Composites: Resins, Fillers, Reinforcements, Natural Fibers & Nanocomposites

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Composites: Resins, Fillers, Reinforcements, Natural Fibers &
Nanocomposites
Published on January 2011

Report Summary

The North American fiber-reinforced plastic/composite market is estimated at 2.7 billion pounds in 2010 and is expected to increase to
about 3.1 billion by 2015, reflecting a 2.8% compound annual growth rate (CAGR).

Construction/infrastructure and automotive products are the key applications of this market since they comprise about 60% of total
volume. This sector is valued at 836 million pounds in 2010 and is expected to reach 963 million pounds in 2015, a 2.9% compound
annual growth rate (CAGR).

The largest growth will be experienced by the very low volume aerospace market led by the introduction of composite commercial
aircraft exterior parts such as fuselages and wings. This sector is estimated at 20 million pounds in 2010 and should increase at a 7%
compound annual growth rate (CAGR) to reach 28 million pounds in 2015.

INTRODUCTION

REASONS FOR DOING THE STUDY

The emergence of new technologies and markets warrants a reappraisal of the reinforced plastics market, often called
“composites.” Nanocomposites and long-fiber reinforced thermoplastics are the two most prominent and potentially
commercially important examples that have begun to impact this market.

In addition, a review of reinforced plastics is needed with a view towards appropriately segmenting the major components of this
market into its resin, technology, and applications components. Fillers and reinforcements need to be carefully defined when it comes
to their principal functions and effects on properties of substrate resins since many terms and market estimates used within this
industry are not clear cut.

Another important reason for undertaking this report is to assess the current and future scenario of this market in terms of the current
financial recession, which has had an enormous impact on two of the largest applications of reinforced plastics, namely construction
and automotive.

SCOPE OF THE STUDY

This report covers usage of both thermosets and thermoplastics that use fillers and reinforcements to increase their respective
property profiles. Fillers will be differentiated from reinforcements, which in turn, will include both fibrous and non-fibrous variants.

The term “fillers/reinforcements” will be used when generally referring to these materials as in most literature
references, mainly because many nontechnical sources often do not distinguish fillers from reinforcements. For the purposes of this

Composites: Resins, Fillers, Reinforcements, Natural Fibers & Nanocomposites Page 1/24


report, the following are defined as fillers and not reinforcements: aluminum trihydrate (ATH), barium sulfate, calcium carbonate, and
kaolins. Talcs, mica, silicas, and wollastonite are treated as non-fibrous reinforcements. Fibrous reinforcements will include all glass
fiber variants, carbon, boron, ceramic, aramid, and stainless steel fibers, and so forth. The major exception will be nanocomposites,
which are based on fillers and will be included in the study. There have been quite a few lengthy reports based solely on composites.

A basic premise in distinguishing between a “filler” and a “reinforcement” is whether the primary function
of the material is used to enhance property profiles of substrate resins. If the answer is “yes,” then it can be considered
a “reinforcement.” This definition is, of course, arbitrary, especially since in many cases mineral “fillers”
are used in conjunction with fibrous materials, most notably glass.

Another source of confusion is the constant overlapping of the terms “reinforced plastics” and
“composites.” One distinction between these two terms, cited by some within the industry, is that the latter refers to
those reinforced resins that can “support a load” or are “structurally reinforced.” This definition is also
arbitrary.

Therefore, in this report, the terms “reinforced plastics” and “composites” will be used interchangeably
unless specifically designated by suppliers or in the trade literature as one or the other. In other instances, the term “reinforced
plastics/composites” will be used.

Current and forecasted quantitative market estimates will be provided for all appropriate thermoset and thermoplastic fiber-reinforced
resins by application, along with detailed descriptions of the major types of reinforcements. Fillers will be discussed in detail as well,
but will not be considered in the quantitative analysis of reinforced plastics/composites. It should also be pointed out that many
compounded resin formulations contain both fillers and reinforcements and many glass fiber reinforced resins contain other fibrous
and non-fibrous minerals.

Furthermore, the volumes of product shown in the tables refer only to the estimated weight of the resins and exclude weights of
reinforcements. The quantitative information contained in all data tables refers to the North American market, although there will be a
great deal of information provided for the global market.

Applications covered will include: automotive; construction/infrastructure including anti-corrosion and panel products; marine markets;
aerospace; electronic parts/components; appliances; consumer products (sport and leisure, lawn/garden products, etc.); and a
miscellaneous category including the power market, wind energy products, medical, and others.

METHODOLOGY

Both primary and secondary research methodologies were used in preparing this study. A comprehensive review and analysis was
undertaken of literature related to this industry, which is known by several names (e.g., reinforced plastics, composites, etc.). This
analysis included resins, applications, markets, technology, producers and suppliers, trade named products, new developments,
environmental issues, and so forth. Follow up calls were made to key contacts within the industry to clarify and/or expand on key
issues pertinent to the reinforced plastics/composites industry.

