia Pacific, and most notably China, is the largest consumer of ABS with 43.5% of total world consumption in 2002. With consumption of around 2.0 million tonnes in 2002, China is the leader in ABS processing by far. In addition to its domestic production of 600,000 tpa, China has had to import in excess of 1.3 million tonnes of ABS, mostly from Taiwan (45%), Korea and Japan. Over the next few years, the annual growth rate of approximately 8% is expected to lead to a further widening of the demand gap to as much as 1.6 million tonnes by 2005, despite the rising domestic capacities. North America consumes 34.3% of world ABS production, Europe 13.6%, and Japan the remaining 8.6%. While China is growing its share of world ABS consumption, Japan, Europe and the USA have witnessed a small reduction in their shares since 1999. Table 4.15 shows percentage share of total world ABS consumption by market sector for the period 1999-2002.

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Table 4.15 Percentage share of world ABS consumption by market sector, 1999-2002 1999 2000 2001 2002 Automotive 23.7% 24.4% 24.6% 24.7% Electrical & Electronics 25.8% 25.7% 25.2% 25.0% Consumer products 24.1% 24.7% 24.8% 25.0% Industrial 10.3% 9.2% 9.3% 9.1% Other 16.1% 15.9% 16.2% 16.1%

In terms of end user markets, the electrical & electronics sector and consumer products sector are the largest consumers of ABS, each with around a quarter of total demand. The main application for ABS in these market sectors is equipment housings for consumer appliances and business equipment. The automotive sector is the next most important user of ABS with 24.7% of total world consumption, followed by ‘other markets’ with 16.1% and industrial 9.1%.

4.2.4 Polycarbonate (PC) Table 4.16 shows world consumption of polycarbonate by sector for the period 1999-2002.

Table 4.16 World consumption of polycarbonate by sector for the period 1999-2002 (000 tonnes) 1999 2000 2001 2002 Automotive 290 314 269 283 Electrical & Electronics 402 431 401 426 Consumer products 358 458 471 497 Medical 308 328 302 323 Other 168 195 178 185 TOTAL 1526 1726 1621 1714

World consumption of polycarbonate amounted to 1.7 million tones in 2002. Polycarbonate has been one of the ‘star’ performers’ in the engineering plastics sector in recent years. Between 1995 and 2000, the average annual growth in world polycarbonate consumption was 15-20%. In 2001 however, there was a major contraction in demand for polycarbonate with world consumption falling by 6-7%. This was largely attributable to the downturn in major markets such as automotive, construction and E&E, but also to relatively high stocks that converters had built up in previous years. The US market saw a decline in polycarbonate consumption of over 16% in 2001, with Japanese consumption lower by over 14%. The decline in Europe was more modest at just over 6.5%, while ‘other Asia Pacific’ countries showed demand growth in excess of 5%. In 2002, world demand recovered by 5.7% with the Asia Pacific region and the ‘rest of the world’ registering the fastest growth. Western European demand grew by 6.3%, while consumption growth in the USA and Japan was much more modest. For the period 2002-2007, world polycarbonate consumption is projected to increase at a compound annual growth rate of between 8-10%, compared with 15-20% achieved in the period 1995-2000. Nevertheless, this growth projection remains above average for the engineering plastics sector. While lower world economic growth and maturing markets will have a dampening effect on future growth, demand will be bolstered by continuous product development, new applications development and fast growing end user markets. Optical media, particularly DVDs, will continue to be the main driving force of the market for the foreseeable future. There are also good growth prospects for PC/ABS blends because of their inherent flame retardant properties, medical devices and automotive glazing systems.

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Table 4.17 shows percentage share of total world polycarbonate consumption by region for the period 1999-2002. Table 4.17 Percentage share of world polycarbonate consumption by region, 1999-2002 1999 2000 2001 2002 Western Europe 26.2% 27.8% 27.6% 27.8% North America 30.9% 29.6% 26.4% 25.8% Japan 9.6% 9.3% 8.5% 8.2% Rest of Asia Pacific 31.5% 31.3% 35.2% 35.8% Rest of World 1.9% 2.1% 2.3% 2.5%

Asia is the largest consumer of polycarbonate with 44% of total world consumption in 2002. Japan is included in this figure and accounts for 8.2% of world consumption. Europe accounts for 27.8%, followed by North America with 25.8% and ‘rest of the world’ with 2.5%. The countries of the Pacific Rim and China are rapidly increasing their share of world polycarbonate production and consumption with significant capacity building taking place in this region. Western Europe, Japan and North America are seeing a decline in their share of production and consumption. Table 4.18 shows percentage share of total world polycarbonate consumption by market sector for the period 1999-2002. Table 4.18 Percentage share of world polycarbonate consumption by market sector, 1999-2002 1999 2000 2001 2002 Automotive 19.0% 18.2% 16.6% 16.5% Electrical & Electronics 26.3% 25.0% 24.7% 24.9% Consumer products 23.5% 26.5% 29.1% 29.0% Industrial 20.2% 19.0% 18.6% 18.8% Other 11.0% 11.3% 11.0% 10.8%

Consumer products such as optical data storage media and appliances, is the major user of polycarbonate with 29% of total world consumption, followed by electrical and electronics with 24.9%, industrial 18.8% and automotive 16.5%. ‘Other markets’, comprising packaging, medical optical lenses and sports equipment, with 10.8% of total consumption, account for the remainder.

4.2.5 Polyoxymethylene (POM) Table 4.19 shows world consumption of POM by sector for the period 1999-2002. Table 4.19 World consumption of POM by sector for the period 1999-2002 1999 2000 2001 2002 Automotive 182.5 194 189 192 Electrical & Electronics 132.5 142 136 139 Consumer products 117 124 122 126 Industrial 98 103 97 98 Other 43 46.5 47 49 TOTAL 573 609.5 591 604

In 2002, total world consumption of polyacetal was 604,000 tonnes. The share of copolymers has increased from 75% in 1997 to just over 78% in 2001.

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Consequently, the share of homopolymers has dropped from 25% in 1997 to 22% in 2001. World POM consumption has been growing at a lower rate than the engineering plastics market as a whole. Between 1995 and 2000, the average annual growth in world polyacetal consumption was 6.0%. In 2001, demand was lower by 3% due to the downturn in major markets such as automotive and E&E. Demand recovered by an estimated 2.2% in 2002 with the Asia Pacific region registering the fastest growth. Western Europe and North America grew in line with world market demand as a whole, with consumption growth in Japan continuing to fall. In Japan, domestic demand for POM has been on a downward path since the early 1990s. The main reason for reduced demand is the shift in automotive and electrical goods production from mainland Japan to other Asian countries where production costs are lower. For the period 2002-2007, world polyacetal consumption is projected to increase at a compound annual growth rate of between 3-4%, which is somewhat lower than recent historical growth trends. The more mature North American and European markets will grow at a lower rate while China and other developing Asian economies will grow POM consumption by around 7% per annum. POM consumption in Japan will continue to stagnate. Future demand for POM will, however, be sustained by product and applications development. In automotive markets, POM is expected to make further inroads in under-the-bonnet, electrical systems and interior applications. The use of POM for car interior applications for example, should be boosted by the development of odour-free products, which overcome the problem of odour emissions previously associated with use of polyacetal inside the car. Other interesting product developments expected to encourage greater use of POM in the car include the use of so-called outsert technology (metal-plastic composites), and the combination of POM with injection moulded ‘soft’ components, including NBR rubber and polyester elastomers. Another interesting growth market for POM is medical technology, where new applications are being found. For example POM is being used for production of housings in needleless injection systems and also for inhaler casings. Consumer products and sports equipment markets also have positive growth potential. Table 4.20 shows percentage share of total world polyacetal consumption by region for the period 1999-2002. Table 4.20 Percentage share of world POM consumption by region, 1999-2002 1999 2000 2001 2002 Western Europe 28.8% 29.5% 29.6% 29.6% North America 23.7% 23.5% 23.0% 23.0% Japan 15.7% 13.8% 13.9% 13.1% Rest of Asia Pacific 31.8% 33.1% 33.5% 34.3%

Asia is the largest consumer of polyacetal with 47.4% of total world consumption in 2002, with Japan accounting for 13.1%. Europe is the next most important consumer of polyacetal with 29.6% of total world consumption, with North America accounting for the remaining 23% of demand. The share of Asia Pacific countries, excluding Japan, will continue to grow during the next five years given the additional production capacity that is planned to come on stream. Table 4.21 shows percentage share of total world polyacetal consumption by market sector for the period 1999-2002.

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Table 4.21 Percentage share of world POM consumption by market sector, 1999-2002 1999 2000 2001 2002 Automotive 31.8% 31.8% 32.0% 31.8% Electrical & Electronics 23.1% 23.3% 23.0% 23.0% Consumer products 20.4% 20.3% 20.6% 20.9% Industrial 17.1% 16.9% 16.4% 16.2% Other 7.5% 7.6% 8.0% 8.3%

In terms of end user markets, the automotive sector is the major user of polyacetal with 31.8% of total world consumption, followed by electrical and electronics with 23.0%, consumer products 20.9% and industrial products 16.2%. ‘Other markets’, which include medical devices, account for the remaining 8.3% of total demand.

4.2.6 Polymethyl Methacrylate (PMMA) Table 4.22 shows world consumption of PMMA by sector for the period 1999-2002. Table 4.22 World consumption of PMMA by sector for the period 1999-2002 (000 tonnes) 1999 2000 2001 2002 Automotive 137 147 136 144 Electrical & Electronics 48 51 48 50.5 Consumer products 47 52 51 54 Industrial 530 565 538 567 Other 159 171 163 173 TOTAL 921 986 936 988.5

Total world consumption of PMMA was 988,000 tonnes in 2002. Cast sheet, extrusion sheet and moulding compounds each account for roughly a third of total production. Between 1997 and 2000, the average annual growth in PMMA consumption for the mature markets of Western Europe and the USA was only 2-3%. In contrast, China and the Pacific Rim countries have witnessed much higher growth. Demand for PMMA is expanding rapidly in these countries, especially in the areas of signboards, light fixture covers, automotive tail-light covers and aquarium tanks. In 2001, global PMMA demand was down by just over 5% due to a slowdown in major markets such as construction and lighting and the automotive industry. Consumption fell sharpest in Japan, Europe and North America. Global demand recovered by an estimated 5-6% in 2002, with Europe experiencing the fastest growth. China and Pacific Rim countries were not far behind. North American and Japanese demand showed only a small recovery in 2002. For the period 2002-2007, world PMMA consumption is projected to increase at a compound annual growth rate of between 3-4%. The more mature North American and European markets will grow at around their historical trend rate of 2-3% per annum, while China and other developing Asian economies will show much higher growth in PMMA consumption. In contrast, the Japanese market will continue to stagnate. Table 4.23 shows percentage share of total world PMMA consumption by region for the period 1999-2002.

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Table 4.23 Percentage share of world PMMA consumption by region, 1999-2002 1999 2000 2001 2002 Western Europe 27.7% 28.4% 27.2% 28.4% North America 43.3% 42.6% 42.9% 41.9% Japan 14.3% 13.8% 13.0% 12.5% Rest of Asia Pacific 14.7% 15.2% 16.8% 17.1%

North America is the largest consumer of PMMA with 41.9% of total world consumption in 2002. Europe is second largest on 28.4%, followed by Asia with 19.6%. As with other polymer types, the share of Asia Pacific countries, excluding Japan, will continue to grow during the next five years given the additional production capacity that is planned to come on stream in these countries. Table 4.24 shows percentage share of total world PMMA consumption by market sector for the period 1999-2002. Table 4.24 Percentage share of world PMMA consumption by market sector, 1999-2002 1999 2000 2001 2002 Automotive 14.9% 14.9% 14.5% 14.6% Electrical & Electronics 5.2% 5.2% 5.1% 5.1% Consumer products 5.1% 5.3% 5.4% 5.5% Industrial 57.5% 57.3% 57.5% 57.4% Other 17.3% 17.3% 17.4% 17.5%

The industrial sector, which includes construction and lighting applications, is the major user of PMMA with 57.4% of total world consumption. The second largest user of PMMA is the automotive market with 14.6% of world consumption, followed by consumer products and electrical and electronics. ‘Other markets’, with 17.5% of total demand, include optical media, packaging and medical devices. The optical media sector is expected to show the most exciting growth rates for the sector over the coming years.

4.2.7 Polyphenylene Oxide (Ether) Blends (PPO and PPE) Table 4.25 shows world consumption of PPO/PPE blends by sector for the period 1999-2002. Table 4.25 World consumption of PPO/PPE blends by sector for the period 1999-2002 (000 tonnes) 1999 2000 2001 2002 Automotive 180 191 181 185 Electrical & Electronics 99 106 96 99 Consumer/Recreation 19 19 18 18 Industrial 32.5 35 32.5 34 Other 17 17 17 17 TOTAL 347.5 368 344.5 353

In 2002, total world consumption of PPO/PPE blends was estimated at 353,000 tonnes. Between 1995 and 2000, the global average annual growth rate for PPO/PPE blends was 6%. Europe has shown the strongest growth with particularly high demand from the automotive sector. North American market growth has been slower because of higher penetration rates in key applications in the automotive applications market, such as body panels.

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In 2001, global PPO/PPE demand was down by 6.4% due to a downturn in major markets such as automotive and E&E. Demand fell the sharpest in North America (-7.1%) and Japan (-6.7%). Global demand went through a modest recovery in 2002, with an estimated growth rate of 2.5%. For the period 2002-2007, world PPO/PPE blend consumption is projected to increase at a compound annual growth rate of between 5-6%. The more mature North American market will grow at much slower rate, while Europe will continue to grow at around the historical trend rate of 6% per annum. China and other developing Asian economies, which currently have very low consumption of PPO/PPE, will show the highest rates of growth. Table 4.26 shows percentage share of total world PPO/PPE consumption by region for the period 1999-2002. Table 4.26 Percentage share of world PPO/PPE consumption by region, 1999-2002 1999 2000 2001 2002 Western Europe 26.0% 26.1% 26.6% 26.6% North America 50.4% 49.5% 49.1% 49.0% Asia 23.6% 24.5% 24.4% 24.4%

North America is the largest consumer of PPO/PPE blends with 49% of total world consumption in 2002. Europe is the second largest market with 26.6%, followed by Japan with 24.4%. Table 4.27 shows percentage share of total world PPO/PPE consumption by market sector for the period 1999-2002. Table 4.27 Percentage share of world PPO/PPE consumption by market sector, 1999-2002 1999 2000 2001 2002 Automotive 51.8% 51.9% 52.5% 52.4% Electrical & Electronics 28.5% 28.8% 27.9% 28.0% Consumer/Recreation 5.5% 5.2% 5.2% 5.1% Industrial 9.4% 9.5% 9.4% 9.6% Other 4.9% 4.6% 4.9% 4.8%

Automotive is by far the largest user of PPO/PPE compounds with 52.4% of total world consumption. The second largest user is the E&E sector with 28% of world consumption, followed by industrial and consumer products. ‘Other markets’ account for the remaining 4.8% of world consumption. The automotive sector is expected to remain the fastest growing market for PPO/PE blends. Product development has been an important driver in the use of these materials in the past with new and improved grades being introduced to the market. PPO/PPE will continue to replace metal and other plastics in automotive applications during the next five years.

4.2.8 Polyphenylene Sulfide (PPS) Table 4.28 shows world consumption of PPS by sector for the period 1999-2002. In 2002, total world consumption of PPS compounds was just over 50,000 tonnes. Assuming a filler content of 45%, this is equivalent to polymer consumption of approximately 27,500 tonnes. Between 1995 and 2000, the average annual growth in world PPS consumption was 11-12%. However, demand was lower by nearly 9% in 2001 due to the downturn in major markets such as automotive and E&E. The small appliances sector has been more resilient. Market growth

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recovered in 2002 with global growth estimated at 4.2%. Most of the renewed purchasing is probably attributable to restocking by converters rather than an upturn in final demand. Table 4.28 World consumption of PPS by sector for the period 1999-2002 (000 tonnes) 1999 2000 2001 2002 Automotive 25 27 25 26 Electrical & Electronics 13 14 13 13 Consumer products 3 3 3 3 Industrial 5 6 5 6 Other 3 3 3 3 TOTAL 48 53 48 50

For the period 2002-2007, world consumption of PPS compounds is projected to increase at a compound annual growth rate of between 8-10%. The more mature North American and European markets will grow at a much slower rate, while China and other developing Asian economies will show the highest rates of growth. Table 4.29 shows percentage share of total world PPS consumption by region for the period 19992002. Table 4.29 Percentage share of world PPS consumption by region, 1999-2002 1999 2000 2001 2002 Western Europe 19% 19% 19% 19% North America 26% 26% 25% 25% Japan 38% 38% 39% 37% Rest of Asia Pacific 17% 17% 17% 18%

The Asia Pacific region, including Japan, is the largest consumer of PPS with 55% of total world consumption in 2002. Japan is the highest consumer with 37% of total world PPS consumption, but South Korea and Taiwan are becoming more important. North America consumes 25% and Europe the remaining 19%. Table 4.30 shows percentage share of total world PPS consumption by market sector for the period 1999-2002. Table 4.30 Percentage share of world PPS consumption by market sector, 1999-2002 1999 2000 2001 2002 Automotive 51% 51% 51% 51% Electrical & Electronics 27% 27% 27% 27% Consumer Products 5% 5% 5% 5% Industrial 11% 11% 11% 11% Other 6% 6% 6% 6%

The automotive sector is the major user of PPS with 51% of total world consumption, followed by electrical and electronics with 27%. ‘Other industries’ account for the remaining 22% of world demand. There is still excellent growth potential for PPS in core markets such as automotive and E&E. PPS will continue to replace metals and thermosets and challenge other engineering plastics, especially given the higher heat requirements in automotive under-the-bonnet and electrical applications. New product and applications development will also play an important role in sustaining future market growth.

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4.2.9 Polyetherimide (PEI) Table 4.31 shows world consumption of polyetherimide by sector for the period 1999-2002. Table 4.31 World consumption of polyetherimide by sector for the period 1999-2002 (000 tonnes) 1999 2000 2001 2002 Automotive 6.6 7.5 7.0 7.3 Electrical & Electronics 4.0 4.5 4.1 4.3 Consumer products 0.7 0.7 0.7 0.7 Industrial 1.3 1.5 1.4 1.4 Other 0.7 0.7 0.7 0.7 TOTAL 13.2 15.0 13.8 14.5

In 2002, total world consumption of polyetherimide was estimated at 14,500 tonnes against a peak demand of 15,000 tonnes in 2000. Between 1995 and 2000, the global average annual growth rate for polyetherimide was 12-13%. In 2001, global polyetherimide demand declined by 7.8% due to a downturn in the world economy. Demand fell the sharpest in Europe (-10.3%), Japan (-9.7%) and North America (-7.8%). Global demand staged a modest recovery in 2002, with an estimated growth rate of 5.2%. For the period 2002-2007, world polyetherimide consumption is projected to increase at a compound annual growth rate of between 10-11%. Table 4.32 shows percentage share of total world polyetherimide consumption by region for the period 1999-2002. Table 4.32 Percentage share of world polyetherimide consumption by region, 1999-2002 1999 2000 2001 2001 Western Europe 20.0% 20.0% 19.5% 19.5% North America 60.5% 60.1% 60.1% 60.1% Japan 9.8% 9.9% 9.7% 9.4% Rest of Asia Pacific 9.8% 9.9% 10.7% 11.0%

North America is by far the largest consumer of PEI with 60.1% of total world consumption in 2002. Europe is the second largest market with 19.5%, followed by Asia with 20.4%. Table 4.33 shows percentage share of total world PEI consumption by market sector for the period 1999-2002. Table 4.33 Percentage share of world polyetherimide consumption by market sector, 1999-2002 1999 2000 2001 2002 Automotive 50.1% 50.1% 50.6% 50.3% Electrical & Electronics 30.1% 30.0% 30.0% 29.9% Consumer products 4.9% 4.9% 4.8% 4.9% Industrial 10.0% 10.0% 9.8% 9.9% Other 4.9% 4.9% 4.8% 4.9%

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Automotive is the largest user of PEI with 50.3% of total world consumption in 2002. The second largest user is the E&E sector with 29.9% of world consumption, followed by industrial with 9.9%, consumer products (4.9%) and ‘other markets’ (4.9%). The automotive sector is expected to remain the fastest growing market for polyetherimide. There is still much scope for replacement of thermosets and other plastics by PEI in key automotive applications. Consumer products such as food service containers and microwavable ovenware, also offer good growth potential.

4.2.10 Polysulfone (PSU), Polyethersulfone (PES) Table 4.34 shows world consumption of PSU/PES by sector for the period 1999-2002. Table 4.34 World consumption of PSU/PES by sector for the period 1999-2002 (000 tonnes) 1999 2000 2001 2002 Automotive 4.1 4.4 4.3 4.5 Electrical & Electronics 6.1 6.8 6.4 6.6 Consumer products 3.0 3.2 3.1 3.4 Industrial 2.7 3.0 2.7 2.9 Other 5.1 5.5 5.3 5.3 TOTAL 20.8 22.9 21.7 22.7

Total world consumption of PSU/PES was estimated at 22,700 tonnes in 2002 compared with peak demand of 22,900 tonnes in 2000. Between 1995 and 2000, the global PSU/PES demand increased at an annual rate of between 15-16%. In 2001, global PSU/PES demand declined by 5.3% due to the sharp downturn in key market sectors. There was a modest recovery in world demand during 2002, with estimated growth of 4.7%. For the period 2002-2007, world PSU/PES consumption is projected to increase at a very respectable compound annual growth rate of between 10-11%. Growth will however be lower than the historical trend rate due to the downturn in demand from key markets and maturing applications. Table 4.35 shows percentage share of total world PSU/PES consumption by region for the period 1999-2002. Table 4.35 Percentage share of world PSU/PES consumption by region, 1999-2002 1999 2000 2001 2002 Western Europe 19.2% 19.7% 19.2% 19.4% North America 58.7% 58.3% 58.7% 57.1% Japan 11.1% 11.0% 10.9% 11.2% Rest of Asia Pacific 11.1% 11.0% 11.3% 12.2%

North America is by far the largest consumer of PSU/PES with 57.1% of total world consumption in 2002. Europe is second largest market with 19.4%, followed by Asia with the remaining 23.4%. Table 4.36 shows percentage share of total world PSU/PES consumption by market sector for the period 1999-2002. The E&E sector is the largest user of PSU/PES with 28.6% of total world consumption in 2002. The second largest user is the automotive sector with 19.7% of world consumption, followed by consumer products with 14.7% and industrial with 12.8%. ‘Other markets’ account for the remaining 23.3% of market volumes. The most important market included under the ‘others’

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category is medical devices, which accounts for around 15% of total world consumption. PSU/PES has excellent growth potential in medical applications, and also in automotive markets as a replacement for metal and thermosets. Food service technology is another potential growth market. Table 4.36 Percentage share of world PSU/PES consumption by market sector, 1999-2002 1999 2000 2001 2002 Automotive 17.7% 19.2% 18.6% 19.7% Electrical & Electronics 26.7% 29.7% 27.8% 28.6% Consumer products 12.9% 14.0% 13.3% 14.7% Industrial 11.6% 13.1% 11.8% 12.8% Other 22.1% 24.0% 23.2% 23.3%

4.2.11 Liquid Crystal Polymer (LCP) Table 4.37 shows share of world consumption of LCP by sector for the period 1999-2002. Table 4.37 World consumption of liquid crystal polymers by sector for the period 1999-2002 (000 tonnes) 1999 2000 2001 2002 Automotive 0.8 0.9 0.8 0.9 Electrical & Electronics 11.2 13.5 12.3 13.3 Consumer Products 1.2 1.4 1.3 1.5 Industrial 1.2 1.4 1.3 1.4 Other 0.6 0.7 0.7 0.8 TOTAL 14.9 18.0 16.4 17.8

In 2002, total world consumption of LCP amounted to 17,800 tonnes against peak demand of 18,000 tonnes in 2000. LCP is a relatively new material that has established a strong market position in recent years because of its unique properties. Between 1997 and 2000, global demand for LCP grew at an annual average rate of between 15-20%. The main driving force was the strong growth in key end user sectors such as telecommunications and electronics. In 2001, global LCP consumption declined by 9-10% due to a downturn in key applications such as cellular phones and personal computers. In Japan, LCP consumption fell by 15-20% due to a sharp contraction in US demand for IT products, a major market for Japanese producers. European and North American demand was down by 5-10% in 2001. There was a sharp recovery in global demand last year with an estimated growth rate of 8.6%. Asia showed the highest growth, but there were also strong performances from Europe and North America. The prospect for LCP growth over the next few years is positive. For the period 2002-2007, world LCP consumption is projected to increase at a compound annual growth rate of between 12-15%. More stringent customer material specifications and future technological developments requiring a very high speed of innovation will fuel market demand. New standards such as Universal Mobile Telecommunications System (UMTS) and Bluetooth will open up new growth markets for LCP. Also, portable information devices are expected to grow further and LCP is extending its reach into fibres and films. Table 4.38 shows percentage share of total world LCP consumption by region for the period 19992002. The Asia Pacific region, and Japan in particular, is the largest consumer of LCP, with 58.2% of global demand in 2002 because of the high concentration of electrical goods produced in the region. North America represents 27.6% and Western Europe the remaining 14.2%. The European 51


market however increased substantially in the late 1990s due to technological leadership in the mobile telecommunications industry and the growing market penetration of hard-metric plug-in connectors. Table 4.38 Percentage share of world LCP consumption by region, 1999-2002 1999 2000 2001 2002 Western Europe 13.4% 13.8% 14.3% 14.2% North America 28.0% 27.8% 28.1% 27.6% Asia 58.6% 58.4% 57.6% 58.2%

Table 4.39 shows percentage share of total world LCP consumption by market sector for the period 1999-2002. Table 4.39 Percentage share of world LCP consumption by market sector, 1999-2002 1999 2000 2001 2002 Automotive 5% 5% 5% 5% Electrical & Electronics 75% 75% 75% 75% Consumer products 8% 8% 8% 8% Industrial 8% 8% 8% 8% Other 4% 4% 4% 4%

Electronics and telecommunications are the largest users of LCP with a share of 75% of total world consumption in 2002. Consumer products such as audio and video equipment, account for 8% with industrial applications also accounting for 8%. Automotive represents 5% of total consumption.

4.2.12 Polyetheretherketone (PEEK) Table 4.40 shows percentage share of world consumption of PEEK by sector for the period 19992002. Table 4.40 World consumption of PEEK by sector for the period 1999-2002 (000 tonnes) 1999 2000 2001 2002 Automotive 0.5 0.6 0.7 0.5 Electrical & Electronics 0.2 0.3 0.4 0.3 Consumer products 0.0 0.0 0.0 0.0 Industrial 0.3 0.4 0.4 0.3 Other 0.2 0.2 0.2 0.2 TOTAL 1.2 1.4 1.7 1.3

PEEK has enjoyed substantial growth in demand during the second half of the 1990s. Between 1995 and 2001, global demand for PEEK grew at an annual average rate of between 15-20%. The excellent balance of properties has enabled PEEK to replace traditional materials in many demanding applications. PEEK has also benefited from strong growth in mobile phones and the Internet during the last decade. However, in 2002, total world consumption of PEEK fell by around 23% to 1,300 tonnes. This was due to the general economic downturn and particularly to the major reduction in sales of semiconductors. Demand from the key US market fell sharpest because of a fall-off in sales to the electronics market. Asia Pacific volumes were down by 25% while European volume fell by around 15%.

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The prospect for PEEK growth over the next few years is positive. For the period 2002-2007, world PEEK consumption is projected to increase at a compound annual growth rate of between 12-15%. New applications development continues to drive demand for PEEK. According to Victrex, the leading PEEK producer, there were 249 new applications in 2002 compared with 184 in the previous year. Other reasons for optimism about future prospects are the Invibio medical implants business, which is performing ahead of expectations, and the technical development of the Victrex proprietary ionomer for the fuel cell alliance with Ballard Power Systems, which is also progressing well, with Ballard not proceeding with further development of its own ionomer for the time being. Injection moulding applications are growing at the fastest rate. Stock shapes have traditionally been the largest market, but now compounding takes about the same volume. Over 50% of new applications in 2001 involved injection moulding. Film and extrusion blow moulding uses are also expanding. Table 4.41 shows percentage share of total world PEEK consumption by region for the period 1999-2002. Table 4.41 Percentage share of world PEEK consumption by region, 1999-2002 1999 2000 2001 2002 Western Europe 48% 47% 48% 52% North America 42% 43% 42% 38% Asia Pacific 10% 9% 10% 10%

Europe is the largest consumer of PEEK with 52% of global demand in 2002. North America represents 38% and Asia accounts for the remaining 10%. Table 4.42 shows percentage share of total world PEEK consumption by market sector for the period 1999-2002. Table 4.42 Percentage share of world PEEK consumption by market sector, 1999-2002 1999 2000 2001 2002 Automotive 41% 40% 42% 41% Electrical & Electronics 20% 21% 21% 20% Consumer products 0% 0% 0% 0% Industrial 26% 27% 24% 26% Other 13% 12% 12% 13%

Automotive is the largest user of PEEK with a share of 41% of total world consumption in 2002. Industrial applications are the next most important sector with 26%, followed by electronics and telecoms with 20%. ‘Other markets’, including medical and developing applications, represent the remaining 13% of world PEEK demand. The share of electronics and telecoms is higher in Asia than in Europe because of the large number of equipment manufacturers located in the region. Likewise, the share of the automotive sector is much higher in Europe, at around 50% of PEEK demand, than in Asia.

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5 Automotive Applications for Engineering and High Performance Plastics 5.1 Introduction In 2002, the automotive industry consumed 2,851,000 tonnes of engineering and high performance plastics. Automotive demand was growing at between 7-8% per annum during the three years to 2000. However, consumption fell sharply in 2001 due to the downturn in world economic activity. There was a steady recovery in demand last year, but total consumption remains below 2000 levels. Engineering polymers and high performance plastics are used to manufacture more demanding applications in the car. The most valued properties of engineering plastics for automotive applications are their high heat resistance, dimensional stability, strength and resistance to a range of chemicals. These properties have led to their replacement of traditional materials such as metal and thermosets in motor vehicles. Polycarbonate and acrylics have also been replacing glass in light lenses and instrument panel displays. The use of plastic has grown significantly in automotive applications during the last two decades. This is due in particular to its lightness and hence greater fuel efficiency than metal, Plastic also offers greater design flexibility, reduces development time and lowers assembly costs. In Europe, the use of plastics in automotive manufacturing increased by 115% between 1990 and 2000 to 2.75 million tonnes. This represents an increase of about 40 kg per car, from 70 kg in 1980 to 110 kg per car in 2000. Plastic now accounts for around 9.5% of the total weight of the average passenger car. Various polymers are used in over 1,000 different parts of all shapes and sizes, from instrument panels and interior trim to bumpers and radiator grilles, fuel tanks and engine parts. The material selection for a particular application will depend primarily on the ability to meet the required specification and also on polymer price and total systems cost. The total systems cost includes the cost of the polymer, processing cost and tooling and assembly cost, and is a prime consideration for cost-conscious car manufacturers. Future trends in the use of plastics for automotive applications will be influenced by a number of important factors. Cost and weight reduction will remain an important driver for the motor manufacturers, which will favour plastic instead of metal. Environmental considerations will play an increasingly important role in terms of emission standards and the need to increase plastics recycling from end-of-life vehicles. Finally, there will be increasing demand for higher quality materials and greater use of safety and comfort features in the average car. 5.2 Future Prospects for the World Automotive Industry World vehicle production declined in both 2001 and 2002, and the prospects for a recovery during 2003 are very uncertain. According to the International Organisation for Motor Vehicle Manufacturers (OICA), total world production of motor vehicles declined by 3.8% in 2001 to 56.0 million units, compared to record production of 58.3 million units in the previous year. Table 5.1 shows world motor vehicle production by region for the period 1999-2001. There was wide variation in production between major world regions. The European Union and South America showed modest growth of 1% while the NAFTA region declined by 10%. In Asia, Japan and South Korea declined by 4%, while China and Thailand experienced strong growth of 13% and 12%, respectively. The emerging countries have shown significantly stronger growth than the developed countries.

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Table 5.1 World motor vehicle production by region, 1999-2001 (000 units) 1999 2000 2001 European Union 16,928 17,142 17,313 East & Central Europe 2,544 2,702 2,675 Turkey 298 430 253 North America 17,633 17,698 15,574 South America 1,681 2,076 2,138 Asia-Oceania 16,870 17,928 17,748 Africa 301 317 370 TOTAL 56,255 58,293 56,071 Source: OICA

In 2002, motor vehicle production showed a further sharp decline. Provisional estimates indicate that production was down by around 5%, with the steepest falls being in the three major markets of Western Europe, North America and Japan. Even the emerging markets struggled in 2002, with growth being reported only in China and Australia. For 2003, industry estimates are for a further decline in world motor vehicle production of between 2-3%. A modest recovery is predicted for the second half of the year, depending on the trends in world economic growth. Going forward, the outlook is much brighter with industry sources projecting much stronger growth from 2004 onwards. The current consensus industry projection is for average annual growth rates of 2-2.5% during the period 2005-2010. The brightest prospects for automotive growth will be Latin America, Eastern Europe and Asia, except Japan. 5.3 Future Trends for Engineering Polymers in Automotive Markets The most important factors influencing trends in use of engineering and high performance plastics in the automotive markets are discussed next.

5.3.1 Recycling of End-of-Life-Vehicles EU Directive In September 2000, the European Union issued Directive 2000/53/EC on recovery and recycling of end-of-life-vehicles (ELV). The objective of the legislation is to preserve scarce material resources by reducing the amount of waste being dumped from end-of-life vehicles into landfill sites. Under the directive, 80% of a vehicle’s weight must be recycled or reused in 2006, rising to 85% in 2015. Currently more than 75% by weight of an average car is recycled. A very high proportion of the material being recycled is metal such as sheet steel, plain steel, cast iron and aluminium. Plastics on the other hand, are not currently being recycled in large quantities from end-of-life-vehicles. It is estimated that plastics account for around 9.5% by weight of all materials used in the manufacture of vehicles. Probably just about 8% of total plastics in end-of-life-vehicles are mechanically recycled, the rest being land filled. Plastic therefore contributes less than 1% by weight of total automotive materials currently recycled. The use of plastic for manufacture of automotive parts has been growing during the last few decades. Many different types of plastic are used in hundreds of applications. These range from commodity polymers such as PVC and polyethylene to high performance engineering plastics. Furthermore, most of the high performance plastics contain a range of additives, fillers and reinforcements to enhance properties. Polymer blends such as PC/PBT and PC/ABS are also quite common in automotive applications. Both the plastics and car manufacturers face a major challenge to meet the recovery and recycling targets for plastics from end-of-life-vehicles. Not only are many different types of plastic being

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used, making sorting difficult, but also plastic components are very often quite small and difficult to dismantle. Given that scale is important for economical recycling schemes, it may be difficult and costly for recyclers to gather sufficient amounts of single-plastic parts to make recycling worthwhile. Only the large and single-plastic components such as bumpers and instrument panels, which can be easily identified and dismantled, may be suitable for mechanical recycling. However, the price of virgin plastics will continue to play a vital role, as recovery of plastics in vehicles is slow and costly. If the price of virgin plastics is cheaper than recyclate, then there will not be a market for recycled materials. The amount of plastic in vehicles is forecast to grow further, hence, the pressure grows for more plastic recycling from ELVs. This is being driven by the need to reduce CO2 emissions, which means lighter vehicles and hence use of more plastics. There is however more optimism for the long-term future of recycling. Taxation on the use of landfill and the rising price of oil may force people to find alternative solutions. In response to the ELV directive, the plastic manufacturers and automotive industry joined forces in 1998 forming the European Thematic Network (ETN) for the ecologically efficient treatment of plastics in ELVs. The network looked at three ways of dealing with plastic taken from old cars: dismantling, material recycling, and shredder residue treatment and use. ETN found that market conditions remained the deciding factor in how much plastic was recovered and recycled. Recycling needs market potential and without the economics the system will completely fail. Even the Automotive Shredder Residue (ASR) working group fell across the same stumbling blocks and claimed that there was not enough high value material SR. Results for this vary greatly depending on the municipality handling the waste. This means that implementing recycling as the norm will be a tough job in the short term. Nobody thinks they should be paying for cars to be dismantled and reused. Several people in the industry believe that the end consumer should foot the bill. This type of scheme has gained acceptance in the Netherlands, where the first purchaser pays a fee when they buy, which is intended to help cover the cost of recycling. However, although this has worked well there, it may be hard to gain acceptance amongst the public in other countries. French and German plastics converters are working, separately, on a number of industry-specific solutions to conform to the EU End-of-Life-Vehicle (ELV) directive. The French plan, EDIT (Eco Design Interactive Tool) was launched in 1999 by the national association of plastics converters, Federation de la Plasturgie, in cooperation with other tier one suppliers, polymer producers and car manufacturers such as PSA and Renault. EDIT’s ‘eco-design’ project aims to develop and design new car components with very low environmental impact throughout the product’s life cycle. It provides the automotive industry with precise information on the polymer content of a plastic automotive component so that it will be better able to anticipate the materials’ impact on the environment during processing, during the component’s life, as well as at the end of its life, when recycling is called for. The first tool to be developed is a centralised database, SIGMA, which records polymer content and additives authorised or banned by the EU, as well as heavy metals. In Germany, car manufacturers such as Audi, BMW, DaimlerChrysler, Ford, Opel, Porsche and VW, have committed themselves to recycling 95% of vehicle weight by the year 2015. As the industry association Verband der Automobilindustrie (VDA) is aware that some substances in automotive materials present environmental risks through vehicle use, disposal and/or recycling, it has commissioned EDS to develop a software solution to simplify recycling. Other European carmakers, including Volvo, are also cooperating, and participation by the US industry is being discussed. There are differences between the French and German projects. While French plastics converters for data bank purposes require polymer producers to declare 90% of their materials’ composition,

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the German automotive industry asks that 100% of polymer composition be recorded in the IMDS data base. The EDIT programme offers a good basis for negotiations between plastics converters and car manufacturers, Tier one suppliers can be equipped with tools that allow them to improve the environmental impact of the car component as early as the design phase. As both the French and the German projects have a European focus, teams from the two countries have been meeting in Brussels with the Association of Plastics Manufacturers in Europe (APME) to work on bringing the two databases closer together. The EDIT programme has already anticipated international requirements. It will add filters to its SIGMA data to detect whether any of the substances contained in the material will make the component fail to meet national or international regulations and/or car manufacturers requirements in worldwide markets. The French project team is developing an additional tool that would enable tier one suppliers to draw up end-of-life scenarios. They could then anticipate whether the material would lend itself to mechanical recycling or whether incineration for energy recovery would be preferable.

5.3.2 Proposed EU Legislation to Reduce Fuel Emissions Forthcoming EU environmental legislation aimed at reducing fuel consumption and CO2 emissions will be a key factor in stimulating more use of plastic in motor vehicles. The EU has stated that by 2005 the average CO2 emissions for new cars must be 120 g/km. The automotive industry has countered with an offer of 140 g/km by 2008, with a further reduction by 2011. The automotive industry claims that they will need to improve fuel economy by 25-40% to meet these suggested targets. It has also been estimated that if car engines remain unchanged, then average vehicle weight will have to be reduced by 300 kg to meet the CO2 targets. At the same time vehicle weight is increasing by 15 kg per year as more features are added. This factor alone will pave the way for use of more plastics to keep average weight lower.

