Ethan Clarke
Royalex, initially called Royalite, was first manufactured in the 1940s by US Rubber Co. in Chicago. The company was later renamed Uniroyal, and in 2000, Spartech Corporation took over the Royalex Manufacturing Division, securing the rights to manufacture Royalex. Royalex is a composite material with an outer layer of vinyl and hard acrylonitrile butadiene styrene plastic (ABS) and an inner layer of ABS foam. It was primarily used in the manufacture of canoe hulls, offering advantages such as lightness, rigidity, and resistance to UV damage. However, due to low production volume, PolyOne, the company that purchased Spartech in 2013, decided to shut down Royalex production.
| Characteristics | Values |
|---|---|
| First Manufactured | In the 1940s by U.S. Rubber, later renamed Uniroyal Inc. |
| Invented By | Bob Pooley |
| Composition | Composite material with an outer layer of vinyl and inner layers of ABS plastic and ABS foam |
| Applications | Used for manufacturing durable canoes, caravans, tractor cabs, car parts, aerospace, medical and electronic markets |
| Ownership Changes | Bought by Spartech Corporation in 2000, then PolyOne in 2013, and later sold to an investment firm in 2017 |
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What You'll Learn
Royalex was developed in the 1970s
Royalex, a composite material with an outer layer of vinyl and hard acrylonitrile butadiene styrene plastic (ABS) and an inner layer of ABS foam, was developed in the 1970s. The layers are bonded by heat treatment. The material was first known as Royalite, invented by Bob Pooley at the US Rubber Co.'s Chicago plant. It was simply called Royalite at the time.
Pooley and his associates continued to work on Royalite, introducing a foaming/expandable element at the Uniroyal plant in Warsaw, Indiana. The resulting product was named Royalex to recognize the expanding core. Although it was very tough and versatile, the material was expensive compared to available alternatives.
Many industries were attracted to evaluate Royalex. Items produced included caravans, tractor cabs, and a concept car designed by Ford's Chief Designer, Gene Bordinat, in 1965. This resulted in the 'Ford XP Bordinat Cobra'.
The best-known use of Royalex is for the manufacture of canoe hulls. It is lighter, more resistant to UV damage from sunlight, more rigid, and has greater structural memory than non-composite plastics used for this purpose, such as polyethylene. It is also quieter and more user-friendly in cold or hot conditions than aluminium.
In 2000, Spartech Corporation took over the Uniroyal Royalex Manufacturing Division and secured the rights to manufacture Royalex at their factory in Warsaw, Indiana.
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Bob Pooley invented Royalite at US Rubber Co
Bob Pooley invented Royalite, also known as Royalex, at the US Rubber Co's Chicago plant. US Rubber Co, also known as the United States Rubber Company, was founded in Naugatuck, Connecticut, in 1892. It was formed by the consolidation of nine rubber manufacturing companies, one of which was owned by Charles Goodyear, the inventor of the rubber vulcanization process.
In the 1940s, the company was called US Rubber, and it invented ABS plastic sheets. The company changed its name to Uniroyal, Inc. in 1961 to create a unified brand for its products and subsidiaries. Uniroyal then developed Royalex in the 1970s. Royalex was a composite material with an outer layer of vinyl and hard acrylonitrile butadiene styrene plastic (ABS) and an inner layer of ABS foam. The layers were bonded by heat treatment.
Bob Pooley and his associates continued to work on Royalite at the Uniroyal plant in Warsaw, Indiana, to introduce a foaming/expandable element. The resulting product was named Royalex to recognize its expanding core. Royalex was extremely tough, and while it could be dented, such dents could be recovered by applying a handheld hot air gun to re-expand the core. It was also versatile and attracted many industries for evaluation. However, it was expensive compared to available alternatives, and the need for a different build technique when using Royalex limited its acceptance in large-scale production.
In 2000, Spartech Corporation took over the Uniroyal Royalex Manufacturing Division and secured the rights to manufacture Royalex at their factory in Warsaw, Indiana. In 2013, Spartech was purchased by PolyOne, which decided to shut down Royalex production due to low volume. The last sheets of Royalex were shipped from the factory in December 2013, and production was shut down in April 2014.
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Royalite was later renamed Royalex
Royalite, a type of ABS plastic sheet, was first manufactured in the 1940s by U.S. Rubber Co., which was later renamed Uniroyal. The plastic was developed at the company's Chicago plant by Bob Pooley.
