The Flame-retardant Recycled
Plastic SORPLAS™ Environmentally
Conscious Material
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Overview
“SORPLAS”(Sustainable Oriented Recycled Plastic) is a type of flame-retardant polycarbonate with a high recycled content. It is formed from recovered polycarbonates having different material characteristics such as water bottles or optical discs, blended together with an originally-developed flame retardant(PSS-K) and other additives, to optimally suit its required applications (Figure 1).
The flame retardant originally developed by Sony Semiconductor Solutions Corporation can provide polycarbonates the same level flame retardancy as other general flame retardants, but with less than one-tenth of the amount(Figure 2). Therefore, it can preserve the properties inherently possessed by polycarbonates, such as their strength, flame resistance, and durability.
Technical Features
Our original flame retardant (PSS-K)
This flame retardant has a chemical structure that can further enhance the flame retardancy of polycarbonates even in extremely small amounts. Therefore, while phosphorus-based and other flame retardants require up to around a dozen percent of the total amount to be mixed, PSS-K can achieve equivalent levels of flame retardancy with less than 1%, resulting in 99% of recycled content. Since the amount added is extremely small, the properties inherently possessed by 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 issues regarding molding the 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 strength will be weakened.
With virgin plastics, raw materials that suit the material characteristics required by products can be used, but with recycled materials, measures to utilize the characteristics of the recycled materials themselves are required. In particular, it has been very difficult to use plastic with a high percentage of recycled materials for large exterior parts because it is necessary to ensure extremely accurate moldability and strength, as well as the appearance quality such as gloss and color toning.
In order to overcome such issues, with “SORPLAS” the properties of recovered polycarbonates are closely analyzed, and compositions which are aligned to the demands of customers 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
The goal of “SORPLAS” is to realize a sustainable society by the utilization of recycled materials. Since recycled materials are generated by the disposal of products intended to enrich the lifestyles of society, 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 are also polycarbonate materials whose demand is currently increasing.
With “SORPLAS”, we are constantly searching for optimal recycled materials so that we can provide solutions to minimize environmental impacts while maximizing material performance, in accordance with such trends in demand throughout our world.
Introduction of “SORPLAS” manufacturing process
“SORPLAS” is produced by a very simple process which involves pulverizing and treating recovered materials such as discs and water bottles currently used as raw materials, and then mixing them with our original flame retardant (PSS-K), coloring agents, and other additives.
This is an introduction of its process, which includes details on treatment and mixing procedures.
Use Cases
Flat-screen TV housing
As television design trends toward larger and flatter models, the needs for the plastic required for housings and internal parts are changing with the times. To meet these changing needs in a timely manner, we are developing “SORPLAS”.
On some products, “SORPLAS” is used on the rear cover of the television, which has the largest surface area. “SORPLAS” maintains a high finished quality while reducing virgin plastic usage by up to about 50% compared to conventional methods.
Laptop
"SORPLAS" is adopted as various components of laptops. It is used as lightweight and durable enclosures, highly reliable internal components, AC adapters and battery packs that require impact resistance and long-term thermal degradation.
In Getac's products introduced in 2024, "SORPLAS" is utilized in supporting components such as Cap top, Hinge and Keyboard which support their rugged body, as well as the power button. Going forward, we will continue to collaborate with Getac in utilizing "SORPLAS" in various components and develop further use cases.
Applications
This product group is used in the environmentally conscious materials sector for applications such as flat-screen TV housing and laptop.
This product group is used in the recycling sector for applications such as sorting materials and flat-screen TV housing.
This product group is used in the appliance housing materials sector for applications such as flat-screen TV housing.
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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
SORPLAS is a trademark of Sony Group Corporation. SORPLAS is an environment-oriented plastic developed and provided by Sony Semiconductor Solutions Corporation.
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