Polymer Solutions for High Temperature Applications

Transcription

1 Polymer Solutions for High Temperature Applications Eric Martin, PhD Technical Development EMEA 1 Technology & Polymer Days 2016 September 21 th Gjövik, Norway

2 Agenda 1. Solvay Group Overview 2. Solvay Specialty Polymers Overview 3. Polymer Solutions for High Temperatures Thermoplastics Elastomers 4. Metal-to-Plastic Solutions 2

3 More than 150 years of innovation and many to come 1863 Ernest Solvay invents the Solvay process for producing soda ash 1950 Solvay invents the plastic bottle 2015 Solvay flies around the world with Solar Impulse 1880 Solvay is the first industrial multinational to operate in the US and Europe simultaneously 1990 Solvay invents precipitated silica for green tires 1878 Solvay innovates in social welfare (paid vacations, social security, 8-hour day) 1911 & 1927 The congresses bring together the greatest physicists of their day 2011 Solvay acquires Rhodia nd Chemistry for the Future Solvay Prize 3

4 We are a world leader in the chemical industry 30,900 employees 145 industrial sites 21 major R&I centers 53 countries 12.4 billion of net sales 2,336 million of REBITDA Play the Solvay video Pro forma 2015 figures including Cytec (unaudited) 4

5 Our activities are divided into Operating Segments Advanced Formulations Performance Chemicals Advanced Materials Functional Polymers Specialty Polymers Composite Materials Silica Special Chem 5

6 Agenda 1. Solvay Group Overview 2. Solvay Specialty Polymers Overview 3. Polymer Solutions for High Temperatures Thermoplastics Elastomers 4. Metal-to-Plastic Solutions 6

7 Specialty Polymers at a Glance Diversified end markets with superior growth potential Aerospace 26% Net sales 30% Net sales 44% Net sales Automotive Batteries Consumer & Construction Electrical & Electronics Americas 9 production sites 2 R&I centers Europe 7 production sites 4 R&I centers Asia & RoW 2 production sites 4 R&I centers Healthcare 2015 Data Industrial & Environment 1.9 bn Net sales 2015 ~3,700 employees 18 production sites 10 R&I centers 7

8 A Global Presence Close to Our Customers 8

9 Positioned for Growth Solutions for a Diverse Range of Growing Markets 5% Batteries 10% Healthcare 23% Automotive 16% Consumer & Construction 2% Aerospace 17% Industrial & Environment 27% Electrical & Electronics 9

10 Engineering Innovation Every Day 2015 data Strong R&I Investment ~ 50 proprietary processes 10 R&I centers ~ 600 dedicated resources Long-term incubation projects (10yrs +) Customer Partnership 170+ Growth projects Long-term partnerships for adaptive and innovative solutions Accelerated Programs Many years track record in delivering innovation Advanced engineering CAD/CAE and design services Process optimization 33% of net sales realized with products < 5-y 40+ New product grades 3,500+ Patents in force Creating value for our Customers 10

11 KetaSpire PEEK PrimoSpire SRP Light weight / metal replacement OUR SPECIALTY POLYMERS ON BOARD Solstick Energy capture Halar ECTFE Energy capture Fomblin PFPE Lubrication Ixef PARA Radel PPSU Amodel PPA LEDs Solef PVDF Energy storage Torlon AI Light weight / metal replacement TegraCore TM PPSU Insulation Structure 11

12 Agenda 1. Solvay Group Overview 2. Solvay Specialty Polymers Overview 3. Polymer Solutions for High Temperatures Thermoplastics Elastomers 4. Metal-to-Plastic Solutions 12

13 Specialty Polymers Comprehensive Portfolio Aromatics, Fluoropolymers, Barrier Polymers, Performance Compounds Key Performance Factors Lightweighting Fire resistance Mechanical performance Resistance to harsh elements Broad range of temperatures Surface properties 13

