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April 8, 2016
D825-TV
Plastics Advisor Alert
(TechVision)
Plastics for the Aerospace Industry
Thermoplastics and composites can replace metals and
thermosets in the aerospace industry
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Section Slide Numbers
Innovations in Plastics for the Aerospace Industry 3
Openair Plasma Technology by Plasmatreat 4
KYDEX by Curbell Plastics 5
Tegralite by Solvay 6
Nylatron® 66 SA FST by Quadrant Engineering Plastic Products 7
SPD-Smart Electronically Dimmable Windows by Isoclima 8
VICTREX PAEK by Victrex 9
3D Printed Economy Class Seat that can Reduce Aeroplane Costs by SABIC 10
ThermoPlastic Consolidated Laminate by Toho Tenax 11
Strategic Insights 12
Key Patents 15
Industry Contacts 18
Contents
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Innovations in Plastics for the Aerospace Industry
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1
2
3
Pretreatment methods, which are normally used, do not activate
the surface to a great degree like corona treatment.
Usually, the pretreatment processes involve the use of solvents
containing volatile organic compounds (VOCs) which are
harmful for the environment.
The pretreatment methods normally produce a lot of scrap and
the processes are not in-line with mechanical methods such as
roughening.
Unmet Needs Technology Profile
Who
The technology was
developed by Plasmatreat, a
US-based company involved
in the development of high
efficiency surface
pretreatment methods for
various types of materials.
Where
This technology was
developed in the company’s
manufacturing facility in
Illinois, USA.
What
Openair Plasma is a simple, safe, and
environmental friendly technology.
This does not require any chamber system unlike
the low pressure plasma technology
It can be used for cleaning; activating; and coating
plastics metals, glass, and composites
Here; the process can be done under normal
pressure; only air, electrical power, and the
production line are required.
Innovation Attributes
This technology can be used
to treat carbon fiber
reinforced plastics which are
used in aircraft. It improves
the stability of the plastics.
This technology helps in
superior quality processing in
downstream bonding and
painting operations of the
aircraft.
The technology enables the
plasma pretreatment of the
materials to be done in-line
along with the other
processes such as blasting
Potential Applications
The technology can be used in
the aircraft industry and also in
all the areas of industrial
manufacturing.
The technology involves high
speed and produces very low
scrap. Hence, the process
efficiency is very high.
Commercialization
Strategy The company is looking to
commercialize this technology
by partnering with other
companies in Europe and Asia
Pacific.
Openair Plasma technology uses atmospheric pressure for pretreatment and does not require any other set-up apart from air, electrical
power, and existing production line. This technology also reduces the expenses and hence it is unique in its own way.
Analyst Perspective
Marketing
Strategy
The company promoted
this technology at
different events such as
INDUSTRIE Paris in
2016 and Highly-
functional Material
World in Japan in 2016.
Openair Plasma Technology by Plasmatreat New pre-treatment technology of plastics under atmospheric conditions
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Unmet Needs Technology Profile
Innovation Attributes
Potential Applications Commercialization
Strategy The company plans to
collaborate with leading
universities to improve properties
such as toughness. It also plans
to commercialize this product by
partnering with companies.
The product has very high impact resistance and is easy to thermoform unlike other products. Hence, this will be able to capture a good
portion of the aerospace products market.
Plastics sheets such as acrylonitrile butadiene styrene
(ABS) and high impact polystyrene (HIPS) that are used
in aircraft interiors do not have high impact resistance.
Thermoplastics used in the aerospace industry
especially for deep-draw parts are not easy to
thermoform.
What
Where Who
KYDEX is a thermoplastic sheet that is a
combination of ABS and polyvinyl chloride
(PVC).
The product was developed
in the company’s
manufacturing facility in
Orchard Park, New York,
USA.
The product was
developed by Curbell
Plastics, a US-based
company that
manufactures plastic
sheets, rods, films,
adhesives, and sealants.
The product is used where
toughness and complex
thermoforming is required. Hence,
it is used in thermoformed
equipment housings, airplane, bus,
kiosks, and point of purchase
(POP) displays.
