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MATERIALS & SUSTAINABILITY PRODUCTS


NEW COPOLYMER TO HELP CONSUMER ELECTRONICS INDUSTRY ACHIEVE NET-ZERO EMISSION GOALS


Newly introduced by SABIC is the LNP ELCRIN EXL7414B copolymer, the company’s first bio- based polycarbonate (PC) copolymer. Designed to help advance the consumer electronics industry’s net-zero carbon emissions goals, the new material is the first grade in an expanding portfolio to secure the International Sustainability and Carbon Certification Plus (ISCC+) designation. The copolymer is formulated with over 50% bio-based content from waste materials, which do not compete with the food chain according to the mass balance approach. A preliminary SABIC internal assessment indicates that each kilogram of the new bio-based resin provides two


kilograms of CO2 reduction as compared to the fossil-based alternative. LNP ELCRIN EXL resin joins SABIC’s fast-growing bio-based materials offering, which also includes ULTEM resins and LNP THERMOCOMP compounds. Chinese brand realme (www.realme.com) has chosen the LNP ELCRIN EXL7414B copolymer resin for the battery cover of its new GT 2 Pro smartphone. Demonstrating its continuing innovation, realme is now one of the first electronics companies to use a bio-based copolymer. “Our collaboration with SABIC to successfully incorporate this new bio-based copolymer in our


demanding electronics applications. It uses a non-brominated, non-chlorinated flame retardant formulation that meets the UL 94 V0 standard at 0.6 mm. Both LNP ELCRIN EXL7414 and new LNP


GT 2 series smartphone has helped us achieve competitive differentiation and a stronger sustainability posture,” said Chase Xu, global vice president and chief marketing officer, realme. “The use of bio-based materials is an important selling point for consumers, who increasingly seek out sustainable products. Further, the adoption of LNP ELCRIN EXL copolymer resin has enabled our company to advance its environmental goals without any compromise in product performance. This application is the latest result of our productive, ongoing relationship with SABIC.” In addition to lowering carbon footprint by


reducing the use of fossil-based feedstocks, SABIC’s LNP ELCRIN EXL7414B copolymer resin delivers exceptional performance for


ELCRIN EXL7414B copolymer resins help address the harmonized International Electrotechnical Commission’s new IEC 62368-1 standard, which replaced the previous IEC 60065 Audio Video and IEC 60950 IT Equipment standards with stronger safety requirements. For example, this new standard, which took effect in December 2020, requires hazardous energy sources such as lithium-ion batteries to be contained via built- in safeguards to help prevent the energy from transferring to device users. The excellent processability of the bio-based


LNP ELCRIN EXL7414B copolymer resin enables ultra-thin part designs that save weight and space, and offers opportunities for shorter cycle times and higher throughput vs. standard PC. The new material also provides excellent low-temperature ductility (-40˚C) for impact strength when a device is dropped, and good chemical resistance to withstand ultraviolet (UV)-cured painting.


SABIC www.sabic.com/en COMPANY PROFILE A SUSTAINABLE APPROACH TO THE PLASTIC INJECTION MOULDING PROCESS


Pentagon is committed to its organisational sustainability programme and regularly brings together representatives from all areas of the business to discuss continuous improvement initiatives. In terms of sustainability in its manufacturing process, there are several


considered areas when looking at new products. These can include cutting down waste by the introduction of direct hot tip feed systems or recycling waste back into production at controlled levels. The design for manufacture (DFM) stage is where the company actively


considers the suitability of recycled materials or bio polymers as opposed to specified virgin materials. Where looking at moulding projects for equipment used within the medical environment and for products in other industry sectors, there are more environmentally friendly thermoplastic options available. Many customers approach the company with a specified grade of thermoplastic suitable for their product which has been researched and sourced by their design team for both environmentally and sustainability considerations. Pentagon will, however, highlight alternatives should it believe that there would be a comparable and suitable suggestion for the products that meet the needs of its end use. The mould shop processes recycled Polypropylene, ABS and Polycarbonate, which currently have a combined annual usage of around 6.5 tonnes. It also looks at other elements such as coring out of a product to reduce the volume of plastic used for product manufacture. Pentagon adopts a conscientious approach to mould tool design with a keen


focus on negating the need for waste plastics in processing. Optimal cavitation, utilisation of hot runner systems, minimising waste, improving yields, and optimising the process are all considerations. Through a measured and documented trialling process, its moulding


technicians ensure that all trial settings and its effects are recorded so as not to repeat processing errors causing excess waste at the development phase. Once optimum processing settings are achieved, all documentation is held against product records for reference. Should any processing issues manifest in future production runs, the company ensures they are documented, and process


improvements are implemented. When a customer’s product


reaches the final production stages, the technicians deliver process optimisation to eliminate production of waste product. Regular patrol inspections ensure any product that is substandard is picked up at the earliest opportunity and any processing issues are rectified. Having several experienced quality


inspectors allows Pentagon to operate a concise waste mitigation programme through quality control, continual monitoring and working to reduce scrappage throughout the injection moulding process. Scrap rates are monitored and recorded, where viable waste product is reground on site and used for the manufacture of company trade show giveaway’s, or disposed of appropriately according to specific regulations. In broader terms of the business, its Sustainability Committee are also


working on a number of other initiatives including: • Conscientious purchasing of new equipment and machinery • Sustainable packaging options • Instillation of hand dryers • Paperless process and print reduction • Installation of mains water drinking machines • Conscientious stationary and sundry supplies • Supply partners with detailed sustainability and ethical commitments. As a UK manufacturer, Pentagon recognises its environmental responsibility


and that consideration needs to flow through all areas of the business in order to ensure it is maximising its sustainability efforts.


Pentagon T: 01403 264397 sales@pentagonplastics.co.uk. FEBRUARY 2022 DESIGN SOLUTIONS 15


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