Table of Content

Chapter- 1: INTRODUCTION

REASONS FOR DOING THE STUDY 1



SCOPE OF THE STUDY 1
METHODOLOGY 2
ABOUT THE AUTHOR 3
RELATED BCC REPORTS 3
BCC ONLINE SERVICES 3
DISCLAIMER 3

Chapter-2: SUMMARY

SUMMARY TABLE NORTH AMERICAN FIBER REINFORCED PLASTIC MARKET BY APPLICATION, THROUGH 2015 (MILLION
POUNDS) 4
SUMMARY FIGURE NORTH AMERICAN FIBER REINFORCED PLASTIC MARKET BY APPLICATION, 2009-2015 (MILLION
POUNDS) 5
SUMMARY (CONTINUED) 6

Chapter-3: FILLERS AND REINFORCEMENTS

BACKGROUND 7
PROPERTY PROFILES 7
CHARACTERISTICS OF FILLERS/REINFORCEMENTS 8
TABLE 1 PROFILE OF CHARACTERISTICS OF FILLERS/REINFORCEMENTS 8
TABLE 2 OVERVIEW OF CHARACTERISTICS AND APPLICATIONS OF FILLERS/REINFORCEMENTS 9
FILLER/REINFORCEMENT USAGE WITH SPECIFIC RESINS 10
TABLE 3 FILLER/REINFRORCEMENT USAGE WITH SPECIFIC RESINS 10
FILLERS 11
OVERVIEW 11
ALUMINA TRIHYDRATE (ATH) 11
Background 11
Properties 11
Grades 12
A Recent Development 12
BARIUM SULFATE 12
CALCIUM CARBONATE 12
Background 12
Grades 13
As Plastic Fillers 13
Automotive Applications 13
CALCIUM SULFATE 13
Background 13
Applications 14
KAOLINS 14
Background 14
Grades 14
REINFORCEMENTS 15
OVERVIEW 15
NON-FIBROUS 16
Talcs 16
Background 16
Grades 16



Applications 17
Mica 17
Background 17
Properties 17
Applications 18
Thermosets 18
Thermoplastics 18
Wollastonite 18
Background 18
Applications 19
Silicas 20
FIBROUS 20
Background 20
Reinforcement Types 20
Overview 20
Mats 20
Woven Fabrics 21
Knitted Fabrics 21
Braids 21
Preforms 21
Glass-Fiber Reinforcements 21
Production 21
Types of Fiberglass 22
Background 22
Types of Glass Fibers 22
Sizing 23
Microspheres 23
Background 23
Solid Microspheres 23
Hollow Microspheres 23
TABLE 4 ADVANTAGES OF SOLID GLASS MICROSPHERES 24
Applications 24
New Development 24
Glass Fiber Suppliers 24
TABLE 5 GLASS FIBER SUPPLIERS 25
Carbon Fibers 25
Background 25
Manufacture 26
Product Types 26
Applications 27
Largest Users of Carbon Fiber Reinforced Plastics 27
The Military 27
Commercial Aircraft 28
Producers 28
Recent Developments 28
Usage in Non-Sports Cars 28
BMG Developments 28
Metallized Carbon Fibers 29
End-of-Life Recycling 29
Aramid Fibers 29



Background 29
Production 30
Properties 30
Usage 30
Ceramic Fibers 30
Background 30
Applications 31
Suppliers 31
Boron Fibers 31
Stainless Steel Fibers 32
Natural Fibers 32
Background 32
Background (Continued) 33
Types of Natural Fibers 34
Overview 34
Flax Fibers 34
Jute Fibers 34
Kenaf Fibers 34
Hemp Fibers 35
Global Cultivation of Selected Natural Fibers 35
TABLE 6 GLOBAL PRODUCTION OF SELECTED NATURAL FIBERS 35
Source: Trade literature 35
Processing 35
Comparison with Glass Fibers 36
Pricing 37
Review of Possible Stumbling Blocks to Natural Fiber Reinforcements 37
Suppliers of Natural Fibers 37
Composite Products 37
Flexform Technologies 37
Quadrant Plastic Composites 38
Overview 38
Other Potential Applications 39
New Advances 39
Sabic IP 39
In-Line Compounding and Molding of Biocomposites 39
Use of Sunflower Hull Fibers 40
Bamboo Fiber Reinforcement Usage 40
RheTech Introduces Biocomposite 40
Market Estimates and Forecasts 40
NANOCOMPOSITES 41
BACKGROUND 41
CHARACTERISTICS 42
BENEFITS 42
MECHANICAL ASPECTS 42
PROCESSES 43
EARLY WORK WITH PLASTICS 43
APPLICATIONS 43
CARBON NANOTUBES 44



NANOCOMPOSITE SUPPLIERS 45
TABLE 7 SELECTED NANOCOMPOSITE SUPPLIERS 46
RECENT NANOCOMPOSITE CONFERENCE 46

Chapter-4: REINFORCED PLASTICS

BACKGROUND 47
THERMOSETS 48
OVERVIEW 48
TABLE 8 SELECTED PROPERTIES AND MANUFACTURING PROCESSES OF REINFORCED THERMOSETS 48
PROCESSING 49
Background 49
Hand Lay-Up 49
Spray-Up 49
Pultrusion 49
Filament Winding 50
Reinforced Reaction Molding (RRIM) 50
SHEET MOLDING COMPOUNDS (SMC) 51
Background 51
Advantages 51
SMC Process Choices 51
SMC Formulations 52
TABLE 9 TYPICAL SMC FORMULATION (WEIGHT PERCENT) 52
Technology 52
Advantages 53
SMC Compounders 53
TABLE 10 SELECTED KEY SMC PRODUCERS 53
Markets 54
Other Process Challenges 54
Use of Nanoparticles 54
Applications 54
TABLE 11 SPECIFIC SMC AUTOMOTIVE EXTERIOR APPLICATIONS 54
New Developments 55
SMC Products for Mass Transit 55
Other IDI SMCs 55
Direct Process for Mixing and Molding SMC 55
A New SMC Center 55
BULK MOLDING COMPOUNDS (BMC) 55
Overview 55
Background 56
Technology 56
Advantages 56
Applications 57
BMC Compounders 57
New Developments 57
Bulk Molding Compounds, Inc. 57
New Starfire Products 58
THERMOPLASTICS 58
BACKGROUND 58
REINFORCEMENT DETAILS 59



