An Engineer s Guide to Specify the Right Thermoplastic
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1 AGENDA An Engineer s Guide to Specify the Right Thermoplastic Steve Maki Vice President Technology smaki@rtpcompany.com 1. Define Compounding 2. Plastic Resin Selection Process 3. Application Case Studies 4. Compounding To Enhance Performance 5. New RTP Technologies rtpcompany.com rtp@rtpcompany.com INDEPENDENT SPECIALTY COMPOUNDER COMPOUNDING PROCESS Compounder We blend thermoplastic resins with fillers, additives, and modifiers Raw Materials Finished Product Specialty We create engineered formulations Independent We are unbiased in our selection of raw materials Blender Extruder Cooling Pelletizer Classifier 1
2 COMPOUNDING OBJECTIVES COMPOUNDING EXTRUDERS Mixing Dispersive Distributive Agglomerates Dispersion Distribution Single Screw Twin Screw Co-Kneader PUTTING COMPOUNDING INTO PERSPECTIVE Resin Selection Conductive carbon black surface area = 130 m 2 /gram 34 grams carbon black = surface area of football field (4460m 2 ) Dispersing a 20% carbon black compound is similar to evenly coating a football field with 136 grams of plastic! 2
3 THE DILEMMA PLASTIC SELECTION PROCESS 60 thermoplastic resins additives = 1000 s of potential compounds Step 1: Use Resin Morphology Step 2: Use Thermal & Cost Requirements Step 3: Fine Tune & Special Features Which ONE Do I Choose For My Application??? PLASTIC SELECTION PROCESS MORPHOLOGY Step 1: Use Resin Morphology The form and structure the molecules of a polymer take upon solidification Step 2: Use Thermal & Cost Requirements Step 3: Fine Tune & Special Features Amorphous Semi-Crystalline 3
4 MORPHOLOGY MORPHOLOGY CHARACTERISTICS Amorphous Semi-Crystalline Low Shrinkage Compare Amorphous Semi-Crystalline Low Warpage Tight Tolerances Transparency Molecular packing (shrinkage) Resistance to molecular disentanglement (chemical/abrasion resistance) Melting characteristics (flow) Light refraction (opacity) Mold Flow Ease Chemical Resistance Wear Resistance MORPHOLOGY CHARACTERISTICS MORPHOLOGY OF THERMOPLASTICS Lens? Fuel Float? Precision Printer Chassis? Tool Housing? Multiple Pin Connector? Pulley? Grease Fitting? Laptop Cover? Low Shrinkage Low Warpage Tight Tolerances Transparency Mold Flow Ease Chemical Resistance Amorphous Semi-Crystalline Amorphous Polyetherimide (PEI) Polyethersulfone (PES) Polysulfone (PSU) Amorphous Nylon Polycarbonate (PC) Acrylic (PMMA) Acrylonitrile Butadiene Styrene (ABS) Styrene Acrylonitrile (SAN) High Impact Polystyrene (HIPS) Polystyrene (PS) Semi-Crystalline Polyetheretherketone (PEEK) Polyphenylene Sulfide (PPS) Polyphthalamide (PPA) Polyamide (PA/Nylons) Polybutylene Terephthalate (PBT) Polyethylene Terephthalate (PET) Acetal (POM) Polylactic Acid (PLA) Polypropylene (PP) Polyethylene (HDPE, LDPE, LLDPE) Wear Resistance 4
