ENERGY-EFFICIENT SOLUTIONS WITH SILICONE ELASTOMERS
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1 ENERGY-EFFICIENT SOLUTIONS WITH SILICONE ELASTOMERS Engineering Silicones, May, 15th, 2012 Peter Gustafsson, Udo Wachtler CREATING TOMORROW'S SOLUTIONS
2 ALMOST A CENTURY OF SUCCESS Wacker Chemie AG Founded in 1914 by Dr. Alexander Wacker Headquartered in Munich WACKER Group (2011) Sales: 4.91 billion EBITDA: 1.1 billion R&D: 173 million Investments: 981 million Employees: 17,168 Company Profile Corporate Communications, March 2012, Slide 1
3 A WELL-BALANCED PORTFOLIO Group sales in 2011: 4,910 million Total divisional sales in 2011 (incl. internal sales): 5,107 million** * 1,448 million * 145 million * 992 million SILTRONIC WACKER SILICONES WACKER POLYMERS WACKER POLYSILICON WACKER BIOSOLUTIONS * 928 million * 1,594 million * Including internal sales ** Balance of other / consolidation -197 million Company Profile Corporate Communications, March 2012, Slide 2
4 CONTENT Silicone elastomers chemistry and classification Value chain and global market Characteristics of silicone elastomers in regard to sustainability Application examples LED technology Solar industry Insulators in power, transmission & distribution UV-curing silicone elastomers Flame retardant silicone elastomers Automotive/Transportation Summary Engineering Silicones, May, 15, 2012 Slide 3
5 WHAT ARE SILICONES? Si Si Si Si Si Quartz Silicon metal Silane Polydimethylsiloxane Engineering Silicones, May, 15, 2012 Slide 4
6 SILICONE RUBBER FROM SAND TO THE OEM SAND SILICON SILOXANE SILICONE POLYMER (GUM) BASE COMPOUND RUBBER PART (MOLDING) OEM (CONSUMER) PRODUCT OR TIER ½ COMPONENT Engineering Silicones, May, 15, 2012 Slide 5
7 HIGH CONSISTENCY RUBBER ELASTOSIL SILICONE ELASTOMERS HTV LSR RTV-2 hardness (DIN 53505) tensile strength (DIN S1) elongation at break (DIN S1) tear resistance (ASTM D 624) compression set (DIN ISO 815-B)* rebound resilience (DIN 53512) ShA 6 12 N/mm % N/mm 10 40% 35 65% 3 85 ShA 5 9 N/mm % N/mm 10 50% 40 60% very soft to 50 ShA 2 6 N/mm % 8 25 N/mm 40 70% 20 50% * determined at 175 C, 22 h Engineering Silicones, May, 15, 2012 Slide 6
8 MECHANICAL PROPERTIES IN COMPARISON SILICONE ELASTOMER ORGANIC RUBBER EPDM NR VMQ Hardness [Shore A] Tensile strength [N/mm²] Elongation at break [%] Tear resistance [N/mm] Rebound resilience [%] Compression set [%] (150 C/3d) 64 n.a. 10 Engineering Silicones, May, 15, 2012 Slide 7
9 MINOR INFLUENCE OF THERMAL AGING ON MECHANICAL PROPERTIES OF SILICONE ELASTOMERS Hot air storage (14 d / 150 C) EPDM NR VMQ Hardness [Shore A] Tensile strength [N/mm 2 ] Elongation [%] 0 d d 53 n.a d d 10 n.a d d 200 n.a. 590 Weight loss [%] 14 d Engineering Silicones, May, 15, 2012 Slide 8
10 SILICONE RUBBER PERFORMS MUCH BETTER IN REPEATED TEMPERATURE EXCHANGE Tensile strength (N/mm²) Silicone Rubber EPDM Cycles One Cycle: 1h/-60 C and 1h/200 C Engineering Silicones, May, 15, 2012 Slide 9
11 HEAT- AND OILRESISTANCE ACCORDING ASTM-D 2000/SAE J 200) 250 FKM FPM heat resistance ( C) % VA 44% ACN 48% ACN FVMQ HT-ACM ACM HNBR HNBR NBR 34% ACN CO/ECO VMQ MVQ AEM EVM CM/CSM 18% ACN CR 40% VA SBR Engineering Silicones, May, 15, 2012 Slide 10 IIR BR EPDM NR maximum swell in oil IRM 903 (%)
12 SILICONE ELASTOMERS PROVIDE EXCELLENT LOW TEMPERATURE FLEXIBILITY AND HEAT RESISTANCE NR HNBR FKM EPDM ACM VMQ Working temperature range [ C] Engineering Silicones, May, 15, 2012 Slide 11
13 OUTSTANDING DEEP TEMPERATURE FLEXIBILTY AND HEAT RESISTANCY Cold Flexibilty ( C) acc DIN NR SBR CR CR IIR NBR ECO CO/ECO cristallization CM/CSM HNBR HNBR EPDM ACM EVM AEM Compounding FVMQ BR BR VMQ FKM * Temperatur, bei der nach 1000 h 50 % der Ausgangsbruchdehnung verbleiben Heat resistance* ( C) SILICONE RUBBER WIDELY USED HIGH PERFORMANCE MATERIALS Dr. Udo Wachtler, Silicone Rubber, April 2006, Slide 12
14 ADVANTAGES OF SILICONE ELASTOMERS Good long-term heat stability up to 180 C (with heat stabilizers up to 250 C and 300 C peak temperature) Low temperature flexibility down to -50 C Constant mechanical and electrical properties over a wide temperature range Excellent weathering, UV and ageing resistance Outstanding electric properties (excellent insulation) Low flammability (no toxic products evolved, insulating silica dioxide remains) High transparency Pigmentable in nearly every color Engineering Silicones, May, 15, 2012 Slide 13