Uniroyal continued to innovate with Royalite, introducing a foaming/expandable element to the plastic at its plant in Warsaw, Indiana. This new version of Royalite was renamed Royalex to recognize its expanding core. Royalex was a composite material with an outer layer of vinyl and hard acrylonitrile butadiene styrene plastic (ABS), and an inner layer of ABS foam. The layers were bonded by heat treatment.
Royalex was known for its durability and versatility. It could be designed to form virtually any finished thickness by adding extra sheets. However, it was also expensive compared to available alternatives. Royalex was used in a variety of applications, including the manufacture of canoe hulls, caravans, tractor cabs, and concept cars.
Despite its versatility, Royalex ultimately faced production shutdowns due to low volume. The rights to manufacture Royalex changed hands several times, from Uniroyal to Spartech Corporation in 2000, and then to PolyOne in 2013. The last sheets of Royalex were shipped from the factory in December 2013, and production was shut down in April 2014.
While Royalex is no longer in production, it left a significant impact on the plastics industry, showcasing the potential of composite materials and expanding the possibilities for product design and manufacturing.
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Royalite was used in aerospace and railcars
Royalite, a type of plastic, was first manufactured in the 1940s by U.S. Rubber, which later became known as Uniroyal. The company developed the world's first ABS plastic sheet. In the 1970s, Uniroyal developed Royalex, a composite material made from ABS plastic and vinyl. This new material was used in the manufacturing of durable canoes, caravans, and automotive parts.
Over the years, Royalite has been used in various industries, including aerospace and railcars. Eric Lattanner, who dedicated 45 years of his career to Royalite, stated that the product line became the number one fire-rated thermoplastic sheet extruder in the world. Royalite was successful in meeting the changing specifications for fire-resistant materials in public use, making it suitable for use in aerospace and railcar interiors.
In the aerospace industry, Royalite materials were specified for use in original equipment manufacturer (OEM) parts. The high-performance characteristics of Royalite, such as its exceptional high-heat performance and strength, made it a popular choice for applications requiring movement resistance and boiling water sterilization. Additionally, Royalite's flame-retardant properties were advantageous in equipment housing and device enclosures.
In the rail industry, Royalite was used in interior passenger railcars. The fire-rated properties of Royalite sheets met the industry's safety standards and specifications. Royalite's thermoformability and pressure-forming capabilities allowed for the production of parts with various thicknesses and textures, making it a versatile choice for railcar interior applications.
Royalite's use in aerospace and railcars showcases its adaptability and safety characteristics. By meeting industry standards and specifications, Royalite contributed to the development of innovative solutions in these sectors.
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Royalex was used to make canoes
Royalex, a composite material with an outer layer of vinyl and hard acrylonitrile butadiene styrene plastic (ABS) and an inner layer of ABS foam, was first developed by Bob Pooley at the US Rubber Co.'s Chicago plant in the 1940s. It was initially called Royalite. Later, Pooley and his associates continued to work on Royalite at the Uniroyal plant in Warsaw, Indiana, to introduce a foaming/expandable element. The resulting product was named Royalex to recognise the expanding core.
However, Royalex canoes are more expensive than aluminium canoes or canoes made from traditionally moulded or roto-moulded polyethylene hulls. Royalex is also unable to be made as light as fibre-reinforced composites made with Kevlar or carbon fibre, making it less suitable for high-performance paddling.
In 2000, Spartech Corporation took over the Uniroyal Royalex Manufacturing Division and secured the rights to manufacture Royalex at their factory in Warsaw, Indiana. In 2013, Spartech was purchased by the plastics company PolyOne, which decided to shut down Royalex production due to low volume. The last sheets of Royalex were shipped from the factory in December 2013, and production ceased in April 2014.
There are no equivalent materials for canoemakers as of January 2014, but T-Formex, a Royalex equivalent, has been developed and is manufactured by the canoe manufacturer Esquif. Canoes made from this material are available from Esquif and several other manufacturers, including Swift and Wenonah.
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Frequently asked questions
Royalite plastic was first manufactured in the 1940s by U.S. Rubber, which was later renamed Uniroyal Inc.
Royalite plastic is a composite material made of an outer layer of vinyl and hard acrylonitrile butadiene styrene plastic (ABS) and an inner layer of ABS foam.
Royalite plastic was used for manufacturing durable canoes, caravans, tractor cabs, cars, and Christmas figurines.