5.3.3 Development of ‘Mono-Material Systems’ Producers of automotive components are seeking to reduce costs by switching to simpler processes and creating higher added value through weight reduction and use of more effective materials. Reflecting the growing importance of recycling, many OEMs are demanding the use of only one polymer or material for car interior applications such as instrument panels, and car sub-modules. Many industry insiders are convinced that future instrument panels will be based on a singlepolymer system with polypropylene being the favoured base polymer. Leading compounder A. Schulman, USA, is a strong advocate of ‘mono-material’ schemes for an all-polyolefin interior, so that automotive recyclers could easily separate out large pieces of one family of resins for recycling. In May 2001, the company received approval from General Motors for its ‘Invision’ soft-touch polyolefin materials. Schulman is marketing this high-performance alternative to PVC for a wide variety of car interior components. The company claims these products would address market demand for PVC-free parts that are soft and leather-like in texture without sacrificing scratch resistance, weatherability, colourability and moisture resistance. 5.4 Polyamide

5.4.1 Consumption Trends Automotive is the largest market sector for polyamide accounting for 34% of world market volume in 2002. Polyamide has successfully and continually replaced metal parts in many different automotive applications over the last few decades. The main reasons for the success of polyamide in automotive applications is its lower weight, lower cost and better functionality than competing

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materials. The share of polyamide in motor vehicle construction will increase in future as new applications continue to be developed. Table 5.2 shows polyamide consumption in automotive applications by world region for the period 1999-2002. Table 5.2 Polyamide consumption in automotive applications by world region for the period 1999-2002 (000 tonnes) 1999 2000 2001 2002 Western Europe 220 240 225 235 North America 229 240 216 222 Japan 58 61 54 55 Rest of Asia Pacific 86 95 93 100 Rest of World 45 50 46 48 638 686 634 660

In 2002, total polyamide consumption in automotive applications was 660,000 tonnes against 638,000 tonnes in 1999. Market tonnage declined in 2001 due to the contraction in world automotive production, but then recovered in 2002, particularly in Western Europe. North American consumption of polyamide fell sharpest in 2001, as car production was down by around 15%. Table 5.3 shows percentage share of polyamide in automotive applications by world region for the period 1999-2002. Table 5.3 Percentage share of polyamide in automotive applications by world region for the period 1999-2002 1999 2000 2001 2002 Western Europe 34% 35% 35% 36% North America 36% 35% 34% 34% Japan 9% 9% 9% 8% Rest of Asia Pacific 13% 14% 15% 15% Rest of World 7% 7% 7% 7%

In 2002, Western Europe is the largest user of polyamide in automotive, accounting for 36% of total consumption. North America is the second largest market with 34%, followed by ‘Rest of Asia Pacific’ with 15% and Japan with 8%. The share of China and other Pacific Rim countries is growing and is forecast to increase further in future because of the trend for car manufacturers to relocate production to lower cost economies.

5.4.2 Current Applications Polyamide is used in all of the main automotive application areas. Under-the-bonnet applications is by far the largest area of application followed by electrical and lighting systems, exterior and interior applications. The main under-the-bonnet applications for polyamide include the air intake manifold, the air and cooling systems, peripherals, throttle body housing, the cylinder head cover, the water-glycol circuit and engine parts. High performance PA is also used to make tubing for under-the-bonnet applications such as fuel systems.

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It is estimated that the polyamide market penetration rate in air intake manifolds was 65% in 2000. This is forecast to increase to around 85% by 2005. Material suppliers are continuing to develop grades with improved hydrolysis resistance, which enables them to withstand continuous contact with hot water and glycols. Polyamide plays a major role in all the electrical and electronic equipment used in cars. It is found in the peripherals, sensors, switches, relays and electronic housing. The main applications of polyamide in the automotive exterior parts sector are rear mirror housing, door handles, windscreen wiper parts, sun roof frames, lock covers, wheel trims, fuel filler caps, painted parts such as wheel trims, and skirts and grilles. Polyamide is not yet used on its own for manufacture of body parts but can be used in combination with other polymers. It is also beginning to be used in manufacture of modular front-end carriers using the Bayer hybrid technology. In car interiors, the main applications are door handles, key lock systems, internal rear mirror, push buttons, switch control panels, steering lock casings, speedometer casings, arm rests, back-lit heater control panels, back light indicators and ashtrays.

5.4.3 Market Trends The key trends influencing further use of polyamide in automotive applications are discussed next.

5.4.3.1 Inter-Polymer Substitution Polyamide is being threatened by polypropylene in a number of automotive applications. High performance grades of polypropylene are taking share from PA in engine covers and air intake manifolds. This trend is due to better properties and the lower price of polypropylene compared with polyamide. Furthermore, polypropylene has better sound dampening properties than polyamide and can reduce sound by 5 db compared with PA, which is a major advantage for PP in electrical applications. Polyamide is also being challenged by metallocene catalyst polypropylene in climate control units and air filtration applications.

5.4.3.2 Competition from Metal Metal replacement has been a main driver for the use of polyamide in automotive applications in the past. Most of the obvious replacement of metal by PA has already taken place in the car interior, exterior and electrical systems areas. Under-the-bonnet applications however still offer some scope for further penetration by polyamide, particularly for high-performance grades. Polyamide for instance has been replacing metal in manufacture of the air inlet manifold for a number of years. Industry estimates are for PA to achieve market penetration in Europe of 85% by 2005. Levels in NAFTA and Japan are expected to be somewhat lower, but growth rates there somewhat higher. Global production of inlet manifolds made of polyamide reached 18 million in 2001. Metal may, however, come back to threaten plastic because of the trend towards high-powered small volume engines which generate a lot of heat per unit volume, and from higher emission standards. There is some re-substitution taking place with plastics being replaced by steel for some under-thebonnet parts. Steel-makers are improving their products to make thinner and lighter steel sheet with even higher tensile strength steel.

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Magnesium may also come back to challenge plastic in the medium to longer term. Additional capacity due on-stream over the next five years will exert a downward movement in magnesium prices, which will make magnesium more competitive with plastics. Magnesium has only a slightly higher density than plastic, but better properties and hence the weight advantage of plastic is quite low. Magnesium can also withstand higher temperatures than plastic. The battle over the next 5-10 years will be between magnesium alloys and plastic.

5.4.3.3 Developments in Processing Technology The further development of moulding technology will benefit the use of plastic in the passenger car. For example, fusible core technology has made rapid progress, with major investment by leading moulders throughout Europe. The commercial adoption of air inlet manifolds moulded by this route for the Ford Mondeo, the Citroen Xantia, and other new model introductions, is stimulating substantial new demand, principally for glass fibre reinforced, heat stabilised polyamide 66 compounds. Friction welding of separately moulded individual components and blow moulding of high molecular weight natural and glass-reinforced polymers are also opening up new opportunities. Developments in blow moulding include process variants such as suction blow moulding. EMSGrivory has developed the Ecosys process for extending three-layer, semi-flexible water pipes for engine cooling systems. They have a PA12 resin layer and an inner layer made of a polyolefin compound, bonded by a tie layer.

5.4.3.4 Development of Hybrid Technology Bayer achieved a breakthrough in 1996 with the development of hybrid technology in structural components. The hybrid technology binding plastics and steel lowers weight and also lowers module costs and creates a high load-bearing capacity while allowing high energy absorption. A steel and PA6 glass-reinforced instrument panel developed by the team Bayer-General MotorsFisher Guide has entered series production in the US. The technology is also used in components for doors, seats, front ends and bumper brackets.

5.4.3.5 Development of In-Mould Painting Systems In-mould painting is a new technology, which will underpin the use of polyamide for car component manufacture in the coming years. The process is a variant of sandwich moulding, producing parts with a thermoplastic core fully encased within a polymer-based paint. To date, it has been proven with PP and polyamides. Advantages to processing companies include the elimination of conventional paint lines. This saves capital costs and avoids the component handling necessary prior to painting. The paint, based on powder coating technology, is supplied as a granular solid. It is fed into one barrel of a two-component injection moulding machine and, when heated, passes through a pseudo-thermoplastic phase to soften and flow. After moulding it hardens and crosslinks. Weld lines are not an issue with solid colours, but further work is needed before metallic colours can be used.

5.4.3.6 Development of the 42-Volt Electrical System The number of electrically operated systems in vehicles has risen rapidly over the past few years and the 12- and 14-volt systems currently in use will be approaching their limits. With additional electrical systems such as access to the Internet, air-conditioning, ABS, heatable rear windows, door-locking systems, electric seat adjustment and on-board computers, then the 42-volt systems currently available in prototype form will be an absolute necessity.

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In terms of electrical properties and heat resistance, the components used for 42-volt electric circuits will need to satisfy more stringent demands than the 12- or 14-volt systems. The conventional fuse housings in polyether sulfone or polysulfone polymers will not withstand a 42volt fuse blowing without suffering damage. On prototype systems, these housings have been injection moulded in a new translucent grade of DuPont’s Zytel polyamide, which has fulfilled the vehicle manufacturers’ requirements. The automotive industry is reckoning on the 42-volt systems being definitively introduced in 2007. Individual car models will be equipped with these systems beforehand, however, and possibly even with two systems in parallel.

5.4.3.7 New Applications Development BASF AG and the French automotive supplier MGI Coutier S.A. have manufactured throttle systems of glass fibre-reinforced polyamide. Coutier, as a tier-one supplier, is a direct supplier to Renault, PSA, Ford, VW, GM and Fiat. In 2002, Delphi Automotive has introduced an innovative air suspension module, which is used in Land Rover’s new Range Rover, which relies on an air spring damper strut. The front module incorporates a complex piston, which is made from DuPont’s Zytel polyamide. The material is a 35% glass reinforced grade, which combines high temperature resistance with high burst and compressive pressure strength. 5.5 Acrylonitrile-Butadiene-Styrene (ABS)

5.5.1 Consumption Trends In 2002, the automotive market accounted for around a quarter of total ABS consumption. The ABS automotive applications market has been growing more slowly in recent years, particularly in the more developed regions such as Western Europe and North America. This trend is due to growing competition from other polymers such as polypropylene and unsaturated polyesters. ABS has however benefited from developments of continuous mass processing technology, which has meant enhanced colour consistency and eliminated the need for painting. The process produces low-gloss products, a desirable feature for applications in the automotive sector. Table 5.4 shows ABS consumption in automotive applications by world region for the period 19992002. Table 5.4 ABS consumption in automotive applications by world region for the period 1999-2002 (000 tonnes) 1999 2000 2001 2002 Western Europe 180 194 184 186 North America 385 410 390 394 Japan 61 63 56 58 Rest of Asia Pacific 440 490 475 515 TOTAL 1066 1157 1105 1153

In 2002, total ABS consumption in automotive applications was 1,153,000 tonnes compared with 1,066,000 tonnes in 1999. Volumes declined in 2001 due to the major contraction in world automotive production, but have since recovered in 2002. Table 5.5 shows percentage share of ABS in automotive applications by world region for the period 1999-2002.

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Table 5.5 Percentage share of ABS in automotive applications by world region for the period 1999-2002 1999 2000 2001 2002 Western Europe 17% 17% 17% 16% North America 36% 35% 35% 34% Japan 6% 5% 5% 5% Rest of Asia Pacific 41% 42% 43% 45%

Asia, including Japan, is by far the largest user of ABS in automotive, accounting for 50% of total consumption in 2002. North America is the second largest market with 34%, followed by Western Europe with 16%. The share of China and other Pacific Rim countries is growing fast and is forecast to increase further in future because of the trend for car manufacturers to relocate production to lower cost economies.

5.5.2 Current Applications Interior parts are the largest area of application for ABS in the automotive market accounting for around 60% of total market volume. The main applications are instrument panels, loudspeaker grilles, door handles, door trim, glove box compartment lids and centre consoles. PC/ABS blends are also used in many of these applications, mainly in higher value cars. Exterior parts account for just over a quarter of the total volume of ABS used in the automotive market. The principal applications are wheel trim, mirror and light housings. ABS can also be found, usually in combination with polycarbonate as a blend, in electrical systems housing. The material is rarely found in under-the-bonnet applications because of its lower temperature resistance compared with other polymers. ABS is also used in combination with polycarbonate for electrical parts such as navigation systems housing. PC/ABS is considered to have good growth prospects in navigation systems housing. A small amount of ABS is used in under-the-bonnet applications.

5.5.3 Market Trends The key trends influencing further use of ABS in automotive applications are discussed next.

5.5.3.1 Replacement of Traditional Materials The potential use of ABS both inside and outside the car has almost reached saturation as the material has almost completely replaced die-cast metal in key applications such as light and mirror surrounds. PC/ABS blends however remain a popular choice for instrument panels in some luxury models and demand will continue to grow. PC/ABS should also see good growth prospects in navigation systems housing.

5.5.3.2 Inter-Polymer Substitution ABS is not expected to displace many other types of plastics in automotive applications in future. There is however a possibility that PC/ABS blends may be one of the candidates being considered by OEMs to replace styrene-maleic anhydride copolymer (SMA) in some interior applications. Manufacturers are known to be looking for alternatives to SMA copolymer. There is a stronger possibility of ABS being challenged by other plastics such as polypropylene. Future trends within the car interior are likely to see the increasing development of one-material

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solutions for integrated components to facilitate assembly and recycling. Within dashboards there is a move towards softer materials as the standards found in larger luxury models are increasingly demanded for smaller models. Improving grades of unfilled PP are expected to continue taking market share from ABS in interior panels on the grounds of weight and cost. BASF has introduced an improved polystyrene grade that could provide low-cost competition for ABS products. The PS ‘495 F’ is noted for its outstanding toughness and flowability, as well as for high rigidity and good heat resistance. It can be used to produce big parts with a complex geometry and a low wall thickness. The company claims that the notched impact strength has been improved by 60%, and thus raised to the level of standard ABS grades. Many applications that require ABS today could also be implemented in PS ‘495 F’. 5.6 Polybutylene Terephthalate (PBT)

5.6.1 Consumption Trends Automotive is the largest market for PBT with 41% of total world market volume in 2002. PBT has experienced strong growth in automotive markets in recent years. It is finding increasing use, for instance, in headlight frames, windscreen wipers, central-locking housings and electrically operated windows. Table 5.6 shows PBT consumption in automotive applications by world region for the period 19992002. Table 5.6 PBT consumption in automotive applications by world region for the period 1999-2002 (000 tonnes) 1999 2000 2001 2002 Western Europe 40 45 45 47 North America 75 80 73 75 Japan 30 33 31 32 Rest of Asia Pacific 33 38 36 38 Rest of World 3 4 3 4 TOTAL 181 200 188 196

In 2002, total PBT consumption in automotive applications was 196,000 tonnes compared with 181,000 tonnes in 1999. Volumes declined in 2001 to 188,000 tonnes due to the downturn in world automotive production, but showed a modest increase in 2002. Table 5.7 shows percentage share of PBT in automotive applications by world region for the period 1999-2002. Table 5.7 Percentage share of PBT in automotive applications by world region for the period 1999-2002 1999 2000 2001 2002 Western Europe 22% 23% 24% 24% North America 41% 40% 39% 38% Japan 17% 17% 16% 16% Rest of Asia Pacific 18% 19% 19% 20% Rest of World 2% 2% 2% 2%

North America is the largest user of PBT in automotive, accounting for 38% of total consumption in 2002. The share of North America has been declining since 1999, due mainly to the sharp

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downturn in US car production after 2000, and the greater market maturity of many PBT automotive applications. Western Europe is the second largest market with 24%, followed by ‘Rest of Asia Pacific’ with 20% and Japan with 16%. Western Europe has grown its share of total consumption in recent years due largely to new applications for PBT and a lower decline in car production than in the USA. The share of China and other Pacific Rim countries is growing fast and is forecast to increase further in future.

5.6.2 Current Applications Electronic components and housings is the main applications area for PBT in the automotive sector accounting for over 60% of total volume. Exterior applications are the next most important market, followed by interior applications. PBT has only limited use in under-the-bonnet applications. PBT has been replacing metal in automotive electrical components where its high stiffness and strength combined with good heat ageing performance are particularly valuable. Resistance to fuels and lubricants is also vital here. Glass fibre-reinforced grades made from PBT also have especially low warpage. In addition, PBT has excellent electrical and thermal long-term performance. The low flammability of flame retardant grades is an added advantage. Applications include electric motor covers, gear housings, fuel boxes and relays, sensors, lamp reflector body and brackets, connectors, ignition coils and bobbins and brake booster valve bodies. The main applications for PBT in the car interior include parts of the instrument panel such as ashtrays and other interior trim. For exterior applications PC/PBT blends are used mainly in the manufacture of automotive bumper fascia. Other uses for PBT include windscreen wiper arms, mudguards, mirror housings and door handles. PBT is used in applications where a high quality, weather resistant surface is a key requirement for components. Under-the-bonnet applications is the smallest area of application for PBT in automotive. Typical applications include parts for the carburettor.

5.6.3 Market Trends The key trends influencing further use of PBT in automotive applications are discussed next.

5.6.3.1 Growth in Electrical Applications The amount of electrical and electronics components in cars is growing and will continue to grow during the forecast period as manufacturers build-in greater safety and comfort features into their cars. PBT is the major polymer for these applications and is well placed to take advantage of the trend. Another important trend encouraging further growth for PBT in electrical systems will be the development of modular sub-assemblies, incorporating electrical and electronic parts.

5.6.3.2 Replacement of Metal Parts PBT has been replacing metals in automotive applications, because of its high stiffness and strength, good heat ageing performance and resistance to fuels and lubricants. Metal replacement will not however, be as much an influence on PBT demand in future because most of the potential replacement has already taken place.

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5.6.3.3 Inter-Polymer Substitution PBT has been replacing polyamide in some new models in electrical switches, connectors and motor housings because of its better dimensional stability. OEMs are also becoming more demanding in applications such as window lift motor housing. There is a small threat from polypropylene in some interior applications. Polypropylene has a cost advantage in some areas, and PBT’s key properties of strength, low water absorption, temperature and chemical resistance, are not often required for interior applications.

5.6.3.4 New Product Development Bayer has introduced a new grade of Pocan, a hydrolysis-resistant grade of PBT, specifically for connectors used in automotive production. The new grade was developed in cooperation with the Nuremberg-based subsidiary of FCI Automotive, a leading manufacturer of connectors. Bayer claims that the new product is able to satisfy the extreme demands placed on the ageing resistance of such components. It adds that using the new material will help carmakers reduce costs by eliminating the need for expensive, highly heat-resistant speciality polymers especially for airbags. In airbags and belt tensioning systems, these connectors link the ignition unit to the control system and power supply. 5.7 Polycarbonate (PC)

5.7.1 Consumption Trends Automotive accounts for 17% of total world polycarbonate market volumes in 2002. Polycarbonate has achieved good growth in automotive applications in recent years, mainly by replacement of glass headlamp lenses, but also in car interior applications. Polycarbonate has however almost fully penetrated all possible car interior applications and about 85% of all car headlamp lenses are now produced using polycarbonate. Exterior trim and bumper fascia markets are also reaching saturation. Hence, future growth potential from traditional applications will be restricted. Developments in the use of polycarbonate for automotive glazing, which is currently being commercialised, may lead to a substantial increase in demand for the material in future. Table 5.8 shows polycarbonate consumption in automotive applications by world region for the period 1999-2002. Table 5.8 Polycarbonate consumption in automotive applications by world region for the period 1999-2002 (000 tonnes) 1999 2000 2001 2002 Western Europe 55 59 48 51 North America 120 130 100 104 Japan 25 27 20 21 Rest of Asia Pacific 85 92 95 100 Rest of World 5 6 6 7 TOTAL 290 314 269 283

In 2002, total polycarbonate consumption in automotive applications was 283,000 tonnes against 290,000 tonnes in 1999. Volumes declined sharply in 2001 to 269,000 tonnes due to the downturn in world automotive production. In 2001, North American polycarbonate sales volume fell by 30,000 tonnes to 100,000 tonnes. Total world consumption of polycarbonate in automotive applications remains below 1999 levels, despite a modest pick up in volumes during 2002.

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Table 5.9 shows percentage share of polycarbonate in automotive applications by world region for the period 1999-2002. Table 5.9 Percentage share of polycarbonate in automotive applications by world region for the period 1999-2002 1999 2000 2001 2002 Western Europe 19% 19% 18% 18% North America 41% 41% 37% 37% Japan 9% 9% 7% 7% Rest of Asia Pacific 29% 29% 35% 36% Rest of World 2% 2% 2% 2%

North America is the largest user of polycarbonate in automotive, accounting for 37% of total consumption in 2002. The share of North America has however been declining since 1999, due mainly to the sharper downturn in US car production after 2000, and the greater market maturity of many polycarbonate automotive applications. The ‘Rest of Asia Pacific’ is the second largest market with 36%, followed by Western Europe with 18% and Japan with 7%. As in many other polymer classes, the share of China and other Pacific Rim countries is growing fast and is forecast to increase further in future because of the trend for car manufacturers to relocate production to lower cost economies. On the other hand, the shares of North America and Japan have fallen significantly in the last three years.

5.7.2 Current Applications Polycarbonate is used mainly for manufacture of car light lenses. Glass car headlight lenses have been virtually replaced by transparent plastics. Plastic can resist high levels of heat, are shatterresistant and can be moulded into almost any shape. Plastics’ versatility also gives the automotive engineer greater freedom for design and placement of car headlights. The main applications for polycarbonate in the car interior are lenses for instrument panel displays and ceiling lights. Typical applications for PC/ABS in the car interior are instrument panels where fast cycle times are desired and interior components where impact strength, dimensional stability and high heat performance are required. PC/ABS is also used in many other small application areas such as door handles, loudspeaker grilles, B-post finishes, navigation systems housing and interior trim. A small amount of PC/PBT is used inside the car, mainly for the manufacture of interior trim. Pure polycarbonate resin is rarely used for exterior body parts. However, PC/ABS is used for manufacture of applications such as mirror housings, light housings and wheel trim. PC/PBT is found almost entirely in exterior applications, the most notable applications being bumper fascias and also body panels. The body panels of the Smart Car for example, are made from PC/PBT blends. PC/PBT blends account for only 5% of the global bumper fascia market.

5.7.3 Market Trends The key trends influencing further use of polycarbonate in automotive applications are discussed next.

5.7.3.1 Development of Automotive Glazing In mid 1997, Exatec GmbH & Co., a 50-50 joint venture involving Bayer AG and GE Plastics was established to develop hard-coated polycarbonates for glass replacement in vehicles. It is claimed that PC windows can give a weight saving of around 40% compared with glass. Product and systems development is concentrating mainly on the rear and side windows, with the project 67


consisting of three different stages. Starting with the creation of a basic substitute for glass, the next stage is to develop windows with integrated functions and moulded-on connections. Finally, the aim is to produce complete body panels, in which not only transparent areas of PC, but also other elements such as ventilator grilles, lamp housings and wheel-arch covers can be integrated by multi-component injection moulding.

5.7.3.2 Replacement of Glass Lenses Polycarbonate has been replacing glass headlamp lenses over many years, and has now achieved a high rate of market penetration. Polycarbonate lenses make a saving of up to 1 kg in weight compared to glass, Polycarbonate lenses give much greater freedom for improvement of optical efficiency and they can be recycled. The high penetration rate in car headlamp lenses will however imply lower growth for PC in future. The use of polycarbonate in automotive sidelights however is seen as a potential growth market.

5.7.3.3 Inter-Polymer Substitution PMMA is the main competitor to polycarbonate in automotive lighting applications. Polycarbonate carries a price differential compared to PMMA, and when this narrows there is a tendency for s small amount of switching to occur. PC/ABS remains a popular choice for manufacture of instrument panels, particularly for top of the range vehicles. OEMs are also starting to use more PC/ABS for middle of the range car instrument panels because of its better quality compared with other polymers such as polypropylene. There is also a possibility that PC/ABS blends may be one of the candidates being considered by OEMs to replace SMA in some interior applications. Manufacturers are known to be looking for alternatives to SMA copolymers. While PC/ABS continues to perform well for instrument panels, there is still a threat being posed by long glass fibre-reinforced polypropylene. High temperature PMMA also poses a threat to some small polycarbonate applications inside the car and may be a threat for inner headlamp lenses in a few years time. Finally, Noryl PPO/PA blends are challenging PC/PBT in bumper fascia applications for mid to top of the range vehicles. 5.8 Polyoxymethylene (POM)

5.8.1 Consumption Trends Automotive is the largest market for POM, representing 32% of total world volume in 2002. The polyacetal content in passenger cars has been increasing steadily during the last couple of decades but is now slowing down due to growing competition from other polymers and market maturity of key applications. The development of new products and technologies will however mean that use of POM in the car will continue to grow in future. Table 5.10 shows POM consumption in automotive applications by world region for the period 1999-2002. In 2002, total POM consumption in automotive applications was 192,000 tonnes against 183,000 tonnes in 1999. Volumes declined in 2001 to 189,000 tonnes due to the downturn in world automotive production. In 2002, there was a modest pick up in sales volumes.

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Table 5.10 POM consumption in automotive applications by world region for the period 1999-2002 (000 tonnes) 1999 2000 2001 2002 Western Europe 59 65 64 65 North America 39 41 39 40 Japan 25 23 22 21 Rest of Asia Pacific 60 65 64 66 TOTAL 183 194 189 192

Table 5.11 shows percentage share of POM in automotive applications by world region for the period 1999-2002. Table 5.11 Percentage share of POM in automotive applications by world region for the period 1999-2002 1999 2000 2001 2002 Western Europe 32% 34% 34% 34% North America 21% 21% 21% 21% Japan 14% 12% 12% 11% Rest of Asia Pacific 33% 34% 34% 34%

Western Europe and ‘Rest of Asia Pacific’ are the largest users of POM in automotive, each accounting for 34% of total consumption in 2002. North America is the second largest consumer with 21% of total consumption, followed by Japan with 11%. The shares of both North America and Japan have been declining since 1999. North America’s share has fallen mainly due to the sharp downturn in US car production after 2000, and the greater market maturity of many POM automotive applications. Japan has also seen a sharp fall in car production and a growing trend for car manufactures to produce offshore. The ‘Rest of Asia Pacific’ has benefited from these trends, and will continue to account for a growing market share.

5.8.2 Current Applications Electrical and lighting hardware systems are the largest area of application for POM in automotive markets accounting for 40% of total market tonnage. Interior parts is the second largest area with 35%, followed by under-the-bonnet parts with 15%, and exterior parts with 10%. Some of the main applications for POM in electrical systems include mountings and brackets for lamp reflectors, gear trains for helical window lift gears, interior input control switches such as multi-function turn signal switches and master light control units, seat adjustment systems, climate control systems and door lock systems. Polyacetals are particularly valued in these applications for their chemical and high temperature resistance, dimensional stability and low wear and friction (gear trains). Interior applications is the second biggest area of application for POM in automotive. In the car interior applications market, acetal is mainly used for door handles, lock mechanisms, loudspeaker grilles, parts for safety systems, sun roof systems, fasteners, manual window systems and seat release buttons. Under-the-bonnet applications for POM include the fuel delivery module and brake systems. They are valued for their outstanding fuel resistance, dimensional stability, reduced swelling and improved fatigue and creep resistance. The main applications for POM in car exteriors are windscreen wipers and door handles.

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5.8.3 Market Trends The key trends influencing further use of POM in automotive applications are discussed next.

5.8.3.1 Inter-Polymer Substitution The growth in use of polyacetals for automotive applications has been much more influenced by its replacement of metal rather than other polymers. There is a potential threat to polyacetals from polyamide. Some OEMs may be encouraged to switch from POM to polyamide for interior applications such as instrument panels, grilles and switches, because of the higher formaldehyde emissions from POM.

5.8.3.2 Product Developments The introduction of better products is creating more opportunities for POM in the automotive market. A new line of UV-stabilised soot-pigmented POM produced by Ticona, for example, is claimed to be more resistant to UV rays due to a better light blocking system. The new materials, which Ticona recommends for windscreen wiper and fuel tank covers, among other applications, use a combination of UV absorbers and free radicals that the company says ensures far less colour differentiation. Ticona has also recently launched an odour-free product, which it is hoped will persuade OEMs to continue using polyacetals for car interior applications.

5.8.3.3 Technology Development The development of outsert technology (metal-plastic composites) offers good growth potential for POM in automotive applications. Another forward-looking application being developed is the combination of POM with injection moulded ‘soft’ components, including NBR rubber and polyester elastomers.

5.8.3.4 Growth in Electrical Systems More electrical systems are being incorporated into each new generation of motor vehicle to ensure greater passenger comfort and safety. These include automatic window systems, electronic seat adjustment, climate control systems, navigation systems and in-car entertainment. Electrical systems make extensive use of POM.

5.8.3.5 Replacement of Metal Metal replacement has been a key driver of demand for polyacetal in automotive applications. Most of the potential replacement has however already occurred and so replacement of traditional materials will be a lower influence on future growth trends. 5.9 Polymethyl Methacrylate (PMMA)

5.9.1 Consumption Trends Automotive accounts for 15% of total PMMA world market volume in 2002. Acrylics have almost fully penetrated all potential glass replacement applications both inside and outside the car, especially in North America and Western Europe. There is however better growth potential in Asia.

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Table 5.12 shows PMMA consumption in automotive applications by world region for the period 1999-2002. Table 5.12 PMMA consumption in automotive applications by world region for the period 1999-2002 (000 tonnes) 1999 2000 2001 2002 Western Europe 40 44 39 43 North America 63 67 63 65 Japan 21 21 18 18 Rest of Asia Pacific 13 15 16 18 TOTAL 137 147 136 144

In 2002, total world consumption of PMMA in automotive applications was 144,000 tonnes against 137,000 tonnes in 1999. Along with other engineering plastics, PMMA volumes declined in 2001 to reach 136,000 tonnes due to the downturn in world automotive production. In 2002, market volumes recovered slightly, but are still below 2000 levels. Table 5.13 shows percentage share of PMMA in automotive applications by world region for the period 1999-2002. Table 5.13 Percentage share of PMMA in automotive applications by world region for the period 1999-2002 1999 2000 2001 2002 Western Europe 29% 30% 29% 30% North America 46% 46% 46% 45% Japan 15% 14% 13% 12% Rest of Asia Pacific 9% 10% 12% 13%

North America is the largest user of PMMA in automotive accounting for 45% of total consumption in 2002. Western Europe is the second largest consumer with 30% of total consumption, followed by ‘Rest of Asia Pacific’ with 13% and Japan with 12% of total world consumption. Once again, the most interesting feature of world consumption patterns is the declining share of Japan and the sharp increase in ‘Rest of Asia Pacific’ region. This is mainly attributable to the trend for car manufactures to produce offshore in other Asian countries to reduce their costs.

5.9.2 Current Applications Electrical and lighting systems are the largest application area for PMMA in the automotive market accounting for two-thirds of total market tonnage. Interior parts account for the remaining third of market tonnage. Acrylics are used mainly as a glass replacement material in automotive lighting systems. Automotive lighting systems includes car headlights, brake lights, indicator lights, back-up lights and fog lights. These lenses are mostly made from polycarbonate, and to a lesser extent, acrylics. Acrylics are used mainly to manufacture lenses for rear lights, indicator lights and brake lights. They cannot be used for manufacture of inner or outer headlamp lenses, where the temperature requirements are too high. The main automotive interior applications for PMMA include dashboard dial covers, dashboard lights, ceiling light covers and emblem covers. Glass car headlight lenses have been virtually replaced by transparent plastics. These plastics can resist high levels of heat, are also shatter-resistant and can be moulded into almost any shape.

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Plastics’ versatility gives the automotive engineer greater freedom for design and placement of car headlights.

5.9.3 Market Trends The key trends influencing further use of PMMA in automotive applications are discussed next.

5.9.3.1 Replacement of Glass Car Headlamp Lenses Glass replacement for headlamp lenses has been the key driver of acrylics in automotive applications. The glass replacement market both inside and outside the car is however almost fully penetrated, which restricts future growth potential. On the other hand, the headlamps and rear lights on new cars are getting bigger for design and safety reasons. Hence, the amount of polymer required per headlamp is increasing. Major changes are imminent in both headlamp and rear light systems with the incorporation of plastics-based LED (Light Emitting Diode) brake-light systems and ‘light box’ systems, whereby an easily accessible single light source is used to provide exterior lighting for the car via acrylic fibre-optic wires. The incorporation of a ‘light box’ will eliminate the need for high heat resistant plastics in automotive lighting systems, allowing substitution for even lighter plastic lenses that retain their ability to resist impacts.

5.9.3.2 New Applications Development The number of dials and displays on the car instrument panels is growing due to incorporation of additional safety and comfort features in more new cars. This is raising demand for PMMA for manufacture of dial and light covers.

5.9.3.3 Inter-Polymer Substitution Acrylics will continue to challenge polycarbonate in glass replacement applications. There may be a possibility that higher temperature resistant acrylics could challenge polycarbonate for inner headlamp lenses in future. There is also a small chance that acrylics may be used by some OEMs instead of other plastics such as ABS for B-posts. 5.10 Polyphenylene Oxide (Ether) Blends (PPO and PPE)

5.10.1 Consumption Trends Automotive is by far the largest market for PPO/PPE blends, representing 52% of total world volume in 2002. Automotive is a growing market for PPO/PPE blends, with particularly good prospects for exterior, and to a lesser extent, interior applications. Some of the major suppliers, most notably GE Plastics, are very active in promoting the use of their Noryl product range and have developed new and improved grades in recent years. Table 5.14 shows PPO/PPE blends consumption in automotive applications by world region for the period 1999-2002. In 2002, total PPO/PPE blend consumption in automotive applications was 185,000 tonnes compared with 180,000 tonnes in 1999. Volumes declined in 2001 to 181,000 tonnes due to the downturn in world automotive production. There was a modest recovery in sales volumes during 2002.

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Table 5.14 PPO/PPE blends consumption in automotive applications by world region for the period 1999-2002 (000 tonnes) 1999 2000 2001 2002 Western Europe 45 48 46 47 North America 99 103 97 99 Japan 36 40 38 39 TOTAL 180 191 181 185

Table 5.15 shows percentage share of PPO/PPE blends in automotive applications by world region for the period 1999-2002. Table 5.15 Percentage share of PPO/PPE blends in automotive applications by world region for the period 1999-2002 1999 2000 2001 2002 Western Europe 25% 25% 25% 25% North America 55% 54% 54% 54% Japan 20% 21% 21% 21%

North America is by far the largest consumer of PPO/PPE blends in automotive, accounting for 54% of total consumption in 2002. Western Europe is the second largest consumer with 25% of total consumption, followed by Japan with 21%. The shares of all major regions have remained fairly stable during the last four years.

5.10.2 Current Applications Modified PPO/PPE blends are used in a wide range of demanding automotive applications as replacement for metal and thermosets. Exterior parts are the largest application area for PPO/PPE blends accounting for 45% of total market tonnage. Interior parts are the second largest area with 30%, with under-the-bonnet applications representing 15% and electrical systems 10% of market tonnage. The main applications are described below. •

Bumpers and fascias – The materials have excellent low temperature impact after painting. High modulus (typically 30-50% greater than TPO) and high heat resistance enable thinner walls for lighter weight and reduced cycle times.

•

Front-end modules – PPO blends have high elongation, low specific gravity and long-term heat resistance.

•

Instrument panels – Main benefits are strong chemical and impact resistance.

•

Under-the-bonnet components – Main features of PPO/PPE blends are chemical resistance, impact resistance and vibration dampening, plus good sound/vibration dampening and resistance to the temperature and moisture extremes typically found under the hood.

•

Grille opening reinforcements – GE Plastics NORYL PPX resins are a popular choice for this application, which requires materials that are tough and dimensionally stable for component system performance, and also moisture, heat and vibration resistant.

5.10.3 Market Trends The key trends influencing further use of PPO/PPE in automotive applications are discussed next. 73


5.10.3.1 Inter-Polymer Substitution The better heat resistance and conductivity have led to replacement of other polymers by PPO/PPE in bumper systems. Also, its better heat resistance and lower odour emissions give PPO/PPE an advantage over PC/ABS for instrument panels. PPO/PPE does however face tough competition from other polymers in key application areas, and manufacturers must convince automotive designers and component manufacturers that it is a better product in terms of quality and total systems cost for it to displace other established systems. PPO/PPE blends cost two to three times more than higher end polyolefins for bumper systems. While the price of PPO blends is likely to come down gradually as production increases, high cost may deter some potential customers.

5.10.3.2 Development of New Applications PPO/PPE blends are finding new applications in the car. The Mercedes A Series for example, uses Noryl PPO/PA blends for the front mudguards. According to Mercedes, these mudguards return to their original shape after a minor accident without any repairs or a paint job being necessary. GE Plastics is also planning to develop more applications for Noryl outside the car during the next two years. The replacement of metal and polyamide for tank flaps is a potential target.

5.10.3.3 New Product Development Constant product development has been a feature in the development of the PPO/PPE product family. Higher conductivity, mineral-filled and low odour emission grades are some examples of how the product has been improved to open up new market opportunities. GE Plastics also introduced an improved, conductive version of Noryl GTX (PPO/PA blend), which dispensed with the need to prime plastic parts before painting them. By adding conductive material, it was possible to develop a thermoplastic that makes it easier to paint hard-to-reach places. 5.11 Polyphenylene Sulfide (PPS)

5.11.1 Consumption Trends Automotive is by far the largest market for PPS, representing 51% of total world volume in 2002. PPS use in automotive markets has seen strong growth in recent years due mainly to its replacement of metal, thermosets and other types of plastic, in more demanding applications. Continued good growth is expected during the next five years. Table 5.16 shows PPS consumption in automotive applications by world region for the period 1999-2002. Table 5.16 PPS consumption in automotive applications by world region for the period 19992002 (000 tonnes) 1999 2000 2001 2002 Western Europe 5 5 5 5 North America 6 7 6 7 Japan 9 10 10 10 Rest of Asia Pacific 4 5 4 5 TOTAL 25 27 25 26

In 2002, total PPS consumption in automotive applications was 26,000 tonnes compared with 25,000 tonnes in 1999. Volumes declined from 27,000 tonnes in 2000 to 25,000 tonnes in 2001 due 74


to the downturn in world automotive production. There was a small improvement in sales volumes in 2002. Table 5.17 shows percentage share of PPS in automotive applications by world region for the period 1999-2002. Table 5.17 Percentage share of PPS in automotive applications by world region for the period 1999-2002 1999 2000 2001 2002 Western Europe 19% 19% 19% 19% North America 26% 26% 25% 25% Japan 38% 38% 39% 38% Rest of Asia Pacific 17% 17% 17% 18%

Japan is the largest consumer of PPS for automotive, accounting for 38% of total consumption in 2002. North America is the second largest consumer with 25% of total consumption, followed by Western Europe with 19% and ‘Rest of Asia Pacific’ with 18%. The ‘Rest of Asia Pacific’ region is increasing at the fastest rate in recent years due to its growing share of automotive production.

5.11.2 Current Applications PPS is an ideal choice for automotive parts exposed to high temperatures, automotive fluids, or mechanical stress. PPS is a lighter weight alternative to metals that is resistant to corrosion by salts and all automotive fluids. The ability to mould complex parts to tight tolerances and insert moulding capability accommodate multiple component integration. Under-the-bonnet is the largest application area for PPS accounting for 70% of total market tonnage. Electrical parts account for the remaining 30%, as PPS is rarely used for manufacture of interior and exterior parts. PPS is used in the following automotive applications. •

Fuel/Induction Systems – EGR (exhaust gas recirculation) components, fuel flow sensors, fuel line connectors, fuel pump components, fuel rails, injector bobbins, throttle bodies/deactivator.

•

Coolant Systems – extension tubes, heater core tanks, thermostat housings, valve components, water inlets/outlets, water pump impellers.

•

Brake Systems – ABS brake pistons, ABS motor components, booster pistons, electric brakes, valve bodies.

•

Electrical Systems – alternator components, connectors, ignition components, motor brush cards, sensors, switches.

•

Powertrain/Transmission – engine gasket carriers, lock-up collars, seal housings, servo covers, servo pistons, shift cams/forks, stators and transmission pistons.

•

Automotive Lighting – bulb housings, reflectors, sockets.