14 A Unique Portfolio of Solutions Through Continuous Research and Innovation Aromatics Fluoropolymers Barrier Polymers Performance Compounds LCP HPPA PEEK PAI PSU PPS PTFE PVDF PFA FKM PFPE PVDC XLCP Aerospace Automotive Batteries Consumer and Construction Electrical/ Electronics Healthcare Industrial and Environment Currently produced also in Asia On-going investments for additional production in Asia 14

15 Product Families Advanced Lightweighting Solutions TegraLite TegraCore PPSU Structural Foam Solef e-pvdf 3D Foams Films Composites Virantage PESU Tougheners Biomaterials for Implantable Devices Solviva Biomaterials Eviva PSU Veriva PPSU Zeniva PEEK Cross-linkable Compounds Cogegum XLPO-HFFR Polidan PEX/XLPE Polidiemme XLPO Films Ajedium Films Fluorinated Elastomers Tecnoflon FKM Base Resistant Ionic Curable Low Temperature Peroxide Curable Tecnoflon PFR FFKM Fluorinated Fluids Fomblin HC PFPE Fomblin PFPE Lubricants Galden PFPE Solvera PFPE Fluoropolymers Algoflon PTFE Dispersions Fine Coagulated Powders Granulars Micronized Powders Halar ECTFE Hyflon AD Hyflon PFA & MFA Hylar PVDF Hylar 5000 PVDF for Architectural Coatings Polymist PTFE Solef PVDF Functional Fluids Fluorolink PFPE Fomblin PFPE Functional Liquid Crystal Polymers Xydar LCP Polyamide-imides Torlon PAI Polyamides, Aromatic Amodel PPA Ixef PARA Kalix HPPA Omnix HPPA Polyesters, High-performance Lavanta HPP Polyketones, Aromatic AvaSpire PAEK KetaSpire PEEK Polymer Processing Aids Solef PVDF Tecnoflon NM FKM Polyphenylene, Sulfide Ryton PPS Polyvinylidene Chloride Diofan PVDC Ixan PVDC Extrusion Resins Ixan PVDC Soluble Powders Sulfone Polymers Acudel modified PPSU Radel PPSU Udel PSU Veradel PESU Specialty Materials Aquivion PFSA Hyflon AD Long Fiber Compounds Solvene EAP Torlon AI for Coatings 15

16 Specialty Polymers Products Use Temperature Range Fluids Elastomers Thermoplastics Galden PFPE Galden Fomblin Y PFPE Fomblin Y Fomblin M/Z PFPE Fomblin M/Z Tecnoflon FFKM FFKM Tecnoflon FKM FKM Polidan /Cogegum XL PE /Polidiemme XLPE Ixan PVDC PVDC Ixef /Kalix /Omnix PARA PARA Amodel PPA PPA Ryton PPS PPS Radel PPSU PPSU Veradel PESU PESU Udel PSU PSU AvaSpire PAEK PAEK KetaSpire PEEK PEEK Torlon PAI PAI Xydar LCP LCP Halar ECTFE ECTFE Solef PVDF PVDF Algoflon /Polymist PTFE PTFE Hyflon MFA MFA Hyflon PFA PFA Short-term use temperature Long-term use temperature Temperature [ C] 16

17 Specialty Polymers Products Thermal Rating in Oil Service 17

18 Agenda 1. Solvay Group Overview 2. Solvay Specialty Polymers Overview 3. Polymer Solutions for High Temperatures Thermoplastics Elastomers 4. Metal-to-Plastic Solutions 18

19 Solef PVDF Melt-processable fluoropolymers with high mechanical properties and low permeability Key Features Continuous service temperature up to C Excellent chemical resistance Good mechanical properties and flexibility Low permeability to most gases and liquids High abrasion resistance Excellent resistance to Rapid Gas Decompression (RGD) Outstanding weathering resistance Resistance to s-co 2 Metal protection Key Applications Oil & Gas pipes, risers and flowlines Binders and materials for separators in Li-Ion batteries Fittings and valves Membranes Wire and cable jacketing Yield stress of melt-processable fluoropolymers (@23 C MPa) Internal fluid containment barrier in flexible risers Field track record over 20 years 19