The sheet is tough, durable and is easy to
thermoform deep-draw parts
The sheet provides excellent impact
resistance, good strength and stiffness
The product is easy to machine and
fabricate using normal processes and
equipment.
Analyst Perspective
Future Plans Curbell Plastics is developing more variations of KYDEX,
which will be meant for more targeted and customized use.
The company wants this product to be of choice when it
comes to areas where complex thermoforming is required.
The product has various
grades such as
KYDEX® 100,
KYDEX® T Sheet for
O&P. All these grades
have different
customized properties.
Different grades
KYDEX by Curbell Plastics Thermoplastic sheet with very high impact resistance
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Unmet Needs Technology Profile
Innovation Attributes
Potential Applications Commercialization
Strategy The company is collaborating
with Aonix Advanced Materials,
JSP, and 3A Composites to
commercialize this product.
Tegralite can improve efficiency of aircraft as it consumes less fuel and is lightweight. Thus, the product is disruptive in its own way in the
aerospace components market.
Metals and heavier plastic parts used in aerospace
industry are unable to resist shock, impact and high
temperature
Plastics used in the aerospace industry are very costly
and require high maintenance which increases the
overall cost of aircraft maintenance cost.
What
Where Who
Tegralite is a family of high performance
thermoplastic based materials. It includes
foams, composites and sandwich structures.
The product was
developed in the
company’s
manufacturing facility
in Brussels, Belgium.
The product was
developed by Solvay, a
Belgium-based chemical
company. It is a diversified
company that serves many
industries such as
electronics, aerospace,
and energy.
The product is used various
applications in aircraft—from
floor to ceiling, radomes, cargo
compartments, engine covers
and so on.
The product requires less labor costs for primary
and secondary operations. Hence for the more
complex parts, the savings are higher.
The product is completely thermoplastic in
nature due to which on board welding is
possible unlike thermosets.
The product reduces the overall weight of
the aircraft and fuel consumption. Hence it
increases the efficiency and cost
effectiveness
Analyst Perspective
Future Plans Solvay expects that Tegralite can address the order backlog in
commercial aviation. It is trying to expand the Tegralite range of
products (with new and improved properties), which are market
ready.
Tegralite has various
grades like Tegracore
PPSU foam and
thermoplastic sandwich
structures, which are
used in aircraft cabins
and other aircraft
applications.
Different grades
Tegralite by Solvay Thermoplastic solution for increasing time and cost efficiencies
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The product is extremely lightweight and is fire smoke and toxicity retardant. It also complies with Federal Aviation Regulations FAR 25.853. All
these factors make it a attractive proposition for the global market.
Analyst Perspective
Aerospace companies are in constant need of lightweight and flexible materials, which can tolerate high
temperature and pressure without any degradation.
Technology Profile The product was developed by
Quadrant Engineering Plastic
Products, which is involved in
the manufacture of high
performance polymers such
as ultra high molecular weight
polyethylene, nylon.
Nylatron® 66 SA FST is a specially
designed high quality polyamide
material that can be used in aircraft. It
is the first engineering plastic product
to be available in semi-finished forms
(rods and sheets).
The product was
developed in the
company’s
manufacturing
facility in Tielt,
Belgium.
Who
What
Where
Innovation Attributes The product complies with the Federal Aviation Regulations FAR
25.853. It is the first engineering plastic to achieve this standard.
The product is fire-, smoke-, and toxicity retardant, which enables it to
withstand temperatures of up to 175 degrees C.
It has a very beneficial cost-performance ratio. It is extremely
lightweight, easy to machine, and produces minimal sound/noise.
Potential Applications
The product is mainly used for aircraft interiors
where metal parts like brackets, seal bushings,
slide rails and duct seals have traditionally been
used.
Marketing Strategy
Quadrant Engineering Plastic Products
showcased this product at the Paris Air Show in
June 2015. It also showcased the product at the
Singapore Air Show in 2016.