5.11.3 Market Trends The key trends influencing further use of PPS in automotive applications are discussed next.

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5.11.3.1 Replacement of Traditional Materials PPS growth has mainly come about by replacement of parts made from metal and thermosets, both under-the-bonnet and in electrical applications. While PPS may cost more than most metals and thermosets, the total production cost of PPS parts is very competitive with traditional materials, which has encouraged growth.

5.11.3.2 Inter-Polymer Substitution Increasing temperature requirements under-the-bonnet has led to PPS replacing other plastics such as polyamide. Also, the share of diesel engines is increasing which is further encouraging growth in high temperature thermoplastics such as PPS at the expense of other plastics. Polyamide and polyesters continue to challenge PPS in certain applications in which the superior performance properties of PPS are not critical. Also, the high cost of PPS compared to PBT and polyamide, means that it remains uncompetitive with these materials in many applications.

5.11.3.3 New Applications Development The US company Plastic Molding Corporation (PMC), is using the polyphenylene sulfide (PPS) from Ticona GmbH for the production of fuel pumps. The company claims that PPS achieves air chamber tolerances in production of below 0.05 mm, a figure that appeared impossible with other materials in the production of various fuel pumps. PPS is also finding new moulding applications under-the-bonnet because of its advantages and properties.

5.11.3.4 New Product Developments The new PPS grade in Ticona’s Fortron range resists aggressive media such as gasoline, diesel or liquefied natural gas when used, for example, as a barrier layer in fuel lines. Tests carried out at the US manufacturer of flexible fuel lines, Total Containment Inc., showed, among other things, that it is suitable for UL listing. 5.12 Polyetherimide (PEI)

5.12.1 Consumption Trends Automotive is by far the largest market for polyetherimide, representing 50% of total world volume in 2002. Polyetherimide usage in automotive applications has been increasing in recent years due to its replacement of metal, thermosets and bulk moulding compounds (BMC). There is still scope for further use of PEI in car electrical and under-the-bonnet applications, which will underpin good growth prospects. Table 5.18 shows polyetherimide consumption in automotive applications by world region for the period 1999-2002. Total polyetherimide consumption in automotive applications was 7,000 tonnes in 2002. Demand for PEI was increasing up to 2001 when consumption fell due to the downturn in world automotive production. In 2002, there was a modest recovery in sales volumes.

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Table 5.18 Polyetherimide consumption in automotive applications by world region for the period 1999-2002 (000 tonnes) 1999 2000 2001 2002 Western Europe 1 2 1 1 North America 4 5 4 4 Japan 1 1 1 1 Rest of Asia Pacific 1 1 1 1 TOTAL 7 8 7 7

Table 5.19 shows percentage share of PEI in automotive applications by world region for the period 1999-2002. Table 5.19 Percentage share of polyetherimide in automotive applications by world region for the period 1999-2002 1999 2000 2001 2002 Western Europe 20% 20% 19% 19% North America 60% 60% 60% 60% Japan 10% 10% 10% 9% Rest of Asia Pacific 10% 10% 11% 11%

North America is the largest consumer of PEI for automotive, accounting for 60% of total consumption in 2002. Western Europe is the second largest consumer with 19% of total consumption, followed by ‘Rest of Asia Pacific’ with 11% and Japan with 9%.

5.12.2 Current Applications Electrical and lighting systems are the largest application area for PEI in the automotive market, accounting for 90% of total market volume. Under-the-bonnet parts account for the remaining 10% of market volume. PEI is used in applications that require a high heat resistance material, high strength, modulus and broad chemical resistance. The principal automotive applications for PEI include transmission components, throttle bodies, ignition components, thermostat housings, bezels, reflectors, lamp sockets, and electromechanical systems such as fuses, gears, bearings, solenoid bodies, ignition switches and oil pump drives. PEI is also widely used in automotive lighting applications such as headlight reflectors, fog light reflectors, bezels and light bulb sockets. PEI is selected for its high heat resistance (up to 200 °C), ability to be metallised without a primer, and its competitive systems cost versus thermosets. PEI is also widely used in the aircraft industry. Main applications include air and fuel valves, food tray containers, steering wheels, interior cladding parts and semi-structural components. PEI is selected for internal aircraft applications for its inherent flame retardancy and low smoke emissions. It also has excellent chemical resistance to fuels and fluids used in the aircraft industry.

5.12.3 Market Trends The key trends influencing further use of polyetherimide in automotive and aircraft applications are discussed next.

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5.12.3.1 Replacement of Traditional Materials A key driver of PEI growth in automotive applications is replacement of metal, thermosets and bulk moulding compounds (BMC), due to its greater cost efficiency in manufacture of complex parts. The dimensional stability offered by PEI is another selling point together with its high heat performance and chemical resistance. There is still scope for further use of PEI in car electrical and under-the-bonnet applications, which will underpin its continued growth. Polyetherimide is also now being used in the headlamp systems in some US cars instead of BMC. The benefits claimed by GE Plastics for its Ultem product are greater ease of design and processing, lower scrap, simpler post-processing and melt recyclability.

5.12.3.2 Growth in Electrical Systems PEI is most often found in electrical systems, a market segment which is showing the fastest growth for plastics in the automotive industry. New and improved electrical systems are being introduced into each new generation of passenger car to give better safety and comfort features. This will continue to bolster growth in use of PEI in future.

5.12.3.3 Inter-Polymer Substitution Polyetherimide is in competition with other less expensive high performance polymers such as PSU and PES. It is however a very cost effective material and the total systems cost of using PEI compares favourably with competing materials.

5.12.3.4 Product Development Attention is focused on improving the flow of the material in order to reduce cycle times for injection moulding complex and thin-walled components. GE Plastics has found for example that the viscosity of PEI can be reduced by 50% with the addition of a small amount of PPO polymer. The mechanical properties of PEI remain constant with the addition of the PPO. There are also advantages with glass fibre-reinforced materials. For example, the typical processing temperature with 30% glass fibre-reinforced PEI (360-380 °C) blended with 21% PPO can be reduced to 310-340 °C. This flow-optimised technology can find applications in, for example, automotive headlamp reflectors, lamp bases, throttles, chip carriers and aerials. 5.13 Polysulfone (PSU), Polyethersulfone (PES)

5.13.1 Consumption Trends Automotive markets represented 20% of total world PSU/PES consumption in 2002. PSU/PES has found growing usage in automotive applications in recent years. A key driver has been replacement of metal and thermoset materials. Table 5.20 shows PSU/PES consumption in automotive applications by world region for the period 1999-2002. Total PSU/PES consumption in automotive applications was 4,500 tonnes in 2002 compared with 4,100 tonnes in 1999. Demand for PSU/PES was increasing at a fast rate up to 2001, when consumption fell due to the downturn in world automotive production. There was some recovery in sales volumes during 2002.

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Table 5.20 PSU/PES consumption in automotive applications by world region for the period 1999-2002 (000 tonnes) 1999 2000 2001 2002 Western Europe 0.7 0.8 0.8 0.8 North America 2.5 2.7 2.6 2.7 Japan 0.4 0.5 0.5 0.5 Rest of Asia Pacific 0.5 0.5 0.5 0.6 TOTAL 4.1 4.4 4.3 4.5

Table 5.21 shows percentage share of PSU/PES in automotive applications by world region for the period 1999-2002. Table 5.21 Percentage share of PSU/PES in automotive applications by world region for the period 1999-2002 1999 2000 2001 2002 Western Europe 17% 19% 18% 18% North America 62% 61% 61% 59% Japan 10% 10% 11% 11% Rest of Asia Pacific 11% 10% 11% 12%

The North American market is easily the largest consumer of PSU/PES for automotive, accounting for 59% of total consumption in 2002. Western Europe is the second largest consumer with 18% of total consumption, followed by ‘Rest of Asia Pacific’ with 12% and Japan with 11%.

5.13.2 Current Applications PES and PSU are very high temperature resistant amorphous thermoplastics that are used where the performance requirements exceed the capabilities of other engineering plastics such as polyamide, PBT and polyacetals. PES and PSU can also replace thermosets, metals and ceramics. The main reasons for PES/PSU being used in automotive applications are their high stiffness, continuous operating temperatures, high mechanical strength, good electrical insulation properties, resistance to lubricants, and good dimensional stability. In the car, the main applications for PSU and PES are found under-the-bonnet such as battery caps, oil pumps, oil control pistons, transmission parts, carburettor parts, bearing cages and ignition components. PES and PSU are also found in car headlights (screens, housings and reflectors). Glass fibre-reinforced PES is also particularly well suited to engine oil circulation systems. In engine oil circulation systems glass fibre-reinforced PES is particularly suitable, since the polymer matrix ensures the necessary thermal and dimensional stability when in contact with hot engine oil. In addition there are the outstanding mechanical and tribological characteristics up to high temperatures. PES/PSU are also used for aircraft interior and exterior components.

5.13.3 Market Trends 5.13.3.1 Replacement of Thermosets The direct metallisability of injection moulded PES components using vacuum coating processes combined with increased freedom regarding the design of headlights is a great advantage over thermosets. A substantially simplified production process offsets the higher price of PES. Thus the

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intermediate steps necessary with thermosetting polymers such as cleaning, drying and painting are eliminated. 5.14 Liquid Crystal Polymers (LCP)

5.14.1 Consumption Trends Automotive is one of the smallest markets for LCP, representing just 5% of total world volume in 2002. Table 5.22 shows LCP consumption in automotive applications by world region for the period 1999-2002. Table 5.22 LCP consumption in automotive applications by world region for the period 19992002 (000 tonnes) 1999 2000 2001 2002 Western Europe 0.1 0.1 0.1 0.1 North America 0.2 0.3 0.2 0.2 Japan 0.4 0.5 0.5 0.5 TOTAL 0.8 0.9 0.8 0.9

Total LCP consumption in automotive applications was 900 tonnes in 2002 against 800 tonnes in 1999. Demand for LCP was increasing up to 2001 when consumption fell due to the downturn in world automotive production. In 2002, there was a modest recovery in sales volumes. Table 5.23 shows percentage share of LCP in automotive applications by world region for the period 1999-2002. Table 5.23 Percentage share of LCP in automotive applications by world region for the period 1999-2002 1999 2000 2001 2002 Western Europe 13% 13% 13% 13% North America 28% 28% 26% 25% Japan 59% 59% 62% 62%

Japan is by far the largest consumer of LCP for automotive, accounting for 62% of total consumption in 2002. North America is the second largest consumer with 25% of total consumption, followed by Western Europe with 13%. Japan’s market share has grown from 59% in 1999.

5.14.2 Current Applications Liquid crystal polymers have excellent dimensional stability and creep resistance, especially at very high temperatures. They are highly resistant to many chemicals, including concentrated acids, bases and hydrocarbons. They also display outstanding fatigue resistance and high dielectric strength performance over a very wide temperature range. These properties make them especially suitable for automotive ignition system components, lamp sockets, transmission system components, pump components, coil forms and sensors.

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5.14.3 Market Trends 5.14.3.1 Lead-Free Soldering Methods The introduction of the lead-free soldering method has led to an increase in the temperature requirements of between 20-30 °C and thus created a demand for products with improved properties.

5.14.3.2 Material Replacement Materials that are resistant to high temperatures such as ceramics, metals and thermosets, may be driven out of their existing application areas and replaced by the more cost-efficient injection moulding process with LCP. 5.15 Polyetheretherketone (PEEK)

5.15.1 Consumption Trends Automotive is the largest market for PEEK polymers accounting for 41% of total world volume in 2002. PEEK is one of the leading high-performance plastics that are replacing metal for under-thebonnet applications. Table 5.24 shows PEEK consumption in automotive applications by world region for the period 1999-2002. Table 5.24 PEEK consumption in automotive applications by world region for the period 1999-2002 (000 tonnes) 1999 2000 2001 2002 Western Europe 0.3 0.3 0.4 0.4 North America 0.2 0.2 0.3 0.2 Japan 0.03 0.03 0.04 0.02 TOTAL 0.5 0.6 0.7 0.5

Total PEEK consumption in automotive applications was 500 tonnes in 2002. Demand for PEEK was growing at a fast rate up to 2002 when consumption fell due to the downturn in world automotive production. Table 5.25 shows percentage share of PEEK in automotive applications by world region for the period 1999-2002. Table 5.25 Percentage share of PEEK in automotive applications by world region for the period 1999-2002 1999 2000 2001 2002 Western Europe 59% 59% 59% 65% North America 35% 36% 36% 31% Japan 6% 5% 6% 4%

Western Europe is by far the largest consumer of PEEK polymers in automotive, accounting for 65% of total consumption in 2002. North America is the second largest consumer with 31% of total consumption, followed by Japan with 4%.

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5.15.2 Current Applications With the trend towards higher operating temperatures and miniaturization in the engine compartment, plastics replacing metals also offer weight reduction, noise reduction and functional integration. PEEK is one of those high performance polymers that can be used in very demanding applications as a replacement for metal. The most important performance benefits of PEEK are enhanced dry and lubricated surface interaction, outstanding mechanical performance over a wide temperature range, ease of processing and excellent fatigue properties. Key automotive applications are found under-the-bonnet, including piston units, seals, washers, bearings and various active components used in applications such as transmission, braking and air-conditioning systems. In the aerospace market, PEEK polymers are replacing aluminium and other metals in a wide range of applications. The polymer combines outstanding physical and thermal characteristics with light weight and ease of processing. High numbers of large volume components with fine tolerances can be cost-effectively formed and used without assembly or modification. Applications for PEEK in the aerospace industry include critical engine parts as the polymer can withstand high temperatures and the tribological interaction of dry and lubricated material contacts. In aircraft exterior parts, PEEK provides excellent resistance to rain erosion, while for aircraft interior components, its inherent flame retardancy and low smoke and toxic gas emission reduce hazard in the event of a fire. In aircraft electrical systems, the polymer is used for manufacture of convoluted tubing to protect wires and fibre optic filaments. PEEK is also used to protect the wire harnesses used in commercial aircraft engines.

5.15.3 Market Trends 5.15.3.1 New Applications Victrex has developed a number of new applications for PEEK polymers in the automotive market in recent years as a replacement for metal and aluminium. These are described next. In the engine control system, the piston used to regulate airflow in the engine control system, comprises a metal bushing overmoulded with PEEK polymer. This was designed and manufactured by VDO Adolf Schindling AG, a business unit of the Mannesmann Automotive Division. ZF Friedrichshafen AG of Germany has replaced nitride metal with Victrex PEEK polymer for the starting disks in Ecomat local transportation bus gears. Robert Bosch GmbH of Germany has replaced metal with a carbon fibre filled grade of PEEK polymer for a number of functional components in its second generation ABS brake system. PEEK polymer oil screens are well established on Mercedes-Benz trucks. Developed by KarcomaArmaturen GmbH, Germany, the screens maintain their high mechanical strength after repeated exposure to hot oil at temperatures in excess of 180 °C. PEEK polymers are being used in the power transmission thrust washers from Borg-Warner Automotive. Used in Chrysler’s Viper high performance sports car, the washers withstand immersion in lubricating oil and operate over a wide temperature range. 5.16 Polyphthalamide (PPA)

5.16.1 Consumption Trends Market data is unavailable for PPA, given the limited number of suppliers.

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5.16.2 Current Applications Solvay’s Amodel PPA resin features an excellent stiffness-to-cost ratio and a high strength-toweight ratio, both of which are superior relative to PBT, PPS, PEI, PET and PA 6,6. Its thermal performance is exceeded only by polyetheretherketone (PEEK) and some LCPs; its warpage and dimensional stability match PPS. Amodel resin has lower moisture absorption than PA 6,6, and its broad chemical resistance is exceeded only by a handful of more costly speciality polymers. PPA is used for many types of automotive components including sensors and solenoids, halogen lamp sockets and fog lamp assemblies, motor end caps and housings, fuel system components (flanges, fuel rails, fuel line connectors), anti-lock braking system components, cooling and heating system components (thermostat housings, oil filter housings, turbo charger air coolers). PPA is also used in a range of high temperature applications in the automotive electronics sector such as lamp sockets, electronics connectors, high-temperature switches, and sensors. PPA provides high strength, stiffness and impact resistance, plus a heat deflection temperature of 282 °C (540°F). PPA resin is also dimensionally stable and resists corrosion.

5.16.3 Market Trends 5.16.3.1 New Applications In 2002, Solvay Advanced Polymers announced a number of new automotive applications for Amodel PPA resins. PPA replaced aluminium in the fuel-air rail in a system developed by Synerjet for use in European motor scooters. Heat resistance was a major consideration in the selection of PPA, because of the proximity of the rail to the cylinder head where operating temperature can be as high as 160 °C. Delphi Automotive chose Amodel for the engine air control valve for an outboard engine application. Amodel was selected by Chrysler for the thermostat housing on the 2.4 litre, 4-cylinder vehicle that is standard on rear-wheel drive versions of the new Jeep Liberty sports utility vehicle. Amodel was selected for a key injection moulded component on the current and new GEN11 and Global series of brake vacuum boosters from Delphi Automotive Systems.

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6 Electrical and Electronics Applications for Engineering and High Performance Plastics 6.1 Introduction This section examines the use of engineering and high performance plastics in electrical equipment and electronics industries, including telecommunications. Applications covered are electronics parts and components such as switches and connectors, business and electrical equipment housing, wire and cables, electrical lighting parts and lenses. The world electrical and electronics market has shown strong growth since the mid 1990s on the back of the Internet and telecommunications revolution. This has been extremely good news for plastics producers given the developing uses for plastic in E&E applications as a replacement for traditional materials such as metal and thermosets. In Western Europe, for example, the electrical and electronics industry grew at an average annual rate of 4.3% between 1995-2000. According to the APME, a total of 13.5 million tonnes of electrical and electronic appliances were produced, using 1.48 million tonnes of plastics in 2000. The amount of plastic material used in electrical and electronic products in terms of weight rose from 15% in 1980 to 20% in 2000. Cables and electrical components, with 595,000 tonnes, are the largest applications for plastics in 2000, followed by information technology and telecommunications. Large domestic appliances (refrigerators, dishwashers, microwave ovens etc.), is the third largest consumer. The domestic appliances sector was followed by consumer electronics (television sets, video recorders, radios, DVD players etc.) with 217,000 tonnes. Some 63% of the ABS used by the electrical and electronics industry annually goes into these applications. The segment of small domestic appliances (toasters, cookers, vacuum cleaners etc.) consumes a quite impressive amount of 151,000 tonnes of plastics. E&E sector growth has slowed considerably since 2000 due to the world economic slowdown and the major downturn in the IT and telecom sectors. Demand in the key high technology and electronics sectors was down by 30% in 2001. The mobile phone and IT sectors were down further in 2002, but are predicted to undergo a modest recovery from the second half of 2003. For 2005, APME predicts an increase of plastics consumption in the western European electrical and electronics industry to 1.9 million tonnes. At that time, the amount of plastics waste created in this segment is forecast to reach 1.1 million tonnes. 6.2 Trends and Market Drivers Important trends that are driving the E&E industry, which are influencing materials selection and performance include: 1. Thin-wall design, as a means of reducing system cost. 2. The ability to meet more stringent technical specifications. This includes the new European Union standard IEC-60335-1, which introduces tougher testing methods for materials used in unattended domestic appliances. 3. The quest for high quality and reliability, driven by expected application lifetimes of 5-20 years. 4. Growing market requirements for materials that are either halogen free, or have low halogen content. 85


5. Low warpage materials are being more generally adopted as a means of improving productivity and reducing shrinkage. 6. OEMs are increasingly looking to adopt a ‘smart design’ approach, focused on design for manufacturing and assembly (DFMA). Ease of installation for professional installers is also becoming increasingly important, and can in many cases be improved by using snap fit features and ductility of engineering thermoplastics. 7. Design flexibility offered by engineering thermoplastics is increasingly being used to differentiate products from the competition. In response to these trends, and as a means of achieving significant cost-cuts while continuing to improve quality and reliability. OEMs are increasingly using engineering thermoplastics, often replacing thermoset and metal. 8. Miniaturization, which increases the temperature and mechanical requirements of plastic materials. Further miniaturisation, pressure from competitors, and increasing demands on quality and durability will greatly promote the use of engineering plastics in electrical and electronic applications. 9. Consolidation and globalisation are well-advanced trends in the E&E industry. To support these trends, suppliers increasingly require a global sales and marketing network capable of supporting customers both locally, and on a global scale. Trends in the telecoms market that are affecting material selection are summarized below. 1. Technological convergence. Established technologies are merging with new ones, converging all communication tools into a single medium to which fixed or wireless connection is also becoming increasingly seamless. 2. Development of global standards for telecom equipment is beneficial to market growth. 3. Product differentiation and personalization is a key driver for individual product sales. 4. In the mobile phones, WAP phones and personal digital assistants markets, increased functional integration is placing ever-increasing demands on the materials from which these devices are made. 5. Growing demand for wireless communication, fuelled by the merging of cordless and cellular technologies; while the Internet and new developments such as IMT 2000 (the 3rd generation global communication standard) are redefining communication technologies. The collapse of the mobile telephone market in the second half of 2000 and subsequent downturn in other electronic markets, and especially computer production, has led to new structures emerging in the production market. The changes have prompted massive outsourcing of production steps by the big OEM electronics groups. During the boom, these companies built up huge capacities of their own, which are now recording high losses and acting as millstones around their necks. Only 13% of production has been outsourced so far but this figure could soon rise to 70%. Reports have also featured on the American-Asian production group Flextronics, with its successful strategy of all-in production for OEMs in central industrial parks located in low-wage countries. The company has grown rapidly and has more than 70,000 employees worldwide and sales of $12 billion in 2001. Many plastics converters working directly or indirectly in the electronic supply sector are now forced to cooperate with this group, whose main capacities are concentrated in China, Mexico and Hungary.

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‘Enclosure systems’ is the magic word at the companies, which produce electronic components of all different types. These are systems that unite components in a wide range of materials and with different functions in an overall system that is generally encased in plastic. The overall market for these systems is put at some $4 billion for 2003. In line with this strategy of focusing on application customers, Dow Chemicals set up its new Dow Inclosia Solutions business unit for the electronics industry. Shortly after the company was founded, Finnish injection moulding company Eimo, announced a development partnership with the new Dow division. Further concentrations in the new, global marketplace through mergers, alliances and cooperation will be vital for the survival of small and medium-sized companies. 6.3 Future Prospects for the World E&E Industry The world electronics and telecom markets have experienced a substantial downturn since 2000. This has resulted in a major decline in demand for engineering and high performance plastics. There are signs that demand may be about to recover in several important end user markets, which should bolster future demand prospects for plastic materials. An examination of some leading indicators of future end user market demand shows that there is some cause for optimism. Tables 6.1, 6.2 and 6.3 present market forecasts by some leading IT and telecom industry consultants for key applications. Table 6.1 shows worldwide shipments of cellular phones. Table 6.2 shows personal computer sales and Table 6.3 shows monitor and display sales. Table 6.1 Worldwide shipments of cellular phones Millions of units 2002 2003 Cellular phones 404.4 434.8 Annual growth (%) -2.4 7.5 Source Strategy Analytics, London

Table 6.2 Personal computer sales Millions of units 2002 2003 Worldwide 136.2 147.5 US 47.4 50.8 Asia Pacific, excl Japan 25.0 29.0 Worldwide annual growth (%) 2.0 8.0 Source: IDC, Framingham, MA

Table 6.3 Monitor and display sales Millions of units 2002 2003 CRT monitors 79.2 80.1 CRT televisions 152.5 158.5 LCD monitors 28.4 37.1 LCD televisions 1.4 3.0 Plasma displays 0.5 0.9 Front/rear projection 5.1 6.0 Total 267.1 285.7 Annual growth (%) 2.0 6.7 Source: iSuppli/Stanford Resources, Boston, MA

2004 489.9 12.7

2004 163.8 55.8 35.0 11.0

2004 79.1 166.1 52.9 5.9 1.7 7.2 313.0 9.5

All three sectors are expected to show a substantial recovery in sales during the next two years. 87


Another major indicator of future demand for plastics in the E&E sector is the fortunes of the world semiconductor industry. According to the Semiconductor Industry Association (SIA), global semiconductor sales revenues for 2002 reached $140.7 billion, a 1.3% increase from 2001. The recovery that began in the final quarter of 2001 continued throughout 2002, which is a good performance, given the lackluster demand in the Information Technology market. For 2003, the SIA predicts 19.8% growth with revenues increasing to $169.3 billion. The worldwide wireless sector recorded the most vigorous growth. Unit sales of handsets grew by double-digits in the fourth quarter of 2002, producing growth of 13.2% in Flash and 6.8% in Digital Signal Processors. New subscribers continue to set records in Asia, particularly in China, which is adding some 5 million new users each month. PCs continue to be the single largest end market for semiconductors, accounting for 30% of total chip consumption. There is some evidence that the corporate buyer is returning to the market. During the December quarter due to increased PC demand, microprocessors and DRAMs were up 10.1% and 7.6% respectively. The consumer sector, including DVDs and digital cameras, continues to drive new growth, especially in application specific products. WiFi (802.11) has emerged as another brisk growth driver for semiconductors, as Wireless Local Access Networks (WLAN) are spreading rapidly around the world. The compound annual growth rate of WLAN is expected to exceed 35% over the 2000-2005 forecast period. Asia Pacific continues to be the world’s fastest growing market, recording a 29% increase in chip sales during 2002, pushing it past the Americas as the world’s largest market, with a 36% share. For the year 2002, chip sales declined 13% in the Americas, 8% in Japan and 8% in Europe from 2001 levels, as electronic equipment production continues an unprecedented migration to facilities in the Asia Pacific region. 6.4 Developments in Industry Regulations and Standards

6.4.1 The EU Directive on Electrical & Electronics Waste Under a new EU Directive on Waste Electrical and Electronic Equipment (WEEE), the electrical and electronics industries will be required to take back used computers, refrigerators and other scrap free of charge and recycle them according to environmentally friendly methods starting in 2005. This was agreed in October, 2002 by the EU Council of Ministers and the European Parliament conciliation committee. The directive foresees minimum quotas of 50% (household appliances) to 75% (large appliances) for mechanical recycling of electrical and electronic equipment starting in 2007. If the Council of Ministers and the European Parliament approve the compromise agreement, the new directive could take effect from 2003. Member states would then have until mid 2004 to transpose the legislation into national law. In any case, the process will consume considerable sums of money. The E&E industry in Germany, arguably the EU’s largest market for such products, has calculated annual costs of €350-500m for the handling of an estimated 1.1 million tonnes of scrap. The Industry Council for Electronic Equipment Recycling (ICER) is reviewing all the materials used in electrical products and will be recommending use of plastics that are compatible with recycling. They will then issue phase-out guidelines for other materials to suppliers. ICER claims that ideally the same polymer should be used throughout a product. If that is not possible, then compatible types should be used. This will help separation at end-of-life for recycling, as the resulting blend will be a usable alloy.

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6.4.2 EU Directive (IEC-60335-1) on Unattended Domestic Appliances New flame retardant regulations relating to unattended domestic appliances have been introduced as part of the EU Directive IEC 60335-1, which aims to harmonise material testing methods. The new standards have particular relevance for polyamide and polyesters used in these applications, but are not a problem for polycarbonates, which pass the new tests, even without the addition of flame retardants. The new standard introduces the concept of the Glow-Wire Ignition Temperature (GWIT) test. The GWIT is a measure of ignitability of a material. To determine the temperature, three test specimens are brought into contact with a glowing wire, each for thirty seconds. The material passes if it does not ignite in any of the three specimen tests, and/or a flame is visible for no longer than five seconds. It receives its grade in the form of a so-called GWIT classification, which is 25 °C higher than the maximum temperature at the top of the glow wire that did not cause ignition of the material in the three tests. Plastics for parts carrying over a 0.2 A current in unattended domestic appliances such as refrigerators, washing machines and dishwashers must now undergo GWIT testing under the new regulations. A material can only be considered usable if a specimen proves that it has a GWIT of 850 °C at a thickness conforming to the wall thickness of the application. If it does it may be used without restriction for the domestic appliances listed in the standard. If it fails, further timeconsuming tests must be carried out on the material. 6.5 Polyamide

6.5.1 Consumption Trends The electrical & electronics sector is the second most important market for polyamide accounting for 24% of total world demand in 2002. The use of PA in electrical applications has grown significantly in recent decades due to its excellent flame retardancy, and good balance of mechanical and thermal properties. Polyamide also permits better functionality and design at a lower cost than competing materials such as thermosets and metal. Table 6.4 shows polyamide consumption in E&E applications by world region for the period 19992002. Table 6.4 Polyamide consumption in E&E applications by world region, 1999-2002 (000 tonnes) 1999 2000 2001 2002 Western Europe 171 184 173 180 North America 113 117 106 110 Japan 39 41 37 38 Rest of Asia Pacific 85 95 92 101 Rest of World 33 37 34 36 TOTAL 441 474 442 465

In 2002, total polyamide consumption in E&E applications amounted to 465,000 tonnes against 441,000 tonnes in 1999. Market tonnage declined in 2001 due to the major downturn in world E&E markets. Demand recovered slightly in 2002, particularly in China and Western Europe. Table 6.5 shows percentage share by world region of polyamide in E&E applications for the period 1999-2002.

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Table 6.5 Percentage share by world region of polyamide in E&E applications, 1999-2002 1999 2000 2001 2002 Western Europe 39% 39% 39% 39% North America 26% 25% 24% 23% Japan 9% 9% 8% 8% Rest of Asia Pacific 19% 20% 21% 22% Rest of World 7% 8% 8% 8%

Western Europe is the largest user of polyamide in E&E, accounting for 39% of total consumption in 2002. North America with 23% is the second largest market, followed by Asia with 30%. The share of China and other Pacific Rim countries is growing and is forecast to increase further in future because of the trend for E&E manufacturers to relocate production to lower cost economies.

6.5.2 Current Applications The main applications for polyamides in the E&E sector are low-voltage switchgears, connectors, bobbins and electromotor parts in a range of electrical equipment including household appliance and mobile phones. Low-voltage switchgears include miniature circuit breakers, residual current devices, fuses, switches, and relays and contactors. The connectors market consists of various sub-segments including automotive connectors, printed circuit board connectors, industrial connectors, wire-to-wire connectors, and various other types. Polyamide is used for the manufacture of tubes for protection of wire and cables. Due to its high temperature resistance, flexibility and chemical resistance, PA tubes are mainly used in automotive under-the-bonnet applications. Polyamide is also used to make the filaments in electric light bulbs.

6.5.3 Market Trends The key trends influencing further use of polyamide in E&E applications are discussed next.

6.5.3.1 Product Developments A new, easy-flow, special grade of Durethan polyamides was unveiled from Bayer AG in 2002. The company claims a 15% reduction in cycle time for the thin-wall technique. The low melt viscosity of these easy-flow variants also means that the filling pressure in the mould can be reduced by up to 30% for non-reinforced grades. These new grades are especially suitable for parts in the E&E sector. Bayer is also launching a number of new flame retardant Durethan grades that comply with the stricter testing methods relating to unattended domestic appliances (IEC60335-1). Possible applications include housing parts for pumps, electrical switches integrated into the control panel of washing machines or dishwashers and light-bulb sockets in refrigerators. In 2001, DSM Engineering Plastics introduced a new grade of Akulon PA6. The flow properties of ‘Akulon Ultraflow’ are up to 80% better than those of standard-grade PA6, and cycle times in injection moulding can be reduced by up to 25%. There are many possible new applications for the material, although it is especially suitable for thin-walled parts. DSM also introduced a flame retardant, reinforced grade of PA46 with its ‘Stanyl High Flow’. This has the same flow 90


characteristics as LCP and is 40% cheaper. As a rival to LCP, DSM is targeting electronics applications. In 2001, Mitsui Chemicals announced that it had developed a new grade of aromatic polyamide, which was designed to improve reflow solder resistance. In the electronics parts market, there is a shift from lead-eutectic solder to lead-free solder. Improvement of heat resistance is required for resins because lead-free solder has a higher melting point than conventional solder.

6.5.3.2 Inter-Polymer Substitution PBT and polyamide 66 are the most commonly used plastics for electrical connectors. The two polymers together have a market share of 10-15% in the $25 billion world market for connectors, of which North America accounts for $10 billion. For reinforced polyamide 66, an annual growth rate of 5-7% is forecast for the years 2000-2002. Higher performance plastics such as LCP and PPS are increasingly taking over in the electronics segment from the PA66 that has so far dominated the scene. Most electrical connectors (300 million per year) are used in computers and their peripherals, followed by telephone and data transmission applications. 6.6 Acrylonitrile-Butadiene-Styrene (ABS)

6.6.1 Consumption Trends The E&E sector is an important market for ABS accounting for 25% of total world demand in 2002. Table 6.6 shows ABS consumption in E&E applications by world region for the period 1999-2002. Table 6.6 ABS consumption in E&E applications by world region, 1999-2002 (000 tonnes) 1999 2000 2001 2002 Western Europe 130 144 120 122 North America 505 510 470 474 Japan 175 175 162 165 Rest of Asia Pacific 350 390 380 406 TOTAL 1160 1219 1132 1167

In 2002, total ABS consumption in E&E applications amounted to 1,167,000 tonnes against 1,160,000 tonnes in 1999. Market tonnage declined in 2001 due to the major downturn in world E&E markets. In 2002, demand recovered slightly in North America and Europe, but showed much higher growth in China and other Pacific Rim countries. Table 6.7 shows percentage share by world region of ABS in E&E applications for the period 1999-2002. Table 6.7 Percentage share by world region of ABS in E&E applications, 1999-2002 1999 2000 2001 2002 Western Europe 11% 12% 11% 10% North America 44% 42% 42% 41% Japan 15% 14% 14% 14% Rest of Asia Pacific 30% 32% 34% 35%

North America is the largest user of ABS in E&E, accounting for 41% of total consumption in 2002. ‘Rest of Asia Pacific’ with 35% is the second largest market, followed by Japan with 14%

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and Western Europe with 10%. These consumption patterns largely reflect the location of major producers of IT and telecommunications equipment. The share of China and other Pacific Rim countries is growing and is forecast to increase further in future because of the trend for E&E manufacturers to relocate production to lower cost economies.

6.6.2 Current Applications ABS is the preferred material for IT and telecom equipment housings and covers because of its good toughness, strength, rigidity and chemical resistance, excellent surface finish and easy processing. The material also has excellent antistatic properties. ABS and PC/ABS blends are used in housings for many different products from personal computers, photocopiers and fax machines, to mobile phones and personal organisers.

6.6.3 Market Trends The key trend influencing further use of ABS in E&E applications is product improvement to comply with tougher international standards. World environmental safety standards such as TCO99, Blue Angel, White Swan or EU are getting tighter. At the same time resins must satisfy the fire safety criteria of UL. Producers are responding to these trends by introducing new eco-conforming, flame retardant (FR) technology. PC/ABS blends in particular, provide an exceptional combination of high flow and strength, which permits thinner walls, while reducing cycle time and improving aesthetics. 6.7 Polybutylene Terephthalate (PBT)

6.7.1 Consumption Trends E&E is the second most important market for PBT and represents 32% of total world demand in 2002. Table 6.8 shows PBT consumption in E&E applications by world region for the period 1999-2002. Table 6.8 PBT consumption in E&E applications by world region, 1999-2002 (000 tonnes) 1999 2000 2001 2002 Western Europe 33 36 34 36 North America 32 35 32 34 Japan 38 44 40 41 Rest of Asia Pacific 34 40 38 40 Rest of World 3 4 3 3 TOTAL 140 159 147 154

In 2002, total PBT consumption in E&E applications amounted to 154,000 tonnes compared with 140,000 tonnes in 1999. Demand was growing at a fast rate up to 2001 when market tonnage declined due to the downturn in world E&E markets. In 2002, demand was up slightly in Europe and North America, but showed much stronger growth in China and other Pacific Rim countries. Table 6.9 shows percentage share by world region of PBT in E&E applications for the period 19992002. Japan and ‘Rest of Asia Pacific’ are the leading users of PBT in E&E, accounting for 27% and 26% respectively of total world consumption in 2002. Europe is the next largest market, followed by North America. These consumption patterns largely reflect the location of major producers of IT 92


and telecommunications equipment. The share of China and other Pacific Rim countries is growing and is forecast to increase further in future because of the trend for E&E manufacturers to relocate production to lower cost economies. Table 6.9 Percentage share by world region of PBT in E&E applications, 1999-2002 1999 2000 2001 2002 Western Europe 24% 23% 23% 23% North America 23% 22% 22% 22% Japan 27% 28% 27% 27% Rest of Asia Pacific 24% 25% 26% 26% Rest of World 2% 3% 2% 2%

6.7.2 Current Applications PBT is used in E&E applications for its electrical insulation properties, good heat resistance and chemical resistance. The main applications or PBT in the electrical and electronics industry include specialist light bulbs and lamp holders, housings for sockets and switches, printed circuit board connectors and sockets, junction boxes, capacitor housings, electronic connectors, fans and coil formers. Other applications include keytops for telephone keypads and LED displays. PBT is applied in a wide range of products in the lighting industry. Well known is the lamp base of the energy saving lamp, where PBT is selected for a combination of properties: heat resistance, dimensional stability, colour stability and laser markability.

6.7.3 Market Trends The key trends influencing further use of PBT in E&E applications are discussed next.

6.7.3.1 New Products A new, easy-flow, special grade of Pocan polyester compounds from Bayer promise a 15% reduction in cycle time for the thin-wall technique. The low melt viscosity of these easy-flow variants means that the filling pressure in the mould can be reduced by up to 30% for nonreinforced grades. According to Bayer, these new developments are especially suitable for parts in the E&E sector. Pocan DP 2004 is a non-reinforced, halogen-free PBT that is able to satisfy the criteria of IEC 60335-1, the European Union standard relating to materials used for unattended domestic appliances. Pocan DP 4035, is a halogen-free flame retardant polyester, with 30% glass fibrereinforcement for E&E applications. Both grades have improved electrical properties, such as smoke behaviour and tracking resistance, compared to traditional halogen based materials. These grades also offer advantages in material recycling, particularly with regard to imminent EU regulations on electrical waste. Compounders A Schulman and PolyOne have introduced a new PBT/PET blend aimed at electrical parts. The Schulman blend contains an additive mix that prevents the usual reaction between the two resins when blended. The new blend has higher mechanical and thermal properties than the comparable PBT only compounds. The blends contain 35% PET. A 30% glass-fibre reinforced grade has been used for housing an electric motor. PolyOne’s Bergadur PBT/PET blends deliver higher heat stability, better flow, lower shrinkage and better surface finish than pure PBT. Targeted applications are housings for electrical devices and automotive.

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6.7.3.2 Development of PBT Polymer Blends PBT polymer blends combine the properties of partially crystalline PBT with those of amorphous thermoplastics such as ABS and polycarbonate. The amorphous partner improves the warpage behaviour (low thermal expansion, higher impact strength, and an improved surface quality), while PBT ensures the temperature and chemical resistance of the blend. These properties in general and the low warpage in particular, makes PBT blends a perfect choice for use on housings for electronic systems which require maximum imperviousness to all weathering conditions.

6.7.3.3 Lead-Free Soldering Methods The introduction of the lead-free soldering method has led to an increase in the temperature requirements of between 20-30 °C and thus created a demand for products with improved properties. The higher heat requirements for the materials used in the process may lead to increased use of high temperature thermoplastics at the expense of PBT. 6.8 Polycarbonate (PC)

6.8.1 Consumption Trends E&E is the second most important market for polycarbonate and represents 25% of total world demand in 2002. Table 6.10 shows polycarbonate consumption in E&E applications by world region for the period 1999-2002. Table 6.10 Polycarbonate consumption in E&E applications by world region, 1999-2002 (000 tonnes) 1999 2000 2001 2002 Western Europe 110 115 100 106 North America 60 65 50 52 Japan 51 54 48 49 Rest of Asia Pacific 170 184 190 205 Rest of World 11 13 13 14 TOTAL 402 431 401 426

In 2002, total polycarbonate consumption in E&E applications amounted to 426,000 tonnes compared with 402,000 tonnes in 1999. Demand was growing at a fast rate up to 2001 when volumes declined due to the downturn in world E&E markets. In 2002, demand was up slightly in North America and Japan, but rose more substantially in Europe and Pacific Rim countries. Table 6.11 shows percentage share by world region of polycarbonate in E&E applications for the period 1999-2002. Table 6.11 Percentage share by world region of polycarbonate in E&E applications, 19992002 1999 2000 2001 2002 Western Europe 27% 27% 25% 25% North America 15% 15% 12% 12% Japan 13% 13% 12% 12% Rest of Asia Pacific 42% 43% 47% 48% Rest of World 3% 3% 3% 3%

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The ‘Rest of Asia Pacific’ is the leading consumer of polycarbonate in E&E, accounting for 48% of total world consumption in 2002. The share of China and other Pacific Rim countries is growing and is forecast to increase further in future because of the trend for E&E manufacturers to relocate production to lower cost economies. Europe is the next largest market with 25% of total consumption, followed by North America and Japan, each with a 12% market share.