15 SILICONE ELASTOMERS CAN BE CATEGORIZED INTO HIGH AND ROOM TEMPERATURE CURE SILICONES Silicone Elastomers High Temperature Curing Room Temperature Curing High Consistency Rubber (HTV) Liquid Silicone Rubber (LSR) 2-Component (RTV-2) 1-Component (RTV-1) peroxide cure platinum cure platinum cure platinum cure condensation cure condensation cure Engineering Silicones, May, 15, 2012 Slide 14
16 SILICONE ELASTOMERS REPRESENT ONE FIFTH OF THE GLOBAL SILICONES MARKET 2009 OF 8.0 BILLION EURO* Other Applications 10% Electrical Energy 20% Automotive 25% Silicone Elastomer Market BN EUR* 10% Electronics Photonics Medical and Health Care 15% 20% Machinery * Source: WACKER estimates Engineering Silicones, May, 15, 2012 Slide 15
17 SILICONE ELASTOMERS EXHIBIT A WEALTH OF UNIQUE MATERIAL CHARACTERISTICS Characteristics with special focus on sustainability and durability Excellent heat-stability (standard grades: 200 C; special grades: C) Low glass transition temperature (standard grades: -50 C; special grades: -120 C) Excellent long-term flexibility paired with very good mechanical properties Excellent long-term stability vs. wheathering and irradiation Excellent biocompatibility & physiological inertness Low flammability (no toxic combustion products) Free of plasticizers Engineering Silicones, May, 15, 2012 Slide 16
18 WACKER S LSR AND HTV PORTFOLIO INCLUDES GENERAL PURPOSE AND SPECIALTY GRADES LSR HTV General purpose General purpose High tear Healing free High tear Low Compression set Media resistant Highly trransparent Media resistant Fatique resistant Self-adhesive Colored Self-adhesive High green strength Flame retardant Flame retardant Low temp. flexibility Heat resistant Heat resistant High elasticity Oil bleeing Oil bleeding High damping LOW COF LOW COF Steam resistant Electrical conductive Electrical conductive Colored Engineering Silicones, May, 15, 2012 Slide 17
19 WACKER SILICONE ELASTOMERS SHOW PERFORMANCE IN MEDICAL APPLICATIONS Megatrend: Growing and Ageing Population Silicone Elastomers in Medical and Health Care Applications Medical Care Pourable silicone elastomers for medical devices, for example podology, liners, breast prothesis, dental or wound care Health Care Fabricator Silicone elastomers for the fabrication of rubber parts, for example medical tubings, seals and gaskets, masks or valves and baby care articles Engineering Silicones, May, 15, 2012 Slide 18
20 WACKER SILICONE ELASTOMERS SHOW PERFORMANCE IN ENERGY, ELECTRICS & ELECTRONICS Megatrend: Renewable Energy and Energy-Efficiency Silicone Elastomers in Electrical and Electronic Applications Transmission & Distribution Medium and high voltage insulation, for example insulators, arresters, cable accessories or transformers Wire & Cable Various cable applications, for example ignition cables, safety cables or sleevings Electronics & Photonics Encapsulation, potting, coating, sealing and bonding of electronic components and devices Solar Industry Sealing, bonding, potting in photovoltaic modules or fresnel lenses in concentrator modules Engineering Silicones, May, 15, 2012 Slide 19
21 SILICONE ELASTOMERS SHOW EXCELLENT PERFORMANCE IN MANY OTHER INDUSTRIES Megatrend: Rapid Growth of Emerging Markets Infrastructure and Mobility Silicone Elastomers are Used in a Broad Field of Applications Mold Making Silicone elastomers for moldmaking, rapid prototyping, pad printing or composite manufacturing Machinery & Transportation Silicone elastomers for encapsulation, potting, coating, sealing and bonding in various industry application Automotive Rubber Fabrication of rubber parts or textile coatings for automotive applications and the transportation industry Rubber Rubber parts for various applications, for example household, sports, fashion, construction or machinery Engineering Silicones, May, 15, 2012 Slide 20