COMMODITY THERMOPLASTICS 59
Background 59
Polypropylene 59
Background 59
Upgraded Polypropylene 60
Polypropylene Producers 60
TABLE 12 U.S. MARKET SHARES OF LEADING GLOBAL POLYPROPYLENE PRODUCERS 61
Fiber-Reinforced Polypropylene Products 61
TABLE 13 KEY FIBER-REINFORCED POLYPROPYLENE PRODUCTS 61
Examples of Reinforced Polypropylene Product Lines 62
New Products and Developments 62
Ticona 62
Use of Banana/Glass Fibers 63
Bamboo Fiber Reinforced Polypropylene 63
Use of Wheat Straw Fibers with Polypropylene 63
RTP New Long-Glass Polypropylene for Automotive Products 63
Quadrant's GMT 63
Ferro's New Products 64
PolyOne's New Reinforced Polypropylenes 64
Asahi Plastics Short Glass Polypropylene 64
Lower Density Reinforced Polypropylenes from Borealis 64
Sabic Europe Adds Stamax Products 64
Polyethylenes 65
Background 65
Need for Additives 65
Polyethylene Producers 65
TABLE 14 SELECTED MAJOR GLOBAL HDPE PRODUCERS AND CAPACITIES 66
High Density Polyethylene (HDPE) 66
Reinforced Polyethylenes 67
Some Details on Commercial Reinforced HDPEs 67
Spartech 67
Ticona's Celstran Additions 67
Flax-Fiber Reinforced Polyethylenes 68
Cellulose Fiber HDPE Composites 68
Polyvinyl Chloride 68
Overview 68
Forms of PVC 68
Processing 69
Background 69
Extrusion 69
Calendering 69
Consumption Patterns 69
Producers 69
Reinforced PVC 70
TABLE 15 NORTH AMERICAN MARKET FOR FIBER-REINFORCED COMMODITY THERMOPLASTICS, THROUGH
2015 (MILLION POUNDS) 70
TABLE 16 NORTH AMERICAN MARKET FOR FIBER-REINFORCED POLYETHYLENE BY APPLICATION, THROUGH
TABLE 17 NORTH AMERICAN MARKET FOR FIBER-REINFORCED POLYPROPYLENE BY APPLICATION, THROUGH



TABLE 18 NORTH AMERICAN AUTOMOTIVE MARKET FOR FIBER-REINFORCED POLYPROPYLENE, THROUGH 2015
(MILLION POUNDS) 72
POLYSTYRENE 72
General Purpose Polystyrene 72
High Impact Polystyrene (HIPS) 72
Background 72
Properties 73
Applications 73
Styrenic Polymer Producers 73
The New Domestic Styrenic Scenario 74
Processing 75
Overview 75
TABLE 19 FABRICATION METHODS AND USES FOR POLYSTYRENE 75
Injection Molding 75
Extrusion 75
Reinforced Polystyrene Products 76
TABLE 20 NORTH AMERICAN MARKET FOR FIBER-REINFORCED POLYSTYRENE MARKET BY APPLICATION, THROUGH
ACRYLONITRILE-BUTADIENE-STYRENE (ABS) 77
Background 77
Properties 77
Processing 77
Grades 78
Producers 78
Overview 78
Capacities 78
TABLE 21 ESTIMATES OF SELECTED ABS PRODUCERS AND CAPACITIES (MILLIION POUNDS) 78
Applications 79
Reinforced ABS Products 79
Examples of Reinforced ABS Products 79
TABLE 22 NORTH AMERICAN MARKET FOR FIBER-REINFORCED ABS BY APPLICATION, (MILLION POUNDS) 80
STYRENE MALEIC ANHYDRIDE (SMA) 80
Background 80
Fiber-Reinforced SMA 81
TABLE 23 NORTH AMERICAN MARKET FOR FIBER-REINFORCED SMA BY APPLICATION, THROUGH 2015 (MILLION
POUNDS) 82
ENGINEERING THERMOPLASTICS (ETPS) 82
Background 82
Nylon 82
Background 82
Properties 83
Major Types 83
Nylon 66 83
Nylon 6 83
Producers and Capacities 84
TABLE 24 NYLON PRODUCERS AND CAPACITIES (MILLION POUNDS PER YEAR) 84