20 Hyflon PFA Fully-fluorinated, melt-processable fluoropolymers with the highest temperature rating and broadest chemical resistance Key Features Hyflon PFA Higher melting point >300 C Intrinsic processing stability (up to 420 C) Improved surface smoothness Mechanical properties / dimensional stability from 200 C to 260 C Excellent long-term aging resistance Good flexibility and ductility, even down to 100 C Universal chemical resistance Good permeation resistance Key Applications Cable jacketing (Control lines,...) Lining Industrial coatings and linings 20

21 Algoflon PTFE & Polymist PTFE Fully-fluorinated polymers showing best-in-class thermal performance and chemical resistance Key Features Chemical inertness Outstanding temperature resistance Extremely low coefficient of friction Non-stick properties from cryogenic to 260 C Exceptional release and water repellent properties Outstanding heat resistance Key Applications Filtration membranes Linings for industrial applications Gaskets, seals E/E insulators and electrical tapes Additives (Algoflon L,Polymist PTFE) 21

22 KetaSpire PEEK One of the most chemically resistant thermoplastics with excellent strength and fatigue resistance along with a continuous-use temperature of 240 C Key Features High-purity Exceptional resistance to organics, acids and bases Low CLTE Very good wear and abrasion resistance Excellent dimensional stability Best-in-class fatigue resistance Key Applications Aerospace: fasteners, brackets, wiring and fluid handling systems Automotive: thrust washers, bearings, seal rings, brake systems parts, gears Healthcare: instruments, operating room equipment Oil & Gas: compressor plates, seals, wire coatings Semicon: Chemical Mechanical Planarization (CMP) rings, wafer carriers 22

23 KetaSpire PEEK Long-term Thermo-oxidative Behavior Tensile strength at break after aging for 8000 hours Tensile Strength [MPa] Aging Temperature [ C] Unfilled KetaSpire PEEK 30% GF KetaSpire PEEK 30% CF KetaSpire PEEK Properties are retained after heat aging at high temperatures 23

24 AvaSpire PAEK A versatile family of polyaryletherketones tailored to provide new and unique combinations of performance and value Key Features Higher stiffness from 150 C to 190 C vs PEEK Improved toughness vs PEEK UL-94 V0 rating at 0.8 mm Comparable strength and stiffness at up to 20-30% lower cost Excellent aesthetics and colorability Key Applications Aerospace: interiors, wiring systems, conducts Automotive: engine and brake system parts Healthcare: instruments, operating room equipment Mobile electronics: structural parts Oil & Gas: compressor plates, wire coatings, liners 24

25 Torlon PAI Amorphous thermoplastic with high strength and stiffness up to 275 C Key Features Excellent strength and toughness from cryogenic to 275 C Best-in-class friction and wear performance Excellent resistance to lubricants, greases and fuels Resistant to strong acids and most organics Inherent flame resistance Low CLTE Key Applications Automotive: transmission seal rings, thrust washers, engine parts E/E: connectors, semicon process equipments Industrial: bushings, bearings, gears, hydraulics Aerospace: fasteners, fixture & mechanical parts Units -196 C 23 C 135 C 232 C Tensile Strength MPa break % Flexural Strength MPa Flexural Modulus GPa

26 Thermoplastics Long-term Use Temperature vs Deflection Temperature 26

27 Unreinforced Thermoplastics Heat Deflection Temperature vs Chemical Resistance 27

28 Powders & Ajedium TM Films Powders Micronized powders Electrical wire coatings S & WB Coatings: Anti-corrosion, non-stick cookware, industrial anti-friction Additives / Reinforcement Laser sintering Composites Ajedium TM Films Mono & Multi-layer structure Photovoltaics front- and back-sheets Architectural films Aerospace thermal acoustic insulation blankets Composites Ajedium TM Films - Key properties comparison 28

29 Agenda 1. Solvay Group Overview 2. Solvay Specialty Polymers Overview 3. Polymer Solutions for High Temperatures Thermoplastics Elastomers 4. Metal-to-Plastic Solutions 29