Commercialization Strategy
The company is planning to commercialize this
product across the aerospace industry by
partnering with other companies operating in this
segment such as aircraft manufacturers, suppliers
to the aircraft industry.
Nylatron® 66 SA FST by Quadrant Engineering Plastic Products Innovative polyamide material for withstanding extreme temperatures
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The product has the ability to adjust to the amount of light and the degree of transparency on its own which is quite unique. Hence, this product
is quite disruptive and on commercialization has the capacity to capture a good portion of the market.
Analyst Perspective
Windows used in aircraft can not adjust to light or heat automatically and also can not change their level of
transparency.
Technology Profile Isoclima, is a Italy-based glass
processing company catering to
the aerospace and building &
construction industries. It is a
licensee of Research Frontiers,
developer of Suspended Particles
Device (SPD)-Smart light-control
technology
SPD-Smart Electronically Dimmable
Window is developed using SPD-Smart
EDW film technology of Research
Frontiers, and SABIC’s polycarbonate
LEXAN (that has high optical clarity).
This product is a part of the CromaLite
range.
The product was
developed in
Isoclima’s
manufacturing
facility in Este,
Province of
Padua, Italy.
Who
What
Where
Innovation Attributes The product can instantly adjust to the amount of light, glare, and heat
passing through the window.
The product can change its level of transparency rapidly, uniformly, and
precisely to any level independent of the window size.
The product uses LEXAN brand of SABIC, which is why it has high
impact resistance, optical clarity, abrasion resistance as well as
enhanced light transmission.
Potential Applications
The product is mainly used for aircraft interiors
such as windows. It can also be applied on curved
surfaces. Apart from the aerospace industry, it is
also used in roofs of big buildings
Marketing Strategy
Isoclima and SABIC Innovative Plastics
showcased this new generation of CromaLite
brand of Electronically Dimmable Windows at
Aircraft Interiors Expo in Hamburg, Germany, in
April 2015.
Commercialization Strategy
The company is looking to commercialize this
product by partnering with companies like SABIC
and Research Frontiers. Isoclima uses the
technology of Research Frontiers and Lexan
brand of polycarbonate of SABIC.
SPD-Smart Electronically Dimmable Windows by Isoclima Innovative smart glass that can adjust automatically to light
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The product has the ability to reduce aircraft weight by 60%. In addition, it can be processed at lower temperatures than other composites,
which leads to energy savings. These factors will help the product to capture the global aerospace market.
Analyst Perspective
Metals or thermosets used in aircraft increase the overall weight of the aircraft considerably.
Technology Profile
The product was developed by
Victrex, an UK-based
company involved in the
manufacture and marketing of
high performance aromatic
polyketones.
Victrex has developed the
polyaryletherketone (PAEK)-based
polymer. PAEK can be used along with
fiber-reinforced Victrex
polyetheretherketone (PEEK) polymer
for aircraft interiors. The product uses a
hybrid molding technology, which
enables overmolding of the PAEK-based
composite.
The product was
developed in the
company’s
manufacturing
facility in
Cleveland, UK.
Who
What
Where
Innovation Attributes The PAEK-based polymer can deliver up to 60% of weight savings
compared to stainless steel or titanium
The polymer has an optimum level of crystallinity which helps in good
mechanical properties like strength, stiffness and temperature properties
The polymer along with reinforced thermoplastic composite can be
processed at a temperature of 40 degrees C, which is lesser than that of
traditional composites.
Potential Applications
The product is mainly used for aircraft interiors
such as brackets. Commercial aircraft use
thousands of brackets from the cockpit to the tail
of the plane. The polymer can also be used in
other industries such as automotive, energy, and
consumer electronics.
Partnerships & Collaborations
Victrex is collaborating with Tri-Mack Plastics
Manufacturing Corporation to develop this
polymer. Tri Mack Plastics is a US-based high
performance thermoplastics company, which
supplies to varied industries.
Marketing Strategy
Victrex along with Tri Mack Plastics is marketing
this product by participating in different events and
forums across the world. The reason behind
collaborating with Tri Mach Plastics is to help the
product capture the US market.