Fiber-Reinforced Nylons 84
Examples of Commercial Reinforced Nylons 85
TABLE 25 SELECTED EXAMPLES OF COMMERCIALLY IMPORTANT FIBER REINFORCED NYLONS 85
New Developments 85
Filament Wound Nylon 85
Lanxess New Product 86
BASF Enters Long-Glass Fiber Reinforced Nylon Market 86
Cold Weather Reinforced Nylon 86
Ube Industries' New Reinforced Nylons 86
Reinforced Nylon Cell Phone Housings 86
TABLE 26 NORTH AMERICAN MARKET FOR FIBER-REINFORCED NYLON BY APPLICATION, THROUGH 2015 (MILLION
POUNDS) 87
TABLE 27 NORTH AMERICAN MARKET FOR FIBER-REINFORCED NYLON IN THE AUTOMOTIVE MARKET, THROUGH
Polybutylene Terephthalate (PBT) 87
Background 87
Properties 88
Applications 88
Producers 89
TABLE 28 GLOBAL PBT PRODUCERS AND CAPACITIES (MILLION POUNDS) 89
Fiber-Reinforced PBT Products 89
TABLE 29 EXAMPLES OF REINFORCED PBT PRODUCTS 90
Polyethylene Terephthalate (PET) 90
Overview 90
Engineering-Grade PET 91
Reinforced PET 91
Examples of Reinforced PET Products 92
TABLE 30 REINFORCED PET PRODUCTS 92
TABLE 31 NORTH AMERICAN MARKET FOR FIBER-REINFORCED THERMOPLASTIC POLYESTER BY APPLICATION,
THROUGH 2015 (MILLION POUNDS) 93
TABLE 32 NORTH AMERICAN MARKET FOR FIBER-REINFORCED THERMOPLASTIC POLYESTER IN THE AUTOMOTIVE
MARKET, THROUGH 2015 (MILLION POUNDS) 93
Polycarbonates 94
Background 94
General Grades 94
Impact of Bisphenol A on Polycarbonate Usage 94
Processing 94
Properties 95
TABLE 33 NORTH AMERICAN POLYCARBONATE PRODUCERS AND CAPACITIES (MILLION POUNDS/YEAR) 96
Fiber-Reinforced Polycarbonates 96
TABLE 34 SELECTED EXAMPLES OF COMMERICALLY IMPORTANT REINFORCED POLYCARBONATES 96
A New Development 96
TABLE 35 NORTH AMERICAN MARKET FOR FIBER-REINFORCED POLYCARBONATE BY APPLICATION, THROUGH



Polyacetals 97
Background 97
Grades 98
Properties 98
Processing 99
Producers 99
Examples of Polyacetal Reinforced Products 99
Polyphenylene Sulfides (PPS) 100
Background 100
Properties 100
Advantages and Disadvantages 101
Producers 101
Applications 101
PPS Fiber-Reinforced Products 102
TABLE 36 SELECTED REINFORCED POLYPHENYLENE SULFIDE PRODUCTS AND SUPPLIERS 102
New Developments 102
Ticona's New Fortron Reinforced Grades 102
Celanese Expands Production 102
TABLE 37 NORTH AMERICAN MARKET FOR FIBER-REINFORCED POLYPHENYLENE SULFIDE, BY APPLICATION,
Polyimides/PEI/PAI 103
Background 103
Properties 103
Polyetherimides (PEIs) 104
Polyamideimides (PAIs) 104
New Products 104
PAI Grades Show Wear-Resistant Properties 104
Overall Polyimide Fiber-Reinforced Products 105
TABLE 38 NORTH AMERICAN MARKET FOR FIBER-REINFORCED POLYIMIDE, BY APPLICATION, THROUGH 2015 (MILLION
POUNDS) 105
Liquid Crystal Polymers (LCPs) 105
Background 105
Properties 105
Applications 106
LCP Fiber-Reinforced Products 106
Polysulfones 107
Background 107
Types of Polysulfones 107
Grades 108
Properties 108
Applications 108
Producer Scenario 109



BASF 109
Solvay 109
Sumitomo Chemical 110
Polysulfone Fiber-Reinforced Products 110
Polymer Alloys/Blends 110
Background 110
PC/ABS 111
Background 111
Grades and Properties 111
Applications 111
Reinforced Grades 112
PPO/HIPS 112
Background 112
Grades 112
Applications 113
PPO/Nylon 113
Background and Properties 113
Grades and Applications 114
PC/PBT 114
Background 114
Properties 114
Applications 115
PC/PET 115
Fiber-Reinforced Polymer Alloy/Blend Grades 115
TABLE 39 NORTH AMERICAN MARKET FOR FIBER-REINFORCED POLYMER ALLOYS/BLENDS, BY APPLICATION,
Other Engineering Thermoplastics 116
Styrene Acrylonitrile (SAN) 116
Background 116
Producers 117
Fiber-Reinforced SAN Products 117
Polyketones 118
Background 118
Properties 118
Applications 118
Polyketone Composites 119
New Products 119
Vertec Polymers 119
Fiber-Reinforced PEEK Sheet Products 119
RTP Advances 119
TABLE 40 NORTH AMERICAN MARKET FOR MISCELLANEOUS FIBER-REINFORCED THERMOPLASTICS, BY APPLICATION,
MARKET SUMMARY FOR FIBER-REINFORCED THERMOPLASTICS 120
TABLE 41 NORTH AMERICAN MARKET FOR TOTAL FIBER-REINFORCED THERMOPLASTIC, THROUGH 2015 (MILLION
POUNDS) 121