6.8.2 Current Applications In the field of electrical lighting, polycarbonate is used to manufacture traffic light signal panels, globe lamps and other types of electric light covers. Its high transparency and light transmission means that lamp covers made from PC offer optimum luminous efficiency. The materials’ particularly high level of impact strength also provides extensive protection against accidental damage. In electrical installations/cables, PC is used in various applications including clamping and multipoint connector strips, power distribution box cover and housing, and switch panels. Its accurate reproduction of detail and high dimensional stability, together with its virtually isotropic shrinkage behaviour, ensure that complex parts will fulfil all their functions. PC is also used for high-grade, visible surfaces, such as various kinds of front panel, because of the wide range of surface finishes available. Polycarbonate is also applied to business and telecommunications equipment, usually in the form of a blend with PBT. It is used for data input keyboards, housing covers for computers, desktop calculators and magnetic discs. PC and PC/PBT blends are also used for mobile telephone housings. PC is valued in these items for its high impact strength, flame retardance, high heat resistance and good surface finish.

6.8.3 Market Trends The key trends influencing further use of polycarbonate in E&E applications are new products. In 2002, Dow commercialised a new polycarbonate grade for the information technical equipment market that uses a proprietary silicone-based flame retardant technology. Dow claims that it provides better thermal and light stability than those using bromine-based flame retardants, and has improved impact strength and heat resistance, than PC containing phosphates. Growth will be driven mainly by the use of flame-retardant PC grades for use in liquid crystal display monitors. GE Plastics introduced two new Cycloloy PC/ABS grades aimed at electronics applications that require flame retardance. The two new products are aimed at high heat and thin wall applications. The high heat series has a heat deflection temperature of 120 °C and thin wall UL94 performance with a VO at 1.6 mm. This makes it ideal for phone chargers, adaptors, battery packs, printers and copiers. The thin wall grade uses unfilled technology and has a VO at 1.2 mm. It is aimed at applications such as laptop PCs. 6.9 Polyoxymethylene (POM)

6.9.1 Consumption Trends E&E is the second most important market for POM and represents 23% of total world demand in 2002. Table 6.12 shows POM consumption in E&E applications by world region for the period 19992002.

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Table 6.12 POM consumption in E&E applications by world region, 1999-2002 (000 tonnes) 1999 2000 2001 2002 Western Europe 13 16 15 15 North America 17 17 16 17 Japan 38 37 35 34 Rest of Asia Pacific 65 72 70 73 TOTAL 133 142 136 139

In 2002, total POM consumption in E&E applications amounted to 139,000 tonnes compared with 133,000 tonnes in 1999. Demand was growing steadily up to 2001 when market tonnage fell due to the downturn in world E&E markets. In 2002, demand recovered slightly in all regions, except Japan. Table 6.13 shows percentage share by world region of POM in E&E applications for the period 1999-2002. Table 6.13 Percentage share by world region of POM in E&E applications, 1999-2002 1999 2000 2001 2002 Western Europe 10% 11% 11% 11% North America 12% 12% 12% 12% Japan 29% 26% 26% 24% Rest of Asia Pacific 49% 51% 51% 53%

The ‘Rest of Asia Pacific’ region is by far the leading user of POM in E&E, accounting for 53% of total world consumption in 2002. Japan is the next largest market with 24%, followed by North America and Western Europe. The predominance of Asia reflects the location of major producers of IT and telecommunications equipment. The share of China and other Pacific Rim countries is growing and should increase further in future because of the trend for E&E manufacturers to relocate production to lower cost economies.

6.9.2 Current Applications In the electric appliances industry POM is used to make casings, gearwheels, clutches, bearings, carriers and gears. In electronics, POM is used for telephone keypads, coil bobbins, switches, spring elements, armature supports, videocassettes, outsert boards for VCR, CD players and camcorders. POM is valued in E&E applications for its high toughness (down to –40 °C), high hardness and stiffness, very good heat deflection resistance (operating temperature up to 100 °C), and good electrical and dielectric properties.

6.9.3 Market Trends The key trend influencing the use of POM in E&E applications is product improvement. Suppliers are introducing better grades for E&E applications with superior toughness and better flow properties. DuPont for example, has recently introduced the Delrin 311DP grade. Improved static dissipating properties is another feature that suppliers have been improving, such as the Delrin 300AS and 300AT grades.

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6.10 Polymethyl Methacrylate (PMMA)

6.10.1 Consumption Trends E&E is a minor market for PMMA and represents only 5% of total world demand in 2002. Table 6.14 shows PMMA consumption in E&E applications by world region for the period 19992002. Table 6.14 PMMA consumption in E&E applications by world region, 1999-2002 (000 tonnes) 1999 2000 2001 2002 Western Europe 12 13 12 13 North America 20 21 20 21 Japan 7 7 6 6 Rest of Asia Pacific 9 10 10 11 TOTAL 48 51 48 51

In 2002, total PMMA consumption in E&E applications amounted to 51,000 tonnes against 48,000 tonnes in 1999. Demand was growing slowly up to 2001 when market tonnage declined due to the downturn in world E&E markets. In 2002, demand recovered slightly in all regions. Table 6.15 shows percentage share by world region of PMMA in E&E applications for the period 1999-2002. Table 6.15 Percentage share by world region of PMMA in E&E applications, 1999-2002 1999 2000 2001 2002 Western Europe 25% 25% 25% 25% North America 42% 41% 42% 41% Japan 15% 14% 13% 12% Rest of Asia Pacific 19% 20% 21% 22%

North America is the leading user of PMMA in E&E, accounting for 41% of total world consumption in 2002. Western Europe is the second largest market with 25%, followed by ‘Rest of Asia Pacific’ with 22% and Japan with 12%. The predominance of Asia reflects the location of major producers of IT and telecommunications equipment. The share of China and other Pacific Rim countries is growing and is forecast to increase further in future because of the trend for E&E manufacturers to relocate production to lower cost economies.

6.10.2 Current Applications In electrical lighting systems, PMMA acrylic resins are used to manufacture a range of lenses for commercial, industrial, residential and railway lighting applications. PMMA is valued for its optical clarity, scratch and chemical resistance, toughness and durability.

6.10.3 Market Trends The key trend influencing further use of PMMA in E&E applications is growth in the LCD market. Growing popularity of liquid crystal display monitors presents strong growth opportunities for PMMA optical grades, which are used to make light conducting plates, an important component of LCD panels. Currently only Japanese producers have the technology to make this grade of PMMA. Asahi Kasei estimates that the share of LCD units in the display market, which includes computer

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monitors, TV and laptop computers, will grow from 15% in 2001 to 35% in 2005. Asahi estimates that world demand for PMMA pellet and sheet for light guides will grow from 22,500 tonnes in 2001 to 69,000 tonnes in 2005. 6.11 Polyphenylene Oxide (Ether) Blends (PPO and PPE)

6.11.1 Consumption Trends E&E is the second most important market for PPO/PPE blends and represents 28% of total world demand in 2002. Table 6.16 shows PPO/PPE blends consumption in E&E applications by world region for the period 1999-2002. Table 6.16 PPO/PPE blends consumption in E&E applications by world region, 1999-2002 (000 tonnes) 1999 2000 2001 2002 Western Europe 27 29 27 28 North America 43 45 40 41 Asia 29 32 29 30 TOTAL 99 106 96 99

In 2002, total PPO/PPE blends consumption in E&E applications amounted to 99,000 tonnes, which is the same level as in 1999. Demand rose sharply in 2000 but slipped back the following year due to the downturn in world E&E markets. In 2002, demand recovered slightly in all regions. Table 6.17 shows percentage share by world region of PPO/PPE blends in E&E applications for the period 1999-2002. Table 6.17 Percentage share by world region of PPO/PPE blends in E&E applications, 1999-2002 1999 2000 2001 2002 Western Europe 27% 27% 28% 28% North America 43% 42% 42% 41% Asia 29% 30% 30% 31%

North America is the leading user of PPO/PPE blends in E&E, accounting for 41% of total world consumption in 2002, followed by Asia with 31% and Western Europe with 28%. The share of Asia has increased slightly during the period 1999-2002.

6.11.2 Current Applications PPO/PPE blends are used in business and computer machine housing, structural and interior components in electrical equipment and telecommunications equipment. PPO/PPE blends are suitable for various telecommunications applications such as enclosures, switchgear, networking devices, flexible circuitry and cable and wire extensions. Key properties are their good chemical resistance to most solvents, fuels and other contaminants, excellent processability, impact performance at extreme temperatures, and thin wall performance that can reduce cycle times. PPO/PPE blends are also used to manufacture battery cases because of their high tensile strength, chemical resistance and thin wall potential.

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6.11.3 Market Trends The key trend influencing further use of PPO/PPE blends in E&E applications is new product development. Continuous product development has been a feature of the PPO/PPE product family. Higher conductivity, mineral-filled and low odour emission grades are some examples of how the product has been improved to open up new market opportunities. GE Plastics also introduced an improved, conductive version of Noryl GTX (PPO/PA blend), which dispensed with the need to prime plastic parts before painting them. By adding conductive material, it was possible to develop a thermoplastic that makes it easier to paint hard-to-reach places. 6.12 Polyphenylene Sulfide (PPS)

6.12.1 Consumption Trends E&E is the second most important market for PPS with 27% of total world demand in 2002. Table 6.18 shows PPS consumption in E&E applications by world region for the period 1999-2002. Table 6.18 PPS consumption in E&E applications by world region, 1999-2002 (000 tonnes) 1999 2000 2001 2002 Western Europe 2.5 2.7 2.5 2.6 North America 3.4 3.7 3.3 3.4 Japan 5.0 5.4 5.1 5.1 Rest of Asia Pacific 2.1 2.4 2.1 2.3 TOTAL 12.9 14.3 12.9 13.4

In 2002, total PPS consumption in E&E applications was 13,400 tonnes against 12,900 tonnes in 1999. Demand was growing steadily up to 2000, but slipped back the following year due to the downturn in world E&E markets. In 2002, demand recovered slightly in all regions, except in Japan. Table 6.19 shows percentage share by world region of PPS in E&E applications for the period 1999-2002. Table 6.19 Percentage share by world region of PPS in E&E applications, 1999-2002 1999 2000 2001 2002 Western Europe 19% 19% 19% 19% North America 26% 26% 25% 25% Japan 39% 38% 39% 39% Rest of Asia Pacific 16% 17% 16% 17%

Japan is the leading user of PPS in E&E, accounting for 39% of total world consumption in 2002, followed by North America with 25% and Western Europe with 19%. The ‘Rest of Asia Pacific’ accounts for the remaining 17% of world consumption. The regional pattern of consumption has been quite stable during the period 1999-2002.

6.12.2 Current Applications For E&E markets, PPS offers excellent flow and low shrinkage for precision moulding of connectors and sockets, superior stiffness and mechanical integrity for reliable assembly, and is the

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most stable material choice for all SMT soldering methods. PPS compounds also have UL94 V-0 flammability ratings without the use of flame retardant additives. Special low flash grades have been developed to meet the needs of high precision moulding applications. In the E&E sector, PPS is also used to manufacture a range of articles including bobbins and connectors, hard disk drives, electronic housings, sockets, switches and relays.

6.12.3 Market Trends The key trend influencing PPS growth in E&E applications is inter-polymer substitution. Higher performance plastics such as LCP and PPS are increasingly taking over in the electronics segment from PA66, which has so far dominated the market. Most electrical connectors (300 million per year) are used in computers and their peripherals, followed by telephone and data transmission applications. PBT and polyamide 66 are the most commonly used plastics for electrical connectors. The two polymers together have a market share of 10-15% in the $25 billion world market for connectors, of which North America accounts for $10 billion. 6.13 Polyetherimide (PEI)

6.13.1 Consumption Trends E&E is the second most important market for PEI accounting for 30% of total world demand in 2002. Table 6.20 shows PEI consumption in E&E applications by world region for the period 1999-2002. Table 6.20 Polyetherimide consumption in E&E applications by world region, 1999-2002 (000 tonnes) 1999 2000 2001 2002 Western Europe 0.8 0.9 0.8 0.9 North America 2.4 2.7 2.5 2.6 Japan 0.4 0.5 0.4 0.4 Rest of Asia Pacific 0.4 0.5 0.4 0.5 TOTAL 4.0 4.5 4.1 4.3

In 2002, total PEI consumption in E&E applications amounted to 4,300 tonnes against 4,000 tonnes in 1999. Demand rose sharply in 2000 but subsequently declined during the following year because of the downturn in world E&E markets. In 2002, demand recovered very slowly in most major world markets. Table 6.21 shows percentage share by world region of PEI in E&E applications for the period 1999-2002. Table 6.21 Percentage share by world region of polyetherimide in E&E applications, 1999-2002 1999 2000 2001 2002 Western Europe 20% 20% 19% 20% North America 60% 60% 60% 60% Japan 10% 10% 10% 9% Rest of Asia Pacific 10% 10% 11% 11%

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North America is by far the leading user of PEI in E&E, accounting for 60% of total world consumption in 2002, Western Europe is the second largest consumer with 20%, followed by ‘Rest of Asia Pacific’ with 11% and Japan with 9%. The regional pattern of consumption has been fairly stable during the period 1999-2002.

6.13.2 Current Applications Polyetherimide resins are inherently flame resistant with low smoke emission which makes PEI suited to a variety of applications in the fields of electrical equipment and electronics. In the telecommunications market, there is an increasing need for high heat resistant materials, especially for high-end connectors in the fibre optics segment. PEI resin offers high heat resistance as well as great flow for thin wall design. Other applications include electrical switches and controls, electrical motor parts, printed circuit boards and connectors. PEI is also used in so-called moulded interconnect devices (MID), because of its unique plating capabilities. PEI allows the combination of electrical functions with the advantages of injection moulded three-dimensional mechanical components in electrical control units, computer components, telecom and mobile phones, internal antennae of duplexers or microfilters, and fibre optic connectors.

6.13.3 Market Trends The key trend influencing further use of polyetherimide in E&E applications is new product development. To meet the ongoing needs for miniaturization in the electronics sector, (increased packing densities and more lightweight carrier materials) ceramic-filled PEI grades have been developed. These grades have excellent electrical and processing properties, and can also be easily metallised. They are suitable for applications such as circuit boards operating in the microwave range, as well as internal aerials, electronic chips and capacitors. 6.14 Polysulfone (PSU), Polyethersulfone (PES)

6.14.1 Consumption Trends E&E is the most important market for PSU/PES accounting for 29% of total world demand in 2002. Table 6.22 shows PSU/PES consumption in E&E applications by world region for the period 19992002. Table 6.22 PSU/PES consumption in E&E applications by world region, 1999-2002 (000 tonnes) 1999 2000 2001 2002 Western Europe 1.1 1.3 1.2 1.3 North America 3.6 4.0 3.7 3.8 Japan 0.7 0.8 0.7 0.7 Rest of Asia Pacific 0.7 0.8 0.8 0.9 TOTAL 6.1 6.8 6.4 6.6

In 2002, total PSU/PES consumption in E&E applications amounted to 6,600 tonnes compared with 6,100 tonnes in 1999. Demand for PSU/PES in E&E applications was growing sharply up to

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2001 when consumption fell because of the lower world demand in E&E markets. In 2002, there was only a modest improvement in demand. Table 6.23 shows percentage share by world region of PSU/PES in E&E applications for the period 1999-2002. Table 6.23 Percentage share by world region of PSU/PES in E&E applications, 1999-2002 1999 2000 2001 2002 Western Europe 18% 19% 19% 19% North America 59% 59% 58% 57% Japan 11% 11% 11% 11% Rest of Asia Pacific 11% 11% 12% 13%

North America is by far the leading user of PEI in E&E, accounting for 57% of total world consumption in 2002, Western Europe is the second largest consumer with 19%, followed by ‘Rest of Asia Pacific’ with 13% and Japan with 11%. There were no major changes to the regional pattern of consumption during the period 1999-2002.

6.14.2 Current Applications PES and PSU have outstanding thermal properties, low creep, even at high temperatures, good flame retardancy, excellent insulation properties and high dielectric strength. The high stiffness, strength and dimensional stability permits use, for example, in pump impellers. Other applications found in E&E include various electrical components such as coil formers; plug-and-socket connectors; injection-moulded printed circuit boards; parts for power circuit breakers; parts for power contactors and relays; transparent covers for signal lamps and switchboards; lamp holders and lampshades; heat shields; sensors; chip carriers; chip trays; battery seals; TV components, hairdryer parts; oven, fan heater and projector components.

6.14.3 Market Trends The key trends influencing further use of PSU/PES in E&E applications are discussed next.

6.14.3.1 Inter-Polymer Substitution In the field of E&E, PES/PSU are subject to growing competition from other less expensive amorphous high temperature plastics due to rising cost pressures. The E&E sector can therefore be expected to show lower growth for PES/PSU in future.

6.14.3.2 New Applications In 2002, Solvay Advanced Polymers announced that a grade of its Radel polyphenylsulfone had been selected by Purolator for the housing of a transaxle fluid filter. The transaxle is part of an electronic powertrain being developed and tested for use in future fuel cell vehicles. Radel was selected for its excellent resistance to the corrosive fluid environment and high temperature resistance. In 2002, Radel was also selected in Saft’s SRM F3 series battery cells that are typically used for electrical backup systems in rail transport systems.

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6.15 Liquid Crystal Polymers (LCP)

6.15.1 Consumption Trends E&E is the by far the most important market for LCP accounting for 75% of total world demand in 2002. Table 6.24 shows LCP consumption in E&E applications by world region for the period 19992002. Table 6.24 LCP consumption in E&E applications by world region, 1999-2002 (000 tonnes) 1999 2000 2001 2002 Western Europe 1.5 1.9 1.8 1.9 North America 3.2 3.8 3.5 3.7 Asia 6.6 7.9 7.0 7.7 TOTAL 11.2 13.5 12.3 13.3

In 2002, total LCP consumption in E&E applications amounted to 13,300 tonnes against 11,200 tonnes in 1999. Demand was growing at a very healthy rate up to 2001, when sales volumes declined due to the downturn in world E&E markets. There was however a substantial recovery in demand during 2002, particularly from Asia. Table 6.25 shows percentage share by world region of LCP in E&E applications for the period 1999-2002. Table 6.25 Percentage share by world region of LCP in E&E applications, 1999-2002 1999 2000 2001 2002 Western Europe 13% 14% 15% 14% North America 28% 28% 28% 28% Asia 59% 58% 57% 58%

Asia is the leading user of LCP in E&E, accounting for 58% of total world consumption in 2002, North America is the second largest consumer with 28%, followed by Western Europe with 14%. The regional pattern of consumption remained largely unchanged during the period 1999-2002.

6.15.2 Current Applications Liquid crystal polymers are produced through an ion-free polycondensation process. This makes LCP particularly well suited for applications in the electronics sector, where often ion concentrations of less than 5 ppm are required. LCP is applied for the manufacture of electrical and electronic components, connecting parts in fibre-optics and telecommunication devices of chemical processing machines, Other examples of electrical applications for LCP include lens holders for optical pick-up parts in CD-ROM, DVD, transformers for miniature modems in laptop computers, miniature relays, coil bobbins and sockets for halogen light fittings. In cellular phones, LCP has established a strong position in the area of connectors, chip card scanners and many other components.

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6.15.3 Market Trends The key trends influencing further use of LCP in E&E applications are discussed next.

6.15.3.1 Inter-Polymer Substitution Higher performance plastics such as LCP and PPS are increasingly taking over in the electronics segment from the PA 66 that has so far dominated the market. Most electrical connectors (300 million per year) are used in computers and their peripherals, followed by telephone and data transmission applications. PBT and polyamide 66 are currently the most widely used plastics for electrical connectors.

6.15.3.2 New Applications In 2001, Siemens Dematic AG adopted DuPont’s Zenite LCP polymer for its new Polymer Stud Grid Array (PSGA) integrated circuit housings. These packages, which are only about 20% bigger than the chip itself, are the first time a thermoplastic resin has been used as a chip carrier. Zenite was selected for its high-temperature resistance, dimensional stability, easy melt-flow and good dielectric properties. Other recent new applications for DuPont’s Zenite LCP resins include: •

Two miniature solenoids use thin-wall coil bobbins moulded from Zenite LCP. The unit at the right operates a security lock, which formerly used a coil form consisting of a brass tube with an insulating sleeve and phenolic flanges assembled with adhesive. The solenoid at the left actuates a valve for medical equipment.

•

Miniature power inductors designed for SMT assembly consist of a coil wound on a ferrite bobbin core that sits on a base injection moulded from Zenite LCP.

•

The thin-wall capabilities of Zenite LCP were crucial to development of five space-saving miniature transformers for modems used in laptop computers.

•

Lens holder for optical pick up parts in CD-ROM, CD-RW and DVD.

6.15.3.3 Lead-Free Soldering Methods The introduction of the lead-free soldering method has led to an increase in the temperature requirements of between 20-30 °C and thus created a demand for products with improved properties. At the same time, materials that are resistant to high temperatures such as ceramics, metals and thermosets, may be driven out of their existing application areas and replaced by the more cost-efficient injection moulding process with LCP. 6.16 Polyetheretherketone (PEEK)

6.16.1 Consumption Trends E&E is an important market for PEEK polymers accounting for 20% of total world demand in 2002. Table 6.26 shows PEEK consumption in E&E applications by world region for the period 19992002. In 2002, total PEEK consumption in E&E applications amounted to 260 tonnes against 240 tonnes in 1999. Demand for PEEK in E&E applications was growing at an annual average rate of between

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15-20% up to 2002 when there was a substantial fall in consumption. This is mostly due to the downturn in world E&E markets. Producers are confident that demand will recover sharply from 2003 onwards. Table 6.26 PEEK consumption in E&E applications by world region, 1999-2002 (000 tonnes) 1999 2000 2001 2002 Western Europe 0.08 0.10 0.13 0.10 North America 0.12 0.15 0.17 0.12 Asia 0.04 0.05 0.06 0.04 TOTAL 0.24 0.30 0.35 0.26

Table 6.27 shows percentage share by world region of PEEK in E&E applications for the period 1999-2002. Table 6.27 Percentage share by world region of PEEK in E&E applications, 1999-2002 1999 2000 2001 2002 Western Europe 33% 34% 36% 38% North America 50% 51% 49% 46% Asia 17% 15% 16% 16%

North America is the leading user of PEEK in E&E, accounting for 46% of total world consumption in 2002, Western Europe is the second largest consumer with 38%, followed by Asia with the remaining 16% of world demand. The market share of Western Europe increased during the period 1999-2002, while North America’s share has declined.

6.16.2 Current Applications PEEK polymers have excellent electrical properties, which make it an ideal electrical insulator, providing parts with long-term operating reliability over widely fluctuating ranges of temperature, pressure and frequency. Its inherent purity, combined with excellent mechanical and chemical stability, minimise contamination and maximise safety during the handling of silicon wafers. Outstanding thermal properties enable PEEK polymer parts to withstand the elevated temperatures associated with soldering processes. Some interesting examples of current applications include coaxial connector jacks used in handsfree telephone kits, surface-mounted trimming potentiometers, which are electro-mechanical devices, known as SMDs, designed to correct voltage or resistance errors in printed circuit boards, and as insulators for connector pins on under-sea environment control equipment.

6.16.3 Market Trends The key trend influencing further use of PEEK in E&E applications is development of new applications. PEEK is finding new applications in the E&E sector. For example, it is being used for manufacture of critical materials designed to transport and protect microchips and electronics. These products are mainly wafer carriers, which are designed for the storage and transport of semiconductors during production. Each wafer carrier is made up of eight parts that are welded and bonded together.

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6.17 Polyphthalamide (PPA)

6.17.1 Current Applications The principal applications for PPA in E&E markets include high brightness LEDs and other optoelectronic devices, SMT electronic components, capacitor and chip carriers, heat sinks and switches. The trend in electronics toward miniaturization of insert-moulded connectors has driven the need for more contacts spaced closer together. This requires tighter tolerances and the use of higher flow resins for thinner walls. PPA resin can be used for sub-miniature, stacking printed circuit board connectors where high density is required. PPA resin is also surface mount compatible and, with its high strength and ability to be injection moulded with fast cycle times, is an excellent fit for applications such as cellular phone connectors. Finally, fully automated wafer loading systems use cassettes moulded from PPA resin to transport silicon wafers into process equipment where heat and chemical resistance are required.

6.17.2 Market Trends The key trend influencing further use of PPA in E&E applications is the development of new products. In 2002, Solvay Advanced Polymers introduced new grades of flame retardant Amodel PPA for use in E&E applications such as connectors, chip capacitors, cell phone components, circuit breakers, contactors, relays and switches. A special feature of the new products is their high conductive tracking index and glow wire flammability temperature performance. They are also more colour stable due to their thermal stability when processed at high temperatures.

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7 Industrial Applications for Engineering and High Performance Plastics 7.1 Introduction This section examines engineering and high performance polymers used in industrial applications. The applications covered are predominantly injection moulded parts for industrial equipment and machinery. The section also covers building and construction applications and mining. Industrial applications are very demanding for plastics and are often found in hostile operating conditions. In particular, industrial applications require materials that can withstand sliding friction, high temperatures and have good chemical resistance. Machine elements, for example, are subject to sliding friction (slide bearings, rollers, thrust washers, piston rings, seals) for mechanical engineering, textile industry and office equipment. Industrial machinery and equipment may have to operate at continuous high temperatures, and be required to have a high degree of resistance to chemicals. 7.2 Future Prospects for Industrial Markets High performance plastics are making inroads into industrial applications that were once the domain of metals and thermosets. Engineering and high performance plastics have a number of advantages over traditional materials due to their flexibility in parts design, ease of processing and lightness. They are also tough, abrasion resistant and can withstand high temperature. Continuous product improvement and innovation means that there will be further scope for growth in many areas of industrial applications in future. Following a period of prolonged growth in industrial markets, demand for engineering and high performance plastics declined in 2001 due to the worldwide downturn in economic activity. GDP growth is expected to show a modest recovery during the next two years, which will lead to higher demand for plastics. However, there is unlikely to be a return to the double-digit growth rates that were experienced during the late 1990s. 7.3 Polyamide

7.3.1 Consumption Trends In 2002, the industrial sector accounted for 7% of total polyamide consumption. Table 7.1 shows polyamide consumption in industrial applications by world region for the period 1999-2002. Table 7.1 Polyamide consumption in industrial applications by world region, 1999-2002 (000 tonnes) 1999 2000 2001 2002 Western Europe 46 49 46 50 North America 48 50 45 47 Japan 24 25 23 24 Rest of Asia Pacific 13 15 14 16 Rest of World 9 10 9 9 TOTAL 140 149 137 146

In 2002, total polyamide consumption in industrial applications amounted to 146,000 tonnes against 140,000 tonnes in 1999. Market tonnage declined in 2001 due to the major downturn in the 107


world economy. There was a slight recovery in demand last year, particularly in China and Western Europe. Table 7.2 shows percentage share by world region of polyamide in industrial applications for the period 1999-2002. Table 7.2 Percentage share by world region of polyamide in industrial applications, 1999-2002 1999 2000 2001 2002 Western Europe 33% 33% 34% 34% North America 34% 34% 33% 32% Japan 17% 17% 17% 16% Rest of Asia Pacific 9% 10% 10% 11% Rest of World 6% 7% 7% 7%

Western Europe is the largest user of polyamide in the industrial sector accounting for 34% of total consumption in 2002. North America with 32% is the second largest market, followed by Japan with 16%. The share of China and other Pacific Rim countries has been growing and is set to grow further in future.

7.3.2 Current Applications Because of its high mechanical properties under tough service conditions, PA is used for the manufacture of machine components, such as bearing cages, pumps, pneumatic connectors or cable chains. Polyamide is used to make a variety of fixation products, such as cable ties, fasteners, staples and drills. It is also used for manufacture of caster wheels for industrial equipment. 7.4 Acrylonitrile-Butadiene-Styrene (ABS)

7.4.1 Consumption Trends In 2002, the industrial sector accounted for 9% of total ABS consumption. Table 7.3 shows ABS consumption in industrial applications by world region for the period 19992002. Table 7.3 ABS consumption in industrial applications by world region, 1999-2002 (000 tonnes) 1999 2000 2001 2002 Western Europe 27 30 24 24 North America 325 285 275 278 Japan 20 21 19 20 Rest of Asia Pacific 90 100 98 103 TOTAL 462 436 416 425

In 2002, total ABS consumption in industrial applications amounted to 425,000 tonnes compared with 462,000 tonnes in 1999. Market tonnage declined in 2000 and 2001 due to the lower world economic growth, with a particularly sharp decline in demand from North America. There was a slight recovery in demand last year, especially in China and Pacific Rim countries.

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Table 7.4 shows percentage share by world region of ABS in industrial applications for the period 1999-2002. Table 7.4 Percentage share by world region of ABS in industrial applications, 1999-2002 1999 2000 2001 2002 Western Europe 6% 7% 6% 6% North America 70% 65% 66% 65% Japan 4% 5% 5% 5% Rest of Asia Pacific 19% 23% 24% 24%

North America is by far the largest user of ABS in the industrial sector accounting for 65% of total consumption in 2002. The ‘Rest of Asia Pacific’ region with 24% is the second largest market, followed by Western Europe with 6% and Japan with 5%. The share of China and other Pacific Rim countries has been growing and is set to grow further in future.

7.4.2 Current Applications The most important application for ABS in the industrial sector is plastic pipes for drainage and sewage, and industrial pipes. The main features of ABS pipe are impact strength, and good chemical, abrasion and weathering resistance. 7.5 Polybutylene Terephthalate (PBT)

7.5.1 Consumption Trends In 2002, the industrial sector accounted for 8% of total PBT consumption. Table 7.5 shows PBT consumption in industrial applications by world region for the period 19992002. Table 7.5 PBT consumption in industrial applications by world region, 1999-2002 (000 tonnes) 1999 2000 2001 2002 Western Europe 8 9 8 9 North America 16 17 15 16 Japan 6 6 5 5 Rest of Asia Pacific 6 7 6 7 TOTAL 36 39 34 37

In 2002, total PBT consumption in industrial applications amounted to 37,000 tonnes compared with 36,000 tonnes in 1999. Market tonnage declined in 2001 due to the sharp downturn in the world economy, with North America experiencing the sharpest fall in demand. There was only a modest recovery in demand last year across all world regions. Table 7.6 shows percentage share by world region of PBT in industrial applications for the period 1999-2002. North America is easily the largest user of PBT in the industrial sector accounting for 43% of total consumption in 2002. Western Europe is the second largest market with 24% of total consumption, followed by ‘Rest of Asia Pacific’ with 19% and Japan with 14%. The share of China and other Pacific Rim countries has been growing during the last few years and should experience further growth in future.

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Table 7.6 Percentage share by world region of PBT in industrial applications, 1999-2002 1999 2000 2001 2002 Western Europe 22% 23% 24% 24% North America 44% 44% 44% 43% Japan 17% 15% 15% 14% Rest of Asia Pacific 17% 18% 18% 19%

7.5.2 Current Applications PBT is used in precision engineering and in the machine construction sector for gearwheels, bearings and other sliding elements. The main features of PBT are its mechanical and physical properties of stiffness and toughness, heat resistance, friction and wear resistance, excellent surface finish and good colourability. PBT also has excellent electrical insulation characteristics and good flow properties leading to short cycle times using standard injection moulding machines. 7.6 Polyoxymethylene (POM)

7.6.1 Consumption Trends In 2002, the industrial sector account for 16% of total POM consumption. Table 7.7 shows POM consumption in industrial applications by world region for the period 19992002. Table 7.7 POM consumption in industrial applications by world region, 1999-2002 (000 tonnes) 1999 2000 2001 2002 Western Europe 28 29 28 29 North America 35 37 34 34 Japan 13 12 11 10 Rest of Asia Pacific 22 25 24 25 TOTAL 98 103 97 98

In 2002, total POM consumption in industrial applications amounted to 98,000 tonnes. Market tonnage declined in 2001 due to the sharp downturn in the world economy, and particularly much lower demand from North America. There was only a slight recovery in demand last year. Table 7.8 shows percentage share by world region of POM in industrial applications for the period 1999-2002. Table 7.8 Percentage share by world region of POM in industrial applications, 1999-2002 1999 2000 2001 2002 Western Europe 29% 28% 29% 30% North America 36% 36% 35% 34% Japan 13% 12% 11% 10% Rest of Asia Pacific 22% 24% 25% 26%

North America is the largest user of POM in the industrial sector accounting for 34% of total consumption in 2002. Western Europe with 30% is the second largest market, followed by ‘Rest of Asia Pacific’ with 26% and Japan with 10%. The share of China and other Pacific Rim countries

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has grown from 22% of world consumption in 1999 and should increase further during the coming years due to higher levels of economic activity.

7.6.2 Current Applications In mechanical engineering, POM is used because it is extremely dimensionally stable, with good sliding friction performance. It is also non-corroding, and has very low friction and wear, making it particularly effective for conveyor belts. It has exceptional resilience and excellent recovery, making it ideal, for example, for use in clips and snap connections. In machine construction, POM is used to manufacture many different parts including valves, small motor parts, chain links (for chain conveyors), ventilator rotors, guide rollers, thread guidance systems in spinning machines, ball and roller bearings, gear wheels and fastening elements. In precision mechanics and watchmaker industries, POM is used for parts for all kinds of measuring devices, high-precision gearwheels, watch hands and gears, components for cameras, CD players and microscopes. 7.7 Polycarbonate (PC)

7.7.1 Consumption Trends In 2002, the industrial sector account for 19% of total polycarbonate consumption. Table 7.9 shows polycarbonate consumption in industrial applications by world region for the period 1999-2002. Table 7.9 Polycarbonate consumption in industrial applications by world region, 1999-2002 (000 tonnes) 1999 2000 2001 2002 Western Europe 105 115 100 107 North America 75 80 70 73 Japan 27 29 25 25 Rest of Asia Pacific 95 97 100 110 Rest of World 6 7 7 8 TOTAL 308 328 302 323

In 2002, total polycarbonate consumption in industrial applications amounted to 323,000 tonnes compared with 308,000 tonnes in 1999. This sector has experienced good growth in recent years, but market demand declined in 2001 due to the general downturn in the world economy and the construction sector in particular. There was only a modest recovery in demand last year, with the strongest growth coming from the Asia region. Table 7.10 shows percentage share by world region of polycarbonate in industrial applications for the period 1999-2002. The ‘Rest of Asia Pacific’ region is the largest user of polycarbonate sheet for industrial applications accounting for 34% of total consumption in 2002. The share of China and other Pacific Rim countries has been growing and is set to grow further in future. Western Europe with 33% is the second largest market, followed by North America with 23% and Japan with 8%.

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Table 7.10 Percentage share by world region of polycarbonate in industrial applications, 1999-2002 1999 2000 2001 2002 Western Europe 34% 35% 33% 33% North America 24% 24% 23% 23% Japan 9% 9% 8% 8% Rest of Asia Pacific 31% 30% 33% 34% Rest of World 2% 2% 2% 2%

7.7.2 Current Applications Polycarbonate sheet is used primarily for glazing systems in the construction sector, which is subject to highly specific requirements. PC sheet is also used for manufacture of signs and displays, and security shields. PC sheeting has a number of important features. It has excellent resistance to breakage over a broad temperature range, high light transmission of over 80% depending on panel type and thickness and good weather resistance. It also has low inherent weight. PC sheet is used, among other things, for glazing on lightweight, transparent hall and stadium roofs. Its low inherent weight compared to glass means that PC sheet offers considerable advantages in the design and static-equilibrium layout of the support structure. 7.8 Polymethyl methacrylate (PMMA)

7.8.1 Consumption Trends In 2002, industrial applications (construction and lighting) accounted for 57% of total consumption, which is the largest end user market for PMMA. Table 7.11 shows PMMA consumption in industrial applications by world region for the period 1999-2002. Table 7.11 PMMA consumption in industrial applications by world region, 1999-2002 (000 tonnes) 1999 2000 2001 2002 Western Europe 148 162 149 164 North America 233 245 235 242 Japan 76 78 70 71 Rest of Asia Pacific 73 80 84 90 TOTAL 530 565 538 567

In 2002, total PMMA consumption in industrial applications amounted to 567,000 tonnes compared with 530,000 tonnes in 1999. PMMA construction and lighting applications have experienced good growth in recent years, but market demand declined in 2001 due to the general decline in world economic activity and in particular to the sharp downturn in the construction sector. There was only a modest recovery in demand last year, with the strongest growth coming from Asia and Western Europe. Table 7.12 shows percentage share by world region of PMMA in industrial applications for the period 1999-2002.

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Table 7.12 Percentage share by world region of PMMA in industrial applications, 1999-2002 1999 2000 2001 2002 Western Europe 28% 29% 29% 29% North America 44% 43% 44% 43% Japan 14% 14% 13% 12% Rest of Asia Pacific 14% 14% 16% 16%

North America is the largest user of PMMA for industrial applications accounting for 43% of total consumption in 2002. Western Europe with 29% is the second largest market, followed by ‘Rest of Asia Pacific’ with 16% and Japan with 12%. The share of China and other Pacific Rim countries has increased steadily since 1999, and is expected to increase further during the next five years.

7.8.2 Current Applications Acrylic sheet is used mainly in the construction and lighting sectors. The main properties of acrylic sheet are their transparency, good mechanical properties, high acoustic and electrical insulation, resistance to high temperature and ease of processing. PMMA has many different applications including: • • • • • • • • • • •

Roofing Security glazing Noise barriers Signs and displays Greenhouses, frames and cloches Cosmetics display stands Baths and bathroom fittings Number plates, windscreens and motorcycle windshields, sun visors Architectural fittings (illuminated information boards, bus shelters, newspaper kiosks, poster displays, acoustic screens, squash courts, basketball panels) Skylights, architectural lighting Swimming pool steps, canopies, tunnels, railings, stair rails

7.9 Polyphenylene Oxide (Ether) Blends (PPO and PPE)

7.9.1 Consumption Trends In 2002, industrial applications accounted for 10% of total PPO/PPE blends consumption. Table 7.13 shows PPO/PPE blends consumption in industrial applications by world region for the period 1999-2002. Table 7.13 PPO/PPE blends consumption in industrial applications by world region, 1999-2002 (000 tonnes) 1999 2000 2001 2002 Western Europe 9 9 9 9 North America 16 17 16 17 Asia 8 9 8 8 TOTAL 33 35 33 34

In 2002, total PPO/PPE blends consumption in industrial applications amounted to 34,000 tonnes compared with 33,000 tonnes in 1999. PPO/PPE blends have shown good growth in recent years, but market demand declined in 2001 due to lower growth in the world economy and a sharp 113


contraction in construction sector activity. There was only a slight recovery in demand during 2002. Table 7.14 shows percentage share by world region of PPO/PPE blends in industrial applications for the period 1999-2002. Table 7.14 Percentage share by world region of PPO/PPE blends in industrial applications, 1999-2002 1999 2000 2001 2002 Western Europe 26% 26% 26% 26% North America 49% 49% 49% 50% Asia 25% 26% 25% 24%

North America is the largest user of PPO/PPE blends for industrial applications accounting for 50% of total consumption in 2002. Western Europe with 26% is the second largest market, followed by Asia with 24%.

