Lee Spring leaps to the top of Its game with first-ever springs
moulded from SABIC Innovative Plastics' Ultra-Tough Ultem* Resin

Lee Spring, a leading global manufacturer of mechanical springs since 1918, offer its technology - LeeP™ plastic composite springs moulded from SABIC Innovative Plastics' Ultem* resin. Among the first springs ever made with high-performance, engineered plastic, LeeP compression springs provide critical advantages over traditional metal alloy springs, enabling this valued SABIC Innovative Plastics customer to expand its business for greater potential success. SABIC Innovative Plastics provided a range of specialized services for this project, including predictive analysis, material characterization and mould optimisation, clearly illustrating how the company helps its customers succeed through its 75-years of materials technologies expertise and innovation.

Ultem resin gives the springs a broad range of high performance properties including high strength-to-weight ratio, no magnetic interference, high corrosion resistance, and dielectric insulation for non-conductive applications. 

"We specifically selected Ultem resin for LeeP because of its superior track record of success in the most demanding application areas vs. competitive materials," said Al Mangels, Lee Spring president. "The resin exceeded our expectations at every step. It's a truly exceptional product that, due to its tougher-than-tough balance of high-performance properties, performs better than any other thermoplastic. When all was said and done, we knew we had set a new industry standard, which, after all, was the goal."

"Thermoplastics have rarely before been used in high-performance springs, so we were venturing into virtually uncharted territory with Lee Spring," said Shawn Lee, product marketing manager, SABIC Innovative Plastics. "But through our strong chemical and materials expertise, and our technical customer support - ranging from initial calculations and predictive analyses to benchmarking how Ultem resin would perform in the new line of springs - we delivered another winner. Equally important, SABIC Innovative Plastics provided a valued customer a major competitive advantage and an opportunity to capture greater market share, which is what we work toward for all of our customers." 

Lee Spring saw an untapped opportunity to expand its market reach with high-performance thermoplastic springs that approach the strength of metal without certain drawbacks. According to Steve Kempf, CEO of Lee Spring, "Our customers' wish list includes strength, heat stability, corrosion resistance, non-magnetic properties, insulation, inertness, low flame toxicity and recyclability. What led us to Ultem resin was its excellent all-around performance combined with great strength. Ultem resin satisfies the full gamut of customer requirements in a single offering."

For example, in marine applications, LeeP springs made with Ultem resin offer longer life due to resistance to salt water. For the medical device industry, LeeP springs avoid the cost of shielding, which is necessary for metal springs that can interfere with diagnostic imaging. Other market sectors that may benefit from the new springs are: medical products and processing equipment, pharmaceutical delivery devices, food processing and packaging equipment, aerospace products, electronics and electrical equipment, water purification systems and automotive interiors.

LeeP Plastic Composite Springs are stocked in a variety of standard sizes, each available in a "rainbow" of strengths formulated from Ultem resin containing various levels of fiber reinforcement.

Robust Performance and Much More Spring rate (a function of shear modulus), cycle life (resistance to fatigue) and creep resistance are key performance measures for these compression springs. Ultem resin not only provides excellent results for these criteria, but also delivers other key properties: 1) Mechanical stability up to 170C, allowing for use in a wide range of environments. 2) High strength-to-weight ratio: Ultem resin is the highest strength amorphous resin in the market. 3) High corrosion resistance and generally compatible with many chemicals including strong acids, weak bases, aromatics, and ketones. 4) Non-magnetic to avoid interference with imaging and other Ferro-sensitive technologies  5) Dielectric insulating material suitable for non-conductive applications. 6) Inert non-contaminating plastic composite protects product purity. 7) Low flammability and toxicity ensure environmental safety. 8) Recyclable and compliant with most global regulations including RoHS and REACH.

For further information on LeeP™ plastic composite springs moulded from SABIC Innovative Plastics' Ultem* resin, view website: www.sabic-ip.com

SABIC Innovative Plastics' non-brominated, non-chlorinated flame
retardant PC film helps E/E OEMs power up for high-end eco protection

SABIC Innovative Plastics offer a breakthrough Lexan* polycarbonate (PC) film technology - Lexan EFR film - that delivers non-brominated, non-chlorinated flame retardance (FR) at thinner gauges than flame-retardant polypropylene (FRPP).

This industry-leading material, enables electrical/electronics (E/E) OEMs to create flatter, lighter-weight notebook computers and other electronic devices while significantly reducing material costs, giving them a competitive advantage. The new Lexan EFR film is a top-choice environmental solution that increases the ability of global E/E manufacturers to go beyond current environmental directives by voluntarily eliminating halogenated additives in their products. This new SABIC Innovative Plastics breakthrough is the latest example of how the company works on behalf of customers to capitalize on its 75-year history as a global plastics industry pioneer. 

"Lexan EFR film is another major proof point of how SABIC Innovative Plastics' continued investment in R&D is raising the bar on materials performance and system cost reduction," said Lennard Markestein, global marketing director for Specialty Film & Sheet, SABIC Innovative Plastics. "As E/E OEMs step up to meet anticipated and ever-tightening environmental requirements, we are taking the initiative in engineering precisely targeted materials technologies to help proactively address these changes. What's more, new Lexan EFR film makes it clear that SABIC Innovative Plastics is very serious about furthering its leadership position by delivering superior environmentally progressive solutions that allow our customers to distance their competition." 