Chapter-5: OTHER IMPORTANT GROUPINGS OF REINFORCED PLASTICS

OVERVIEW 122
GLASS MAT THERMOPLASTICS (GMTS) 122
OVERVIEW 122
BACKGROUND 122
TECHNOLOGY 123
SUPPLIER SCENARIO 123
APPLICATIONS 123
LONG-FIBER REINFORCED THERMOPLASTICS (LFRTS) 124
BACKGROUND 124
OVERVIEW 124
PROPERTIES 124
TECHNOLOGY 125
TWINTEX PRODUCTS 125
ADVANTAGES OF LFRTS 126
LIMITATIONS 126
RESIN MATRICES 126
SUPPLIERS 127
StaMax 127
Ticona Developments 127
APPLICATIONS 128
OTHER NEWS 128
Celanese Buys a LFRT Producer 128
EXAMPLES OF COMPANY PRODUCTS 128
RTP 128
Ticona's Celstran 128
A Key Borealis LFRT 129
LNP LFTPs 129
PolyOne Corporation 129
LFRTs for Thermoforming 129
BASF Becomes a Nylon LFRT Supplier 130
DEMAND 130
TABLE 42 GLOBAL LFTP DEMAND (AS PERCENT OF TOTAL) 130
MARKET ESTIMATES AND FORECASTS 130
THERMOSET RESINS 131
OVERVIEW 131
FIBER-REINFORCED GRADES 131
GENERAL PROPERTIES 132
TABLE 43 FIBER-REINFORCED THERMOSET PROPERTIES AND MANUFACTURING PROCESSES 132
UNSATURATED POLYESTERS 132
Background 132
Ingredients of Unsaturated Polyester Formulations 133
TABLE 44 INGREDIENTS OF UNSATURATED POLYESTER RESIN FORMULATIONS IN DESCENDING ORDER OF
COMMERCIAL USE 133
Types of Unsaturated Polyesters 133
Applications 134
Overview 134
Construction/Infrastructure 134
Bathroom Products 134



Corrosion-Resistant Products 134
Marine Products 135
Transportation 135
Other Applications 135
Non-Reinforced Unsaturated Polyesters 135
Examples of Commercial Reinforced Unsaturated Polyesters 135
TABLE 45 KEY COMMERCIAL REINFORCED UNSATURATED POLYESTERS 136
Soybean Unsaturated Polyesters 136
Biobased Unsaturated Polyesters 136
TABLE 46 NORTH AMERICAN MARKET FOR FIBER-REINFORCED UNSATURATED POLYESTERS BY APPLICATION,
TABLE 47 NORTH AMERICAN MARKET FOR FIBER-REINFORCED UNSATURATED POLYESTER IN THE CONSTRUCTION
MARKET, THROUGH 2015 (MILLION POUNDS) 137
TABLE 48 NORTH AMERICAN MARKET FOR FIBER-REINFORCED UNSATURATED POLYESTER AUTOMOTIVE MARKET,
VINYL ESTERS 138
Background 138
Technologies 138
Properties 139
Characteristics 139
Applications 139
Differences between Unsaturated Polyesters and Vinyl Esters 140
Commercially Important Reinforced Vinyl Esters 140
TABLE 49 KEY COMMERCIAL REINFORCED VINYL ESTERS 140
New Developments/Products 141
TABLE 50 NORTH AMERICAN MARKET FOR FIBER-REINFORCED VINYL ESTERS, BY APPLICATION, THROUGH
EPOXY RESINS 141
Background 141
Chemistry 142
Chemical Epoxy Types 142
Technology 143
Epoxy Systems 143
Background 143
Non-Molded 143
Laminating Systems 143
Molded Epoxies 144
Advanced Epoxy Composites 144
Other Applications 144
Fiber-Reinforced Epoxy Grades 145
New Developments/Products 145
High-Heat Epoxies 145
Wind Blade Epoxies 145
TABLE 51 NORTH AMERICAN MARKET FOR FIBER-REINFORCED EPOXIES BY APPLICATION, THROUGH 2015 (MILLION
POUNDS) 146
PHENOLICS 146



Background 146
Technology 146
Grades 147
Molding Compounds 147
Applications 148
Fiber-Reinforced Phenolic Grades 148
TABLE 52 KEY COMMERCIAL FIBER-REINFORCED PHENOLIC RESINS 148
TABLE 53 NORTH AMERICAN MARKET FOR FIBER-REINFORCED PHENOLIC RESINS BY APPLICATIONS, THROUGH
POLYURETHANES 149
Background 149
Polyureas 149
RIM Products 150
RRIM Products 150
SRIM Products 150
Competing Products 151
Advantages 152
Fiber-Reinforced Polyurethane Products 152
Polyurethane Long Fiber Injection 152
Extended Use of Pultrusion 153
BASF Promoting Sprayed Polyurethane Composites 153
Polyurethane Composites via Filament Winding on the Upswing 153
Bayer Looking at Polyurethane Composites for Large Turbine Blades 153
Bayer Promoting Polyurethane Composites for Automotive Parts 154
Reichhold Develops Polyurethane for Pultrusion 154
TABLE 54 NORTH AMERICAN MARKET FOR FIBER-REINFORCED POLYURETHANES, BY APPLICATION, THROUGH 2015
(MILLION POUNDS) 154
TABLE 55 NORTH AMERICAN MARKET FOR FIBER-REINFORCED POLYURETHANE IN THE AUTOMOTIVE MARKET,
MISCELLANEOUS FIBER-REINFORCED THERMOSETS 155
Diallyl Phthalate (DAP) 155
Background and Applications 155
Thermoplastic Elastomers (TPEs) 156
Overview 156
Cyanate Esters 156
Polybutadiene Resins 157
TABLE 56 NORTH AMERICAN MARKET FOR FIBER-REINFORCED MISCELLANEOUS THERMOSETS BY APPLICATION,
MARKET SUMMARY OF FIBER-REINFORCED THERMOSETS 157
TABLE 57 MARKET SUMMARY OF FIBER-REINFORCED THERMOSETS, THROUGH 2015 (MILLION POUNDS) 158