7.9.2 Current Applications PPO is used in fluid handling and water pump housing, and in the building and construction sector. Fluid handling applications include valves, pumps, piping, connectors, water filtration, irrigation and pool and spa components. The material is valued for its excellent chemical resistance, low specific gravity, low moisture absorption and superior dimensional stability versus competing materials such as polyamide. 7.10 Polyphenylene Sulfide (PPS)

7.10.1 Consumption Trends In 2002, industrial applications accounted for 11% of total PPS consumption. Table 7.15 shows PPS consumption in industrial applications by world region for the period 19992002. Table 7.15 PPS consumption in industrial applications by world region, 1999-2002 (000 tonnes) 1999 2000 2001 2002 Western Europe 1.0 1.1 1.0 1.1 North America 1.3 1.4 1.2 1.3 Japan 2.0 2.2 2.0 2.0 Rest of Asia Pacific 1.0 1.1 1.0 1.1 TOTAL 5.3 5.8 5.2 5.5

In 2002, total PPS consumption in industrial applications amounted to 5,500 tonnes against 5,300 tonnes in 1999. PPS has shown good growth in recent years, but market demand declined in 2001 due to the downturn in world economic activity. There was only a modest recovery in demand last year. Table 7.16 shows percentage share by world region of PPS in industrial applications for the period 1999-2002.

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Table 7.16 Percentage share by world region of PPS in industrial applications, 1999-2002 1999 2000 2001 2002 Western Europe 19% 19% 19% 20% North America 25% 24% 23% 24% Japan 38% 38% 38% 36% Rest of Asia Pacific 19% 19% 19% 20%

Japan is the largest user of PPS for industrial applications accounting for 36% of total consumption in 2002. North America with 24% is the second largest market, followed by Asia and Western Europe, each with 20%.

7.10.2 Current Applications PPS has been replacing metal alloys, thermosets, and many other thermoplastics in mechanical engineering applications in recent years. PPS finds uses in many heavy industrial applications, including some outside the arena of reinforced injection moulding compounds. The thermal stability and broad chemical resistance of PPS make it exceptionally well suited to service in very hostile chemical environments. Besides moulded parts, PPS polymers find applications in fibre extrusion as well as in non-stick and chemical resistant coatings. PPS is well suited for the manufacture of mechanically and thermally highly stressed moulded parts. In machine construction and precision engineering PPS is used for various components such as pumps, valves and piping. PPS is also applied in oil field equipment such as lift and centrifugal pump components, oil patch drop balls, rod guides and scrapers. In the heating, ventilation and air conditioning (HVAC) equipment sector, PPS is used for compressors, muffers/reservoirs, hot water circulation components, induced draft blower housing, motor relays and switches, power vent components and thermostat components. 7.11 Polyetherimide (PEI)

7.11.1 Consumption Trends In 2002, industrial applications accounted for 10% of total PEI consumption. Table 7.17 shows PEI consumption in industrial applications by world region for the period 19992002. Table 7.17 Polyetherimide consumption in industrial applications by world region, 1999-2002 (000 tonnes) 1999 2000 2001 2002 Western Europe 0.3 0.3 0.3 0.3 North America 0.8 0.9 0.8 0.9 Japan 0.1 0.2 0.1 0.1 Rest of Asia Pacific 0.1 0.2 0.2 0.2 TOTAL 1.3 1.5 1.4 1.4

In 2002, total PEI consumption in industrial applications amounted to 1,400 tonnes compared with 1,300 tonnes in 1999. PEI has shown good growth in recent years, but market demand declined in

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2001 due to the general downturn in the world economy. There was very little increase in consumption last year. Table 7.18 shows percentage share by world region of PEI in industrial applications for the period 1999-2002. Table 7.18 Percentage share by world region of polyetherimide in industrial applications, 1999-2002 1999 2000 2001 2002 Western Europe 20% 20% 20% 19% North America 61% 60% 59% 60% Japan 10% 10% 10% 10% Rest of Asia Pacific 10% 10% 11% 11%

North America is the largest user of PEI for industrial applications accounting for 60% of total consumption in 2002. Western Europe with 19% is the second largest market, followed by ‘Rest of Asia Pacific’ with 11% and Japan with 10%.

7.11.2 Current Applications In the industrial sector, the main applications for GE Plastics Ultem products are found in HVAC equipment and fluid handling systems. Ultem offers high modulus, mechanical strength, heat deflection temperatures and good resistance to chemicals. It is very often used as a metal replacement material. PEI is also used for the manufacture of institutional kitchenware. 7.12 Polysulfone (PSU), Polyethersulfone (PES)

7.12.1 Consumption Trends In 2002, industrial applications accounted for 13% of total PSU/PES consumption. Table 7.19 shows PSU/PES consumption in industrial applications by world region for the period 1999-2002. Table 7.19 PSU/PES consumption in industrial applications by world region, 1999-2002 (000 tonnes) 1999 2000 2001 2002 Western Europe 0.6 0.6 0.6 0.6 North America 1.5 1.7 1.6 1.7 Japan 0.3 0.3 0.3 0.3 Rest of Asia Pacific 0.3 0.3 0.3 0.3 TOTAL 2.7 3.0 2.7 2.9

In 2002, total PSU/PES consumption in industrial applications amounted to 2,900 tonnes compared with 2,700 tonnes in 1999. PSU/PES experienced strong growth during the late 1990s, but consumption fell in 2001 due to the general downturn in the world economy. There was only a modest recovery in demand last year. Table 7.20 shows percentage share by world region of PSU/PES in industrial applications for the period 1999-2002.

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Table 7.20 Percentage share by world region of PSU/PES in industrial applications, 1999-2002 1999 2000 2001 2002 Western Europe 21% 20% 20% 21% North America 57% 58% 59% 58% Japan 11% 11% 9% 10% Rest of Asia Pacific 11% 11% 11% 11%

North America is the largest user of PSU/PES for industrial applications accounting for 58% of total consumption in 2002. Western Europe with 21% is the second largest market, followed by ‘Rest of Asia Pacific’ with 11% and Japan with 10%.

7.12.2 Current Applications PSU and PES are used where the performance required exceeds the capabilities of other engineering plastics such as polyamide, POM and polyalkylene terephthalate. The exceptional property spectrum of these materials allows them to replace thermosets, metals and ceramics. The most important features of PSU/PES are high stiffness, high mechanical strength, high continuous operating temperatures, good electrical insulation properties and good dimensional stability. In industrial markets, they are used mainly for manufacture of pumps and valves for use in chemical and petrochemical industries, and in process equipment. In general mechanical engineering, PSU/PES can be used in oil level indicators; parts for pumps; parts for automatic beverage dispensers; parts for milking machines; parts for heat exchangers; packing for absorption and distillation columns; seals and conveyor belt idlers. 7.13 Liquid Crystal Polymers (LCP)

7.13.1 Consumption Trends In 2002, industrial applications accounted for 8% of total LCP consumption. Table 7.21 shows LCP consumption in industrial applications by world region for the period 19992002. Table 7.21 LCP consumption in industrial applications by world region, 1999-2002 (000 tonnes) 1999 2000 2001 2002 Western Europe 0.2 0.2 0.2 0.2 North America 0.3 0.4 0.4 0.4 Asia 0.7 0.8 0.8 0.8 TOTAL 1.2 1.4 1.4 1.4

In 2002, total LCP consumption in industrial applications amounted to 1,400 tonnes against 1,200 tonnes in 1999. LCP has enjoyed strong growth in recent years. However market demand stabilized in 2001 due to the sharp downturn in world economic activity. There was also only a very small recovery in demand last year. Table 7.22 shows percentage share by world region of LCP in industrial applications for the period 1999-2002.

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Table 7.22 Percentage share by world region of LCP in industrial applications, 1999-2002 1999 2000 2001 2002 Western Europe 13% 14% 13% 15% North America 28% 28% 27% 27% Asia 59% 58% 59% 58%

Asia is the largest user of LCP for industrial applications accounting for 58% of total consumption in 2002. North America with 27% is the second largest market, followed by Western Europe with 15%.

7.13.2 Current Applications Many moulded parts for precision machinery that have traditionally been made from metal, thermosets, and a number of other thermoplastics, can be manufactured efficiently and economically using liquid crystal polymers. For these applications, the LCP family has excellent dimensional stability and creep resistance, especially at very high temperatures. When in a molten state its molecules tend to align with the flow, providing even greater strength in the flow direction, which also contributes to its superior wide-temperature range. The physical advantages of low thermal expansion and low mould shrinkage properties are further enhanced in thin-wall sections due to even more pronounced molecular alignment. In addition these resins are highly resistant to many chemicals, including concentrated acids, bases and hydrocarbons. They also display outstanding fatigue resistance and high dielectric strength performance over a very wide temperature range. 7.14 Polyetheretherketone (PEEK)

7.14.1 Consumption Trends In 2002, industrial applications accounted for 26% of total PEEK consumption. Table 7.23 shows PEEK consumption in industrial applications by world region for the period 1999-2002. Table 7.23 PEEK consumption in industrial applications by world region, 1999-2002 (000 tonnes) 1999 2000 2001 2002 Western Europe 0.1 0.2 0.2 0.1 North America 0.2 0.2 0.2 0.1 Asia 0.0 0.0 0.1 0.1 TOTAL 0.3 0.4 0.4 0.3

In 2002, total PEEK consumption in industrial applications amounted to 300 tonnes. PEEK enjoyed strong growth in demand up to the last year. In 2002, market demand declined unexpectedly due to the downturn in the world economy. However, this should prove to be a temporary setback for the polymer with further strong growth being predicted during the next five years. Table 7.24 shows percentage share by world region of PEEK in industrial applications for the period 1999-2002.

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Table 7.24 Percentage share by world region of PEEK in industrial applications, 1999-2002 1999 2000 2001 2002 Western Europe 41% 41% 40% 42% North America 48% 49% 48% 44% Asia 11% 11% 12% 14%

North America is the largest user of PEEK for industrial applications accounting for 44% of total consumption in 2002. Western Europe with 42% is the second largest market, followed by Asia with 14%.

7.14.2 Current Applications PEEK is used for a wide range of industrial applications because of the excellent physical properties and processability, outstanding mechanical properties, chemical and high heat resistance. PEEK polymers outperform metals and other materials in many components used in the industrial, chemical and processing industries. PEEK polymers are now finding applications in food contact applications, following approval from the US Food and Drug Administration. The material is being used in components from complex, high volume injection moulded parts, to machined stock shapes for low volume production. The main benefits of PEEK polymers for these applications are their high continuous operating temperatures (260 °C), high purity, chemical resistance and hydrolytic stability. PEEK is replacing metal in a range of high-end food processing equipment including the boiler pin and steam faucet of a range of high-end catering equipment, such as industrial coffee machines, food pump seals and automatic espresso machines. PEEK is replacing stainless steel in impeller wheels for regenerative pumps. It provides a significant reduction in wear, reduced noise levels and more consistent running properties. PEEK also offers increased application potential in pipe and hose couplings in modern connector technology. They are able to withstand exposure to pressures as high as 25,000 psi and to temperatures as high as 260 °C. Other new applications for Victrex PEEK polymers include: •

An 8 pin-connector has been developed for PEEK for critical applications where high temperatures are generated in oilfield explorations and production.

•

PEEK is also being used as an insulator component of non-invasive sanitary flow-through conductivity sensors. It is also being used for chopper seal faces used in mixing and blending equipment.

Victrex, the main PEEK supplier, is also developing new products. In 2002, Victrex introduced ‘PEEK-HT’, a cost- and weight-saving alternative to metal for industrial, automotive and aerospace applications that demand superior higher temperature resistance. The semi-crystalline, unreinforced polymer is claimed to offer ‘all the key characteristics of natural PEEK polymer, including toughness, strength and chemical resistance.’

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8 Consumer Product Markets for Engineering and High Performance Plastics 8.1 Introduction This section examines the growing use of engineering plastics in consumer products. The main areas of application are domestic appliances, power tools, sports equipment, houseware, cookware and optical data storage media. The domestic appliances market covers: • • •

Small appliances: electric irons, kettles, food processors, etc. Large appliances: cookers, washing machines and refrigerators Brown goods: TV sets, VCR, DVD players, audio equipment.

The consumer products market is changing. Nowadays, consumer products such as washing machines, cookers and fridges, are being selected more on the basis of design and consumer perception, rather than pure functionality. Plastic has played a major role in improving design of many different consumer products and enabled manufacturers to gain a competitive advantage. Some of the most important consumer products using plastics are reviewed next.

8.1.1 Washing Machines The US is the world’s largest market for automatic washing machines. Japan is the second largest market, followed by Germany and France. The main applications, requirements and materials used are as follows. •

Display windows: Require good transparency combined with good scratch resistance. Polycarbonate is ideally suited for display windows.

•

Control panels and top frames: Aesthetic parts like control panels and top frames require the good balance of gloss and impact properties. PC/ABS blends are most commonly used.

•

Stabiliser covers: These very heavy parts, which stabilize the washing machine during washing cycles, generate a tremendous amount of vibration and therefore need to be isolated from the other components. PPO/PPE foams can be considered for the covers for these parts.

•

Door frames: Aesthetic parts that require good platability, PC/ABS blends are often used.

•

Electrical components: Require good mechanical properties (to prevent breakage during assembly), electrical properties, heat performance, tracking resistance and flame retardancy. PA, PBT and PPO/PPE resins provide good electrical, chemical and mechanical properties.

8.1.2 Vacuum Cleaners Between them, North America and Western Europe account for the vast majority of global vacuum cleaner sales. The main applications and materials used are as follows. •

Housings: Key requirements for vacuum cleaner housings are impact resistance, low warpage and aesthetics. PA, ABS and PC/ABS are often selected.

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•

Window displays: Transparency and impact resistance are key requirements. Polycarbonate resin is most often used.

•

Exhaust grills: Key requirements are thermal performance and dimensional stability, PC/ABS resin is most often used.

8.1.3 Cookers The main applications and materials used are as follows. •

Aesthetic parts (knobs and panels): Several materials can be used for knobs and panels, depending on the technical requirements of the part. If aesthetics and impact performance are the sole requirements, PC/ABS and ABS resins can be used.

•

Electrical components (switches and timers): Require good mechanical properties (to prevent breakage during assembly), electrical properties, heat performance, tracking resistance and flame retardancy. PA, PBT and PPO/PPE blends provide good electrical, chemical and mechanical properties.

•

Door handles: Require good dimensional stability and good colour stability at high temperatures. PBT resin is most often used.

8.1.4 Fridges The refrigeration sector is one of the most mature sectors in the global appliance market and market growth is relatively low. The main applications and materials used are as follows. •

Liners and panels: Aesthetic parts that require a good balance of gloss and impact properties provided by ABS and PC/ABS.

•

Handles: Fridge handles also require the good balance of gloss and impact properties provided by PC/ABS and ABS.

•

Electrical components: Require good mechanical properties (to prevent breakage during assembly), electrical properties, heat performance, tracking resistance and flame retardancy. PA, PBT and PPO/PPE blends are often used.

8.1.5 Microwave Ovens The US is currently the world’s largest market for microwave ovens in terms of volume sales. Western Europe is the second largest market; followed by Japan. The importance of microwave oven sales to the major national markets varies significantly, and these variations appear to be related to cooking habits rather than wealth or economic development. For example, microwaves account for a high of 92.9% of sales of large cooking appliances in South Korea, compared to a low of just 15.5% of sales in Italy. In markets like the US and Canada, the importance of microwaves comes from the popularity of convenience foods. The main applications and materials used are as follows. •

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Display panels, doorframes and handles: These exterior components require materials with high gloss, good scratch and impact resistance, and good printability. ABS and PC/ABS resins are well suited to meeting these requirements.


•

Door inner frames: These internal components, especially for the grill versions of microwave ovens, need to withstand significantly higher temperatures. PBT resin meets these requirements.

•

Display windows: Designed to provide very good visibility for timers and electronic displays, require good transparency combined with good scratch resistance. PC resin can therefore be used.

•

Switch holders: Require good heat resistance and flame retardancy. Depending on mechanical and design requirements, various materials can have a fit for switch holders, including PPO/PPE blends.

•

Air guides and fan covers: Require high heat resistance (in excess of 160 °C) and flame retardancy. PBT resin is often used for these applications.

•

Antennae: Require a material that is inert to microwaves, and offers perfect dimensional stability at high temperature (in excess of 160 °C). Polyetherimide resin can be considered for antennae.

8.1.6 Food Containers For food containers requiring good aesthetics, high impact and medium heat performance (< 100 °C), PC resin is most often used. For very high heat resistance (such as ovenable airline catering or microwavable containers), polyetherimide resin can be used.

8.1.7 Lawnmowers •

Petrol wheeled lawnmowers: Key requirements, apart from impact and shrinkage, are chemical resistance and thermal performance. In these applications, PC/PBT resins can be used.

•

Electrical lawnmowers: Key application requirements are impact resistance and shrinkage. In this case, ABS resin is most often selected.

8.1.8 Electric Irons The market trend is towards fully featured, highly specified and designed steam irons that encourage consumers to purchase more frequently. The top end of the market is performing particularly well and is driving the total iron market. The main applications and materials used are as follows. •

Heat shields: As the heat shield is very close to the metal sole of the iron, the key requirements for engineering thermoplastics used in this application are: thermal performance, heat ageing, dimensional stability and colour stability. PBT resin is most often selected for heat shields.

•

Housings – back parts and grips: Where aesthetics and impact performance are the primary requirements, PC and PC/ABS resins can be considered. Where aesthetics and thermal performance are the primary requirements, PBT resin is preferred.

•

Water tanks: The transparency required for water tanks means that PC resin is often selected.

8.1.9 Shavers The main applications and materials used are as follows. •

Electrical shaver housings: Key requirements for shaver housings are impact resistance, hydrolytic stability, resistance to face lotions and dimensional stability, with material selection

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depending on the relative importance of each property. If resistance to face lotions is less important, and aesthetics and translucency are key requirements, PC resin may be the best choice. •

Electrical components: The electrical components of a shaver require good mechanical properties (to prevent breakage during assembly), electrical properties, heat performance, tracking resistance and flame retardancy. PBT and PPO/PPE blends provide good electrical, chemical and mechanical properties. PC and PC/ABS provide good aesthetic and impact properties.

•

Manual shavers: Hydrolytic stability and impact resistance are the key requirements for components including the grip and holding structure. PPO/PPE resin is often used for these applications.

8.1.10 Fryers Global sales are concentrated into four major markets: the US, the UK, France and Germany. Very slow growth is being recorded, reflecting a tendency to move away from deep fat fried foods due to health concerns. The main applications and materials used are as follows. •

Housings, lids, vapour filters, rings and buttons: Major requirements for these types of parts are related to thermal performance, stress-cracking resistance against cooking oils, dimensional stability, food contact compliance and aesthetic properties. PBT resin offers the right balance of properties to meet these requirements.

•

Electrical components: Require good mechanical properties (to prevent breakage during assembly), electrical properties, heat performance, tracking resistance and flame retardancy. PA, PBT and PPO/PPE blends provide good electrical, chemical and mechanical properties. PC and PC/ABS provide good aesthetic and impact properties.

8.1.11 Personal Hygiene Products like toothbrushes and digital thermometers require good UV resistance, impact resistance and aesthetic properties. If UV resistance is the primary requirement, acrylonitrile-styrene-acrylate (ASA) or PC/ASA can be considered; while if impact resistance is the primary requirement, PC and PC/ABS resins can be considered.

8.1.12 Food Mixers Food mixers, processors and steamers are a mature subsector of the small domestic appliance market. The main applications and materials used are as follows. •

Housings: Impact and heat resistance, as well as food contact compliance and colourability, are the key requirements for food processor housings. PC and ABS resins are most often used.

•

Bowls: In most cases, food processor bowls require very good transparency and high impact resistance, as well as food contact compliance. PC resin is often used.

8.2 Future Prospects for the Consumer Products Market Table 8.1 shows growth in consumer expenditure for major countries for the period 2000-2004.

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Table 8.1 Growth in consumer expenditure for major countries, 2000-2004 (% change) 2000 2001 2002 2003 2004 USA 4.3 2.5 3.1 2.3 3.4 UK 5.2 4.1 3.6 2.9 2.5 Germany 1.4 1.5 (0.5) 1.1 2.2 France 2.8 2.8 1.5 1.7 2.8 Italy 2.7 1.1 (0.3) 0.9 2.2 Canada 3.7 2.6 2.6 2.9 2.9 Japan 0.5 1.4 0.8 0.5 0.8 Source: OECD

Consumer spending has held up well in the USA and UK during the last three years, growing at a faster rate than the economy as a whole. In most other major economies such as Germany, France and Italy, consumer spending has been far less resilient, with very low growth in recent years. The year 2003 probably marks the lowest point in the current economic cycle and growth in consumer spending is expected to increase during the next two years for all major economies, with the exception of the UK. Growth rates in consumer spending are, however, unlikely to be as high as those experienced during the period 1999-2000 for at least another couple of years. The more mature application areas such as large appliances, and audio and video equipment, are expected to show the lowest rates of growth in future. Plastics have also achieved a high rate of penetration in these applications, which will limit growth potential. The most exciting application areas for plastic will be in consumer electronics equipment such as DVD machines and video cameras. The sports equipment market also offers some interesting growth prospects for various polymers. 8.3 Market Trends

8.3.1 Growing Use of Special Effects Resins Consumers are demanding products that reflect their individuality and new styles in terms of design and colour are emerging much more quickly. Two plastics producers, Dow and GE Plastics, have responded to these trends by introducing lines of special effect resins. Dow has introduced a line of eight finishes called Effections, which can be used to create coloured moulded parts at a lower cost. Effections special effects come in metallics, glitters, fluorescents, translucents, colour shifting looks, marble and pastel. Instead of tying the new effects to standard colours and resins, the base finishes are customized for each application. GE Plastics has developed as range of resin colour effects under the Visualfx trade name. Twentyone different effects can be incorporated into most of GE Plastics resins to provide stable and consistently reproducible effects using standard tooling. As the colour effects are inherent in the resin the need for compounding and secondary paint operations are eliminated. 8.4 Polyamide

8.4.1 Consumption Trends In 2002, consumer products accounted for 11% of total polyamide consumption. Table 8.2 shows polyamide consumption in the consumer products market by world region for the period 1999-2002.

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8.2 Polyamide consumption in the consumer products market by world region, 1999-2002 (000 tonnes) 1999 2000 2001 2002 Western Europe 78 83 79 85 North America 55 57 51 55 Japan 14 15 13 13 Rest of Asia Pacific 40 45 43 47 Rest of World 14 16 14 15 TOTAL 201 216 200 215

In 2002, total polyamide consumption in consumer product markets amounted to 215,000 tonnes against 201,000 tonnes in 1999. World consumption increased by around 8% in 2000, but then declined in 2001 due to the downturn in world economic activity. In 2002, there was a strong recovery in demand across all major world regions, except Japan. Table 8.3 shows percentage share by world region of polyamide in consumer products for the period 1999-2002. Table 8.3 Percentage share by world region of polyamide in consumer products, 1999-2002 1999 2000 2001 2002 Western Europe 39% 38% 40% 40% North America 27% 26% 26% 25% Japan 7% 7% 7% 6% Rest of Asia Pacific 20% 21% 22% 22% Rest of World 7% 7% 7% 7%

Western Europe is the largest user of polyamide in consumer products accounting for 40% of total world consumption in 2002. North America with 25% is the second largest market, followed by ‘Rest of Asia Pacific’ with 22%. The market share of China and other Pacific Rim countries has been growing and is set to grow further in future.

8.4.2 Current Applications Polyamide us used to make a wide range of consumer products such as power tools and domestic appliance housing. PA can be used for the production processes of parts with complex shapes. It has good dimensional stability and mechanical properties that enhance reliability and weight reduction. It also meets electrical regulations such as UL 94 and provides a good surface finish for consumer products. Another important area is consumer durables such as kitchen tools, hammers, screwdrivers, scissors, and garden tools such as axes and hedge cutters. PA is also used in the manufacture of sports equipment including ski binding and in-line skates. It is valued for its high impact and mechanical strength. 8.5 Acrylonitrile-Butadiene-Styrene (ABS)

8.5.1 Consumption Trends Consumer products are a large market for ABS, accounting for 25% of total ABS consumption in 2002.

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Table 8.4 shows ABS consumption in the consumer products market by world region for the period 1999-2002. Table 8.4 ABS consumption in the consumer products market by world region, 1999-2002 (000 tonnes) 1999 2000 2001 2002 Western Europe 205 225 201 203 North America 142 145 139 141 Japan 106 110 105 108 Rest of Asia Pacific 630 690 670 717 TOTAL 1083 1170 1115 1169

In 2002, total ABS consumption in consumer product markets amounted to 1,1690,000 tonnes compared with 1,083,000 tonnes in 1999. World consumption increased by around 8% in 2000, but then declined in 2001 due to the downturn in the world economy. In 2002, there was a modest recovery in demand in Europe and North America, but China and other Pacific Rim countries saw more substantial growth. Table 8.5 shows percentage share by world region of ABS in consumer products for the period 1999-2002. Table 8.5 Percentage share by world region of ABS in consumer products, 1999-2002 1999 2000 2001 2002 Western Europe 19% 19% 18% 17% North America 13% 12% 12% 12% Japan 10% 9% 9% 9% Rest of Asia Pacific 58% 59% 60% 62%

The ‘Rest of Asia Pacific’ is the largest user of ABS in consumer products accounting for 62% of total world consumption in 2002. This is due to the location of many major consumer products manufacturers in these countries. The market share of ‘China and other Pacific Rim countries is set to grow further in future. Europe with 17% is the second largest market, followed by North America with 12%.

8.5.2 Current Applications In the consumer products market, ABS is used mainly for production of housing and panels for a wide range of domestic appliances and power tools. It can either be used alone or as a blend with PC. ABS is most valued for its toughness and good surface finish. ABS is also used to manufacture toys and sports equipment because it is tough enough to withstand the high mechanical stresses in toys, the variety of colours frequently required, and has a long service life. ABS is used in model railways, toy figures, and musical instruments, such as harmonicas. In garden equipment, ABS is used for items such as hose couplings, hedge trimmers, sprinklers and lawn trimmers. 8.6 Polybutylene Terephthalate (PBT)

8.6.1 Consumption Trends Consumer products account for 14% of total PBT consumption in 2002.

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Table 8.6 shows PBT consumption in the consumer products market by world region for the period 1999-2002. Table 8.6 PBT consumption in the consumer products market by world region, 1999-2002 (000 tonnes) 1999 2000 2001 2002 Western Europe 18 20 21 22 North America 21 22 21 22 Japan 10 10 11 12 Rest of Asia Pacific 8 10 9 10 Rest of World 2 2 2 2 TOTAL 59 64 64 68

In 2002, total PBT consumption in consumer product markets amounted to 68,000 tonnes compared with 59,000 tonnes in 1999. World consumption increased by around 8.5% in 2000, and then stabilized in 2001. The main consumer product applications for PBT proved to be more resilient to the downturn in the world economy during 2001. There was a good recovery in demand across all world regions last year. Table 8.7 shows percentage share by world region of PBT in consumer products for the period 1999-2002. Table 8.7 Percentage share by world region of PBT in consumer products, 1999-2002 1999 2000 2001 2002 Western Europe 31% 31% 33% 32% North America 36% 34% 33% 32% Japan 17% 16% 17% 18% Rest of Asia Pacific 14% 16% 14% 15% Rest of World 3% 3% 3% 3%

North America and Western Europe are the largest users of PBT in consumer products each accounting for 32% of total world consumption in 2002. Japan with 18% is the second largest market, followed by ‘Rest of Asia Pacific’ with 15%.

8.6.2 Current Applications In the area of household and personal care appliances, PBT is the preferred material in applications subject to higher mechanical and/or thermal requirements in conjunction with good chemical resistance. Typical applications include oven door handles, parts for food processors, razors, coffee makers, electric irons, hair dryers and styling brushes. PBT continues to find new applications in the consumer appliances market. DuPont’s Crastin PBT resins for example are being applied to handles for cookware products instead of phenolic thermosets. PBT is also being applied to professional steam ovens, parts for electric irons and oven control panels. 8.7 Polycarbonate (PC)

8.7.1 Consumption Trends Consumer products are the most important market for polycarbonate accounting for 29% of total consumption in 2002.

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Table 8.8 shows polycarbonate consumption in the consumer products market by world region for the period 1999-2002. Table 8.8 Polycarbonate consumption in the consumer products market by world region, 1999-2002 (000 tonnes) 1999 2000 2001 2002 Western Europe 95 142 160 170 North America 135 147 130 134 Japan 32 37 32 33 Rest of Asia Pacific 90 124 140 150 Rest of World 6 8 9 10 TOTAL 358 458 471 497

In 2002, total polycarbonate consumption in consumer product markets amounted to 497,000 tonnes compared with 358,000 tonnes in 1999. World consumption of polycarbonate in consumer products has increased substantially in recent years, mainly due to growth in the optical data storage market. China and Western Europe have been the fastest growing markets for optical data storage media since 1999. Table 8.9 shows percentage share by world region of polycarbonate in consumer products for the period 1999-2002. Table 8.9 Percentage share by world region of polycarbonate in consumer products, 1999-2002 1999 2000 2001 2002 Western Europe 27% 31% 34% 34% North America 38% 32% 28% 27% Japan 9% 8% 7% 7% Rest of Asia Pacific 25% 27% 30% 30% Rest of World 2% 2% 2% 2%

Western Europe is the largest user of polycarbonate in consumer products accounting for 34% of total world consumption in 2002. The ‘Rest of Asia Pacific’ with 30%, is the second largest consumer, followed by North America with 27%. Western Europe and China have increased their share of world consumption in recent years due to growing production of DVDs and CD-ROMs.

8.7.2 Current Applications A growing amount of polycarbonate is used for manufacture of optical data storage media such as CDs, CD-ROMs and DVDs. Optical data storage media contain microscopically small items of information, which need to be read without any errors if possible, even under critical ambient conditions. Only a polymer offering high transparency and dimensional stability, coupled with an extremely high reproduction accuracy and dimensional stability, will be a suitable substrate material. In 2001 more than 25 billion CDs and DVDs were produced, which represents an increase of over 20% over the previous year. In 2001, 430,000 tonnes of polycarbonate were consumed in the optical disc market. By 2005, it is estimated that market tonnage will reach 800,000 tonnes. DVDs will be the fastest growing market segment. In 2001, DVDs accounted for 6% of all optical discs produced, but the share of DVD is projected to rise to 22% by 2005. Bayer claims to be clear world market leader for optical disc applications with around a third of resin sales to the sector.

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Competition in the material segment is between polycarbonate and PMMA producers. The PMMA producers such as Rohm and Atoglas, have identified the potential of the DVD market and are trying to introduce special PMMA formulations. But so far, the acrylate specialists have only managed to present first practical applications. Polycarbonate will be hard to displace. Polycarbonate is applied to a wide range of domestic appliances and consumer products. It can be used separately or in blends with ABS and PBT to manufacture a range of different parts from transparent windows and doors in washing machines, to housings and small domestic appliances such as hair dryers and electric irons. Polycarbonate is used in domestic appliances because it fulfils many different requirements. It has good electrical insulation values to ensure reliable protection to the device. PC has high dimensional stability in heat. It retains its dimensional stability at a long-term service temperature of up to 125 °C. Depending on the load acting on the component, non-reinforced grades of PC will remain dimensionally stable at up to 135 °C. It also has outstanding impact strength, which is retained over a prolonged period of time even when in contact with hot water (< 60 °C). PC is also transparent and permits a good surface finish. To improve the resistance of household appliances to humid conditions, GE Plastics extended its range of polycarbonates that are approved for food contact applications to include ‘Lexan H’. Even when subjected to heat and moisture over longer periods of time, this material retains its optical and mechanical properties, making it particularly suitable for applications such as steamer inserts for vegetables and heat-resistant containers. PC is also used for applications in toys and sports such as ships’ lights, binoculars and compasses. These applications require high mechanical strength and toughness, as well as weather resistance and precision mouldings. In the sports equipment market, PC/PBT blends are used for manufacture of ski bindings, bicycle components and skates. PC/PBT provides ductility, high flow and weatherability. GE Plastics also provides the opportunity for decoration using its VISUALfx effects. 8.8 Polyoxymethylene (POM)

8.8.1 Consumption Trends Consumer products are an important market for POM accounting for 21% of total consumption in 2002. Table 8.10 shows POM consumption in the consumer products market by world region for the period 1999-2002. Table 8.10 POM consumption in the consumer products market by world region, 1999-2002 (000 tonnes) 1999 2000 2001 2002 Western Europe 38 40 39 40 North America 42 44 42 43 Japan 11 10 11 11 Rest of Asia Pacific 26 30 30 32 TOTAL 117 124 122 126

In 2002, total POM consumption in consumer product markets amounted to 126,000 tonnes compared with 117,000 tonnes in 1999. World consumption of POM in consumer products increased by 6% in 2000, but slipped back in the following year due to the downturn in world economic activity. World demand for POM in consumer products recovered slightly in 2002. 130


Table 8.11 shows percentage share by world region of POM in consumer products for the period 1999-2002. Table 8.11 Percentage share by world region of POM in consumer products, 1999-2002 1999 2000 2001 2002 Western Europe 32% 32% 32% 32% North America 36% 35% 34% 34% Japan 9% 8% 9% 9% Rest of Asia Pacific 22% 24% 25% 25%

North America is the largest user of POM in consumer products accounting for 34% of total world consumption in 2002. Western Europe is the second largest consumer with 32% followed by ‘Rest of Asia Pacific’ with 25%. The latter region is growing its share of world consumption as more consumer product manufacturers relocate to lower cost economies.

8.8.2 Current Applications In domestic and leisure applications, POM is used for parts in sanitary fittings, curtain hooks, buckles, clips, guide rollers for audio and video tape cassettes, cutlery baskets for dishwashers, kettles, tea and coffee makers, espresso machines, window and door mountings, inserts for dishwashers, parts for vacuum cleaners, pastille dispensers, parts for garden sprinkler systems and plumbing fittings. POM is also applied to toys and sports gear: tennis racquet grips, ski bindings, small parts for model railways and cars, rod holders for surf boards and sail pulleys. POM is finding new applications in the sporting goods market. In snowboard binding, POM is used because of its low temperature performance. For the manufacture of the chassis and high back, it is favoured because of the outstanding strength, stiffness and durability. POM is also being used for buckles because of its stiffness. POM can also be found in adjustable soles of ski boots. It is chosen for its durability, rigidity, impact and UV resistance and excellent performance at temperatures below minus 20 °C. 8.9 Polymethyl Methacrylate (PMMA)

8.9.1 Consumption Trends Consumer products are a small market for PMMA accounting for just 5% of total world consumption in 2002. Table 8.12 shows PMMA consumption in the consumer products market by world region for the period 1999-2002. Table 8.12 PMMA consumption in the consumer products market by world region, 1999-2002 (000 tonnes) 1999 2000 2001 2002 Western Europe 10 11 10 11 North America 19 20 19 20 Japan 5 6 6 6 Rest of Asia Pacific 13 15 16 17 TOTAL 47 52 51 54

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In 2002, total PMMA consumption in consumer product markets amounted to 54,000 tonnes compared with 47,000 tonnes in 1999. World consumption of PMMA in consumer products increased by 10.5% in 2000, but declined slightly during the following year because of the downturn in world economic activity. World demand for PMMA in consumer products recovered slightly in 2002 across most of the major world regions. Table 8.13 shows percentage share by world region of PMMA in consumer products for the period 1999-2002. Table 8.13 Percentage share by world region of PMMA in consumer products, 1999-2002 1999 2000 2001 2002 Western Europe 21% 21% 20% 20% North America 40% 38% 37% 37% Japan 11% 12% 12% 11% Rest of Asia Pacific 28% 29% 31% 32%

North America is the largest user of PMMA in consumer products accounting for 37% of total world consumption in 2002. ‘Rest of Asia Pacific’ is the second largest consumer with 32%, followed by Western Europe with 20%. As in other polymer groups, the Asia Pacific region is growing its share of world consumption as more consumer product manufacturers relocate to lower cost economies.

8.9.2 Current Applications In the consumer products and appliances market, PMMA can be used in applications such as dishes, salad bowls, salt cellars, pepper pots, scales, covers, doors for microwave ovens, washing machine windows and control panels, and vacuum cleaner windows. PMMA provides transparency, very high impact resistance, chemical resistance and a high gloss finish. It is also resistant to most aqueous, inorganic and saline solutions, as well as grease, mineral oils and many solvents. PMMA is found in applications such as instrument panels, satellite dishes and photocopier trays to printer hoods and fax covers, acoustic screens, HIFI equipment and remote controls. PMMA is also used to make pens and other items of stationery, children’s toys and furniture. 8.10 Polyphenylene Oxide (Ether) Blends (PPO and PPE)

8.10.1 Consumption Trends Consumer products are not a major market for PPO/PPE blends accounting for just 5% of total consumption in 2002. Table 8.14 shows PPO/PPE blends consumption in the consumer products market by world region for the period 1999-2002. Table 8.14 PPO/PPE blends consumption in the consumer products market by world region, 1999-2002 (000 tonnes) 1999 2000 2001 2002 Western Europe 5 5 5 5 North America 9 9 8 8 Japan 5 5 5 5 TOTAL 19 19 18 18

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In 2002, total PPO/PPE blends consumption in consumer product markets amounted to 18,000 tonnes against 19,000 tonnes in 1999. World consumption of PPO/PPE blends in consumer products declined slightly during period 1999-2002 due to the world economic downturn. Table 8.15 shows percentage share by world region of PPO/PPE blends in consumer products for the period 1999-2002. Table 8.15 Percentage share by world region of PPO/PPE blends in consumer products, 1999-2002 1999 2000 2001 2002 Western Europe 26% 26% 28% 28% North America 47% 47% 44% 44% Asia 26% 26% 28% 28%

North America is the largest user of PPO/PPE blends in consumer products accounting for 44% of total world consumption in 2002. Asia and Western Europe each account for 28% of market demand. Asia and Western Europe have grown their share of world consumption during the period 1999-2002.

8.10.2 Current Applications PPO/PPE blends are used in a variety of domestic appliances, mainly for the manufacture of electrical components where high heat resistance and mechanical strength are key requirements. They are also used to manufacture power tools and consumer appliance enclosures because of their high heat and chemical resistance, durability and impact performance, and excellent thin wall processing properties. PPO/PPE blends also have lower specific gravity than most polyamides, which results in lower weight parts. 8.11 Polyphenylene Sulfide (PPS)

8.11.1 Consumption Trends Consumer products are a small market for PPS representing only 5% of total consumption in 2002. Table 8.16 shows PPS consumption in the consumer products market by world region for the period 1999-2002. Table 8.16 PPS consumption in the consumer products market by world region, 1999-2002 (000 tonnes) 1999 2000 2001 2002 Western Europe 0.5 0.5 0.5 0.5 North America 0.7 0.7 0.6 0.6 Japan 1.0 1.1 1.0 1.0 Rest of Asia Pacific 0.4 0.5 0.5 0.6 TOTAL 2.6 2.8 2.6 2.7

In 2002, total PPS consumption in consumer product markets amounted to 2,700 tonnes compared with 2,600 tonnes in 1999. World consumption of PPS in consumer products increased by 7.5% in 2000, but slipped back in the following year due to lower growth in the world economy. There was only a marginal recovery in PPS demand for consumer products in 2002, the best growth being achieved in Asia Pacific.