VICTREX PAEK by Victrex Polymer that can deliver weight savings of up to 60% in an aircraft
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The 3D printed seat can be made from less than 15 components and is compliant with the regulations of the aircraft industry. It can also reduce
aircraft cost. Thus, it has the ability to capture the aircraft interiors market.
Analyst Perspective
Aircraft seats are made up of more than 150 components, which increase the overall manufacturing cost of seats and as a
result the increase in price is passed down to the traveller.
Technology Profile The product was developed by
SABIC, a Saudi Arabia- based
diversified manufacturing
company involved in
chemicals and industrial
polymers.
The seat was made from SABIC’s
ULTEM 9085 resin. The three-
dimensional (3D) printing was done by
Stratasys using SABIC’s resin. The
resin is compatible for 3D printing, is
toxicity compliant, has low moisture
absorption and has design flexibility.
The product was
developed in the
company’s
manufacturing
facility in Riyadh,
Saudi Arabia.
Who
What
Where
Innovation Attributes The seat meets all the regulatory requirements of the aircraft industry
and OEM (original equipment manufacturer) specific heat release,
flame, and smoke requirements The use of 3D printing has enabled quick prototyping of the required
design without the need for tooling, which results in the seat being
produced with less than 15 components The ULTEM resin is lightweight, can be recycled, and is inexpensive.
Hence, it addresses the need to control costs related to raw materials,
processing.
Potential Applications
The product can be used not only for making
seats, but also in other aircraft interiors such as
dividers, security partitions, oversized interior
windows, backlit signs and panels.
Commercialization Strategy
SABIC is partnering with other companies
operating in this segment for commercializing
this product.
Marketing Strategy
SABIC has showcased this innovative 3D printed
seat at the Aircraft Interiors Expo in Hamburg,
Germany, in 2015.
3D Printed Economy Class Seat for Aircraft by SABIC Innovative aircraft seat made of fewer components
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The product has high mechanical properties and is resistant to solvents and chemicals. It can be processed by thermoforming and is
recyclable. All these properties make this product a lucrative option for the global aircraft components market.
Analyst Perspective
Most of the plastics that are used in aircraft components are not recyclable and can benefit from increased strength.
Technology Profile The product was developed by
Toho Tenax, a Japanese
company that manufactures
carbon fibre composites. It is
part of the Teijin Group.
ThermoPlastic Consolidated Laminate
(TPCL) is made of multiple layers of
thermoplastic (polyetheretherketone
[PEEK]) and is impregnated with
carbon woven fabric. The product can
be processed by heating it above its
melting temperature in a mold within a
press.
The product was
developed in the
company’s
manufacturing
facility in Tokyo,
Japan.
Who
What
Where
Innovation Attributes The product has high mechanical properties such as strength, stiffness,
toughness, flexural strength, and tensile strength.
It is resistant to chemicals and solvents, has very low flammability and
toxicity, and produces less smoke when burnt. It can be stored and
shipped at room temperature. The product can be processed by thermoforming and the cycle time is
short. It is also recyclable and is compliant with the regulations of the
aerospace industry.
Potential Applications
The product can be used for making structural
components such as brackets, clips in aircrafts. It
is used in the Airbus A350 aircraft.
Different grades
Toho Tenax offers this product in different sizes
from 800 millimeter to 1200 millimeter with
varying stacking sequences of the thermoplastic
layers and special surface layers.
Marketing Strategy
Toho Tenax is marketing this product by
partnering with companies across the value chain
as well as showcasing the product in different
events, seminars, and conferences across the
globe.
ThermoPlastic Consolidated Laminate by Toho Tenax High strength thermoplastic sheets that can be used in aircraft components
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Strategic Insights
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Competitive Landscape and Patent Analysis
Intellectual Property (IP)
• A total of 4500 patents were granted from 2011 to
2015 for plastics used in the aerospace industry.
• The key assignees include The Boeing Company,
PPG Industries, Ethicon, and Airbus.
• The United States has filed the maximum number
of patents in the last 5 years.
• In the last 5 years, 7922 patents were filed
globally and out of which 4500 were granted.