Chapter-6: APPLICATIONS

OVERVIEW 159
AUTOMOTIVE 159
OVERVIEW 159



TABLE 58 HISTORICAL, CURRENT, AND PROJECTED U.S. AUTOMOTIVE SALES, THROUGH 2015 (MILLION UNITS) 160
TABLE 59 ESTIMATED HYBRID AUTO SALES FOR THE U.S., THROUGH 2015 (THOUSAND UNITS) 160
CAFE ISSUES 160
RECENT EXAMPLES OF INCREASED USE OF REINFORCED PLASTICS WITHIN THE AUTO INDUSTRY 161
Overview 161
Coolant Systems 161
Air-Intake Manifolds 162
Rear-Seat Carrier 162
Plastic Radio Housings 162
Powertrain Parts 162
Reinforced Plastic Tailgates 162
Underbody Heat Shield 163
Truck Trailer Panels 163
Seats Made from Reinforced Plastics 163
Reinforced Plastic Air-Intake Manifold Systems 163
Reinforced Nylon Cylinder-Head Covers 163
LyondellBasell Products 164
Example of Natural Fiber Composites for the Auto Market 164
Carbon Fiber Reinforced Plastic Cars 164
What about Chinese Cars and Use of Reinforced Plastics' 164
AUTOMOTIVE UNDER-THE-HOOD 164
Overview 164
Key Factors of UTH Resin Market 165
TABLE 60 SELECTED AUTOMOTIVE UNDER-THE-HOOD FIBER-REINFORCED RESINS BY PART 166
Recent Developments in Auto UTH Reinforced Plastic Parts 166
DuPont's New Zytel Nylon 166
Potential Replacement of Steel in Fuel Systems 167
Plastic Oil Pans 167
Engine Valve Cover 167
TABLE 61 NORTH AMERICAN MARKET FOR FIBER-REINFORCED PLASTIC AUTOMOTIVE UNDER-THE-HOOD MARKET BY
RESIN, THROUGH 2015 (MILLION POUNDS) 168
AUTOMOTIVE INTERIORS 168
Background 168
Overview of Specific Fiber-Reinforced Plastic Auto Interior Applications 169
Seat Structures 169
Background 169
Front Seat Bases 169
Front Seat Shells 169
Seat Backs 169
Rear Seats 170
Child Safety Seats 170
Instrument Panel Structures (IPs) 171
Overview 171
ABS 171
PC/ABS 171
Polycarbonates 171
Polypropylene 172
Polyurethanes 172
PPO/HIPS 172



SMA 173
Door Panels and Trim 173
Consoles 173
Overview 173
Resin Usage 174
Flooring 174
Package Shelves/Trays 175
Headliners 175
Background 175
Resin Usage 175
Recent Developments in Auto Interiors 176
Celstran Products Being Promoted for Auto Interiors 176
Sabic IP Products 176
Glass Bubbles Replace Talc Fillers 176
TABLE 62 NORTH AMERICAN MARKET FOR FIBER-REINFORCED PLASTICS IN AUTOMOTIVE INTERIORS, THROUGH
AUTOMOTIVE EXTERIORS 177
Background 177
Use of Reinforced Plastics/Composites 177
Fuel Efficiency Scenario 178
Bumper Systems 178
Background 178
Products 178
Bumper Beams 179
Doors 180
Body Panels 180
Overview 180
Horizontal vs. Vertical Body Panels (Steel vs. SMC) 180
Specific Thermoplastics 181
General Decision Factors for Body Panels 181
Overview 181
Carbon Fiber SMC 181
Need for Class A Finishes 182
Other SMC Competition 182
Other Considerations 183
Paint-Free SMCs' 183
New Developments of Reinforced Plastics in Automotive Exteriors 184
Magna International Developments 184
Quadrant Plastic Composites' New Bumper Beams 184
SMC for Body Panel Applications 184
Sabic IP and Azdel Combine to Produce Lighter Body Panels 184
Molded-in-Color Panels 184
TABLE 63 NORTH AMERICAN MARKET FOR FIBER-REINFORCED PLASTICS AUTOMOTIVE EXTERIOR MARKET, THROUGH
THE FUTURE FOR REINFORCED PLASTICS/COMPOSITES SEEMS BRIGHT IN THE AUTOMOTIVE MARKET 186
WHAT ABOUT FUEL CELLS IN AUTOS' 187
Background 187
Possible Future Scenario 187



Types of Fuel Cells and Components 187
Materials and Processes 188
Other Items of Interest 188
Companies Involved 189
What Does the Future Hold' 189