30 Tecnoflon FKM Elastomers are used in applications exposed to aggressive chemicals and high heat environments Key Features Bisphenol-curable Excellent processability Good mechanical and sealing properties Available as base polymers or formulated with incorporated cure systems Suitable for any molding process Peroxide-curable Better chemical resistance than bisphenols Unmatched tensile properties Outstanding long-term sealing performance Solvay s proprietary technology, for compression, transfer or injection molding Key Applications O-rings, seals, gaskets, hoses Other complex molded parts DMA of Low T FKM and standard FKM 30

31 Elastomers Minimum Use Temperature vs Chemical Resistance 31

32 Tecnoflon FFKM Perfluoroelastomers show the highest performance among all elastomers Key Features Resistant to nearly every chemical class Heat resistance up to 300 C Proprietary cross-linking agent Ultra-high purity Key Applications O-rings, seals, gaskets, hoses Other complex molded parts Effect of Cross-linking Agents on FFKM Stress Relaxation at 300 C 32

33 Elastomers Long-Term Use Temperature vs Chemical Resistance 33

34 Agenda 1. Solvay Group Overview 2. Solvay Specialty Polymers Overview 3. Polymer Solutions for High Temperatures Thermoplastics Elastomers 4. Metal-to-Plastic Solutions 34

35 Metal-to-Plastic Solutions A portfolio of enabling solutions with key performance attributes A technology roadmap committed with widespread implementation in key market segments A rapidly growing industry footprint through acquisitions and strategic partnerships An ambition to become an industry leader in high-performance lightweight materials High-performance Composites Thermoplastic tapes and laminates for short cycle-time processing TegraCore TM PPSU Foams Thermoformable rigid foam PVDF Bead Foams Injection moldable/direct part production UltraMaterials TM Composites Semi-continuous process/suitable for mass production Application Support Advanced testing and simulation tools for part design validation PPSU foams Thermoset composites Long fibers Films PVDF foams Thermoplastic composites PPS resins Solvay Portfolio of Solutions 35

36 TegraCore TM PPSU Foam Advanced lightweight foam core for insulation and structural applications Key Features Closed micro-cell structures Lightweight: 50 kg/m3 High strength-to-weight ratio Dimensional stability/mechanics up to 180 C Excellent damage tolerance (crack propagation control) FST performance (exceeds FAR ) Key Applications Cabin applications from floor to ceiling Seat Shells, privacy panels and monuments Sidewalls and dividers Cargo compartments Engine covers Catering trolleys Impact test comparison 36

37 Solef PVDF Bead Foam Injection-moldable expanded PVDF foam for direct part production Key Features e-pvdf Foam free of additives and produced without chemical blowing agents Inherent purity and inertness of PVDF Lightweight (density down to 60 g/l) Improved thermal insulation and resilience Meets FAR & AITM standards JSP steam chest molding technology Key Applications Aerospace: ducting O&G: pipe, pump, manifold insulation CPI: pipe insulation 37

38 Safety Data Sheets (SDS) are available by ing us or contacting your sales representative. Always consult the appropriate SDS before using any of our products. Neither Solvay Specialty Polymers nor any of its affiliates makes any warranty, express or implied, including merchantability or fitness for use, or accepts any liability in connection with this product, related information or its use. Some applications of which Solvay s products may be proposed to be used are regulated or restricted by applicable laws and regulations or by national or international standards and in some cases by Solvay s recommendation, including applications of food/feed, water treatment, medical, pharmaceuticals, and personal care. Only products designated as part of the Solviva family of biomaterials may be considered as candidates for use in implantable medical devices. The user alone must finally determine suitability of any information or products for any contemplated use in compliance with applicable law, the manner of use and whether any patents are infringed. The information and the products are for use by technically skilled persons at their own discretion and risk and does not relate to the use of this product in combination with any other substance or any other process. This is not a license under any patent or other proprietary right. All trademarks and registered trademarks are property of the companies that comprise the Solvay Group or their respective owners. 2016, Solvay Specialty Polymers. All rights reserved. Template v 1.6