Highly Toughened Gap Filling Adhesives For Enhanced Body Structure Reinforcement Daniel Sophiea / Raymond Bis Dow Automotive Systems GDIS2018

Transcription

1 Highly Toughened Gap Filling Adhesives For Enhanced Body Structure Reinforcement Daniel Sophiea / Raymond Bis Dow Automotive Systems GDIS2018

2 Content BETAMATE LWR Product Family Advantages of chemistry Advantages over manually applied tapes High modulus grade BETAMATE LWR Mid and low Modulus Grade BETAMATE LWR Performance Differences Recommended areas of use 3 Trademark of The Dow Chemical Company

3 Dow Automotive Product Line Body 180 C, 30 Paint C, 30 Trim 25 C Repair BETAMATE LWR is a toughened epoxy hybrid chemistry for use in the body shop Elastic PU Sealants: BETAFILL Elastic PU Adhesives\Sealants: BETASEAL, BETAMATE, BETALINK Structural PU Adhesives: BETAFORCE Elongation % 800 Toughened Epoxy Adhesives: BETAMATE Structural Epoxy Adhesives: BETAMATE Expandable Epoxy Hybrid Adhesives: BETAMATE Structural PU Adhesives: BETAFORCE LWR Trademark of The Dow Chemical Company Lap Shear Strength (MPa)

4 BETAMATE LWR Expandable Adhesives Typical body B-Pillar Structural BETAMATE Designed for BIW substrates Mass efficient solution Toughness and body stiffness Applied in bulk Application of BETAMATE LWR Structural BETAFOAM 5

5 BETAMATE LWR Products One Part Epoxy Hybrids Body Shop Bake bonds through oily substrates Toughened Absorbs energy and does not become brittle at cold temperatures Expandable Fills gaps and compensates for Robotically applied in bulk Designed to endure wash and e-coat cycles metal separation and movement during thermal loads 6

6 Robotically Applied Expandable Structural Adhesive Expands 150% by volume fills gaps Robotic Application Removes risk of human error Faster cycle times Removes added labor and piece costs Tailored Application bead dimensions Useful for areas that are difficult to weld Robust adhesion to a variety of metals Useful for areas with variable design gaps up to 15 mm Can bond substrates with different CLTE 5mm Uniform Expansion 7

7 Tape vs. Paste Application Tape Adhesive Material Applied Parts Mated Thermal Load Expansion & Cure 8 Paste Adhesive

8 BETAMATE LWR Product Family Low modulus Storage Modulus Loss Modulus Tan δ High Modulus High Modulus (Crash Worthiness Stiffness Torsional rigidity) Fills gaps to improve structural integrity Weld accessibility Thermal expansion Galvanic corrosion 9 Before Bake Temp ( C) After Bake Low Modulus (NVH Performance moderate structural bond, class A surfaces)

9 BETAMATE LWR Product Family Product Status Modulus Applications BETAMATE LWR High Modulus Implemented MPa Stiffness, crash worthiness BETAMATE LWR Medium Modulus BETAMATE LWR Low Modulus Commercially available 4 th Quarter 2018 Commercially available 2 nd quarter MPa Tape replacement, NVH MPa NVH, Low distortion to class A surfaces 10

10 Key Areas Targeted For BETAMATE LWR High modulus for crash and torsional stiffness Mid modulus for areas that need high stiffness and have mild distortion issues Low modulus for areas that have surfaces more sensitive to defects in the class A surface 11

11 Typical Uses for BETAMATE LWR High Modulus Key areas for crash performance in pillar areas Rocker panels for stiffness and torsional rigidity Sun roof support rings (non class A surface) 12

12 Flexural Load (lbs-force) BETAMATE LWR High Modulus 300 Force Deflection Response (Standard Bake 171 C) Toughened Material 150% Volume Expansion 101% Volume Expansion Non toughened Material 150% Expansion Deflection (in.) 13

13 Special Case: Bonding Class A Surfaces Class A Surfaces present special challenges Read-through Outer panel distortion Rigidity loss by light weighting Each application is unique Reflected light showing surface distortion LWR performance tailored to alleviate distortion Issues 14

14 Metal strain Thermal Load and Induced Strain Thermal loads cause: Metal expansion Induced strain Returns to original state upon cooling 0 Near Perfect Hysteresis of Non-bonded Part Heat Up Cool Down Heat Up Cool Down Temp C 15

15 Metal strain Adhesives and Residual Strain When bonding two parts together the adhesive hardens and can prevent perfect hysteresis This can result in visual defects in class A surfaces 0 Residual Strain Remains After Cooling Original Heat/Cool Adhesive bonded part C 16

16 Metal strain Balancing Performance Residual strain levels can be minimized through the optimization of LWR cured performance properties 0 Remaining Residual Strain high modulus mid modulus low modulus Temp C 17

17 BETAMATE LWR Low Modulus Possible applications on: lift gates doors roofs pillars and other class A areas in need of stiffness and improved NVH response Lower Modulus (compared to most structural adhesives) Lower Tg (compared to most structural adhesives) Areas with more contour and/or stiffness utilize mid modulus such as front and rear header areas and roof perimeter mid modulus low modulus Better NVH response (compared to most anti-flutters) More structure than anti-flutter material 18

18 PLI PSI Strength Differences Lap Shear Strength 0 low mid high Modulus T-Peel Strength Lap Shear and T-peel geometry 10 0 low mid high Modulus

19 Conclusion BETAMATE LWR is a new tool for engineers that offers: Expansion Robotic application Tailored performance Potential cost savings 20

20 For More Information Raymond Bis Dow Automotive Dr. Tyler Auvil Dow Automotive Mansour Mirdamadi Dow Automotive Thank You!! 21