Chapter-7: CONSTRUCTION/INFRASTRUCTURE

BACKGROUND 190
CONSTRUCTION MARKET OVERVIEW 190
U.S HOUSING STARTS 190
TABLE 64 U.S. HOUSING STARTS FOR SINGLE-FAMILY HOMES, 1982-2009 (THOUSAND UNITS) 191
RECENT COMMENTS ON THE HOUSING MARKET 191
ADVANTAGES OF REINFORCED PLASTICS/COMPOSITES 191
SOME BARRIERS TO REINFORCED PLASTICS/COMPOSITE USAGE 192
INFRASTRUCTURE APPLICATIONS 192
Background 192
Advantages of Composites 193
Roadblocks 193
Infrastructure Repair 194
Jacketing 194
Concrete Reinforcement 194
Background 194
Rebars/PlateBonding 195
Concrete Highway Pavement 195
Wave Power Converters 195
Fiberglass Towers 195
BRIDGES 195
Background 195
Bridge Cables from Composites 196
PIPE 197
Background 197
Fiberglass Reinforced Thermoset Plastic Pipe 197
Background 197
Allyl Resins 198
Bismaleimides and Furan Resins 198
Phenolic Resins 198
Epoxy Resins 199
Unsaturated Polyester Resins 199
Water-Pipe Systems 199
Overview 199
Composites Used in Offshore Drain Pipe Repair 200
BATHROOM FIXTURES AND COMPONENTS 201
PANELS 201
Overview 201
Natural Fibers for Panels 202
ANTI-CORROSION MARKETS 202



Background 202
Types of Corrosion-Resistant Resins 203
Markets 203
Resurgence in Corrosion-Resistant Composites 204
Examples of an Industry Impacted by Corrosion: Underground Storage Tanks 204
Return of the Corrosion Market for Composites' 205
TABLE 65 NORTH AMERICAN MARKET FOR FIBER-REINFORCED PLASTIC CONSTRUCTION/INFRASTRUCTURE BY RESIN,
TABLE 66 NORTH AMERICAN MARKET FOR FIBER-REINFORCED PLASTIC CONSTRUCTION/INFRASTRUCTURE BY
SEGMENT THROUGH 2015 (MILLION POUNDS) 206
TABLE 67 NORTH AMERICAN CONSTRUCTION/INFRASTRUCTURE MARKET FOR FIBER-REINFORCED UNSATURATED
POLYESTER BY SEGMENT, THROUGH 2015 (MILLION POUNDS) 207
TABLE 68 NORTH AMERICAN CONSTRUCTION/INFRASTRUCTURE MARKET FOR FIBER-REINFORCED EPOXY BY
SEGMENT, THROUGH 2015 (MILLION POUNDS) 207
MARINE MARKETS 207
OVERVIEW 207
MATERIALS 208
Glass 208
Carbon 209
Aramid 209
Epoxy/Vinyl Ester 209
TRENDS IN MARINE COMPOSITES 209
MARINE REINFORCED PLASTICS/COMPOSITES PLUSES AND MINUSES 209
TABLE 69 NORTH AMERICAN MARKET FOR FIBER-REINFORCED PLASTIC MARINE PRODUCTS, THROUGH 2015 (MILLION
POUNDS) 210
ELECTRONICS 211
OVERVIEW 211
MARKETS 211
GROWTH 211
TECHNOLOGIES 211
REINFORCED PLASTICS MOVE AHEAD IN ELECTRONICS 212
PRINTED CIRCUITBOARDS (PCBS) 212
Background 212
Definitions 213
Physical Composition 213
Types of Rigid Boards 213
Assembly Technologies 213
E-Glass Suppliers 214
Issues Facing Plastics Usage 214
PCB Substrates 214
TABLE 70 IMPORTANT TECHNICAL FACTORS TO CONSIDER WHEN SELECTING PCB SUBSTRATE MATERIALS 214
Rigid PCBs 215
Background 215
Standard FR-4 Epoxy Resin 215
Higher-Performance Epoxies 215
Other Materials 216
Types of Reinforcements 216



Impact of Lead-Free Soldering 217
Aramid Fibers 217
CONNECTORS 217
Background 217
Function of Connectors 218
Trends 218
Resin Selection 218
TABLE 71 NORTH AMERICAN MARKET FOR FIBER-REINFORCED PLASTIC ELECTRONICS, THROUGH 2015 (MILLION
POUNDS) 220
CONSUMER PRODUCTS 220
BACKGROUND 220
SPORTS/RECREATION EQUIPMENT 220
Background 220
General Resin Usage 221
Skis and Other Winter Sports Equipment 221
Recreation Boards 222
Bicycles 222
Specific Reinforced Plastics Products Used in Sports & Recreation Products 223
LAWN/GARDEN EQUIPMENT 223
Overview 223
Resin Usage 223
TABLE 72 NORTH AMERICAN MARKET FOR FIBER-REINFORCED PLASTIC CONSUMER PRODUCTS MARKET, THROUGH
APPLIANCES 225
OVERVIEW 225
APPLIANCE USAGE IN U.S. HOUSEHOLDS 226
KEY APPLICATIONS FOR PLASTICS IN APPLIANCES 226
FIBER-REINFORCED PLASTIC USAGE 226
TABLE 73 NORTH AMERICAN MARKET FOR FIBER-REINFORCED PLASTIC APPLIANCE MARKET, THROUGH 2015 (MILLION
POUNDS) 227
AEROSPACE 227
OVERVIEW 227
BACKGROUND 228
MILITARY AIRCRAFT 228
INTERIOR PARTS 229
COMPOSITION OF REINFORCED PLASTIC PARTS 229
MATERIAL USAGE 229
POTENTIAL PROBLEMS 229
SUPPLIERS 230
NEW DEVELOPMENTS 230
Bis-Maleamide Resins (BMIs) 230
New Cook Composite Products 230
The Drive for Composite Tooling 230
Production Has Begun for Airbus A350 XWB 230
Epoxy Usage 231