22 WACKER SILICONE ELASTOMERS IMPROVE THE MANUFACTURING PROCESS AND THE PRODUCT Applications Silicone lens Gold wire Silicone encapsulation LED chip Reflector Heatsink Encapsulation of LED chips Manufacture of highly transparent LED optics Encapsulant for sensitive LED chips with bond wire Benefits of WACKER LUMISIL / SEMICOSIL Resistant to UV radiation Heat-resistant (> 250 C) Lead-free soldering possible (above 260 C) Lens production directly on LED chip in a single step Engineering Silicones, May, 15, 2012 Slide 21
23 SILICONE ELASTOMERS PLAY A MAJOR ROLE IN POWER GENERATION, TRANSMISSION AND DISTRIBUTION Germany s Electricity Grid The network of high-voltage and extra-high-voltage lines has a length of over 100,000 km. It is estimated that about 3.75 million insulators are in use. In Europe, tens of millions of insulators are therefore in use.* Advantages of Silicone Elastomers in Power Generation, -Transmission and -Distribution UV-Beständigkeit UV resistance thermische Stabilität Heat resistance Schwerbrennbarkeit Fire resistance Hydrophobie Hydrophobicity Erosions- und Kriechstromfestigkeit Erosion and tracking resistance Korona- und Ozonbeständigkeit Corona and ozone resistance Unempfindlich gegenüber mechanischer Belastung Unaffected by mechanical loading *Source: WACKER estimate Engineering Silicones, May, 15, 2012 Slide 22
24 OPTIMIZED POTTING PROCESSES WITH UV-ACTIVATED SILICONES IMPROVE EFFICIENCY Application Example in Electronics Potting/Coating of Power Modules Replaced process: two subsequent coating/potting processes with each step requiring 30 minutes curing at 150 C Optimized continuous process with 5 minutes curing at room temperature Application Example in Photovoltaics Potting of Junction Boxes Optimized process: 1K system - no mixing or dosing equipment needed From 4 hours curing at room temperature to 10 minutes curing at room temperature Engineering Silicones, May, 15, 2012 Slide 23
25 LOW DENSITY / NON ABRASIVE FULFILLS UL 94 V MM ELASTOSIL LR 3011/50 FR LR 3011/50 FR pc LR 3001/55 FR oil resistant npc LR 3001/60 FR oil resistant npc LR 3170/40 self adhesive npc Viscosity (0.9 s -1 ) [mpas] Density [g/cm³] Hardness Shore A Tensile strength [N/mm²] Elongation [%] Tear resistance [N/mm] Compression set (22h/175 C) [%] (22h/150 C) Color dark grey dark grey whitish beige dark grey Processing non abrasive abrasive abrasive non abrasive UL Yellow Card New! UL 94 V mm UL 94 V mm UL 94 V0 4 mm UL 94 V0 3 mm Engineering Silicones, May, 15, 2012 Slide 24
26 USE OF FIRE SAFETY CABLES Engineering Silicones, May, 15, 2012 Slide 25
27 FLAME RETARDANT HCR-SERIES EL R 770 CERTIFIED ACCORDING TO EUROPEAN RAILWAY STANDARDS SILICONE RUBBER Dr. Thomas Frese, S-E-R, June 2011, Slide 26
28 HARD/SOFT COMPOSITES CAN BE GENERATED BY USING UNDERCUTS AND PRIMERS Current technologies for hard/soft composites Drawbacks of undercuts and primers Silicone Substrate undercut additional processing step restricted design solvents included priming, surface treatment self-adhesion Engineering Silicones, May, 15, 2012 Slide 27
29 SELF-ADHESIVE SILICONE RUBBER INCREASES THE PRODUCTION EFFICIENCY Benefits of Self-Adhesive HTV and LSR Silicone Rubber Adhesion to a variety of rubbers, plastics and metals No undercut, no primer needed No solvents Join and seal in one step Suitable for various designs Higher efficiency in the production process: One-step process (adhesion during cure) High degree of automation, no assembly (2k injection molding, coextrusion, molding) Engineering Silicones, May, 15, 2012 Slide 28
30 ENERGY-EFFICIENT SOLUTIONS WITH SILICONE ELASTOMERS FOR LONG-TERM USE Summary Their special characteristics and excellent properties make silicone elastomers the ideal material in many applications: Ingredients not known to be harmful in any way End product is ideal for long-term use: durability and flexibility Manufacturing efficiency is boosted: reduction in energy consumption and costs Silicone elastomers help conserve energy and save on resources thanks to durable end products. Engineering Silicones, May, 15, 2012 Slide 29
31 ENERGY-EFFICIENT SOLUTIONS WITH SILICONE ELASTOMERS THANK YOU FOR YOUR ATTENTION! Engineering Silicones, May, 15, 2012 Slide 30
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