The Flame-retardant Recycled Plastic SORPLAS™ Environmentally Conscious Material
Technology
Environmentally Conscious Material

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.

Figure 1: Development of SORPLAS through optimal blending to suit applications

Figure 1: Development of SORPLAS through optimal blending to suit applications

Figure 2: Amount of various flame retardants added to make PC flame retardant

Figure 2: Amount of various flame retardants added to make PC flame retardant

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.

Figure 3:Manufacturing process of virgin PC and SORPLAS

Figure 3:Manufacturing process of virgin PC and SORPLAS

Applications

Environmentally Conscious Material

This product group is used in the environmentally conscious materials sector for applications such as flat-screen TV housing.

Recycle

This product group is used in the recycling sector for applications such as sorting materials and flat-screen TV housing.

Housing Material

This product group is used in the appliance housing materials sector for applications such as flat-screen TV housing.

Related Products & Solutions

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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