TABLE 74 NORTH AMERICAN AEROSPACE MARKET FOR FIBER-REINFORCED PLASTIC, THROUGH 2015 (MILLION
POUNDS) 231
MISCELLANEOUS APPLICATIONS 232
BACKGROUND 232
MEDICAL 232
Overview 232
Orthopedic Implants and Prostheses 232
Overview 232
Composites May Move Into Orthopedics/Prosthesis 233
POWER MARKET 233
Overview 233
Distribution/Utility Poles 233
A Recent Development 234
Cross Arms 234
Summary of Benefits that can be Derived from Composites in the Power Market 235
OTHER TRANSPORTATION MARKETS 235
Overview 235
Rail Applications 235
Background 235
Monorails 236
Phenolic Composite Usage in Mass Transit 236
Recreational Vehicle Market (RVs) 236
WIND ENERGY PRODUCTS 237
Background 237
Technology 237
Ashland Chemical 237
TPI Composites 238
Owens Corning 238
PPG's New Product 238
Ahlstrom Corporation 238
LM Glasfiber, Inc. 238
Vestas Wind Systems 238
Three-Company Partnership 239
Other Noteworthy Developments in Wind Blade Production 239
OILFIELD RELATED APPLICATIONS 239
WATER DESALINATION 240
REINFORCED PLASTIC IN-GROUND TANKS 240
TABLE 75 NORTH AMERICAN MISCELLANEOUS MARKET FOR FIBER-REINFORCED PLASTICS, THROUGH 2015 (MILLION
POUNDS) 241
SUMMARY OF FIBER-REINFORCED PLASTICS APPLICATIONS MARKET 241
TABLE 76 NORTH AMERICAN MARKET FOR FIBER-REINFORCED PLASTICS APPLICATIONS, THROUGH 2015 (MILLION
POUNDS) 242

Chapter-8: COMPOSITE MARKET GROWTH IN ASIA MOVES FORWARD

OVERVIEW 243
AUTOMOTIVE PRODUCTS 243
OTHER NOTEWORTHY NEWS 243



Chapter-9: ENVIRONMENTAL ISSUES

BACKGROUND 244
STYRENE EMISSION PROBLEM 244
OVERVIEW 244
CHANGES IN MACT DIRECT FINAL RULE 245
METHODS TO LOWER STYRENE EMISSIONS 245
SUMMARY OF OPTIONS TO REDUCE STYRENE EMISSIONS AND MAINTAIN PRODUCT QUALITY 246

Chapter-10: RECYCLING

OVERVIEW 247
SPECIAL CONCERNS 248
DO COMPOSITES REQUIRE A BETTER SOLUTION FOR THEIR END-LIFE' 248
EFFORTS IN THERMOSET RECYCLING 248
BACKGROUND 248
PYROLYSIS 248
GLASS SEPARATION 248
GRINDING 249
CARBON FIBER RECYCLING 249
NEW EURPOEAN EFFORTS 249
USING RECYCLED SMC 249
RECOVERING CARBON FIBERS 250
RECYCLING LONG-FIBER REINFORCED POLYPROPYLENE (LFPP) 250

Chapter-11: RECENT CORPORATE DEVELOPMENTS/PRODUCTS WITHIN THE REINFORCED

AZDEL SOLD TO KOREAN FIRM 251
SABIC IP PURCHASES RHE MAX LINE 251
DUPONT MOVING AHEAD WITH LONG FIBER AND NANOCOMPOSITES 251
NEW VINYL ESTERS 252
SIKA'S NEW EPOXY RESIN FOR AVIATION USES 252
VICTREX ST POLYMERS 252
TICONA ACQUIRES LFT BUSINESS IN GERMANY 252
ACY DEVELOPS FIBERS FOR IMPLANTS 252
DECOMA INTERNATIONAL PURCHASED MERIDIAN COMPOSITE PLANTS 253
FERRO ADDS NEW FIBERGLAS-REINFORCED COMPOUNDS 253
A NEW REINFORCING AGENT FROM MILLIKEN CHEMICAL 253
RTP DEVELOPS LFTPS WITH HIGH PERFORMANCE RESINS 253
HEXION TO MERGE ITS OPERATIONS 253
COMPANY PROFILES 254
ASHLAND SPECIALTY CHEMICAL COMPOSITE POLYMERS 254
AZDEL, INC. 254
AOC LLC 255
BULK MOLDING COMPOUNDS, INC. 255
COOK COMPOSITES AND POLYMERS (CPP) 256
DSM ENGINEERING PLASTICS NORTH AMERICA 256
FERRO CORPORATION 257
GEORGIA-PACIFIC CHEMICALS LLC 257



HAYSITE REINFORCED PLASTICS 258
HEXION SPECIALTY CHEMICALS 258
IDI COMPOSITES INTERNATIONAL 259
INTERPLASTIC CORPORATION 259
LNP ENGINEERING PLASTICS 259
OWENS CORNING 260
PREMIX, INC. 261
QUADRANT PLASTIC COMPOSITES 261
REICHHOLD CHEMICAL 262
RTP COMPANY 262
TICONA 263

Chapter-12: ACRONYMS

APPENDIX ONE: ACRONYMS 264
ACRONYMS (CONTINUED) 265
ACRONYMS (CONTINUED) 266

Chapter-13: GLOSSARY OF TERMS

APPENDIX TWO: GLOSSARY OF TERMS 267



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