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The PV market is one of the most dynamic global sectors, with compounded annual growth rates above 20 percent1 and significant attention as a viable and growing mainstream alternative energy source. "SABIC provides specialized materials that enable our photovoltaic customers to improve the value of solar energy as a cost-effective environmental solution," said Andrew Kodis, solar marketing director, Innovative Plastics. "Our focus on the photovoltaic market reflects SABIC's active support for environmental trends such as alternative energy, which depend upon technological breakthroughs to make them economically feasible. Our broad portfolio of materials contributes to sustainability in many different ways, particularly by enabling new design approaches."
Several factors are now converging to drive miniaturization in the photovoltaic industry, including efficiency advancements and increased home use of solar panels, calling for flatter, unobtrusive and sometimes integrated designs. "As leaders in the development of polycarbonate for nearly 60 years, we are able to leverage our deep knowledge and industry expertise to foster innovations in solar that help our customers achieve their sustainability objectives," Kodis said.
Industry-leading Electrical and Flame Retardant Performance
The new Lexan EXL 9330S grade surpasses traditional materials in its electrical performance as demonstrated by a comparative tracking index (CTI) Underwriter's Laboratory (UL) standard with PLC-2 rating. Compliance with this tough standard means Lexan EXL 9330S copolymer resists arcing in the presence of moisture and salts and, therefore, can be used in parts that are placed closer together (4 mm vs. 12 mm under Class 3). The flame-retardant material also complies with the UL94 V0 standard at 0.8 mm, allowing thinner-wall parts to be designed.
In addition, Lexan EXL 9330S copolymer provides exceptional low- and high-temperature impact resistance (from -40 °C to 70 °C) and corrosion resistance for good long-term performance and weatherability in a range of demanding outdoor environments.
Potential for System Cost Reduction
With its processing advantages of easy flow for cost-effective thin-wall designs and high throughput, plus easy release from the mold, Lexan EXL 9330S copolymer can reduce the total injection molding cycle time by up to 40 percent.
Pottants and sealants are used in the PV industry to attach the junction boxes and connectors to the solar panel. Alcohol based sealants and pottants are typically compatible with Lexan EXL materials and are recommended for use with the same².
Expanding SABIC's PV Portfolio
This new grade is part of SABIC's portfolio of high-performance, versatile materials for the PV industry. They include Noryl* resin, which provides low density, dimensional stability over a wide temperature range (-40 °C to 140 °C), low warpage, excellent long-term weathering, damp heat performance with exceptional stability of up to 2,000 hours, and outstanding electrical and thermal performance. These properties make it suitable for use in PV junction boxes. Noryl resin also meets the industry's critical need for a long-lasting, outdoor-resistant material. Internal tests show that glass-filled and unfilled Noryl resins can withstand 12,000 hours of ultraviolet exposure. In addition, existing Lexan EXL 9330 and Lexan EXL 9330P materials provide low temperature impact and other benefits similar to Lexan EXL 9330S copolymer. While Lexan EXL 9330 and Lexan EXL 9330P materials are used in designs calling for CTI PLC-3 rated materials, the newly introduced Lexan EXL 9330S copolymer will suit designs that demand CTI PLC-2 properties.
Ultem* resins and LNP* specialty compounds are also being used for internal junction box parts and special connectors. Temperatures in these applications may go up to 180 °C or beyond and dimensional stability requirements are even more stringent. Commercial grades of Ultem resin and LNP compounds have been implemented successfully in PV applications from key industry players.
Innovative Plastics offers its PV customers a combination of high-performance resin technology and application design and development support. The company has a history of successfully translating metal to plastic and work closely with customers to help validate the use of its materials with extensive practical testing. SABIC also works closely with regulatory bodies to help ensure that the economical use of the company's resin technology will meet the performance requirements of PV systems.
Saudi Basic Industries Corporation in profile
Saudi Basic Industries Corporation (SABIC) ranks among the world's top petrochemical companies, and is a global market leader in the production of polyethylene, polypropylene, advanced thermoplastics, glycols, methanol and fertilizers. SABIC manufactures with a global footprint in Saudi Arabia, the Americas, Europe and Asia Pacific. The company operates in more than 40 countries across the world with 33,000 employees worldwide. It has significant research resources with 18 dedicated Technology & Innovation facilities in Saudi Arabia, the USA, the Netherlands, Spain, India and China. SABIC recorded a net income of SR 21.59 billion (US$ 5.73 billion) in 2010, and sales revenues totaled SR 152 billion (US$ 40.5 billion).
Innovative Plastics in profile
SABIC's Innovative Plastics strategic business unit is a leading, global supplier of engineering thermoplastics with an 80-year history of breakthrough solutions that solve its customers' most pressing challenges. Today, Innovative Plastics is a multi-billion-dollar company with operations in more than 35 countries and approximately 9,000 employees worldwide. The company continues to lead the plastics industry with customer collaboration and continued investments in new polymer technologies, global application development, process technologies, and environmentally responsible solutions that serve diverse markets such as automotive, electronics, building & construction, transportation, and healthcare. The company's extensive product portfolio includes thermoplastic resins, coatings, specialty compounds, film, and sheet. Innovative Plastics is a wholly owned subsidiary of Saudi Basic Industries Corporation (SABIC).