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Table 8.17 shows percentage share by world region of PPS in consumer products for the period 1999-2002. Table 8.17 Percentage share by world region of PPS in consumer products, 1999-2002 1999 2000 2001 2002 Western Europe 19% 18% 19% 19% North America 27% 25% 23% 22% Japan 38% 39% 38% 37% Rest of Asia Pacific 15% 18% 19% 22%

Japan is the largest user of PPS in consumer products accounting for 37% of total world consumption in 2002. North America and ‘Rest of Asia Pacific’ are the second largest consumers with 22% followed by Western Europe with 19%. The ‘Rest of Asia Pacific’ region is growing its share of world consumption as more consumer product manufacturers relocate their manufacturing activities from high cost economies to developing countries.

8.11.2 Current Applications PPS offers a combination of high temperature stability, excellent mechanical strength and dimensional stability, along with resistance to corrosion by common solvents, caustic solutions, and dilute acids. The material is challenging metals, thermosets, or other engineering plastics in many domestic appliance applications. In small appliances, PPS is used for a wide range of items such as coffee warmer rings, electric blanket thermostat controls, frying pan handles, hair dryer grills, steam iron valves and toaster switches. In large domestic appliances, PPS is used for defroster plugs, dryer switches, microwave oven turntables, washer pump impellers, motor brush holders and flue collector/transition pipes. 8.12 Polyetherimide (PEI)

8.12.1 Consumption Trends Consumer products are a small market for PEI representing only 5% of total consumption in 2002. Table 8.18 shows PEI consumption in the consumer products market by world region for the period 1999-2002. Table 8.18 Polyetherimide consumption in the consumer products market by world region, 1999-2002 (000 tonnes) 1999 2000 2001 2002 Western Europe 0.13 0.15 0.13 0.14 North America 0.40 0.45 0.40 0.43 Japan 0.06 0.07 0.07 0.07 Rest of Asia Pacific 0.06 0.07 0.07 0.08 TOTAL 0.65 0.74 0.67 0.72

In 2002, total PEI consumption in consumer product markets amounted to 720 tonnes compared with 650 tonnes in 1999. World consumption of PEI in consumer products increased by nearly 14% in 2000, but slipped back in the following year due to the downturn in world economic activity. In 2002, world demand for PEI in consumer products increased by 7.5%.

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Table 8.19 shows percentage share by world region of PEI in consumer products for the period 1999-2002. Table 8.19 Percentage share by world region of polyetherimide in consumer products, 1999-2002 1999 2000 2001 2002 Western Europe 20% 20% 19% 19% North America 62% 61% 60% 60% Japan 9% 9% 10% 10% Rest of Asia Pacific 9% 9% 10% 11%

North America is the largest user of PEI in consumer products, accounting for 60% of total world consumption in 2002. Western Europe is the second largest consumers with 19%, followed by ‘Rest of Asia Pacific’ region with 11% and Japan with 10%.

8.12.2 Current Applications Polyetherimide resin offers high heat resistance, high strength, modulus and broad chemical resistance. PEI is also inherently flame resistant with low smoke emission. PEIs are ecoconforming, and meet stringent eco-label requirements such as TCO99, Blue Angel, White Swan or EU, while meeting the fire safety criteria of UL. These features make PEI a good choice for socalled speed cooking, which is growing in popularity in the foodservice market. Speed cooking combines convection and microwave oven technology, which make cooking faster without sacrificing taste. Polyetherimide is used in cookware and utensils for these new technologies. PEI reusable ovenware can be washed and reheated many times, which makes it suitable for catering dishes. Its wide operating temperature range from –40 to +200 °C means that foodstuffs which are stored in PEI containers can be reheated in hot air ovens, combi-steamers and microwaves, or using thermo-contact technology. 8.13 Polysulfone (PSU), Polyethersulfone (PES)

8.13.1 Consumption Trends In 2002, consumer products represented 15% of total world PSU/PES consumption. Table 8.20 shows PSU/PES consumption in the consumer products market by world region for the period 1999-2002. Table 8.20 PSU/PES consumption in the consumer products market by world region, 1999-2002 (000 tonnes) 1999 2000 2001 2002 Western Europe 0.55 0.64 0.55 0.65 North America 1.70 1.86 1.80 1.85 Japan 0.35 0.35 0.35 0.45 Rest of Asia Pacific 0.35 0.35 0.35 0.42 TOTAL 2.95 3.20 3.05 3.37

In 2002, total PSU/PES consumption in consumer product markets amounted to 3,370 tonnes compared with 2,950 tonnes in 1999. World consumption of PSU/PES in consumer products increased by 8.5% in 2000, but slipped back in the following year due to the downturn in world economic activity. In 2002, world demand for PSU/PES in consumer products grew by nearly 14%.

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Table 8.21 shows percentage share by world region of PSU/PES in consumer products for the period 1999-2002. Table 8.21 Percentage share by world region of PSU/PES in consumer products, 1999-2002 1999 2000 2001 2002 Western Europe 19% 20% 18% 19% North America 58% 58% 59% 55% Japan 12% 11% 11% 13% Rest of Asia Pacific 12% 11% 11% 13%

North America is the largest user of PSU/PES in consumer products accounting for 55% of total world consumption in 2002. Western Europe is the second largest market with 19%, followed by Japan with 13% and ‘Rest of Asia Pacific’ region also with 13%.

8.13.2 Current Applications The high heat resistance (up to 220 °C), good mechanical properties and high fracture resistance, resistance to superheated steam and exceptional resistance to chemicals are reasons for using PSU/PES in the food and households sectors as a replacement for glass, metal, ceramics or porcelain. Typical applications include coffeemakers, microwave dishes and food processors. PSU/PES continues to find new applications in consumer products. For example, in 2002, Solvay announced that Keurig Premium Coffee Systems’ patented ‘Coffee House Taste by the Cup’ brewing system was using injection moulded, heat- and residue-resistant hot water delivery components made from UDEL PSU resins. 8.14 Liquid Crystal Polymers (LCP)

8.14.1 Consumption Trends Consumer products are a small market for LCP, accounting for just 8% of total world LCP consumption in 2002. Table 8.22 shows LCP consumption in the consumer products market by world region for the period 1999-2002. Table 8.22 LCP consumption in the consumer products market by world region, 1999-2002 (000 tonnes) 1999 2000 2001 2002 Western Europe 0.16 0.20 0.17 0.20 North America 0.33 0.40 0.35 0.40 Japan 0.70 0.84 0.78 0.86 TOTAL 1.19 1.44 1.30 1.46

In 2002, total LCP consumption in consumer product markets amounted to 1,460 tonnes against 1,190 tonnes in 1999. World consumption of LCP in consumer products increased by 15-20% in 2000, but slipped back in the following year due to the sharp downturn in world economic growth. In 2002, world demand for LCP in consumer products recovered sharply with growth of 10-15%. Table 8.23 shows percentage share by world region of LCP in consumer products for the period 1999-2002.

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Table 8.23 Percentage share by world region of LCP in consumer products, 1999-2002 1999 2000 2001 2002 Western Europe 13% 14% 13% 14% North America 28% 28% 27% 27% Asia 59% 58% 60% 59%

Asia is the largest user of LCP in consumer products accounting for 59% of total world consumption in 2002. This substantial share is due to the location of many of the world’s leading consumer product manufacturers in Asia. North America is the second largest market with 27%, followed by Western Europe with 14%.

8.14.2 Current Applications LCP is used for manufacture of precision parts for consumer electronics equipment such as audio and video systems. It is also finding new uses in DVD, CD-ROM and CD-RW drives. DuPont for example announced that its Zenite LCP resins were being used for manufacture of lens holders for optical pick up parts in CD-ROM, CD-RW and DVD drives. The high flexural modulus/specific gravity (FM/SG) value of the Zenite® 1000 series enables higher resonance vibration frequency, which is required by optical pickup for precise and fast speed reading, in particular for high value top end drives. LCP also provides high flow, dimensional stability for precision moulding and low mould temperature for mass production.

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9 Other Markets for Engineering and High Performance Plastics 9.1 Introduction Engineering and high performance plastics are used in a wide variety of other market sectors. These include: • • • • • • •

Packaging film and sheet (PA, PC) Blow moulded bottles (PC) Stock shapes (PA, PBT) Optical media (PC, PMMA) Plumbing (POM) Heating and sanitation (PSU/PES) Medical devices (ABS, PC, PBT, POM, PEI, PSU, PES, LCP, PEEK))

The medical devices market is probably the most important in terms of development opportunities for suppliers of engineering and high performance polymers. There are several main trends encouraging greater use of engineering plastics in medical applications. In medical technology, there is an increasing trend for ‘smart’ products. These are made possible by modern processes such as laser marking, two-component injection moulding and MID technology. Current examples include functional drug delivery systems like pens for active ingredient injection and needleless syringes. A key reason for selecting high-performance plastics is the precision with which finely detailed parts can be injection moulded from them. In addition, their excellent slip properties in sliding contact with other materials, high impact strength and low wear ensure reliable functioning of the application long-term. The pace of development is being set by microsystem technology, minimally invasive surgery, diagnostics and new drug delivery and packaging concepts for the pharmaceutical industry. Engineering plastics make an important contribution to reducing costs through functional integration. In medical markets, there are stringent regulatory requirements that must be met before a material can be used for a particular application. It is important to ensure that products that come into close contact with people do not contain any harmful substances that may damage health. Also, more stringent sterilisation methods are generally required for medical devices. Products and materials used for medical applications must be fully characterised, validated and tested for a variety of specifications including USP Class VI, ISO 10993, European Pharmacopoeia and FDA criteria. The EU Medical Devices Directive (93/42/EC) is the most recent framework for specification of medical devices in the European Union. 9.2 Future Prospects for the Medical Devices Market Table 9.1 shows healthcare expenditure for major world regions in 2000. The future prospects for growth in the medical devices market remain good. Plastics will continue to replace traditional materials for medical devices because of their greater design flexibility and excellent cost/performance characteristics. Also, overall spending on medical devices is expected to show continued growth. Spending on healthcare in all major world regions grew well in excess of average GDP during the last decade. For the world as a whole, healthcare spending rose at an

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annual average rate of 6%. The highest growth occurred in ‘rest of the world’, which covers most of the developing countries of southeast Asia and Latin America. Spending on healthcare in the USA rose at an average rate of 7%, while average spend in the EU rose by 5.5% per annum. Table 9.1 Healthcare expenditure for major world regions, 2000 Average Medical Health Market size World Growth rate Devices per Expenditure ($billion) Market (%) 1990-2000 capita ($) (% GDP) EU 41.0 25.6 5.7% 66 5.5% USA 60.0 41.5 13.9% 125 7.0% Japan 24.5 15.0 7.1% 116 4.0% Rest of world 34.5 18.0 n.a. n.a. 15.0% TOTAL 160.0 100.0 n.a. n.a. 6.0%

The USA is the largest market for medical devices with a total value of $60 billion in 2000. The EU market is second largest at $41 billion, followed by Japan at $24.5 billion. In 2000, the EU accounted for 25.6% of the world medical devices market compared to an estimated 31.0% share in 1993. The reduction in overall market share is due partly to rapid expansion in medical technology sales in other markets, partly to market consolidation resulting in better distribution channels, and also because of reducing prices of medical devices. However, the decrease in world market share is also due to a significantly lower expenditure on healthcare (5.7% of GDP in EU compared to 13.9% in the USA and 7.1% in Japan). 9.3 Polyamide

9.3.1 Consumption Trends In 2002, ‘other markets’ accounted for 24% of total world polyamide consumption. Table 9.2 shows polyamide consumption in ‘other markets’ by world region for the period 19992002. Table 9.2 Polyamide consumption in ‘other markets’ by world region, 1999-2002 (000 tonnes) 1999 2000 2001 2002 Western Europe 180 194 183 190 North America 164 156 141 144 Japan 29 30 29 30 Rest of Asia Pacific 54 60 58 63 Rest of World 34 37 35 37 TOTAL 461 477 446 464

In 2002, total polyamide consumption in ‘other markets’ amounted to 464,000 tonnes against 461,000 tonnes in 1999. World consumption increased by around 3.5% in 2000, but then declined in 2001 due to the downturn in world economic activity. In 2002, there was a modest recovery in demand across all major world regions. Table 9.3 shows percentage share by world region of polyamide in ‘other markets’ for the period 1999-2002. Western Europe is the largest user of polyamide in ‘other markets’ accounting for 41% of total world consumption in 2002. North America with 31% is the second largest market, followed by

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‘Rest of Asia Pacific’ with 14%. The market share of China and other Pacific Rim countries has been growing and is set to grow further in future. Table 9.3 Percentage share by world region of polyamide in ‘other markets’, 1999-2002 1999 2000 2001 2002 Western Europe 39% 41% 41% 41% North America 36% 33% 32% 31% Japan 6% 6% 7% 6% Rest of Asia Pacific 12% 13% 13% 14% Rest of World 7% 8% 8% 8%

9.3.2 Current Applications 9.3.2.1 Film and Sheet Polyamide 6 and 66 can be used for extrusion processes due to chemical and mechanical properties. Main applications are found in packaging film. Polyamide is used for manufacture of monolayer and multilayer film, mainly for food packaging, but also for medical applications. Monolayer film is used primarily for sausage casings and sauce packaging pouches. Multilayer films are used for meat and cheese packaging, and boil-in-the-bag foods. PA film is also used in medical and cosmetics packaging. Polyamide films have high barrier properties and good transparency.

9.3.2.2 Stock Shapes Stock shapes, also called semi-finished materials, are extruded or cast rods, mandrels or thickwalled tubes, thick sheets or profiles. Products made from polyamide include bearings, gear wheels, bushes, pulleys, buffers, seals, scrapers and electrical insulation parts.

9.3.2.3 Other Markets Polyamide is also used in a wide range of other injection moulding applications. 9.4 Acrylonitrile-Butadiene-Styrene (ABS)

9.4.1 Consumption Trends In 2002, ‘other markets’ accounted for 16% of total world ABS consumption. Table 9.4 shows ABS consumption in ‘other markets’ by world region for the period 1999-2002. Table 9.4 ABS consumption in ‘other markets’ by world region, 1999-2002 (000 tonnes) 1999 2000 2001 2002 Western Europe 101 107 100 101 North America 320 315 310 313 Japan 50 52 48 50 Rest of Asia Pacific 250 280 270 289 TOTAL 721 754 728 753

In 2002, total ABS consumption in ‘other markets’ amounted to 753,000 tonnes against 721,000 tonnes in 1999. World consumption increased by around 4.5% in 2000, but declined in 2001 due to the lower world economic growth. There was a modest recovery in demand across all major world regions in 2002, with particularly strong growth in Asia. 141


Table 9.5 shows percentage share by world region of ABS in ‘other markets’ for the period 19992002. Table 9.5 Percentage share by world region of ABS in ‘other markets’, 1999-2002 1999 2000 2001 2002 Western Europe 14% 14% 14% 13% North America 44% 42% 43% 42% Japan 7% 7% 7% 7% Rest of Asia Pacific 35% 37% 37% 38%

North America is the largest user of ABS in ‘other markets’ accounting for 42% of total world consumption in 2002. The ‘Rest of Asia Pacific’ with 38% is the second largest market, followed by Western Europe with 13%. The market share of China and other Pacific Rim countries has been increasing since 1999 because of high economic growth and relocation of manufacturers to these lower cost countries.

9.4.2 Current Applications In the medical market, ABS is used for manufacture of housings for devices such as inhalers. Sheet and thermoforming ABS resins provide excellent high and low gloss aesthetics, good thermal colour stability, heat and impact resistance, and stiffness for applications such as luggage, tool cases, showers/bath tubs, signs and recreational vehicles. 9.5 Polybutylene Terephthalate (PBT)

9.5.1 Consumption Trends ‘Other markets’ account for only a small share of PBT consumption with just 5% of the total world PBT market in 2002. Table 9.6 shows PBT consumption in ‘other markets’ by world region for the period 1999-2002. Table 9.6 PBT consumption in ‘other markets’ by world region, 1999-2002 (000 tonnes) 1999 2000 2001 2002 Western Europe 7 8 8 8 North America 5 6 6 6 Japan 3 3 3 3 Rest of Asia Pacific 4 5 4 5 TOTAL 19 22 21 22

In 2002, total PBT consumption in ‘other markets’ amounted to 22,000 tonnes against 19,000 tonnes in 1999. World consumption increased sharply in 2000, but then declined in 2001 due to the downturn in the world economy. There was no real improvement in total demand during 2002, although Asia demand was up sharply. Table 9.7 shows percentage share by world region of PBT in ‘other markets’ for the period 19992002. Western Europe is the largest user of PBT in ‘other markets’ accounting for 36% of total world consumption in 2002. North America with 27% is the second largest market, followed by ‘Rest of

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Asia Pacific’ with 23%. The market share of China and other Pacific Rim countries has been growing and should grow further in future. Table 9.7 Percentage share by world region of PBT in ‘other markets’, 1999-2002 1999 2000 2001 2002 Western Europe 37% 36% 38% 36% North America 26% 27% 29% 27% Japan 16% 14% 14% 14% Rest of Asia Pacific 21% 23% 19% 23%

9.5.2 Current Applications PBT is used in a variety of other injection moulding applications including blood tubes in the medical devices market, wheel hubs, valves and taps, and scissor handles. PBT is also used for manufacture of semi-finished products such as extruded rods, thick-walled tube, and thick sheet and profiles, which are then used for a variety of mechanical precision parts. 9.6 Polycarbonate (PC)

9.6.1 Consumption Trends In 2002, ‘other markets’ accounted for 11% of total world polycarbonate consumption. Table 9.8 shows polycarbonate consumption in ‘other markets’ by world region for the period 1999-2002. Table 9.8 Polycarbonate consumption in ‘other markets’ by world region, 1999-2002 (000 tonnes) 1999 2000 2001 2002 Western Europe 35 48 40 42 North America 81 89 78 80 Japan 11 13 12 12 Rest of Asia Pacific 40 43 45 48 Rest of World 1 2 3 3 TOTAL 168 195 178 185

In 2002, total polycarbonate consumption in ‘other markets’ amounted to 185,000 tonnes compared with 168,000 tonnes in 1999. World consumption of PC in ‘other markets’ increased between 1520% in 2000. In 2001, world consumption fell sharply due to the sharp downturn in world economic growth. There was only a modest recovery in demand last year across most major world markets. Table 9.9 shows percentage share by world region of polycarbonate in ‘other markets’ for the period 1999-2002. Table 9.9 Percentage share by world region of polycarbonate in ‘other markets’, 1999-2002 1999 2000 2001 2002 Western Europe 21% 25% 22% 23% North America 48% 46% 44% 43% Japan 7% 7% 7% 6% Rest of Asia Pacific 24% 22% 25% 26% Rest of World 1% 1% 2% 2%

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North America is the largest user of polycarbonate in ‘other markets’ accounting for 43% of total world consumption in 2002. The ‘Rest of Asia Pacific’ region with 26% is the second largest market, followed by Western Europe with 23%. There was a sharp decline in the market share of North America during the period 1999-2002, while the market shares of Western Europe and ‘Rest of Asia Pacific’ have been growing.

9.6.2 Current Applications Polycarbonate is used in a wide range of ‘other markets’. It is used extensively in the optical industry for visors, protective lenses, industrial lenses and corrective lenses. PC has high transparency, dimensional stability, high temperature resistance, good processability and outstanding impact strength. In the medical devices market, polycarbonate is used in a range of different applications including haemodialysers, surgical instruments, cardiotomy reservoirs, blood centrifuge bowls, IV connectors, safety syringes and ophthalmic media. In the packaging sector, PC is used for manufacture of large reusable water bottles, reusable milk bottles and babies’ bottles. Polycarbonate is non-toxic and tasteless for contact with food, transparent, has high impact strength, is fracture resistant and can be easily cleaned. Polycarbonate is also used in a wide variety of other applications including fountain pens and ballpoint pens, food and catering containers, binocular housings, safety items such as protective goggles and machine hoods, and traffic signs with interior illumination. Some recent market developments are discussed next. GE Plastics has introduced Lexan EXL, an extra tough polycarbonate with added impact resistance and low temperature ductility. These attributes, plus its light weight, make it a great material for a variety of applications including telecommunications, portable electronics and outdoor equipment. It can replace metal and other engineering plastics. Lexan EXL sheet is finding new opportunities in vacuum formed parts, sound barriers and architectural applications. With its new polycarbonate grade ‘Makrolon Hygard’, Makroform GmbH, a joint venture of Bayer and Rohm, is attempting to develop a new market in security applications. Developed with armoured cars, banks or convenience stores or even prisons in mind, the product made of multiple layers of PC or PC/acrylic with bonding inter-layers, comes in six levels of protection, ranging from containment-rated sheet up to bullet resistant strengths capable of withstanding multiple rounds of fire from super-power hand guns. The hard coated surface also has exceptional resistance to abrasion and UV degradation. Polycarbonate is the favoured engineering polymer for production of many parts for the needleless syringe, one of the fastest growing devices in the medical market. It is preferred because of its burst strength, sterilisability and dimensional stability. GE Plastics has recently completed ISO10993 biocompatibility testing on the first tested grade in the Xylex PC.PBT resin product. This will allow the company to push ahead with its plans to further develop uses for Xylex in the field of medical devices. The material has a combination of strength, clarity, and chemical resistance. Target applications for Xylex include disposable medical supplies such as syringes, IV systems and fluid containers. Xylex resin also provides material solutions for non-disposable medical devices such as instrument panels and housings.

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9.7 Polyoxymethylene (POM)

9.7.1 Consumption Trends In 2002, ‘other markets’ accounted for 8% of total world POM consumption. Table 9.10 shows POM consumption in ‘other markets’ by world region for the period 1999-2002. Table 9.10 Polyacetal consumption in ‘other markets’ by world region, 1999-2002 (000 tonnes) 1999 2000 2001 2002 Western Europe 27 30 29 30 North America 4 5 5 5 Japan 3 2 3 3 Rest of Asia Pacific 9 10 10 11 Rest of World 0 0 0 0 TOTAL 43 47 47 49

In 2002, total POM consumption in ‘other markets’ amounted to 49,000 tonnes compared with 43,000 tonnes in 1999. World consumption of POM in ‘other markets’ increased by nearly 10% in 2000. In 2001, world consumption remained stable and showed a modest recovery last year. Table 9.11 shows percentage share by world region of POM in ‘other markets’ for the period 19992002. Table 9.11 Percentage share by world region of polyaacetal in ‘other markets’, 1999-2002 1999 2000 2001 2002 Western Europe 63% 65% 62% 61% North America 9% 10% 11% 10% Japan 7% 4% 6% 6% Rest of Asia Pacific 21% 22% 21% 23%

Western Europe is the largest user of POM in ‘other markets’ accounting for 61% of total world consumption in 2002. The ‘Rest of Asia Pacific’ region with 23% is the second largest market, followed by North America with 10% and Japan with 6%.

9.7.2 Current Applications The most important applications for POM in ‘other markets’ are medical devices and plumbing. POM is used for medical devices such as parts for inhaler systems and insulin pens. The medical market offers many opportunities for POM. Producers such as Ticona for example, have introduced very high-purity grades for medical applications. These special grades have extremely low extractables and low antioxidant content. The materials have also been tested for biocompatibility and conform to FDA regulations. In the plumbing sector, POM is used for water jet regulators in showers, tap outlets, single lever mixer taps and self-cleaning backwash filters.

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9.8.1 Consumption Trends In 2002, ‘other markets’ accounted for 18% of total world PMMA consumption. Table 9.12 shows PMMA consumption in ‘other markets’ by world region for the period 19992002. Table 9.12 PMMA consumption in ‘other markets’ by world region, 1999-2002 (000 tonnes) 1999 2000 2001 2002 Western Europe 45 50 45 50 North America 64 67 65 67 Japan 23 24 22 23 Rest of Asia Pacific 27 30 31 33 TOTAL 159 171 163 173

In 2002, total PMMA consumption in ‘other markets’ amounted to 173,000 tonnes compared with 159,000 tonnes in 1999. World consumption of PMMA in ‘other markets’ increased sharply in 2000. There was a reduction in world consumption for PMMA in 2001 due to the downturn in the world economy. World demand recovered in 2002 by around 6% with all major world markets recording growth. Table 9.13 shows percentage share by world region of PMMA in ‘other markets’ for the period 1999-2002. Table 9.13 Percentage share by world region of PMMA in ‘other markets’, 1999-2002 1999 2000 2001 2002 Western Europe 28% 29% 28% 29% North America 40% 39% 40% 39% Japan 14% 14% 13% 13% Rest of Asia Pacific 17% 18% 19% 19%

North America is the largest user of PMMA in ‘other markets’ accounting for 39% of total world consumption in 2002. Western Europe with 29% is the second largest market, followed by ‘Rest of Asia Pacific’ with 19%. There was a small decline in the market share of North America during the period 1999-2002, while the market shares of Western Europe and ‘Rest of Asia Pacific’ have been growing.

9.8.2 Current Applications Other markets for PMMA are discussed next.

9.8.2.1 Optical Media PMMA is used in optical data storage media such as CDs and DVDs. Substrates made from PMMA provide an optimised balance of high-flow characteristics and heat resistance. They also have good optical characteristics such as high light transmission and low birefringence.

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9.8.2.2 Medical Devices In the medical devices market, PMMA can be used in applications such as blood pressure filters, blood cell traps, peritoneal dialysis cassettes and blood cuvettes. Acrylic resins offer exceptional optical clarity, excellent sterilisability, processability, dimensional stability, bondability and excellent UV transmittance. High impact and medium impact grades are available with exceptional resistance to gamma radiation sterilization and superior UV transmission, for in vitro diagnostic use.

9.8.2.3 Packaging In packaging markets, acrylics are used for applications such as stoppers, jars, cosmetics containers, mascara holders, lipstick tubes, games boxes, surgical and dental instrument cases, musical instrument cases and musical boxes. Fast-growing new applications for PMMA include CD-ROMs and DVDs. PMMA is becoming very competitive to polycarbonate in regard to birefringence and refractive index as well as impact strength, heat resistance, water absorption and other properties. Mobile phones, organisers and pocket personal computers are also present and future growth drivers for PMMA moulding compounds. PMMA is also becoming more competitive with polycarbonate in these applications. Impact-modified PMMA, for example, ensures the desired break resistance. The major acrylics suppliers are also developing new products. Nova Chemicals for example, has commercialised a new acrylic copolymer, Zylar 390, which offers, clarity, toughness and enhanced chemical resistance. Potential applications for the polymer include medical devices, appliance parts, personal care products and consumer electronics. It is already being used as a surgical blood filter canister as a replacement for impact acrylics. The material toughness is between that of polycarbonate and ABS, and Nova is pushing it as an alternative to ABS, polycarbonate and standard acrylics. 9.9 Polyphenylene Oxide (Ether) Blends (PPO and PPE)

9.9.1 Consumption Trends In 2002, ‘other markets’ accounted for 5% of total world PPO/PPE blends consumption. Table 9.14 shows PPO/PPE blends consumption in ‘other markets’ by world region for the period 1999-2002. Table 9.14 PPO/PPE blends consumption in ‘other markets’ by world region, 1999-2002 (000 tonnes) 1999 2000 2001 2002 Western Europe 5.0 5.0 5.0 5.0 North America 8.0 8.0 8.0 8.0 Asia 4.0 4.0 4.0 4.0 TOTAL 17.0 17.0 17.0 17.0

In 2002, total PPO/PPE blends consumption in ‘other markets’ amounted to 17,000 tonnes. World consumption of PPO/PPE blends in ‘other markets’ has remained stable during the period 19992000.

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Table 9.15 shows percentage share by world region of PPO/PPE blends in ‘other markets’ for the period 1999-2002. Table 9.15 Percentage share by world region of PPO/PPE blends in ‘other markets’, 1999-2002 1999 2000 2001 2002 Western Europe 29% 29% 29% 29% North America 47% 47% 47% 47% Asia 24% 24% 24% 24%

North America is the largest user of PPO/PPE blends in ‘other markets’ accounting for 47% of total world consumption in 2002. Western Europe with 29% is the second largest market, followed by Asia with 24%.

9.9.2 Current Applications There are very few applications for PPO/PPE blends in ‘other’ markets’ One example, however, is provided by GE Plastics Noryl PPO, which is being applied to microwavable food packaging. It is also being used for convenience food carryout containers. Noryl PPO is being selected for its improved variable molecular weight (higher melt flow), high heat resistance (microwavable) and great rigidity, which hold food securely. 9.10 Polyphenylene Sulfide (PPS)

9.10.1 Consumption Trends In 2002, ‘other markets’ accounted for 6% of total world PPS consumption. Table 9.16 shows PPS consumption in ‘other markets’ by world region for the period 1999-2002. Table 9.16 PPS consumption in ‘other markets’ by world region, 1999-2002 (000 tonnes) 1999 2000 2001 2002 Western Europe 0.5 0.6 0.6 0.6 North America 0.8 0.9 0.9 0.9 Japan 1.1 1.1 1.1 1.1 Rest of Asia Pacific 0.4 0.5 0.4 0.4 TOTAL 2.8 3.1 3.0 3.0

In 2002, total PPS consumption in ‘other markets’ amounted to 3,000 tonnes against 2,800 tonnes in 1999. World consumption of PPS in ‘other markets’ increased sharply in 2000. Consumption was lower in 2001 due to the downturn in world economic activity and remained stable in 2002. Table 9.17 shows percentage share by world region of PPS in ‘other markets’ for the period 19992002. Table 9.17 Percentage share by world region of PPS in ‘other markets’, 1999-2002 1999 2000 2001 2002 Western Europe 18% 19% 20% 20% North America 29% 29% 30% 30% Japan 39% 35% 37% 37% Rest of Asia Pacific 14% 16% 13% 13%

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Japan is the largest user of PPS in ‘other markets’ accounting for 37% of total world consumption in 2002. North America with 30% is the second largest market, followed by Western Europe with 20%.

9.10.2 Current Applications There are few other significant applications for PPS outside the automotive, E&E, industrial and appliances markets. PPS can however be used in coatings and fibre applications. PPS is used as a coating material on non-stick cookware in competition with Teflon, and in corrosion resistant coatings for industrial parts. PPS fibre is used for manufacture of filter bags, braided sleevings and dryer belts, in competition with fibreglass. PPS is also finding applications in the medical market. For example, in 2002, Solvay Advanced Polymers Radel R polyphenylsulfone was used in the development of sterilisable containers because of its strength to withstand the pressures and vacuums of all autoclaves currently in use. 9.11 Polyetherimide (PEI)

9.11.1 Consumption Trends ‘Other markets’ accounted for only 5% of total world polyetherimide consumption in 2002. Table 9.18 shows PEI consumption in ‘other markets’ by world region for the period 1999-2002. Table 9.18 PEI consumption in ‘other markets’ by world region, 1999-2002 (000 tonnes) 1999 2000 2001 2002 Western Europe 0.13 0.15 0.13 0.14 North America 0.40 0.45 0.40 0.43 Japan 0.06 0.07 0.07 0.07 Rest of Asia Pacific 0.06 0.07 0.07 0.08 TOTAL 0.65 0.74 0.67 0.72

In 2002, total PEI consumption in ‘other markets’ amounted to 720 tonnes compared with 650 tonnes in 1999. World consumption of PEI in ‘other markets’ rose sharply in 2000 but there was a reduction in world demand for PEI in 2001 due to lower economic activity. Demand recovered in 2002, but is still below the level achieved in 2001. Table 9.19 shows percentage share by world region of PEI in ‘other markets’ for the period 19992002. Table 9.19 Percentage share by world region of PEI in ‘other markets’, 1999-2002 1999 2000 2001 2002 Western Europe 20% 20% 19% 19% North America 62% 61% 60% 60% Japan 9% 9% 10% 10% Rest of Asia Pacific 9% 9% 10% 11%

North America is the largest user of PEI in ‘other markets’ accounting for 60% of total world consumption in 2002. Western Europe with 19% is the second largest market, followed by ‘Rest of Asia Pacific’ with 11%.

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9.11.2 Current Applications There are few other significant applications for PEI outside the automotive, E&E, industrial and appliances markets. Polyetherimide resins are however suitable for both disposable and re-usable medical devices. They have a good combination of properties: they are autoclavable, both chemical and lipid resistant, and are available in both clear and opaque grades. The material also withstands dry heat sterilisation at 180 °C, ethylene oxide gas and gamma radiation. 9.12 Polysulfone (PSU), Polyethersulfone (PES)

9.12.1 Consumption Trends In 2002, ‘other markets’ accounted for 23% of total world PSU/PES consumption. Table 9.20 shows PSU/PES consumption in ‘other markets’ by world region for the period 19992002. Table 9.20 PSU/PES consumption in ‘other markets’ by world region, 1999-2002 (000 tonnes) 1999 2000 2001 2002 Western Europe 1.1 1.2 1.1 1.1 North America 2.9 3.1 3.0 3.0 Japan 0.6 0.6 0.6 0.6 Rest of Asia Pacific 0.5 0.6 0.6 0.6 TOTAL 5.1 5.5 5.3 5.3

In 2002, total PSU/PES consumption in ‘other markets’ amounted to 5,300 tonnes compared with 5,100 tonnes in 1999. World consumption of PSU/PES in ‘other markets’ increased by around 8% in 2000. However, consumption of PSU/PES fell in 2001 due to the slowdown in world economic growth, and has remained at similar levels throughout 2002. Table 9.21 shows percentage share by world region of PSU/PES in ‘other markets’ for the period 1999-2002. Table 9.21 Percentage share by world region of PSU/PES in ‘other markets’, 1999-2002 1999 2000 2001 2002 Western Europe 22% 21% 21% 21% North America 57% 56% 57% 56% Japan 11% 11% 11% 11% Rest of Asia Pacific 10% 11% 11% 12%

North America is the largest user of PSU/PES in ‘other markets’ accounting for 56% of total world consumption in 2002. Western Europe with 21% is the second largest market, followed by ‘Rest of Asia Pacific’ with 12%.

9.12.2 Current Applications Other markets for PSU/PES are: •

150

Medical devices: parts and membranes for dialysers; instruments; parts for instruments; surgical theatre luminaries, sterilizing boxes; infusion equipment; secretion bottles and reusable syringes. PSU/PES is preferred in medical devices mainly because it can be sterilised repeatedly and resists stress fracture.


•

Heating and sanitation: rotors for pumps in heating systems; parts for thermostats in heating systems; parts for hot water meters; interior parts for sanitary fittings and pipe fittings.

•

Environmental engineering: membranes and filter housings.

•

Miscellaneous: Binder for non-stick coatings and for coatings resistant to high temperatures.


9.13.1 Consumption Trends In 2002, ‘other markets’ accounted for 4% of total world LCP consumption. Table 9.22 shows LCP consumption in ‘other markets’ by world region for the period 1999-2002. Table 9.22 LCP consumption in ‘other markets’ by world region, 1999-2002 (000 tonnes) 1999 2000 2001 2002 Western Europe 0.1 0.1 0.1 0.1 North America 0.2 0.2 0.2 0.2 Asia 0.3 0.4 0.4 0.5 TOTAL 0.6 0.7 0.7 0.8

In 2002, total LCP consumption in ‘other markets’ amounted to 800 tonnes compared with 600 tonnes in 1999. World consumption of LCP in ‘other markets’ has increased by around a third during the period 1999-2002. Table 9.23 shows percentage share by world region of LCP in ‘other markets’ for the period 19992002. Table 9.23 Percentage share by world region of LCP in ‘other markets’, 1999-2002 1999 2000 2001 2002 Western Europe 13% 14% 14% 14% North America 28% 28% 29% 28% Asia 58% 58% 57% 58%

Asia is the largest user of LCP in ‘other markets’ accounting for 58% of total world consumption in 2002. North America with 28% is the second largest market, followed by Western Europe with 14%.

9.13.2 Current Applications The new techniques of minimally invasive surgery and microsystem technology require innovative solutions, which can often be provided only by engineering plastics. Liquid crystal polymers have been replacing metal in medical devices. LCPs reduce weight and permit completely new equipment design concepts that are not easily achievable with conventional materials. Also, their excellent chemical resistance at high temperatures means that they are ideally suitable for repeated sterilisation.

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9.14 Polyetheretherketone (PEEK)

9.14.1 Consumption Trends In 2002, ‘other markets’ accounted for 13% of total world PEEK consumption. Table 9.24 shows PEEK consumption in ‘other markets’ by world region for the period 1999-2002. Table 9.24 PEEK consumption in ‘other markets’ by world region, 1999-2002 (000 tonnes) 1999 2000 2001 2002 Western Europe 0.08 0.08 0.10 0.09 North America 0.06 0.07 0.08 0.06 Asia 0.01 0.02 0.02 0.02 TOTAL 0.15 0.17 0.20 0.16

Demand for PEEK polymers was growing at between 15-20% per annum during the period 19992001. In 2002, total PEEK consumption in ‘other markets’ actually declined due mainly to the slowdown in world economic growth. Suppliers are, however, confident that demand will recover this year and grow at double-digit rates for the foreseeable future. Table 9.25 shows percentage share by world region of PEEK in ‘other markets’ for the period 1999-2002. Table 9.25 Percentage share by world region of PEEK in ‘other markets’, 1999-2002 1999 2000 2001 2002 Western Europe 52% 48% 50% 55% North America 39% 42% 40% 35% Asia 9% 10% 10% 10%

Western Europe is the largest user of PEEK polymers in ‘other markets’ accounting for 55% of total world consumption in 2002. North America with 35% is the second largest market, followed by Asia with 10%.

9.14.2 Current Applications PEEK polymer is successfully replacing glass, stainless steel and other metals in a growing range of medical applications. PEEK provides cost-effective, innovative parts with excellent wear, heat, electrical and chemical resistance. Applications include dental instruments, endoscopes and haemodialysers. In dentistry, PEEK is replacing aluminium for the handles on dental syringes and sterile boxes that hold root canal files. In surgical and dental instruments that require extensive repeat use, PEEK polymer can withstand up to 3,000 autoclave sterilisation cycles in which temperatures typically reach 134 °C. It maintains high mechanical strength, excellent stress cracking resistance and hydrolytic stability in the presence of hot water, steam, solvents and chemicals.

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10 Leading World Suppliers of Engineering and High Performance Plastics 10.1 Overview There were over fifty producers of engineering and high performance plastics worldwide in 2002. The world’s largest suppliers are global and multi-product companies with production facilities in all three major world regions. In terms of production capacity, the leading suppliers are GE Plastics, Bayer, BASF and DuPont. Table 10.1 shows production capacity for the world’s leading suppliers of engineering and high performance plastics by resin type for 2002. GE Plastics is world market leader in polycarbonate, PBT, PPO/PPE blends and polyetherimide. It is ranked world number three in ABS behind Chi Mei and LG Chem, and also produces PPS. GE Plastics has manufacturing facilities in the USA and Europe. It is also well represented in Asia through joint venture operations with local companies in polycarbonate, ABS and polyesters. Bayer AG is Europe’s leading supplier of ABS, but is some way behind the world’s leading producers. In polycarbonates, Bayer is the second largest world producer behind GE Plastics and is ranked fourth largest world polyamide producer. The company has an ambitious expansion strategy for engineering plastics, particularly for polycarbonate, and plans to invest in capacity expansion, especially in the Asia region. BASF has a broad portfolio of engineering polymers comprising polyamide, ABS, PBT, PSU/PES, POM and PPO. BASF is the world’s second largest producer of polyamide, after DuPont, the third largest POM producer, and world leader in PSU/PES. In ABS, PPO and PBT, BASF is a low to middle ranking world producer. Europe is the major market for BASF engineering plastics, but the company also has operations in Asia and the USA. In 2003, BASF acquired the polyamide business of Honeywell, to significantly enhance its world position in this segment. DuPont has a strong global presence in polyamide, PBT and POM. It is the world’s leading polyamide producer and second largest PBT and POM producer. DuPont is also well positioned in the world LCP market. DuPont production facilities are based predominantly in the USA and Europe, but the company has been growing its presence in Asia, particularly in POM and LCP production. DuPont is known to be keen on expanding its range of engineering plastics, with a particular interest in developing a presence in polycarbonates. There are several other companies with a broad range of engineering and high performance plastics. Ticona, part of the Celanese group of companies, offers PBT, POM, PPS and LCP. The company is world leader in both POM and LCP production, and also has a leading position in PPS and PBT. Ticona is particularly strong in the USA and Europe, but is developing a growing Asian presence through joint ventures and investment in additional capacity. Dow Engineering Plastics offers a wide range of different polymers including ABS, polycarbonate, liquid crystal polymers, polyurethane and polypropylene based polymers. Dow is the world’s fourth largest ABS producer and ranks third in the polycarbonate market. Dow’s ABS business is largely concentrated in Europe and the USA, whereas the company’s polycarbonates are also well represented in Asia through joint ventures.