5 PLASTIC SELECTION PROCESS MORPHOLOGY VS. THERMAL/COST Step 1: Use Resin Morphology Step 2: Use Thermal & Cost Requirements Step 3: Fine Tune & Special Features Amorphous Polyetherimide (PEI) Polyethersulfone (PES) Polysulfone (PSU) Amorphous Nylon Polycarbonate (PC) Acrylic (PMMA) Acrylonitrile Butadiene Styrene (ABS) Styrene Acrylonitrile (SAN) High Impact Polystyrene (HIPS) Polystyrene (PS) Thermal & Cost Increases Semi-Crystalline Polyetheretherketone (PEEK) Polyphenylene Sulfide (PPS) Polyphthalamide (PPA) Polyamide (PA/Nylons) Polybutylene Terephthalate (PBT) Polyethylene Terephthalate (PET) Acetal (POM) Polylactic Acid (PLA) Polypropylene (PP) Polyethylene (HDPE, LDPE, LLDPE) Commodity (<$1.50) Engineered ($1.50-$4.00) High Performance (>$4.00) PLASTIC SELECTION PROCESS ENGINEERED & COMMODITY RESINS Step 1: Use Resin Morphology Step 2: Use Thermal & Cost Requirements Step 3: Fine Tune & Special Features Amorphous Amorphous Nylon Polycarbonate (PC) Acrylic (PMMA) Acrylonitrile Butadiene Styrene (ABS) Styrene Acrylonitrile (SAN) High Impact Polystyrene (HIPS) Polystyrene (PS) Semi-Crystalline Polyamide (PA/Nylons) Polybutylene Terephthalate (PBT) Polyethylene Terephthalate (PET) Acetal (POM) Polylactic Acid (PLA) Polypropylene (PP) Polyethylene (HDPE, LDPE, LLDPE) Commodity (<$1.50) Engineering ($1.50-$4.00) 5
6 AMORPHOUS RESINS SEMI-CRYSTALLINE RESIN Morphology Features -- Low Shrink, Low Warp, Tight Dimensional Tolerances, Transparent (except HIPS & ABS), Poor Chemical & Abrasion, Poor Flow in Thin Mold Sections Amorphous Amorphous Nylon Polycarbonate (PC) Acrylic (PMMA) Acrylonitrile Butadiene Styrene (ABS) Styrene Acrylonitrile (SAN) High Impact Polystyrene (HIPS) Polystyrene (PS) Special Features Transparent/good chem. resistance Optical transparency/high impact Optical transparency/uv stable High impact/high gloss/opaque Transparent/mod. chem. resistance Moderate impact/opaque Transparent/brittle Commodity (<$1.50) Engineering ($1.50-$4.00) Morphology Features -- Excellent Chemical Resistance, Excellent Abrasion Resistance, Good Flow in Thin Mold Sections, Poor Dimensions, Opaque Semi-Crystalline Special Features Nylon 6/12 Less Sensitive to humidity vs. 6&6/6 Nylon 6/6 Better thermal vs. 6/humidity Dep Nylon 6 Hides GF/strong but humidity Dep Polybutylene Terephthalate (PBT) Good electricals/easier to mold Polyethylene Terephthalate (PET) Good electricals/difficult to mold Acetal (POM) Low wear & friction/high fatigue Polylactic Acid (PLA) Green/Low impact & thermal Polypropylene (PP) Poor low temp impact/mod thermal Polyethylene (HDPE, LDPE, LLDPE) Good low temp impact Commodity (<$1.50) Engineering ($1.50-$4.00) PUTTING IT ALL TOGETHER Step 1: Use Resin Morphology Step 2: Use Thermal & Cost Requirements Step 3: Fine Tune & Special Features CD Jewel Case Transparent Flat & Dimensionally Stable Low Cost Test Your Knowledge With Application Examples PS 6
7 Gas Tank Good chemical resistance Good low temperature impact Low cost Auto Tail Lamp Cover Transparent Colors Dimensionally Stable Excellent UV Low Cost HDPE PMMA Plastic Glass Tumblers Transparent Reasonable Thermal & Chemical Resistance (Dishwasher Cycles) Sump Pump Housing Chemical resistance Reasonable thermal resistance Low cost Low Cost SAN PP + GF 7