* Trademarks of SABIC Innovative Plastics IP B.V.
1) "A Bright Future Shines on the Solar Photovoltaic Electricity Market", European Photovoltaic Industry Association Press Release, April 12, 2010.
2) Several alcohol based sealants and pottants have been tested to be compatible with Lexan EXL copolymers. Please contact your local SABIC representative for specific details. In all cases extensive testing of the finished part under actual service conditions is strongly recommended. The performance and interpretation of end-use testing are the end-producer's responsibility.
For further information on SABIC's products for photovoltaic applications, view website: www.sabic-ip.com
For technical product inquiries, view website: www.sabic-ip.com/prtechinquiry
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SABIC Innovative Plastics' mission to help customers drive down system costs while achieving exceptional performance with high-end thermoplastics has led to another industry game-changer - Lexan* XHT clear, high-temperature polycarbonate (PC) copolymers. This innovative family of advanced PC resins features new polymer chemistry with an optimal balance of high heat resistance and high flow, enabling it to offer greatly expanded design options for molding thin-wall parts such as medical devices and electrical fuses. Lexan XHT copolymers also offer excellent clarity and colorability, making them top choices for applications like consumer and industrial lighting and heat shields. They are part of SABIC Innovative Plastics' growing Lexan copolymers portfolio built on the technology foundation laid by Lexan PC resin's 50-year track record.
"With Lexan XHT copolymers, SABIC Innovative Plastics is delivering on a previously unmet market need for a true high-heat resin technology with a near perfect balance of properties vs. other clear, high-heat materials," said Bala Ambravaneswaran, product marketing director, Lexan Copolymers & Special Effects, SABIC Innovative Plastics. "These innovative materials give our customers the high-tech yet practical solutions they need to succeed in new high-performance applications. Following the success of Lexan XHT copolymers in automotive lighting, we are quickly moving into diverse and equally challenging application areas."
Clear Resin delivers highest performance for extreme heat conditions
Lexan XHT copolymers address the need for PC-based materials with end-use temperatures in the range of 140C to 195C. They deliver an industry-leading relative thermal index (RTI) Underwriters Laboratories (UL) rating of 150C, surpassing polyarylate (PAR), polymethyl methacrylimide (PMMI) and other high-heat polycarbonates (HHPC). This exceptional high-temperature performance is achieved through proprietary chemistry that alters the polymer backbone by incorporating specialized monomers.
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Copolymers offer higher performance than compounds, blends and additives, which are not chemically integrated.
Lexan XHT copolymers surpass competitive high-heat materials in other key areas: Lower color shift on ultraviolet (UV) weathering vs. PAR Better color stability under heat aging vs. HHPC Improved tensile and impact strength retention after heat aging vs. HHPC Better resistance to cracks and haze after metallization than HHPC Improved flame retardancy vs. PC, PMMI and HHPC. Compliance with eco protocols and UL94 capability down to V0 at 1mm and 5VA at 3mm in clear and opaque colors Electrical properties suitable for high-heat film applications.
Comparable alternate materials show marked yellowing and haze after extended exposure to heat and UV light, impacting the appearance of the application. In contrast, Lexan XHT copolymers minimize color shift and retain clarity over a long lifespan. The high-heat color stability and clarity of Lexan XHT copolymers make them an excellent candidate for applications including aesthetic and functional enclosures for industrial and commercial lighting, consumer products such as heat resistant helmets and heat shields, electrical components such as fuses, and non-biocompatible healthcare devices that must undergo autoclaving.
These materials have already been proven in automotive applications including bezels, reflectors and lens covers where they enable direct metallization, which eliminates the costs and environmental impact from pre-coating the part with paint or lacquer. When vacuum-metalized, parts made from Lexan XHT copolymers can withstand temperatures of up to 175C without blistering, hazing, delaminating or losing their brilliant luster.
Lexan XHT resins are available in a variety of colors with a clear or opaque base. Special visual effects such as diffusion, metallic and sparkle for custom needs, in challenging applications such as industrial lighting, and glass replacement are also available.
Up to 30 percent higher flow and less scrap reduce system costs
To help designers reduce size, mass and weight, and create thinner-walled flame-retardant parts such as housings for consumer electronics, Lexan XHT copolymer grades offer improved flow characteristics for injection molding. These materials deliver a 30 percent longer flow length and better mold release than competitive high-heat materials, which help decrease melt temperatures and cooling requirements and cut cycle times by as much as 25 percent. In a heat-critical thin wall battery cover application, Lexan XHT resin was able to fill a part with 0.7mm nominal wall thickness.
Further, Lexan XHT copolymers can be recycled, allowing scrap to be reused in molding to raise yield and lower net costs. For example, because these materials can be direct-metalized without lacquering, scrap can be reused in the molding process. These properties can significantly reduce system costs, enabling a competitive advantage for customers.
For further information, view website: www.sabic-ip.com Refer to next page
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