• In the aerospace plastics sector, companies have
filed more patents than universities/research
institutes as the organizations are trying to
find/develop different solutions/properties of
reinforced plastics such as aramid, carbon fiber,
and glass fiber.
Competitive Landscape o North America and Europe are the largest markets for aerospace plastics
industry. Frost & Sullivan estimates that Europe leads with a market share
of 44% while North America accounted for 33% of $8.2 billion global
revenue in 2015. In Europe, investments and supportive government
policies have resulted in a spike in R&D activities for new product
development. Hence, the manufacturers are attracted toward this region.
o Toray, Hexcel Corporation, Hyosung Corporation, Mitsubishi Heavy
Industries, Kaman Corporation, Ensinger and Composite Holding, Cytec
Industries, SABIC, and Toho Tenax are among the key market participants.
NORTH AMERICA
SOUTH AMERICA
AFRICA
EUROPE ASIA
AUSTRALIA
Low
High
Medium
0
200
400
600
800
1000
1200
2011 2012 2013 2014 2015
Gra
nte
d P
ate
nts
Year
No of granted patents, globally (2011-2015)
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Strategic Insights
Key Research and Development Focus
Areas One of the focus areas is on composites and
nanocomposites. Another key focus will be
environmental friendly plastics/composites. 3D printing
of aircraft components is also in focus.
The 2020 Scenario Plastics will be very predominant in the
aerospace market. The key plastics, which
will be used are aramid reinforced plastics,
nanocomposites. High quality plastics,
which will require lower costs to fabricate
will be a key trend in 2020.
Funding Scenario The sector has experienced more funding
from the government (public) compared to
private. For example, Canada-based
Cyclone Manufacturing has received $8
million funding from the Federal Economic
Development Agency for Southern Ontario
to increase production capacity and
customer base.
Adoption Barriers The key barriers are toxicity
issues during the manufacture of
reinforced plastics, high
manufacturing and processing
costs, and flaw detection issues.
Growth Factors Increase in manufacture of
commercial and military aircrafts
with enhanced shelf life and fuel
efficiency along with reduced
maintenance costs are the key
drivers for this sector.
Market Potential Plastics in the aerospace industry
have good market potential due to
the rising application room of
lightweight materials in the
aerospace industry. The market is
expected to reach around $14 billion
by 2020 at a CAGR of 8.1%.
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Key Patents
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Key Patents
No. Patent No. Publication Date Title Assignee
1 EP_2997271_A1 March 23, 2016 Method for producing a corrugated foil bearing
stiffener and obtained stiffener
Liebherr Aerospace Toulouse
Sas
The invention concerns a method for producing a corrugated foil bearing stiffener which involves starting with an austenitic nickel superalloy
sheet (15) having an elasticity limit higher than 500 MPa, and subjecting the sheet (15) to at least one step of press bending plastic deformation
of the entire thickness of same with a deformation energy higher than 10 kJ in a time shorter than 10-5 s in such a way as to create
corrugations.
2 EP_2621995_B1 March 23, 2016 Advanced epoxy resin compositions Dow Global Technologies
An epoxy resin composition of the following chemical structure: where n is a number from 1 to about 3000; each m independently has a value
of 0 or 1; each R0 is independently —H or —CH3; each R1 is independently —H or a C1 to C6 alkylene radical (saturated divalent aliphatic
hydrocarbon radical), Ar is a divalent aryl group or heteroarylene group; and X is a cycloalkylene group, including a substituted cycloalkylene
group, where the substituent group include an alkyl, cycloalkyl, an aryl or an aralkyl group or other substituent group, for example, a halogen, a
nitro, or a blocked isocyanate, an alkyloxy group; the combination of cycloalkylene and alkylene groups and the combination of alkylene and
cycloalkylene group with a bridging moiety in between.