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Table 10.1 Production capacity of leading suppliers by resin type, 2002 (000 tonnes) PA Asahi Kasei Asahi/Chi Mei Atoglas AtoFina BASF Barlo Plastics Europe Bayer Chan Chung Chevron Phillips Chemicals Chi Mei DSM Dainippon Ink & Chemicals Degussa Dow Chemicals DuPont EMS-Grivory Eastman Chemicals EniChem Formosa Plastics Fortron Industries GE Plastics Honeywell Huntsman Chemicals Idemitsu Kohap Kureha Chemicals LG Chem LG Dow Lucite International Mitsubishi Polycarbonatos Polyplastics Radici Repsol Ypf Rhodia Engineering Plastics Röhm Sam Yang Kasei Solvay Advanced Polymers Solutia Sumitomo Techno Polymer Teijin Thai Polyacetal Thai Polycarbonate Ticona Toray Tosoh Co Ube Ube Cycon Ueno Victrex Win Tech Zaklady Azotowe TOTAL

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PBT

ABS

35 45 340

POM

PMMA

PC

30 270

50

PPS

55

40

400

71

PPO/ PPE 65

PEI

15

PSU/ PES

LCP

PEEK

PPA

TOTAL 155 80 270 45 871

5

17 130

30 65

305

650

1115 85

20 10

10

1250 130

30

5

25

600 50

120

1250 160 6

6 20

400

50

185

585

160

5

885 50

3

3

80

80 25

25 7

160

510

850

3

7 45

15

1583 100

100 10

10

100

100 75

75 6 800

6

15

815 65

65 180 30

80

80

40

150

180 140 20

30

2

362 20 198 100 35

8

100 35 250

250 280

280 50

50 3

n.a.

2

n.a.

n.a.

60 90

50

10

60 152

2

290

290

20

250

270

20

20 60

60

90 60

200

165 20

60 8.5 2

6 4

263.5 348 4 80 170 1 2 50

80 170 1 2 50 30 2120

10 810

4440

5

791

40 867

2470

45

195

15

5

33.5

2

0


Solvay Advanced Polymers offers the broadest range of high performance materials of any supplier. These include PPS, PSU/PES, LCP, polyketones, polyarylamide, polyamide-imide and polyphthalamide. The company, which is headquartered in the USA, was established in 2001 following Solvay’s acquisition of BP’s advanced polymers business. Several Asian companies are developing their engineering plastics businesses through investment and joint ventures. The most broadly based operations in terms of product range include LG Chem of South Korea, and the Japanese companies Mitsubishi, Asahi Kasei, Sumitomo, Teijin and Toray. A number of suppliers concentrate on just one particular type of engineering plastic. All of the world’s leading acrylics suppliers for example, specialise only in PMMA production. Some single polymer companies are also leaders in their particular field. Victrex, UK, for example, is market leader in PEEK polymers, while Rhodia Engineering Plastics is a leading polyamide supplier. There are also many regional based engineering plastic suppliers. Many Asian companies for example, sell almost exclusively to countries in that region. Some of the smaller scale European companies such as Repsol, Radici and Enichem, sell mainly to markets in southern Europe. Most engineering and high performance plastics markets are characterised by few suppliers and a high degree of concentration. The top three world suppliers of polycarbonate (GE Plastics, Bayer and Teijin) for example control around 70% of total supply. The top three polyamide suppliers control 55% of world supply and the largest three ABS producers account for 57% of world production. The most extreme cases are polyetherimide, PPA and PSU, where there are only one or two world suppliers of each type of plastic. The trends in market concentration vary by plastic type. The more mature plastics such as polyamide, ABS, PBT and acrylics, saw an increase in the degree of market concentration during the period 1999-2000, following a series of mergers and acquisitions. In contrast, the fastest growing plastic types such as PPS, PEEK and liquid crystal polymers, have witnessed an increase in the number of suppliers as new companies have entered the market. The process of market consolidation in all types of engineering plastics markets is expected to continue in future. However, there was a marked slow down in the number of mergers and acquisitions during the period 2001-2002 due to the economic downturn and uncertain demand trends. There are signs that such activity may be recovering with two notable deals taking place so far this year. BASF acquired Honeywell’s polyamide business in January and DuPont acquired Eastman Chemical’s high-performance LCP business in March. There is also a clear trend for production to shift from western economies to the Far East and developing countries as major customers such as automotive and electronics industries grow their production in lower cost centres. A growing proportion of new capacity building has taken place in the Far East in recent years. At the same time, several engineering polymer producers have closed plants in the USA and Europe due to over-capacity and negative returns. The share of engineering polymer production in the Asia region is expected to grow much further in the coming years. Similar trends taking place in key end user markets such as automotive, electrical & electronics and domestic appliances, are encouraging the process of market concentration and globalisation in engineering plastic supply. The trend toward globalisation in end user markets means that customers are becoming more powerful and demanding of their suppliers. Customers require material availability and consistency on a global scale, which can only be met by global suppliers. Customers are also demanding more customised grades to differentiate themselves in the marketplace. Engineering polymer producers are responding to this growing trend by working more closely with key customers and developing new grades, colours and special effect polymers with one customer in mind.

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Another trend is for engineering polymer producers to move further downstream by offering customers greater access to their knowledge and technology to create higher value services. A number of producers are capitalising on their expertise in part design through flow-simulation software. Dow Automotive for example is injection-moulding parts for the Ford Motor Co. in Brazil, and DuPont has a similar strategy. Meanwhile, Dow’s US-based Inclosia Solutions business is marketing innovative solutions for portable electronics enclosure applications. The company designs, produces (through subcontractors) and sells housings. 10.2 Polyamide (PA)

10.2.1 Major Suppliers Table 10.2 shows the worlds’ leading polyamide suppliers, their production capacities and geographic scope for 2002. Table 10.2 Production capacity of leading polyamide producers, 2002 Capacity Company Location (000 tonnes) DuPont USA 600 BASF Europe 340 Rhodia Europe, USA, Asia 250 Bayer Europe 130 DSM Europe 130 Radici Europe 100 Honeywell Europe, USA 100 Ube Asia 80 Kohap Asia 75 Toray Asia 60 Solutia USA 60 EMS-Grivory Europe 50 AtoFina Europe 45 Asahi Kasei Asia 35 Mitsubishi Asia 30 Zaklady Azotowe Eastern Europe 30 Degussa Europe 5

DuPont de Nemours is the world’s largest manufacturer of polyamide with global capacity of around 600,000 tpa in 2002. DuPont production capacity for polyamide in Western Europe was around 100,000 tpa. DuPont also has a major production facility at Richmond, Virginia, USA. BASF is the second largest supplier of polyamide resins in the world with global production capacity for its Ultramid polyamide of around 340,000 tpa in 2002. In Europe, BASF has plants in Antwerp, Belgium and Ludwigshafen, Germany. Total European capacity is estimated at close to 180,000 tpa. BASF also has a major production site at Freeport, USA. In January 2003, it was announced that BASF is to acquire the engineering plastics business of Honeywell, including Honeywell’s polyamide resin and compounding businesses. Worldwide, Honeywell has production capacity of around 100,000 tpa for polyamide resin with facilities in Europe, the USA and Asia. Honeywell has production capacity for its Capron polyamide of around 30,000 tpa at Rudolstadt, Germany. Rhodia Engineering Plastics business is the world’s third largest producer of polyamide with a global capacity of around 250,000 tpa in 2002. In October 2000, Rhodia, announced a spending

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programme totalling $20 million to boost polyamide production in Europe. Compounding and polyamide polymerisation capacity was increased at sites in France, Italy and Poland. Rhodia also has production facilities in North and South America, China, Taiwan and South Korea. In 2002, Rhodia also opened a new 3,000 tpa PA capacity pant in Brazil. Bayer production capacity for polyamide resins and compounds in Europe is 130,000 tpa. Bayer lifted polyamide capacity by 30,000 tpa at the Uerdingen site in Germany in 1999. DSM total polyamide capacity is 130,000 tpa in 2003. DSM opened a revamped 85,000 tpa polyamide 6 plant in Emmen, the Netherlands in 2000. The unit replaces the polyamide 6 facilities that DSM acquired from Akzo Nobel in 1992. Meanwhile in January 2001, DSM started up its expanded heat resistant polyamide, Stanyl, facility in Geleen, the Netherlands. EMS-Grivory produces a wide range of polyamide homopolymers and copolymers for many different markets. In Europe, EMS-Chemie production capacity for polyamide is around 50,000 tpa in 2002. AtoFina is the world’s only producer of polyamide PA11. It also produces Rilsan PA12 at Normandy, France and in the USA. Production capacity for polyamide is around 45,000 tpa. AtoFina is the world’s leading producer of PA12. The Radici Group is vertically integrated with polymersiation plants in Italy, the US, Brazil and Germany. Radici’s polyamide division has a production capacity of over 100,000 tpa. In 1999, Radici acquired the former family concern of Franz Rauscher GmbH & Co, Germany. Rauscher has a production facility in Lüneburg with a capacity of 10,000 tpa. UBE Industries manufactures polyamide resin in Japan and Thailand and has a production capacity of 80,000 tpa in 2002. UBE currently manufactures PA compounds for the European market at a plant in Spain. However the company has ambitions to become the world’s leading supplier of PA6, PA12 and PA6/66. It is planning to establish production facilities in Europe for polyamide resins and in 2001 set up Ube Engineering Polymers division in Spain to oversee its expansion plans. Other leading world producers include Kohap with 75,000 tpa of capacity in 2002, Toray (60,000 tpa), Solutia (60,000 tpa), Asahi (35,000 tpa), Mitsubishi (30,000 tpa) and Zaklady Azotowe, Poland (30,000 tpa). Degussa-Huls is a supplier of speciality polyamides such as PA12 and copolyamides and has production capacity of 5,000 tpa.

10.2.2 Products The product offerings of the leading world polyamide resin suppliers are summarized in Table 10.3. AtoFina produces polyamides 11 and 12 using the Rilsan trade name. Rilsan B (PA11) and Rilsan A (PA12) are available in different grades: (flexible, rigid, reinforced (carbon fibre, glass fibre or glass beads, self-lubricating, plasticised, impact modified, heat- and light-stabilised, flame retardant), and in a wide range of viscosities, as required by the various processing methods and type of application. BASF produces Ultramid PA6, 66 and various copolymers such as 66/6 and PA6/66, as well as partially aromatic types, all sold under the trade name Ultramid. Bayer supplies a full range of PA6 and 6.6 and partially aromatic types. Durethan A is Bayer’s trade name for its polyamide 66 range. Product offerings include unreinforced, injection moulding grades, impact modified, injection moulding grades increasing viscosity, glass fibre reinforced,

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plus standard injection moulding grades. Durethan B is Bayer’s trade name for its polyamide 6 range. Product offerings include glass fibre-reinforced, impact modified, flame retardant and standard grades. Durethan T is the trade name for partially aromatic, transparent polyamides.

Company DuPont BASF Rhodia Bayer DSM Radici Honeywell Ube Toray Solutia EMS-Grivory AtoFina Degussa

Table 10.3 Product offerings of major polyamide producers Trade name Zytel PA6, PA66, PA6/66, PA6/12 Ultramid PA6, PA66, PA6/66 Technyl PA6, PA66 and TechnylStar compounds Durethan A (PA66), Durethan B (PA6), Durethan T (partially aromatic) Akulon PA6 and PA66 and Stanyl PA46 Radilon PA6, PA66, Heramid PA6, PA66 Capron PA6, PA66, PA66/6 Ube PA6, 6/66 and PA12 Amilan PA6, PA66 Vydene PA66, PA66/6 Grilamid PA12, Grilon PA6, PA66, PA66/6 & Grivory, partially aromatics Rilsan B (PA11), Rilsan A (PA12) Vestamid PA6/12, PA12

DSM offers Akulon PA6 and PA66, and Stanyl PA46 polyamide resins. In 1998, DSM introduced a new class of flame retardant, glass fibre-reinforced materials. The ‘Stanyl NT’ (new technology) PA 46 grades are less susceptible to thermal decomposition and thus cause less corrosion damage to screw, cylinder and mould. DuPont’s Zytel polyamide resins include unmodified polyamide homopolymers (e.g., PA 66 and PA 6/12) and copolymers (e.g., PA 66/6 and PA 6T/MPMDT), plus modified grades produced by the addition of heat stabilizers, lubricants, ultraviolet screens, nucleating agents, tougheners, reinforcements, etc. The majority of resins have molecular weights suited for injection moulding and some are used in extrusion. Minlon is the DuPont trademark for resins based on polyamide reinforced with a mineral or mineral/glass combination, which are widely used in more demanding applications. EMS-Grivory offers a number of different types of polyamide engineering resins. •

Grilamid is the trademark of EMS polyamide 12. Grilamid can be processed using injection moulding or extrusion processes. Products include Grilamid unreinforced, Grilamid reinforced and Grilamid plasticised.

•

Grilon is the trade name of EMS polyamide 6, polyamide 66 and copolyamide grades. Product offerings include Grilon reinforced, Grilon unreinforced, Grilon TS, an unreinforced or reinforced special polyamide grade, which is suitable for injection-moulding methods, and Grilon BT, a stiff, polyamide blend with good impact strength values which can be processed using injection moulding.

•

Grivory is the trade name of EMS partially aromatic polyamides. The product range includes an assortment of unreinforced, glass fibre, carbon fibre and mineral-reinforced thermoplastics. Grivory GV polyamide with glass fibre reinforcement is used for injection moulding applications as a replacement of aluminium and magnesium die-cast parts.

Honeywell polyamide resins include a full range of Capron PA6, PA66 and PA6/66 with grades for all types of processing. Other brands include a family of high impact resistant polyamides under the name ‘Capron Ultra-Tough’. The material, based on Capron PA, is recommended for applications

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requiring low temperature impact resistance, such as sports and motoring. The Capron SE family of glass fibre- and mineral glass fibre-reinforced polyamide 6 resins offers exceptional surface aesthetics, even when processed by gas assisted injection moulding into components with thick wall sections. Rhodia Engineering Plastics manufactures Technyl PA 6 and PA 66 polyamides, and TechnylStar polyamide compounds. TechnylStar, introduced in 2000, is based on proprietary polymerisation and patented compounding technology. TechnylStar retains the thermal, mechanical and chemical properties common to semi-crystalline polyamides but has other unique features such as improved flow characteristics under normal processing conditions, reinforcement, up to 65%, creating materials with very high stiffness and dimensional stability at elevated temperatures, a better quality surface finish and higher processing performance, The Radici Group, Italy, produces a full range of products including polyamide 6 and 66 (sold under the brand name Radilon), co-polyamides and blends. Radici also owns the PA6 and 66 Heramid brands following its takeover of the Franz Rauscher company. Solutia offers a wide range of polyamide 66 and 66/6 copolymer polyamide resins for the injection moulding market under the trade name Vydene. Dow Chemicals and Solutia ended their three-year marketing agreement in 2002, with both firms admitting that the venture did not provide the expected results. Degussa produces speciality types of polyamide, copolyamide 6/12 and PA12, both sold under the Vestamid brand. Amilan is the trade name of Toray’s range of polyamide resins. Ube Industries produces PA6, 6/66 and PA12 resins. 10.3 Polybutylene Terephthalate (PBT)

10.3.1 Major Suppliers Table 10.4 shows the worlds’ leading PBT suppliers, their production capacities and geographic scope.

Company GE Plastics DuPont Ticona Mitsubishi Cham Chung Toray Win Tech BASF Polyplastics Bayer DSM Degussa Teijin

Table 10.4 Production capacity of leading PBT producers, 2002 Location Capacity (000 tonnes) USA, Europe, Asia 160 USA, Europe 120 Europe, USA, Asia 90 Asia 80 Asia 65 Asia 60 Asia 50 Europe 40 Asia 40 Europe 30 Europe 30 Europe 25 Asia 20

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GE Plastics is the world’s largest producer of PBT with global capacity of around 160,000 tpa. This includes a 50:50 joint venture plant with BASF at Schwarzheide, Germany, which began production in 1997. This facility has production capacity of 80,000 tpa in 2002. The Schwarzheide plant is now BASF’s sole production unit for PBT, although it does compound material in the US, in a 10,000 tpa unit in Wyandotte, Michigan. GE Plastics also operates a 120,000 tpa PBT polymerisation unit in Mt Vernon, Indiana, in the US and has a joint venture PBT business with Mitsubishi in Japan. DuPont Engineering Polymers total production capacity is 120,000 tpa in 2002. DuPont commenced production at a new plant located at Uentrop, Germany, in 1997 with original production capacity of 30,000 tpa. Capacity at the Uentrop facility is due to be doubled in 2003. DuPont also opened a new 40,000 tpa US production facility for thermoplastic polyester in 1999. Ticona GmbH is PBT market leader in Japan, second in the US, but has only 10,000 tpa of polyester capacity in Europe, of which 5,000 tpa is PBT production. Globally, total PBT production capacity for Ticona stands at 90,000 tpa in 2002. In 2002, DSM production capacity for PBT at Emmen, the Netherlands. is estimated at about 30,000 tpa. A 50:50 joint venture between Ticona and DSM Engineering Plastics is scheduled to start-up a planned 60,000 tpa PBT plant at Emmen, the Netherlands, in 2005. Bayer AG has compounding capacity of 30,000 tpa for PBT compounds at Uerdinggen in Germany. Bayer has had a long standing relationship with Degussa to supply its PBT resin. Bayer and DuPont plan to start their new 80,000 tpa PBT plant at Hamm-Uentrop, Germany, in Q3 2003. Degussa has PBT polymerisation capacity of around 25,000 tpa at Marl, Germany. Other leading suppliers include Toray with production capacity of 60,000 tpa, Mitsubishi Chemical (80,000 tpa at Yokkaichi, Japan), Win Tech Polymers (a joint venture company between Polyplastics and Teijin with 50,000 tpa capacity), Polyplastics (40,000 tpa), Chan Chung (65,000 tpa) and Teijin (20,000 tpa).

10.3.2 Products The products offered by leading world PBT suppliers are summarized in Table 10.5.

Company GE Plastics DuPont Ticona BASF Bayer DSM Degussa

Table 10.5 Product offerings of major PBT producers Trade name Valoy Crastin Celanex Ultradur resins and compounds Pocan Arnite Vestodur

GE Plastics Valoy thermoplastic polyester resins product line includes grades from 100% unmodified PBT resins to combinations of glass fibre-reinforced, mineral filled, mineral/glassreinforced and flame resistant grades. PC/PBT grades are sold under the Xenoy trade name. DuPont supplies a wide range of Crastin PBT polymers and compounds including glass-reinforced toughened grades and polyester alloys for all major applications.

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Celanex is Ticona’s trade name for PBT resins. Celanex is available in a wide range of grades, including unreinforced, glass and mineral reinforced, polymer blends, impact modified and flame retarded grades. BASF range of PBT polymers and compounds are sold under the Ultradur trade name. Glass fibrereinforced grades made from PBT and ASA (Ultradur S) with low warpage are also available. Automobile exterior applications are a major focus of engineering plastics research at BASF. In 1997, a 50.0% glass fibre-reinforced PBT (‘Ultradur B 4040 G10’) allowed production of components requiring high surface quality as well as extreme stiffness and rigidity for severe mechanical loads. Another new product to emerge from Ludwigshafen R&D was ‘Ultradur S’, a blend of PBT and ASA copolymer. Compared with other PBT types without the ASA component, this amorphous material is said to have extremely low warpage. Both materials are designed for use in windscreen wiper systems, door mirrors and headlamp housings. In 1998, BASF was the first producer to develop a halogen-free, flame-retardant polybutylene terephthalate (PBT), which retains the key properties of PBT, namely dimensional stability, chemical resistance and good toughness. The material is supplied under the brand name ‘Ultradur B 4000’. Compared with PBT that contains halogen, it offers a low smoke density and a very high tracking resistance. Pocan is Bayer’s trade name for its partially crystalline thermoplastic polyesters based on polybutylene terephthalate. Product offerings include PBT filled injection moulding grades, PBT elastomer modified and PBT standard non-reinforced injection moulding grades. PC/PBT blends, elastomer modified and non-reinforced injection moulding grades, are also available. DSM’s range of PBT resins and compounds are sold under the Arnite trade name. PBT products include standard PBT unfilled, 10%, 15%, 30% glass reinforced, toughened PBT with 0%, 20%, 30% glass reinforced and low warpage, 20% and 30% glass reinforced. Degussa supplies Vestodur PBT polymers and copolyesters. The company focuses on highperformance products rather than standard grades. Speciality products include laser-markable grades and high impact grades. Toray PBT resin was developed by combining Toray’s technological expertise in polyester polymerisation and resin-reinforced composites. Toray PBT resin is widely used in connectors and other automobile parts, bobbins, coil cases and other electronic and electrical components, and precision parts for office equipment. 10.4 Acrylonitrile-Butadiene-Styrene (ABS)

10.4.1 Major Suppliers Table 10.6 shows the world’s leading ABS suppliers, their production capacities and geographic scope for 2002. The top three ABS suppliers are Chi Mei Co. of Taiwan, LG Chem and GE Plastics. Chi Mei Corporation, Taiwan’s leading chemical company, is the world’s largest producer of ABS with total production capacity of around 1.25 million tpa. Its main customers are Japanese domestic and business appliances manufacturers. GE Plastics’ global ABS production capacity amounts to 510,000 tpa in 2002. It has two US production plants with capacities totalling 310,000 tpa. GE Plastics is the third largest producer of ABS resins in the European market with capacity of 200,000 tpa in 2002. It has a 70,000 tpa

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production facility in Amsterdam, the Netherlands, and two other 50,000 tpa manufacturing plants at Grangemouth, Scotland, and Beauvais, France. The Amsterdam facility will be closed later in 2003, with production being transferred to the other two European production sites. Table 10.6 Production capacity of leading ABS producers, 2002 Capacity Company Location (000 tonnes) Chi Mei Asia 1,250 LG Chem Asia 800 GE Plastics USA, Europe 510 BASF Europe, Asia 400 Dow Chemicals USA, Europe 400 Bayer Europe, Asia 305 Techno Polymer Asia 290 Toray Asia 200 Ube Cycon Asia 170 EniChem Europe 80 Repsol Europe 35

In 2002, Ube Cycon, a joint venture company owned by Ube Industries and GE Plastics in Japan, agreed to merge the business with Mitsubishi Rayon. The new operation will have ABS production capacity of 176,000 tpa with Ube and Mitsubishi each holding 43% and GE holding 14% of the equity. Bayer is the leading supplier of ABS to the European market with production capacity of 305,000 tpa. Since the acquisition of the 370,000 tpa Monsanto styrene copolymers business, Bayer has nearly doubled its worldwide output, with expansion taking place entirely outside Europe. In 1997, the group took over its Thailand joint venture Bayer Premier Co Ltd and took a majority stake in India’s ABS Industries Ltd, now trading as Bayer ABS Ltd. Bayer also bought the ABS/SAN business of Brazil’s Nitriflex in 1998. BASF is the second largest European producer of ABS with 260,000 tpa of capacity and is ranked fourth largest producer in the world. In 1999, BASF acquired DSM’s 60,000 tpa ABS activities at Geleen, the Netherlands, and plans to expand further in future. Globally, BASF has 400,000 tpa of ABS, SAN and ASA capacity at plants in Ludwigshafen, Germany and Tarragona, Spain, in Europe, as well as in Korea and Australia. In 1998, BASF brought into operation in South Korea, at the Ulsan location of BASF Styrenics Korea Ltd, an ABS plant with production capacity of 160,000 tpa. A similar plant with a capacity of 130,000 tpa started production of ABS, ASA and SAN in 1999 at Altamira, BASF’s Mexican location. The ABS expansion strategy also involves the global introduction of a new product range, which initially takes in three injection moulding and two extrusion grades of the ABS ‘Terluran’ brand. Dow Chemicals has total worldwide ABS production capacity of 400,000 tpa in 2002. It has four ABS production facilities in the USA with a combined capacity of 210,000 tpa. Dow Chemicals is fourth largest European ABS producer with production capacity at the Terneuzen, the Netherlands, plant amounting to 195,000 tpa. Dow raised capacity at Terneuzen by 75,000 tpa last year. Dow plans to use the additional capacity to boost supply of differentiated ABS resins to key global markets including the information technology equipment, appliances and automotive sectors. LG Chem, Korea’s leading chemical company, has raised ABS production at its Ningbo site, China, to 300,000 tpa. LG Chem also recently lifted production capacity for ABS at its Yeosuo,

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Korea, facility by 100,000 tpa to 500,000 tpa. Further expansion is planned for 2006. LG Chem is now rated the world’s third largest ABS producer. Other leading ABS producers include Techno Polymer Co Ltd (Japan) and Toray (Japan). Techno has a 290,000 tpa plant located at Yokkaichi, Japan. Toray manufactures speciality grade ABS at Chiba, Japan and standard grade ABS at a 200,000 tpa plant in Malaysia. Enichem ABS production capacity totals 80,000 tpa from two different plants located in Italy. The Spanish company Repsol is the only other European-based supplier of ABS with a capacity of 35,000 tpa. Neither Enichem nor Repsol have ABS production plants outside Europe.

10.4.2 Products The products offered by major world ABS suppliers are summarized in Table 10.7.

Company Chi Mei GE Plastics Bayer Dow EniChem BASF Toray

Table 10.7 Product offerings of major ABS producers Trade name Polylac Cycolac ABS, Cycoloy PC/ABS Novodur and Lustran ABS Magnum Sinktral Terluran Toyolac

GE Plastics’ Cycolac ABS is available in many different grades. There are general-purpose resins offering toughness and durability, high heat grades for dimensional stability at high temperatures, high impact and flame retardant products, high gloss grades and high flow grades for thin-wall applications. GE Plastics PC/ABS products are marketed using the Cycoloy trade name. Bayer’s ABS polymers are marketed under the trade name of Novodur, while the former Monsanto ABS brand is sold as Lustran. Bayer produces numerous grades of Novodur. These include special hardness and rigidity, heat resistance, low temperature impact strength and flowability. Bayer also produces PC/ABS blends under the trade name Bayblend T. These blends are also available in various grades including special grades with improved flowability, glass reinforced and flame retardant. Dow Europe offers a wide range of Magnum Natural Plus resins that can be used for injection moulding, automotive applications, sheet extrusion, refrigeration appliances and food packaging. Magnum Natural Plus resins are produced in a continuous process that yields a resin with light base colour and excellent processability. Grades include high gloss injection moulding, low gloss injection moulding, and speciality resins including pipe and fittings resins, automotive resins, ignition resistant resins and health care resins. Chi Mei’s ABS resin is marketed under the Polylac trade name. Polylac is available in a wide variety of grades, including general purpose, high impact, high flow, electroplating, extrusion, high heat, flame retardant, low gloss and food contact. UV and other speciality grades are also available. LG Chem offers a wide range of ABS resins and compounds including antistatic grades, flame retardant, high heat resistant, high impact, high rigidity, high gloss, low gloss, extrusion and blow moulding. Enichem Styrenics division manufactures Sinkral ABS for injection moulding and extrusion. Impact resistant and heat resistant grades are available. 163


Toyolac is the trade name of Toray’s range of ABS resins. The range of applications is also growing rapidly for Toyolacparel, a permanent anti-static resin developed using Toray advanced technologies. BASF offers a full range of natural and black ABS resins under the Terluran trade name. Terluran Standard grades were developed specifically to meet the requirements of major customers. Terluran Standard ABS is a two-phase polymer blend. A continuous phase of styrene-acrylonitrile copolymer (SAN) gives the materials rigidity, hardness and heat resistance. The toughness of Terluran Standard is the result of microscopically fine polybutadiene rubber particles uniformly distributed in the SAN matrix. Terluran Standard has a light and very consistent natural colour. 10.5 Polycarbonate (PC)

10.5.1 Major Suppliers Table 10.8 shows the world’s leading polycarbonate suppliers, their production capacities and geographic scope for 2002. Table 10.8 Production capacity of leading polycarbonate producers, 2002 Company Location Capacity (000 tonnes) GE Plastics USA, Europe, Asia 850 Bayer Europe, Asia, USA 650 Teijin Asia 250 Dow Chemicals USA, Europe, Japan 185 Mitsubishi Asia 140 Idenitsu Asia 100 LG Dow Asia 65 Thai Polycarbonate Asia 60 Sam Yang Kasei Asia 50 Sumitomo Asia 50 Asahi/Chi Mei Asia 50 Polycarbonatos South America 20

GE Plastics is the world’s largest supplier of polycarbonate with a market share of 40% and total capacity of 850,000 tpa in 2002. It has 300,000 tpa of capacity in the European market from plants located at Bergen op Zoom, the Netherlands and at Cartagena, Spain. GE also has two major facilities in the USA and another smaller plant in Japan. It started construction of a second 130,000 tpa plant at Cartagena in 2002, which should be completed later this year. It also plans to expand the Burkville plant in the USA by 70,000 tpa, by 2004. Bayer is currently second largest polycarbonate producer in the world with market share of 25%. The company has an aggressive policy for its polycarbonate business, designed to take it to market leadership by the end of 2005. An investment package of €1 billion will see Bayer double Makrolon capacity from the 650,000 tpa at end 2000 to near 1.3 million tpa by 2005. The investment will take place at five production centres around the globe, mainly in Asia. Production at Baytown, Texas and Ta Phut, Thailand, will reach 350,000 tpa each, and a 50,000 tpa plant will come on stream in 2003 at Shanghai, China. It is then planned to double capacity at Shanghai during the following two years. In Europe, output at Urdingen, Germany, and Antwerp, Belgium, will be hiked from 350,000 tpa to 500,000 tpa by 2005. Dow Chemicals has a 105,000 tpa polycarbonate plant at Stade, Germany, and an 80,000 tpa plant at Freeport, Texas. Dow recently increased polycarbonate capacity at Stade and opened a 60,000 tpa of additional capacity at Stade for Calibre optical media grades in 2001. Dow also has a

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polycarbonate joint venture with Japan’s Sumitomo with production capacity of 40,000 tpa in Japan. An additional 10,000 tpa came on stream at the Japanese plant in 2001 along with LG Dow’s 130,000 tpa unit in Yeochon, South Korea. LG Dow Polycarbonate, a joint venture of LG Chem Ltd, Korea, and Dow Chemical, started up a 65,000 tpa polycarbonate plant at Yosu, Korea, to supply Asia Pacific. There are plans to double capacity to 130,000 tpa in 2004, but start-up may be put back for a year or two because of the uncertain nature of the market. Japanese producer Teijin is another major world polycarbonate producer with total production capacity of 250,000 tpa in 2002. Teijin plans to expand capacity for polycarbonate to 300,00 tpa at its two production sites, Matsuyama, Japan, and Singapore. Teijin also set up a polycarbonate resin production and sales company in Zhejiang Province, south of Shanghai in China. A new company called Teijin Polycarbonate China, was established in Jiaxing City in January 2003, and will begin operation of its first production line in April 2005 with a capacity of 50,000 tpa. Teijin also intends to construct a polycarbonate plant in the USA. Other leading Asian based suppliers are Mitsubishi Gas Chemicals with capacity totalling 140,000 tpa, Idemitsu Petrochemicals (100,000 tpa in Taiwan with joint venture partner Formosa Plastics), Thai Polycarbonate (60,000 tpa), Asahi Kasei/Chi Mei (50,000 tpa), Sumitomo (50,000 tpa), and Sam Yang Kasei (50,000 tpa). Polycarbonatos is the leading producer in South America with capacity of 20,000 tpa.

10.5.2 Products Products offered by the leading polycarbonate resin suppliers are summarized in Table 10.9.

Company GE Plastics Bayer Dow Teijin Mitsubishi Idenitsu

Table 10.9 Product offerings of major polycarbonate producers Trade name Lexan PC, Xenoy PC/PBT, Cycoloy PC/ABS Makrolon Calibre PC, Pulse PC/ABS Panlite PC resins Jupilon, Novarex Taflon

GE Plastics polycarbonate resins are sold under the Lexan trade name. The Lexan portfolio contains a wide range of viscosities and product options including halogen-free flame retardancy, impact modification, glass-reinforcement, optical quality and compliance with stringent FDA requirements. Lexan grades are also available with a wide variety of additive options such as UV stabilizers and mould release agents, Lexan EXL can withstand much tougher conditions than conventional Lexan and also has better weatherability, low temperature ductility, impact resistance and flame retardance. Lexan EXL is used in a variety of applications including telecommunications, portable electronics, and outdoor equipment and is available in a variety of opaque colours. The Lexan portfolio has also been expanded to include eco-conforming, FDA-compliant, high flow and glass reinforced grades. GEP also supplies Cycoloy PC/ABS resins. Xenoy PC/PBT resins are supplied for more high impact strength applications. Makrolon is the trade name of Bayer’s extensive range of polycarbonates. Grades include easy flow with release agents and UV stabilizers, medium-viscosity, impact modified, with release agent 165


and good notched impact strength. Bayer also offers Apec high-temperature polycarbonates and Bayblend PC/ABS blends. Dow polycarbonate resins are marketed under the Calibre product range, while PC/ABS blends are sold under the Pulse brand name. Dow’s polycarbonate product range includes a broad family of resin types for different applications. •

Calibre 200 series are used for food contact applications.

•

Calibre 300 series are used for applications in transportation, appliances, business equipment, houseware and recreation.

•

Calibre IM 400 series are high impact grades.

•

Calibre 600 series offer higher melt strength and are applied to blow moulding and profile extrusion applications.

•

Calibre 700 series provide improved light transmission and clarity and are used in optical, transportation and electrical applications.

•

Calibre 890 series provide superior ignition resistance and are used in transportation, business equipment and appliances.

•

Calibre 1000 series resins are used in optical media.

•

Calibre 2000 resins are applied specifically for health care markets.

•

Calibre 5000 series are glass-reinforced grades.

•

Calibre 7000 series are glass-reinforced and ignition resistant resins.

Teijin offers a range of polycarbonate resins under the Panlite trade name. The company also manufactures Panlite polycarbonate sheet. 10.6 Polyoxymethylene (POM)

10.6.1 Major Suppliers The Asia region is the largest producer of POM with just under 50% of world POM capacity. Europe and North America account for 30% and 20% of total world capacity respectively. Table 10.10 shows the world’s leading polyacetal suppliers, their production capacities and geographic scope for 2002. Table 10.10 Production capacity of leading polyacetal producers, 2002 Company Location Capacity (000 tonnes) Ticona Europe, USA, Asia 165 DuPont USA, Europe, Asia 160 Polyplastics Asia 150 Mitsubishi Asia 80 BASF Europe, USA 71 Asahi Kasei Asia 55 Formosa Plastics Asia 25 Cham Chung Asia 20 Thai Polyacetal Asia 20 Toray Japan 20 LG Chem Asia 15 Zaklady Azotowe E Europe 10

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The world polyacetal market is highly concentrated in the hands of a few global businesses. Ticona GmbH claims around a 45% share of the global market, including its Polyplastics joint venture with Daicel Chemical Industries. DuPont is the world’s number two supplier, followed by the BASF/Degussa joint venture Ultraform, and then by smaller Asian players such as Asahi Chemical and Mitsubishi Engineering Plastics. Ticona GmbH, is the engineering plastics subsidiary of Celanese AG, and the leading worldwide POM supplier with total capacity of 165,000 in 2002. The main production sites for acetals are located in Bishop, Texas, and Kelsterbach, Germany. Ticona increased production capacity for polyacetal resins at the Kelsterbach plant, from 77,000 tpa to 100,000 tpa at the end of 2002. DuPont’s worldwide POM production capacity has been increased to around 160,000 tpa in recent years. DuPont has two production sites for POM polymers, one in the Netherlands, and the other in West Virginia, USA. DuPont’s European site, situated at Dordrecht, the Netherlands, has production capacity of 85,000 tpa. In 2001, DuPont announced that production capacity at Dordrecht had been increased by 10,000 tpa. DuPont also has compounding facilities at the two main production sites in addition to compounding facilities in Mexico, Japan, Singapore, China and Korea. In 2002, DuPont announced a joint venture company with Asahi Kasei for production of POM in China. The new plant is due to come on stream in 2004 with an initial capacity of 20,000 tpa. Polyplastics Co Ltd, is a Tokyo-based joint venture between Ticona and Daicel Chemical Industries. In 2000, it opened a 30,000 tpa plant at Kuantan, Malaysia’s Pahang State. This increases Polyplastics’ output to 150,000 tpa. Polyplastics also started construction of a new 60,000 tpa plant in Shanghai during 2002, which is scheduled to go on stream in 2005. With its 45% share of the Polyplastics joint venture in Asia, Ticona’s worldwide POM capacity is 230,000 in 2002. Polyplastics also has a 75% stake in TEPCO, a Taiwanese engineering plastics producer with POM capacity of 20,000 tpa. PTM Engineering Plastics, is a planned joint venture of Ticona and affiliate Polyplastics, with Japan’s Mitsubishi Gas Chemical Company. They are to build a world-scale, 60,000 tpa plant for polyacetal (POM) resins in China, due to start-up in 2004. Mitsubishi already operates a 50,000 tpa POM plant in Japan. BASF has worldwide capacity of 71,000 tpa of the acetal polymer. In 1999, BASF bought Degussa-Hüls 50% share of the two Ultraform polyacetals joint venture businesses. Ultraform GmbH (Ludwigshafen) has capacity to produce 38,000 tpa of POM. Ultraform Company at Theodore, Alabama, has capacity totalling 33,000 tpa. However, over-capacity in the USA and negative economies forced BASF to shut the Theodore plant in 2002, and to source material for US customers under a toll agreement with Ticona. The only other POM producer in Europe is Zaklay Azotowe, Poland, which has production capacity of around 10,000 tpa. Around 80% of the material is exported to Western Europe. Toray entered the POM market in 1998 when affiliated Korean company KTP started production at a 20,000 tpa plant. KTP polyacetals are marketed exclusively by Toray in Japan. Mitsubishi Gas Chemicals is one of Japan’s leading POM producers, based at Yokkachi, Japan. In 2002, the company announced that it was commercialising a new speciality grade of polyacetal, which allows alloying with other thermoplastics. Mitsubishi produces 20,000 tpa of POM in Japan and 60,000 tpa in South Korea through a joint venture with TICO called Korea Engineering Plastics.

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Other POM producers in Asia include Japanese company Asahi with production capacity of 55,000 tpa, Chan Chung (20,000 tpa), Formosa Plastics (25,000 tpa), LG Chem (15,000 tpa) and Thai Polyacetal. Thai Polyacetal is a 74:26 joint venture between Mitsubishi Gas Corp and TOA Chemicals. In 2001, it announced plans to expand production of POM at the Mab Ta Phut, Thailand, site from 20,000 to 45,000 tpa by 2003. In 2001, the Yunnan Gas Co set up a 10,000 tpa POM plant in Yunnan province, China, to meet growing demand. The plant capacity will eventually be raised to 30,000 tpa.