Environmental protection - and much more
Lexan EFR polycarbonate-based film offers flame retardance without the use of brominated or chlorinated additives thus meeting the requirements of the European Union's Restriction of Hazardous Substances (RoHS) and Waste Electrical and Electronic Equipment (WEEE 2006) directives. Further, these new materials have a full listing in the Underwriters Laboratory (UL) yellow card system. According to UL 94, Lexan EFR film - available in clear and opaque versions - delivers V-0 performance above 380 microns; VTM-0 flame resistance performance down to 125 microns for translucent and 100 microns for opaque materials; and complies with TCO-99 eco label requirements.

Compared to FRPP, Lexan EFR film reduces shrinkage by a factor of three, provides significantly higher puncture resistance and tensile strength. These properties make it feasible to use very thin gauges of Lexan EFR film to replace thicker FRPP film without sacrificing performance. Not only do thinner gauges help designers create slimmer and lighter-weight consumer electronics, but down-gauging also lowers total costs by reducing the amount of material required. The new film also provides low moisture absorption, high thermal performance (glass transition temperature of 170ºC) and excellent dielectric strength. 

Target applications for this material include insulation for printed circuits, printed circuit board, disk drive, keyboard, inverters and adaptors, die-cut spacers, labels and overlays.

Electromagnetic interference/radio frequency interference (EMI/RFI) shielding is another important benefit provided by Lexan EFR film. As U.S. and European regulatory agencies continue to tighten restrictions on EMI/RFI emissions, electronic device manufacturers are looking for new shielding solutions to replace metal boxes, conductive paints, plating, metal chassis and conductive polymers that add weight and cost. Lexan EFR film provides a low-cost, lightweight solution for both primary and secondary (problem area) shielding, while maintaining UL recognition. 

Lexan EFR film can be easily fabricated using thermoforming, embossing, clean-edge die cutting, scoring and bending. The product is available globally in matte/polish and velvet/matte finishes and various gauges between 100 and 762 microns. 

A diverse portfolio to meet customer needs
SABIC Innovative Plastics offers many other high-performance materials to meet the evolving requirements of the E/E industry. Noryl* EFR PPO film, the company's first non-halogenated flame retardant film offering, available in an opaque black colour, delivers UL 94 listing of V-0 at 0.250mm-0.55mm (0.010"-0.022") thicknesses. It also provides outstanding properties including high puncture resistance, high tensile strength and fold resistance. It may be used in shielding and insulation barriers, printed circuits, die-cut spacers and insulators, overlays and battery packs and adaptors for computers, laptops, mobile phones, portable devices, DVD players, printers, appliances, and audio/video equipments. 

Another important E/E material from SABIC Innovative Plastics is Ultem* polyetherimide (PEI) film, offering excellent dielectric, high-temperature and chemical resistant properties. Both Noryl and Ultem films carry the Blue Angel, EcoMark (Japan), Nordic Swan and TCO-99 labels, successfully passed stringent Verband der Elektrotechnik Elektronik Informationstechnik e.V (VDE) flammability testing for compliance with the IEC 950 (UL1950) standard for electronic equipment.

For further information on  the new, breakthrough Lexan* polycarbonate (PC) film technology - Lexan EFR film, view website: www.sabic-ip.com

SABIC's lightweight Xenoy* and Lexan* resins deliver all-day comfort to the new 3M^™ Versaflo^™ M-Series safety headgear

Because protective gear is only effective when workers use it, 3M^™ has designed a new exceptionally comfortable, ergonomic line of hardhats and helmets made with SABIC's Innovative Plastics business' lightweight Xenoy* and Lexan* OQ optical quality resins. The new 3M Versaflo^™ M-series respiratory headgear product line uses custom-colored Xenoy polycarbonate/polybutylene terephthalate (PC/PBT) resin for headgear shells and visor frames, enabling thin-wall designs which helps reduce the headgear weight by approximately 15-20 percent compared to the company's previous L-series products. Water-clear Lexan OQ PC resin, used for the visors, provides excellent optical qualities and high impact resistance. SABIC's longstanding relationship with 3M demonstrates the company's focus on working side-by-side with customers to help them achieve competitive differentiation and business success.

"Our relationship with SABIC has steadily expanded through collaboration on important new applications such as the Versaflo M-series products," said Al Solyntjes, lead product development specialist, 3M. "The company provided high-performance resins that met our specific requirements, together with value-added analysis, testing and process optimization services that made a significant contribution to the success of this project. Our customers have reported immediate improvements in comfort and protection with Versaflo M-series headgear."

"Our materials can play a key role in the development of next-generation protective gear that workers feel really good about," said James LeGacy, North America general manager, Performance Compounding, Innovative Plastics. "SABIC's versatile, lightweight resins offer designers new ways to enhance comfort, usability and aesthetics, encouraging consistent use and freeing workers to focus on the job - not their headgear. We're proud of our ongoing work with 3M and its potential for increasing on-the-job safety in challenging environments."

Tough Materials for Tough Jobs
The new 3M Versaflo M-series hardhats and helmets - used as part of powered air purifying respirators (PAPRs) and supplied air (SA) respirator systems - are designed for protection in workplaces such as foundries, automotive refinishing facilities, chemical plants and construction sites.

SABIC's materials offer key performance attributes to withstand these demanding work environments. Compared to glass-filled nylon, which 3M initially considered for the headgear shells, Xenoy resin delivers superior low-temperature ductility for consistent impact performance in cold weather. The material also provides low specific gravity combined with excellent flow for thin-wall parts to reduce weight. Xenoy resin is custom-colored by SABIC at its manufacturing facility in Mount Vernon, Indiana, USA. …../Continued on the next page.