3 US_2016_0076579_A1 March 17, 2016 Attachment bolt for positive locking Lisi Aerospace
The invention relates to a fastening bolt (10) comprising: A screw (11), said screw having a threaded portion (17) and a terminal portion (18)
whose diameter (19) is less than that of the threaded portion, an end surface (21) of said terminal portion comprising a transverse opening
groove (22); A nut (30) comprising a threaded body (32) and an unthreaded crown (34) drilled with at least two holes (35) diametrically
opposite to one another; A rod (23), able to fit in the groove of the screw and in the two lateral holes of the nut to lock the bolt; the threaded rod
of the nut comprises a driving portion (38), as well as a chimney (34) less thick than the driving portion; the nut comes from a method
comprising an elliptical deformation of the chimney previously in a circular shape.
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Key Patents (continued)
No. Patent No. Publication Date Title Assignee
4 US_2016_0075916_A1 March 17, 2016 Insulating coating material and use of same Kaneka Corporation
An insulating coating material is provided herein. In some embodiments, the insulating coating material comprises an insulating film comprising
a polyimide resin, wherein the insulating film, when measuring a tensile elasticity in accordance with ASTM D882, having a stress at 5% strain
of 180 MPa or greater and a stress at 15% strain of 225 MPa or greater, wherein the stress at 15% strain is greater than the stress at 5%
strain.
5 US_2016_0075837_A1] March 17, 2016 Method for removing bubbles in polyimide
solution
Everdisplay Optronics
The present disclosure provides a method for removing bubbles in polyimide solution, including: putting the polyimide solution in an open
container; and emitting microwaves to the polyimide solution using a microwave generator to perform a microwave treatment lasting a time
period so as to remove the bubbles in the polyimide solution. Using the method of the present disclosure to process polyimide solution may
conveniently and quickly remove the bubbles in the polyimide solution. This greatly reduces the time required by the process and thus may
meet industrialization demands. Meanwhile, the method effectively reduces the volatilization of an organic solvent having a low melting point in
the polyimide solution, thereby maintaining proportion stability of the polyimide solution and avoiding defects generated in subsequent coating
processes.
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Industry Contacts
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Industry Contacts
Calvin Yong, Regional Manager, Toho Tenax, Kasumigaseki Common Gate West Tower 3-2-1 Kasumigaseki, Chiyoda-ku 100-8585, Tokyo
Japan. Phone: +81-3-3506-6829. E-mail: [email protected] URL: http://www.tohotenax.com/
Kim Choate, Market Director, Mass Transportation, SABIC Innovative Plastics, PO Box 5101, Riyadh 11422, Saudi Arabia.
Phone: +966-011- 225-8000. E-mail: [email protected]. URL: http://www.sabic.com/
Jeff Leighty, Sales & Marketing Manager, Plasmatreat USA, 2541 Technology Drive, Suite 407 Elgin, Illinois 60124.
Phone: +1-847-783-0622. E-mail: [email protected]. URL: http://www.plasmatreat.com/
Tim Herr, Director, Aerospace Strategic Business Unit Director, Victrex, Seal Sands Middlesbrough TS2 1UB Cleveland UK.
Phone: +44-1642-543150. E-mail: [email protected]. URL: https://www.victrex.com/en/
Tracy Schiedel, Director of Marketing, Curbell Plastics, 7 Cobham Drive Orchard Park, New York 14127. Phone: +1-716-667-3377.
E-mail: [email protected]. URL: https://www.curbellplastics.com/
Frank Johänning, Global Market Manager, Aerospace, Quadrant Engineering Plastic Products, I.P. Noord - Szamotulystraat 14
8700 Tielt, Belgium. Phone: +32-0-51-42-35-11. E-mail: [email protected]. URL: http://www.quadrantplastics.com/en/
Marco Bertolini, Head, R&D and Product Development, Isoclima SpA Alessandro Volta, 14 - 35042 Este (PD) Italy. Phone: +39-0429-55788.
E-mail: [email protected]. URL: http://www.isoclima.net/
Augusto Di Donfrancesco, President, Specialty Polymers GBU, Solvay, Rue De Ransbeek, 310,1120 Brussels, Belgium.
Phone: +32-2-264-2111. E-mail: [email protected]. URL: http://www.solvay.com/en/