10.6.2 Products The products offered by leading POM suppliers are summarized in Table 10.11. Table 10.11 Product offerings of major polyacetal producers Trade name POM copolymers known as Hostaform in Europe, Celcon in the Ticona Americas and Duracon in Asia. DuPont Delrin homopolymers BASF Ultraform copolymers Toray Amilus copolymers Mitsubishi Jupital copolymers Polyplastics Duracon copolymers Asahi Tenac homopolymers & copolymers Formosa Plastics Formosacon copolymers Company

The trade names of Ticona acetals are Hostaform in Europe, Celcon in the Americas and Duracon in Asia. The Kelsterbach site developed Hostaform in the 1960s. The production process used at Kelsterbach is based on a technology developed by the Celanese Corporation. Trioxane is produced from methanol via formaldehyde. After cleaning and subsequent polymerisation, the formulation and extrusion of the various granule types takes place. Hostaform POM copolymers are produced in many different forms. These include basic grades, easy flowing grades, glass-reinforced grades, grades with improved surface slip qualities, high impact grades and UV-stabilised grades and in a wide range of colours. Delrin is the trade name of the DuPont range of acetal homopolymers. The product range includes UV resistant grade resins for low friction and wear, the Delrin P series for optimum processing for highly demanding operating conditions and tough and super tough grades. BASF’s Ultraform is a linear-chained random copolymer of trioxane and another monomer, and has a highly crystalline structure. Ultraform is supplied in many different grades including extrusion grades, standard injection moulding grades, impact modified injection moulding grades, glass fibre reinforced grades and mineral filled injection moulding grades. The Ultraform range also includes special additive grades for improved frictional and wear properties, UV and weather resistance and electrical conductivity. Amilus is a copolymer polyacetal resin developed by Toray. It is widely used for precision electrical and office equipment components.

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10.7.1 Major Suppliers Table 10.12 shows the worlds’ leading acrylic resin suppliers, their production capacities and geographic scope for 2002. Table 10.12 Production capacity of leading PMMA producers, 2002 Company Location Capacity (000 tonnes) Röhm Europe, USA 280 Atoglas Europe, USA 270 Lucite International Europe, USA 170 Sumitomo Asia 90 Asahi / Chi Mei Asia 30 IRG Plastics Europe 17

Vertical integration is a key feature of the acrylics market. The world’s three major acrylics producers: Lucite, Atoglas and Rohm, are all backward integrated into production of the methyl methacrylate (MMA) monomer and forward integrated into production of sheet and moulding compounds. Lucite International is the world’s largest producer of MMA with around a third of total production. It has MMA plants in Europe and the USA. Rohm & Haas has the world’s largest MMA plant with capacity totalling 360,000 tpa at Deer Park, Texas, USA. Rohm & Haas and Atoglas have an agreement whereby the additional production needs of both companies will be met from the Deer Park facility. The companies raised MMA capacity by 115,000 tpa in 2002. The world acrylics market has gone through a period of consolidation in recent years. ICI sold its acrylics business to Ineos (Lucite) in 1999, and BASF sold its moulding compounds business to IRG Plastics in 1997. Rohm & Haas, USA, sold its 50% stake in AtoHaas to joint venture partner AtoFina in 1998 while Degussa and Huls acrylics businesses were put together, following the merger of the two parent companies. There are three major suppliers of PMMA resins and moulding compounds to the world market: Röhm GmbH, Atoglas Acrylics and Lucite International. An enlarged Röhm GmbH was formed in 1999 from a merger of acrylics producer Agomer GmbH, the former Degussa subsidiary, into the former Hüls acrylics offshoot, following the merger of the two parent companies. The new, larger Röhm is the world’s number one producer of PMMA and number three in MMA feedstock. It has 19 subsidiaries producing at 18 locations, in addition to a network of marketing and sales centres. Rohm has two production facilities, for MMA both in Germany. The Worms facility has production capacity of 190,000 tpa and the site at Wesseling has total PMMA capacity of 90,000 tpa. Atoglas Acrylics is the market leader in the European PMMA market. The company was formerly known as AtoHaas, a joint venture involving Elf Atochem of France and Röhm & Haas of the USA. Atoglas has PMMA manufacturing and MMA facilities at Rho, Italy, with polymerisation capacity of 90,000 tpa and at Carling, France, with production capacity also of 90,000 tpa., and also has sites in the USA. The company produces a full range of cast and extrusion sheet and granules. Rohm and Haas sold its 50% share in AtoHaas to joint venture partner Elf Atochem S.A. in 1998. Atochem’s takeover of AtoHaas, gives it a 24% percent share of the world acrylic polymers market.

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Ineos Acrylics bought ICI Acrylics in 1999. The company is the largest world producer of MMA feedstock for PMMA with annual sales of €1 billion in 2001. It has 15 production sites in nine countries and employs more than 2,000 people in Asia, the Americas and Europe. Ineos has 180,000 tpa of capacity for production of MMA at the Billingham site in the UK. The company has a further 325,000 tpa of MMA capacity at two separate locations in the USA. In 2002, the company changed its name to Lucite International after its best-known brand. BASF AG production capacity for MMA is around 36,000 tpa at its facility in Ludwigshafen, Germany. At the end of 1997, BASF sold its PMMA moulding compounds and sheets business to Barlo Plastics NV. Production facilities sold included 22,000 tpa of PMMA and 17,000 tpa of extruded sheets, along with granules, operated by Resart GmbH and Spanish affiliate Critesa S.A., which produces 7,000 tpa of cast sheet. BASF will continue to market the PMMA granules as agent under its Lucryl trademark, along with supplying MMA feedstock. In Asia, Sumitomo Chemicals is one of the leading suppliers of MMA and PMMA resins. In 1998, it set up monomer and polymer production in Singapore and acquired the monomer business from NipponShokubai Co in 2002. Sumitomo has announced that capacity at the Japan and Singapore plants are to be increased by a total of 10,000 tpa to take overall production capacity to 100,000 tpa. In 2001, Asahi Kasei teamed up with Chi Mei for a PMMA project in Taiwan. Chi Mei constructed a 30,000 tpa PMMA resin plant and Asahi Kasei takes the material in pellet and sheet form. Also in 2001, Mitsubishi Rayon Co Ltd and Marubeni Corp announced plans to build a new 40,000 tpa plant for injection moulded PMMA in China. The joint venture, Nantong Rayon Chemical, is scheduled to go on stream in Jiangsu province near Shanghai in autumn 2003, with product to be sold on the Chinese market.

10.7.2 Products Products offered by the leading PMMA resin and compound producers are summarized in Table 10.13.

Company Röhm Atoglas Lucite Barlo Plastics

Table 10.13 Product offerings of major PMMA producers Trade name Acrylic sheets and compounds, sold in North and South America as “Plexiglas” and in Europe as “Altuglas”. Oroglas acrylic resins and Altuglas acrylic sheet. Lucite acrylic sheet, Diakon standard grade acrylic polymers, Perspex cast and extruded acrylic sheet. Lacryl acrylic sheet.

Atoglas produces Oroglas acrylic resins and Altuglas acrylic sheet. Oroglas acrylic resins are used in a wide range of injection, extrusion and blow moulding applications. Special grades are also offered for better impact resistance, resistance to gamma radiation, UV filtering, chemical resistance and food contact grades. Altuglas is the name for cast and extruded acrylic sheet manufactured by Atoglas. Lucite International offers a range of different products. Lucite is the trade name for cast acrylic sheet for baths and spas. Diakon standard grade acrylic polymers are for use in general purpose injection moulding and extrusion. Diakon toughened grades are a range of impact modified acrylic compounds for lighting, automotive, houseware and medical applications.

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Perspex is the trade name for Lucite cast and extruded acrylic sheet. Perspex is available in a wide range of varieties. It is made in standard form and can also be custom produced. Lucite products are offered in many different forms such as liquid, resin, emulsion, polymer, sheet or composites with other materials. Röhm GmbH manufactures acrylic sheets and compounds, sold in North and South America as ‘Plexiglas’ and in Europe as ‘Altuglas’. BASF acrylic sheet is sold under the trade name Lacryl. 10.8 Polyphenylene Oxide (Ether) Blends (PPO and PPE)

10.8.1 Major Suppliers Table 10.14 shows the world’s leading PPO/PPE suppliers, their production capacities and geographic scope for 2002. Table 10.14 Production capacity of leading PPO/PPE producers, 2002 Capacity Company Location (000 tonnes) Asahi Kasei Asia 65 GE Plastics USA, Europe, Asia 45 Mitsubishi Asia 30 Degussa Europe 20 BASF Europe 15 Huntsman Chemicals USA 10 Sumitomo Asia 10

Asahi Kasei Chemicals, Japan, is the world’s largest producer with capacity of 65,000 tpa. GE Plastics is the second largest producer of PPO/PPE with total capacity of 45,000 tpa. Mitsubishi Gas Corporation is the world’s third largest integrated producer of PPE/PPO with capacity of 30,000 tpa. There are also a number of companies producing PPO compounds and blends, most notably Degussa, Huntsman, BASF and Sumitomo. In 2000, GE Plastics completed a 29,000 tpa expansion of polyhenylene oxide production at three sites, including Selkirk (New York, USA), Bergen op Zoom (the Netherlands) and Moka (Japan). GEP also raised PPO capacity by a further 11,000 tpa in 2001 to increase global capacity to 45,000 tpa. The capacity build-up is designed to take account of increasing demand for the group’s ‘Noryl’ PPO product family in such markets as automobiles and telecommunications. A new PPE plant of Asahi Kasei Plastics Singapore Pte Ltd (APS), a wholly owned subsidiary of Asahi Kasei Corporation, and the PPE powder plant of Polyxylenol Singapore Pte Ltd (PXS), a joint venture between APS and Mitsubishi Gas Chemical Co, Inc (MGC), entered commercial operation in December, 2002. Production capacity for PPE powder is currently running at 30,000 tpa. Asahi Kasei plans to double PPE sales over the next several years, for the most part through capacity expansions in Asia and Europe. Following the takeover of the Thermofil compounding group, Asahi Kasei has founded a new subsidiary, Asahi Thermofil, (Brussels), to coordinate its European plastics activities. Degussa, the German chemicals company, produces a number of speciality engineering polymers including polyamide and PPE. Production capacity for PPE resin is around 20,000 tpa in 2002.

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In 2002, BASF sold its ‘Luranyl’ business in Europe and Asia to Romira GmbH, a producer of engineering plastics in Pinneberg, Germany. Production of the blend of PPE and HIPS with a capacity of about 5,000 tpa is being transferred from sites in Germany and Korea to Pinneberg.

10.8.2 Products Product offerings of the major suppliers are described in Table 10.15.

Company Asahi Kasei GE Plastics Degussa Mitsubishi

Table 10.15 Product offerings of major PPO/PPE producers Trade name Xyron modified PPE resins Noryl PPE/PPO blends Vestoran PPE resins Lemalloy modified PPE resins

Asahi Kasei modified PPE resins are marketed under the Xyron trade name. The company offers a broad range of products including automotive grades, high-flow, flame retardant grades, heat resistant, flame retardant grades, enhanced heat resistance grades, high rigidity low warp grades, and glass fibre-reinforced grades. GE Plastics Noryl product range comprises the following products. •

NORYL EF® expandable beads are a copolymer of PPO and expandable polystyrene (EPS), that are used for applications which demand high energy absorption, temperature resistance and light weight.

•

NORYL GTX® is a PPE/PA blend and PPO/PA blend – a polyamide (PA) product which is reinforced with modified polyphenylene ether polymer technology. This technology combines the dimensional stability, low water absorption and heat resistance, inherent advantages of the PPE polymer, with the chemical resistance and flow of polyamide. This gives an extremely chemically resistant material with stiffness, impact resistance and heat performance. The low density of unfilled NORYL GTX resin can provide part-weight savings of up to 25% over glass or mineral filled resins. NORYL GTX resins offer broad environmental resistance to commonly used automotive fuels, greases and oils.

•

NORYL® resin is a modified PPE/PS blend that offers eco-friendly, market-tailored performance, optimised processing and enhanced productivity in applications ranging from computers and business equipment to electrical & electronic appliances to telecommunications. A broad choice of injection-mouldable, extrudable and foamable grades, plus automotivespecific grades and special high modulus grades able to replace stamped steel and die-cast metal in tight tolerance, functional assemblies are offered. Its halogen-free flame retardant characteristics make it particularly suitable for use in public building applications.

•

NORYL® PPX resin fills the gap between the basic properties of high-end polyolefins and the stronger performance characteristics and attributes of engineered plastics. It can be an ideal replacement for traditional materials such as TPO, polyamide and steel due to its high stiffness, toughness and heat resistance that allow for new design freedom across a number of markets. The NORYL PPX portfolio presently includes four commercial grades, featuring two unfilled and two filled grades. Principal applications for Noryl PPX in automotive are bumper fascias and front end modules. The material is also used in many other applications such as fluid handling equipment, power tools and enclosures, battery cases and telecommunications.

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Degussa PPE blends are sold under the trade name Vestoran. Grades include amorphous, high temperature resistant and hot water resistant. The main applications are found in the automotive market including vibration dampers, sealings, switch membranes and door locks. Mitsubishi produces a wide range of PPE/PA blends under the Lemalloy trade name. 10.9 Polyphenylene Sulfide (PPS)

10.9.1 Major Suppliers Table 10.16 shows the worlds’ leading PPS suppliers, their production capacities and geographic scope for 2002. Table 10.16 Production capacity of leading PPS producers, 2002 Company Location Capacity (000 tonnes) Chevron Phillips Chemicals USA 10 Fortron Industries Asia 7 Kureha Chemicals Asia 6 Toray Asia 6 Dainippon Ink & Chemcials Asia 6 Tosoh Asia 4 Solvay Advanced Polymers USA 3 GE Plastics USA 3

The Phillips Petroleum Chemicals Company was the first commercial producer of polyphenylene sulfide and holds over 200 patents in this area. The plant in Borger, Texas, has been producing regular PPS polymer commercially since 1972. The company announced in 2002 that it was expanding capacity at the Texas facility by 7,000 tpa to 17,000 tpa to meet growing demand for the polymer. In 1997, Phillips opened a PPS compounding facility near Antwerp, Belgium. The plant initially had a capacity of 4,000 tpa for ‘Ryton’ PPS compounds, which was later expanded to 15,000 tpa. In summer 2000, Chevron and Phillips combined their chemical operations to form Chevron Phillips Chemicals. The enlarged company is amongst the world’s top five producers of olefins, polyolefins and aromatics. Fortron Industries, Wilmington, North Carolina, USA, is a joint venture company between Kureha Chemical Industry Co Ltd and Ticona. The facility has a capacity of around 7,500 tpa for linear PPS. In 2000, production capacity was raised by 1,800 tpa, and Fortron plans to increase capacity further at Wilmington to 10,000 tpa in 2003, largely through debottlenecking. Kureha also has a production facility for linear PPS in Nishiki, Japan, where capacity was raised to 6,000 tpa in 2001. GE Plastics is the only other major producer of PPS in the USA. Other leading Asian suppliers include Tosoh, Toray, and Dainippon Ink & Chemicals (DIC), the largest PPS manufacturer in Japan. Tosoh Co Ltd has PPS production capacity of around 4,000 tpa at Yokkaichi, Japan. Toray Industries has two production lines, one for crosslinked PPS and another for linear PPS. Total production capacity is close to 6,000 tpa. Dainippon has total production capacity of 6,000 tpa. In 2001, it took over the PPS production of Topren. 173


Solvay Advanced Polymers, Belgium, brought on stream a 10,000 tpa compounding plant for its ‘Ixel’ (polyarylamide) and Primef PPS compounds at Oudenaarde, Belgium, in 2001. The PPS compounds are marketed only in Europe at the present time. Idemitsu Petrochemicals has developed a new production method based on continuous polymerisation and is now gearing up for the construction of a 10,000 tpa plant in Asia in 2003. Albis Plastics GmbH is the leading independent supplier of PPS compounds in Europe. These products are sold under the Tedur trade name.

10.9.2 Products Product offerings of the major PPS suppliers are described in Table 10.17. Table 10.17 Product offerings of major PPS producers Company Trade name Chevron Phillips Chemicals Ryton Fortron Industries / Ticona Fortron Toray Torelina Solvay Advanced Polymers Primef GE Plastics Supec

Chevron Phillips manufactures the full line of cured, linear, and branched polymers under the ‘Ryton’ trade name. Ticona’s Fortron PPS is available in a variety of mineral- and glass-reinforced grades. Fortron® is a trademark of Fortron Industries, a joint venture of Ticona and Kureha Chemical Industry of Japan. Toray’s high-performance PPS plastic, Torelina, is used in a wide range of applications: switches, connectors and other electronic and electrical components, alternators and other automobile components, and office equipment components including housings. Solvay Advanced Polymers produces Primef PPS compounds, which are glass fibre- and/or mineral filler-reinforced thermoplastics. Primef is used for injected parts for applications in electronics, electrical and mechanical engineering, the automotive industry, and the chemical processing industry. Supec is the trade name of the GE Plastics range of PPS resins and compounds. Glass-reinforced grades are available in black and neutral colours. 10.10 Polyetherimide (PEI)

10.10.1 Major Suppliers GE Plastics is the world’s principal supplier of polyetherimide resins and compounds. Manufacturing facilities are located at Mt. Vernon, Indiana, USA, and at Moka, Japan. Total production capacity for Ultem is currently around 15,000 tpa.

10.10.2 Products GE Plastics Ultem product range comprises base polymers, blends and reinforced grades.

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The Ultem 1000 series, the base polymer, offers long-term heat resistance and inherent flame retardance with low smoke evolution. It also maintains its strength at elevated temperatures and good resistance to a broad range of chemicals, including automotive fluids. Ultem resin blends are designed to fill the gap between polycarbonate and polyetherimide resins. Key features are good flow, intermediate heat performance and price. Blends include Ultem 1285, Ultem ATX, a polycarbonate-ester blend, and Ultem HTX. Ultem can also be modified with fillers such as glass (2000 series), minerals (3000) and carbon (7000 series) for exceptionally high performance, strength and dimensional stability. 10.11 Polysulfone (PSU), Polyethersulfone (PES)

10.11.1 Major Suppliers BASF is the world’s major producer of PES and PSU resins, based at Ludwigshafen, Germany. In 2002, BASF increased capacity for PSU and PES from 3,000 tpa to 5,000 tpa. Solvay Engineering Polymers is another important world producer, having acquired the performance plastics business of BP Amoco in 2001. Solvay has production plants for its sulfone polymers at Marietta, Ohio, and at Augusta, Georgia, for the sulfone monomer. In 2001, capacity at the Marietta plant was increased by 40%, while capacity of the Augusta unit rose by 15%. In 2002, production capacity for PPS was raised by a further 15% and capacity to produce the sulfone monomer was raised by a further 10%. Gharda Chemicals of India manufactures Gafone PSU resins and compounds at a facility in India, opened in 1998.

10.11.2 Products BASF Ultrason grades are high-temperature-resistant, amorphous thermoplastics based on polysulfone and polyether sulfone, and are traded as Ultrason S and Ultrason E, respectively. Solvay Advanced Polymers offers a broad range of polysulfone products. •

Udel is the trade name of Solvay’s PSU resin for temperature stressed parts, with very good resistance against hot water and steam (sterilization), transparent, high temperature resistant materials with RTI up to 160 °C.

•

Radel A PES resin is used for transparent and high temperature resistant parts with good chemical resistance, good behaviour in fire, RTI up to 180 °C.

•

Mindel A is a PSU/ABS blend. Mindel B is a glass-reinforced PSU compound. Mindel M is a mineral reinforced PSU compound and Mindel S is a PSU alloy for medical and food applications.

•

In 2003, Solvay extended its range of polysulfone products with the launch of a new highclarity grade to challenge polycarbonate. Udel P-3799 HC meets the growing need for lower colour and is close to white water clarity. The product is also available in a range of bright colours that were not previously possible with PSU. Typical applications for the product include food and beverage containers, tableware, appliance components, dairy equipment, face shields, and lighting components such as lenses and covers for automotive or residential/commercial lighting where temperature requirements approach 150 °C.

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10.12.1 Major Suppliers Table 10.18 shows the world’s leading LCP suppliers, their production capacities and geographic scope for 2002. Table 10.18 Production capacity of leading liquid crystal polymer producers, 2002 Company Location Capacity (000 tonnes) Ticona Europe, USA 8.5 Polyplastics Asia 8 DuPont USA, Asia 5 Esatman Chemicals USA 3 Sumitomo Asia 2 Toray Asia 2 Solvay Advanced Polymers USA 2 Mitsubishi Asia 2 Ueno Asia 1

Ticona GmbH, part of the Celanese group, is the leading world supplier of LCP with global capacity of 8,500 tpa. DuPont is the other major world supplier of LCPs with its Zenite product range. In 2002, Ticona engineering polymers doubled capacity of its ‘Vectra’ LCP plant at Shelby, North Carolina, USA, to 6,000 tpa. The company also produces LCP in Fuji City, Japan, in cooperation with 45% affiliate Polyplastics Co Ltd (a joint venture with Daicel Chemicals Industries). In 2000, Polyplastics increased capacity for Vectra by 2,000 tpa of neat polymer, lifting its annual output to 8,000 tpa of neat polymer or 12,000 tpa of compounds. DuPont has also been expanding its capacity for its Zenite LCP. In 2001, capacity for the LCP basic polymer was doubled to 5,000 tpa at the Chattanooga, USA, location. A further 3,000 tpa will be added at a later date. In parallel to this, DuPont will also be increasing its existing LCP compounding capacity in Utsunomiya, Japan. Sumitomo Chemical’s capacity for LCP is 2,000 tpa and is located at Ehime, Japan. Sumitomo has developed a new manufacturing process for liquid crystal polymers using an organic catalyst. The process produces high-performance LCP and is claimed to achieve substantially improved production efficiency. According to Sumitomo, production capacity of the existing LCP plant in Ehime, Japan, can be doubled to 4,000 tpa simply by installing catalyst feed equipment with a minimum of investment. Moreover, Sumitomo claims that the product manufactured using the new process offers additional benefits such as better flowability and heat stability. Toray, Japan, has production capacity for liquid crystal polymers of around 2,000 tpa. There are plans to raise capacity during the next twelve months. Ueno LCP, Japan, has production capacity for LCP of around 1,000 tpa. Eastman Chemicals, Solvay and Mitsubishi Rayon are all recent entrants into the LCP market. Eastman Chemicals, based in the USA, is now the world’s fourth largest producer of liquid crystal polymers. Eastman opened a 3,000 tpa plant at Tennessee, USA, in 2001. However, in March 2003, it was announced that DuPont Engineering Polymers has acquired Eastman Chemical’s highperformance crystalline plastics business. The deal covers Eastman’s Titan liquid crystal polymers, Thermx PCT and Thermx EG series. Under the agreement, DuPont is buying the technology rights

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and other intellectual property including formulations and marketing information, but not physical assets or people. The Titan LCPs will be integrated into DuPont’s Zenite LCP grouping. Solvay Advanced Polymers entered the LCP market in 2001 when it acquired BP Amoco’s advanced polymers business in exchange for Solvay’s polypropylene assets. Production capacity stands at around 2,000 tpa in 2002. Mitsubishi Rayon began production of LCP compounds at its Toyohashi factory in Japan in 2001. Finally, in 2000, Kuraray of Japan entered into a partnership with US company Rogers, to develop liquid crystal polymer film technology. The company is now commercialising the technology for use in printed circuit boards for a range of telecommunication and data transmission products.

10.12.2 Products Products offered by leading global LCP suppliers are described in Table 10.19 below.

Company Ticona DuPont Eastman Toray Solvay

Table 10.19 Product offerings of major liquid crystal polymer producers Trade name Vectra Zenite Titan Siveras Xydar

Ticona LCPs are sold under the Vectra trade name. There are a wide range of Vectra injection moulding grades offered that vary in relation to melting points, heat resistance, strength and flow capacities. Many variations of filling and reinforcement materials (glass and carbon fibres, minerals, graphite, PTFE and combinations of these) allow the adaptation of these basic polymers to the requirements of many areas of application. Ticona has introduced the heat-resistant ‘Vectra T’ LCP series, developed jointly with Polyplastics Co Ltd, Tokyo. According to the company, this liquid crystalline polymer, which has a melting point of 370 °C, offers improved dimensional stability in heat and also good melt stability, despite its higher heat resistance. Productivity increases will be possible in injection moulding, in particular. In 2000, Ticona introduced a new family of LCPs under the name ‘Vectran’. The new grades were developed for large-scale food and medical packaging applications. Vectran was developed specifically to be co-processable with conventional packaging resins, including operations involving thermoforming. DuPont markets a broad range of liquid crystal polymers under the Zenite trade name. Grades are available in glass- or mineral-reinforced and are suitable for automotive, electronics, appliances and industrial markets. Titan is the trade name of Eastman Chemicals liquid crystal polymers. They are produced in a variety of glass- and mineral-reinforced grades that include low-warp and high-knit-line strength formulations. Siveras is the brand name of Toray’s liquid crystal polymer range. Siveras finds uses in connectors, sensors and other electronic components and CD pickup parts, and in copying machine and fax components in office and audiovisual equipment.

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Solvay Advanced Polymers supplies Xydar liquid crystal polymers in either unreinforced or glass, glass/mineral, or mineral filled grades. 10.13 Polyetheretherketone (PEEK)

10.13.1 Major Suppliers Victrex plc, a management buyout from ICI in 1993, is the main world supplier of PEEK. The company headquarters, R&D and manufacturing facilities are located at Thornton, Cleaveleys in the UK. The company also has sales and distribution centres serving customers in over thirty countries worldwide. The company has consistently invested in additional capacity since formation of Victrex. Production capacity for PEEK is currently 2,300 tpa. An expansion is planned later in 2003 by debottlenecking, which will raise production capacity to 2,800 tpa. Victrex USA serves markets in North America while Victrex Europa GmbH in Germany serves customers in Central Europe. The joint venture named Victrex-MC established between Mitsui Chemicals Inc and Victrex plc is responsible for Japan and the Asia Pacific customers. Victrex is now backward integrated to ensure raw material supplies. In 1999, it bought Laporte’s 4,4-difluorodiphenyl methane plant at Rotherham, UK. In 2000, it purchased a 50% stake from Laporte in a 4,4-difluorobenzophenone plant in the UK. The other 50% is owned by Degussa, which took over Laporte. Solvay Advanced Polymers LLC is the only other established world supplier of polyketones. It is a wholly owned subsidiary of Solvay America Inc, and was formed in November 2001 by combining Solvay’s existing line of engineering polymers with those acquired from BP Amoco. India’s Gharda Chemical Company has recently entered the PEEK market through its speciality Polymer division. The company manufactures a polyetheretherketone at a plant located at Panoli in India with capacity currently running at 120 tpa. In the USA, Gharda PEEK is marketed through JLM Marketing, Florida. Gharda uses a single monomer and has a lower-cost process than Victrex. Apart from colour, which is darker than Victrex PEEK, Gharda materials are 15-20% less expensive and broadly comparable in terms of performance properties. Another new entrant began production of PEEK compounds in 2000. Oxford Performance Materials, a division of Oxford Polymers in the UK, offers Oxpekk PEEK compounds based on copolymer base resins made by Cytec, New Jersey, USA. The compounds are distributed by Infinite Polymer Systems in the USA. In 2002, after failing to find a buyer for its ‘Carilon’ and ‘Carlite’ PEEK, Shell donated the patents for the polymers to a US-based non-profit research institute (SRI, California). The research institute, which performs contract R&D and licenses technologies worldwide, said that it would incorporate the patents into its own polymer technology portfolio.

10.13.2 Products Product offerings of the leading world polyketone resin suppliers are summarized next. Victrex PEEK polymers are available in regular, glass and carbon fibre filled grades for applications in aerospace, automotive, electrical, medical, industrial and food processing equipment. With its ‘PEEK-HT’, high performance plastics Victrex claims to have launched a cost178


and weight-saving alternative to metal for applications that demand superior higher temperature resistance. The semi-crystalline, unreinforced polymer is claimed to offer all the usual characteristics of natural PEEK polymer, including toughness, strength and chemical resistance. Solvay Advanced Polymers markets its aromatic polyketone under the Kadel trade name. The resin range consists mainly of injection moulded grades with glass-reinforced, carbon fibre-reinforced and a special bearing grade. Getone is the trade name of Gharda’s PEEK polymers. The product range includes high viscosity grades for extrusion coating, extrusion and injection moulding and low/medium viscosity grades for extrusion and injection moulding. Glass fibre and carbon fibre-reinforced grades are also available. 10.14 Polyphthalamide (PPA)

10.14.1 Major Suppliers Solvay Advanced Polymers LLC is the only major producer of PPA resins and compounds. The company is a wholly owned subsidiary of Solvay America Inc, and was formed in November 2001 by combining Solvay’s existing line of engineering polymers with those acquired from BP Amoco. Solvay Advanced Polymers headquarters are located at Alpharetta, Georgia, USA.

10.14.2 Products Solvay Advanced Polymers offers a variety of reinforced grades of Amodel PPA depending on the balance of properties needed for a given application. Glass-reinforced grades provide higher stiffness, strength, and creep resistance at elevated temperatures for structural-type applications. Mineral-filled resins offer enhanced dimensional stability and flatness. Some of the mineralfilled grades can be plated and epoxy-coated. Impact-modified grades provide significantly improved toughness with much higher strength and stiffness across a broad humidity and temperature range relative to toughened polyamides. Finally, glass-and-impact-reinforced grades provide an excellent balance of stiffness and impact resistance relative to either glass-or impactmodified grades alone. In addition to these, special grades formulated for applications requiring flame-retardancy, glycol-resistance, typically for automotive applications, and reflectivity, typically for optoelectronic applications such as high brightness LEDs, are available. In 2002, Solvay Advanced Polymers introduced a new range of high temperature Amodel flame retardant grades. The new grades are designed for critical electronics and electrical applications such as connectors, chip capacitors, cell phone components, circuit breakers, contactors, relays and switches. A notable feature of these new grades is their high conductive tracking index (CTI) and glow wire ignition temperature (GWIT). They are also more colour stable due to their improved thermal stability when processed at very high temperatures.

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Directory of Major Suppliers Asahi Kasei Corporation Headquarters Hibiya Mitsui Building 1-2 Yurakucho 1-chome Chiyoda-ku Tokyo 100-8440 Japan Tel: (81) 3 3507 2060 Fax: (81) 3 3507 2495 www.asahi-kasei.co.jp Albis Plastics GmbH Muhlenhagen 35 D - 20539 Hamburg Germany Tel: (49) 40/7 81 050 Fax: (49) 40/7 81 05 361 www.albis.com Atoglas Europe SA F-92800 Puteaux Ile-de-France France Tel: (33) 1 49 00 80 80 Fax: (33) 1 49 00 89 59 www.atoglas.com AtoFina 48 cours Michelet F-92800 Puteaux France Tel: (33) 1 4900 8080 Fax: (33) 1 4900 8396 www.atofina.com BASF Aktiengesselschaft D-67056, Ludwigshafen Germany Tel: (49) 621600 Fax: (49) 621 6042525 www.basf.de Barlo Plastics Europe Leukaard 1 2440 Geel Belgium Tel: (32) 1457 6711 Fax: (32) 1457 6718 www.barloplastics.com

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Bayer AG Plastics Business Group D-51368 Leverkusen Germany Tel: (49) 214 3021 616 Fax: (49) 214 3026 686 www.bayer.com Chevron Phillips Chemicals Technical Plastics Division D-60447 Frankfurt Germany Tel: (49) 6979 3050 Fax: (49) 6979 305 138 www.cpchem.com DSM N.V. Poststraat 1 P O Box 43 NL-6130 AA Sittard The Netherlands Tel: (31) 46 4770077 Fax: (31) 46 4200338 www.dsm.nl Dainippon Ink & Chemicals Inc Corporate Headquarters DIC Building, 7-20, Nihonbashi 3-chome, Chuo-ku Tokyo 103-8233 Japan Tel: (81) 3 3272 4511 Fax: (81) 3 3278 8558 www.dic.co.jp Degussa AG Headquarters Weissfrauenstrasse 9 D-60287 Frankfurt am Main Germany Tel: (49) 69/218 01 Fax: (49) 69/218 3218 www.degussa-huls.de Dow Chemicals Europe Bachtobelstrasse 3 CH-8810, Horgen Switzerland Tel: (41) 1728 2111 Fax: (41) 1728 2988 www.dow.com

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DuPont 2 Chemin du Pavillon P O Box 50 CH-1218 Grand Sacconex, Geneva Switzerland Tel: (41) 22 717 5111 Fax: (41) 22 717 4200 www.dupont.com EMS-Grivory CH-7013 Domat/Ems, Switzerland Tel: (41) 81 6326111 Fax: (41) 81 6327454 www.emschem.com Eastman Chemical Company PO Box 3263 Hertizentrum CH-6300 Zug Switzerland Tel: (41) 41 726 6100 Fax: (41) 41 726 6200 www.eastman.com EniChem SpA Piazza della Republica 16 I-20124 Milan Italy Tel: (39) 2 69771 Fax: (39) 2 520 39514 www.enichem.it Formosa Plastics Corporation USA Corporate Headquarters 9 Peach Tree Hill Road Livingston, NJ 07039-5702 USA Tel: (1) 973 992-2090 Fax: (1) 973 992-9627 http://www.fpcusa.com/ GE Plastics BV Plasticslaan 1, PO Box 117 4600 AC Bergen op Zoom The Netherlands Tel: (31) 164 292911 Fax: (31) 164 292940 www.geplastics.com

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Honeywell/Europe NV Haasrode Research Park B-3001 Leuven Belgium Tel: (32) 1639 1230 Fax: (32) 1639 1371 www.honeywell-plastics.com Huntsman LLC Headquarters 500 Huntsman Way Salt Lake City, Utah 84108 USA Tel: (1) 801 584 5700 Fax: (1) 801 584 5781 www.huntsman.com LG Chem Company Headquarters: LG Twin Tower, East Tower 20, Yoido-dong, Youngdungpo-gu Seoul 150-721 S Korea 150-721, Korea Tel: (82) 2 3773 1114 www.lgchem.com Lucite International 1st Floor Queens Gate, 15-17 Queens Terrace Southampton Hampshire, SO14 3BP United Kingdom Tel: (44) 1254 874444 Fax: (44) 1254 874098 www.ineosacrylics.com Mitsubishi Corporation 6-3, Marunouchi 2-chome, Chiyoda-ku Tokyo 100-8086 Japan Tel: (81) 3 3210 2121 Fax: (81) 3 3210 8935 www.mitsubishicorp.co.jp Polyplastics Co Ltd Head office Kasumigaseki Bldg 2-5 Kasumigaseki 3-chome Chiyoda-ku Tokyo Japan Tel: (81) 3 3593 2444 Fax: (81) 3 3580 0629 www.polyplastics.com

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Radici Plastics GmbH & Co KG Schauenburgerstr. 15 D-20095 Hamburg Germany Tel: (49) 40 33 93 65 Fax: (49) 40 33 58 36 www.radiciplastics.com RepsolYpf SA Passo Castellana 279-280 E-28046, Madrid Spain Tel: (34) 991 348 8000 Fax: (34) 991 314 2821 www.repsol-ypf.com Rhodia Engineering Plastics SA Avenue Ramboz BP 64 F-69192 Saint-Fons Cedex France Tel: (33) 04 72 89 27 00 Fax (33) 04 72 89 27 01 www.rhodia-ep.com Röhm GmbH Chemische Farbrik D-64275 Dormstadt Germany Tel: (49) 6151 1801 Fax: (49) 6151 1802 www.roehm.de Solvay Advanced Polymers, L.L.C. 4500 McGinnis Ferry Road Alpharetta, GA 30005-3914 USA Tel: (1) 770 772 8200 Fax: (1).770 772 8454 www.solvayadvancedpolymers.com Solutia P.O. Box 66760 St. Louis, MO 63166-6760 USA Tel: (1) 314 674 1000 www.solutia.com Sumitomo Chemicals Corporation Tokyo Sumitomo Twin Building (East) 27-1, Shinkawa 2-chome, Chuo-ku Tokyo 104-8260 Japan Tel: (81) 3 5543 5500 Fax: (81) 3 5543 5901 www.sumitomo-chem.co.jp

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Techno Polymer Co. Ltd Head Office 104-31 Yaesu Takaracho Building 6F 1-18-1 Kyobashi, Chuo Tokyo Japan Tel: (81) 35250 2704 Fax: (81) 3 5250 2721 www.techpo.co.jp Teijin 1-1, Uchisaiwaicho 2-chome, Chiyoda-ku Tokyo 100-8585 Japan Tel: (81) 3 3506 4529 www.teijin.co.jp Ticona GmbH D-65444 Kelsterbach P.O. Box 1561 Germany Tel: (49) 6107 7720 Fax: (49) 6107 772 218 www.ticona.com Toray Industries Inc Toray Bldg., 2-1, Nihonbashi-Muromachi 2-chome, Chuo-ku Tokyo 103-8666 Japan Tel: (81) 3 3245 5111 Fax: (81) 3 3245 5555 www.toray.co.jp UBE Europe GmbH Immermannstr. 65 B D-40210 Düsseldorf Germany Tel: (49) 211 1788329 Fax: (49) 211 3613297 www.ube-ind.co.jp Victrex plc Hillhouse International Thornton Cleveleys Lancashire FY5 4QD United Kingdom Tel: (44) 1253 897700 Fax: (44) 1253 897701 www.victrex.com

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Abbreviations and Acronyms ABS APME ASA ASR BHPF BMC CAGR CBT CD COC CTI CUT DCDPS DFMA DVD E&E EDIT EGR ELV EPS ETN EU FM FR GDP GWIT HDT HIPS HVAC ICER LCD LCP LED MID MMA NBR OEM OICA PA PA 11 PA 12 PA 6 PA 612 PA 66 PAI PBT PC PEEK PEI PES PMC PMMA

acrylonitrile-butadiene-styrene terpolymer Association of Plastics Manufacturers in Europe acrylonitrile-styrene-acrylate automotive shredder residue bishydroxyphenol fluorene bulk moulding compounds compound annual growth rate cyclic butylene terephthalate compact disc cyclic olefin copolymer conductive tracking index continuous use temperature 4,4´-dichlorodiphenylsulfone design for manufacturing and assembly digital versatile disc electrical and electronics Eco Design Interactive Tool exhaust gas recirculation end-of-life-vehicle expandable polystyrene European Thematic Network European Union flexural modulus flame retardant gross domestic product Glow-Wire Ignition Temperature heat distortion temperature high impact polystyrene heating, ventilation and air conditioning Industry Council for Electronic Equipment Recycling liquid crystal display liquid crystal polymer light emitting diode moulded interconnect devices methyl methacrylate nitrile rubber original equipment manufacturer International Organisation for Motor Vehicle Manufacturers polyamide polyamide 11 polyamide 12 polyamide 6 polyamide 612 polyamide 66 polyamide-imide polybutylene terephthalate polycarbonate polyetheretherketone polyetherimide polyethersulfone Plastic Molding Corporation polymethyl methacrylate

187


POM PPA PPE PPO PPS PPSU PSGA PSU PTFE PVC SAN SG SIA SMA SMT SNID tpa UL UMTS VDA WEEE WLAN

188

polyoxymethylene polyphthalamide polyphenylene oxide polyphenylene ether polyphenylene sulfide polyphenylene sulfone Polymer Stud Grid Array polysulfone polytetrafluoroethylene polyvinyl chloride styrene-acrylonitrile copolymer specific gravity Semiconductor Industry Association styrene-maleic anhydride copolymer surface mount technology smart network interface device metric tonnes per annum Underwriters Laboratory Universal Mobile Telecommunications System Verband der Automobilindustrie Waste Electrical and Electronic Equipment Wireless Local Access Networks

ISBN: 1-85957-380-0

Rapra Technology Limited Rapra Technology is the leading independent international organisation with over 80 years of experience providing technology, information and consultancy on all aspects of rubbers and plastics. The company has extensive processing, analytical and testing laboratory facilities and expertise, and produces a range of engineering and data management software products, and computerised knowledge-based systems. Rapra also publishes books, technical journals, reports, technological and business surveys, conference proceedings and trade directories. These publishing activities are supported by an Information Centre which maintains and develops the world’s most comprehensive database of commercial and technical information on rubbers and plastics.

Shawbury, Shrewsbury, Shropshire SY4 4NR, UK Telephone: +44 (0)1939 250383 Fax: +44 (0)1939 251118 http://www.rapra.net

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