Flame-Retardant
Recycled Plastic SORPLAS™
Environmentally
Conscious Material
- Home
- Technology
- Environmentally Conscious Material
- Flame-Retardant Recycled Plastic SORPLAS™ Environmentally Conscious Material
Overview
SORPLAS (Sustainable Oriented Recycled Plastic) is a type of flame-retardant polycarbonate with a high recycled content. It is formed from recovered polycarbonates comprising different material characteristics, such as water bottles and optical discs, blended with an originally developed flame-retardant additive (PSS-K) and other additives to optimally suit required applications (Figure 1).
This originally developed additive can provide polycarbonates with the same level of flame retardancy as other general flame retardants within less than one-tenth of the volume (Figure 2). Therefore, it helps preserve the inherent properties of polycarbonates, such as their strength, flame resistance, and durability.
Technical Features
SSS’s original flame-retardant additive (PSS-K)
This flame-retardant additive has a chemical structure that can further enhance the flame retardancy of polycarbonates even in extremely small amounts. While phosphorus-based and other flame-retardant additives require up to around 12% of the total volume to be mixed, PSS-K can achieve equivalent levels of flame retardancy with less than 1%, resulting in 99% of recycled content. Since the added volume is extremely small, the properties inherently possessed by the plastic can be preserved. This makes it possible to produce flame-retardant resins with properties such as high resistance to heat and impact.
Optimal blends of recycled materials
One of the issues with molding plastic is balancing fluidity and strength. If the viscosity of the material poured into the mold is too hard, the material will not flow throughout the mold and, if it is too soft, the material will be weakened.
With virgin plastics, raw materials that suit the required material characteristics of a specific product can be used but, with recycled materials, measures to utilize the characteristics of the recycled materials themselves are required. Previously, it was very difficult to use plastic with a high percentage of recycled materials for large exterior parts because of the need to ensure extremely accurate moldability and strength, as well as maintain appearance quality such as gloss and color toning.
Overcoming these issues, with SORPLAS the properties of recovered polycarbonates are closely analyzed, and compositions which are aligned to customer demands are created through optimal blends of multiple materials. This allows a balance to be reached between fluidity and strength while maintaining a high recycled material content.
Search for recycled materials with the goal of achieving a sustainable society
With SORPLAS, it becomes possible to realize a sustainable society by using recycled materials. Since recycled materials are generated by the disposal of products intended to enrich society’s lifestyles, changes will also occur in the types of recycled materials that should be used according to product trends.
For example, declining trends can be seen in the amounts of production and consumption of optical discs due to their gradual replacement by digital distribution but, at the same time, there is increasing demand for polycarbonate materials. With SORPLAS, our ongoing search for optimal recycled materials enables high-quality materials while reducing environmental impact, in step with changing demands around the world.
Introduction of SORPLAS manufacturing process
SORPLAS is produced by a very simple process which involves pulverizing and treating recovered materials – such as optical discs and water bottles currently used as raw materials – and then mixing them with Sony’s original flame-retardant additive (PSS-K), coloring agents, and other additives.
This is an introduction to the process, which includes details of the treatment and mixing procedures.
Academic Evaluation and Technological Innovation: SORPLAS Research Achievements
SORPLAS technology has been presented at numerous academic conferences and in professional journals. These research presentations have validated SORPLAS from an academic standpoint, highlighting its potential to reduce environmental impact while enhancing material performance. As a pioneering technology, SORPLAS continues to drive progress toward a more sustainable society.
List of Contributions
- ・nano tech (International Nanotechnology Exhibition & Conference) Special Symposium - January 31, 2025
- Title: Feature and future developments of a flame-retardant recycled polycarbonate resin (SORPLAS)
- Presenter: Akito Kuriyama
- ・Japan Industrial Publishing Co., Ltd. Technical Journal "Plastics" - November 2024 Issue
- Title: Characteristics and Future Development of Flame-Retardant Recycled Polycarbonate (SORPLAS)
- Presenters: Akito Kuriyama, Yasushi Inagaki
- ・73rd Symposium on Macromolecules - September 25, 2024
- Title: Expanding Applications of Waste Polycarbonate through Molecular Weight Control Using Active Hydrolysis
- Presenters: Akito Kuriyama, Yasushi Inagaki
- ・Technical Information Institute Technical Book "Plastic Recycling and Recycled Material Modification Technology" - Published February 29, 2024
- Title: Development Case of Flame-Retardant Polycarbonate with High Recycled Content
- Presenter: Yasushi Inagaki
- ・The Japan Electrical Manufacturers' Association (JEMA) "Presentation on Environmentally Conscious Design" - September 27, 2023
- Title: Development of Flame-Retardant Recycled Plastic SORPLAS™
- Presenter: Takahiro Ohe
- ・Science & Technology Co., Ltd. Technical Book "Development Trends in Recycling Systems and Component Technologies for Expanding Circular Use of Plastics" - Published March 30, 2023
- Title: Development of High Recycled Content Flame-Retardant Polycarbonate SORPLAS™
- Presenter: Yasushi Inagaki
Use Cases
Flat-screen TV housing
As television design trends toward larger and flatter models, needs are changing for the plastic that is used for housings and internal parts. To promptly meet these and other changing needs, Sony continues to develop SORPLAS.
For example, SORPLAS is used today on TV rear covers which have the largest surface area. This resin makes it possible to reduce virgin plastic usage by up to approximately 60% while maintaining high-quality finishes.
Sony is also working on practical "Material-to-Material recycling" to reuse plastic recovered from the rear covers of end-of-life televisions in new TV products.
Laptops
SORPLAS is adopted in various laptop components. It is used for lightweight and durable enclosures, highly reliable internal components, and AC adapters and battery packs that require impact resistance and achieve long-life thermal degradation.
In Getac Technology Corporation's products introduced in 2024, SORPLAS is utilized in components such as the cap tops, hinges, and keyboards that support each laptop’s rugged body and in the power button. The Sony-Getac collaboration continues, applying SORPLAS to various components and developing further use cases.
Applications
This product group is used as environmentally conscious materials in flat-screen TV housing, laptops, and other applications.
his product group is used as recycled plastic in various products in the recycling field.
This product group is used as appliance housing materials for applications such as flat-screen TV housing.
Related Products & Solutions
-
Recycled Plastic
The Flame-retardant Recycled Plastic SORPLAS™ Environmentally Conscious Material
Find out more about the flame-retardant recycled plastic SORPLAS™ environmentally conscious material product used in this sector.
Related Links
Recycled TV Components Utilizing SORPLAS™ for BRAVIA™ Parts
The forefront of recycled plastic development
CJC Topics, Japan Environmental Management Association for Industry Resources Recycling Promotion Center
Award ceremony held for Fiscal 2011 “Awards for Resource-Recycling Technologies and Systems”
SORPLAS is a trademark of Sony Group Corporation. SORPLAS is an environment-oriented plastic developed and provided by Sony Semiconductor Solutions Corporation.
Contact Us
For inquiries about Sony Semiconductor Solutions Group and products / solutions, specifications, quotation / purchase requests, etc., please contact us using the Inquiry form from the button below.