8 Safety Glasses Optical transparency High impact Hub Odometer Lens Transparent Good Chemical Resistance Moderate-High Cost OK PC Amorphous Nylon Chemical Beakers Excellent chemical resistance Low Cost Transparent????????? Nail Gun Housing Good chemical resistance Excellent strength, stiffness & impact Good surface finish when reinforced Nylon 6 + GF 8
9 Automotive Intake Manifold Chemical resistance Excellent strength, stiffness & impact Moderate heat resistance Nylon 66 + GF Oil Pan Chemical resistance Excellent strength, stiffness & impact Moderate heat resistance Extremely tight dimensions & flat????????? Electrical Connectors Good flow in thin walls Excellent electrical properties Dimensionally stable in humidity Conveyor Rollers Good abrasion resistance Low wear & friction Moderate cost OK PBT (PET) + GF + FR Acetal 9
10 Lawn Tractor Hood Tight dimensions & low warp Printer Gears Extremely tight dimensions Good abrasion resistance Low wear & friction????????? Chemical resistance Good mold flow????????? MORPHOLOGY DEFICIENCIES Overcoming Resin Deficiencies Via Compounding Amorphous Semi-Crystalline Low Shrinkage D Low Warpage D Tight Tolerances D Transparency D Mold Flow Ease D Chemical Resistance D Wear Resistance D 10
11 DIMENSIONAL STABILITY FIBER REDUCES SHRINK Can We Reduce Shrink Rate & Improve Dimensional Stability of Semi-Crystalline Resins? Y X Shrink Rate X Shrink Rate Y Warp WARP CONTROL STRENGTH & WARP CONTROL Y X Shrink Rate X = Shrink Rate Y Flat Part But Low Strength! Y X Common Loading = 15% Glass Fiber & 25% Mineral or Beads 11
12 TRANSPARENCY Oil Pan Can We Make A Semi-Crystalline Resin Transparent? Chemical resistance Excellent strength, stiffness & impact Moderate heat resistance Extremely tight dimensions & flat Nylon % GF + 25% Mineral NUCLEATION/CLARIFICATION Compounding nucleator into PP or PE controls crystal size to less than wavelength of light = Transparency Melt Phase Nucleation Phase Semi-Crystalline Phase Chemical Beakers Excellent chemical resistance Low Cost Transparent Normal PP Opaque PP PP + Nucleator PP + Nucleator Clarified PP 12
13 CHEMICAL RESISTANCE/MOLD FLOW ALLOYING Can We Improve Chemical Resistance & Mold Flow of Amorphous Resins? Alloy PC with ABS RTP 2500 A Series PC PC/ABS Tensile Strength, psi Flexural Mod, E6 psi Izod Impact, ft lb/in psi, 0 F Fuel Resistance Poor Poor Melt Flow, gm/10 min Clarity Transparent Opaque ALLOYING Alloy PC With Polyester (PBT or PET) RTP 2099 X B PC PC/PBT Tensile Strength, psi Flexural Mod, E6 psi Izod Impact, ft lb/in psi, 0 F Fuel Resistance Poor Fair Melt Flow, gm/10 min Clarity Transparent Opaque Lawn Tractor Hood Tight dimensions & low warp Moderate cost OK Chemical resistance Good mold flow PC/PBT Alloy 13
14 WEAR RESISTANCE PTFE LUBRICATED Can We Make An Amorphous Resin Wear Resistant? Compound PTFE Into PC RTP 300 TFE 15 PC PC/15 PTFE Acetal Wear Factor Dynamic Coef. of Friction WHAT S NEW? New Technologies Printer Gears Extremely tight dimensions Good abrasion resistance Low wear & friction PC + PTFE 14
15 NEW TECH (HEALTHCARE) NEW TECHNOLOGIES (COLOR) RTP 2000 HC Series Increased chemical resistance to healthcare cleaners vs PC, ABS, PC/ABS Good dimensional stability with shrinkage similar to above resins Flame retardant grade for electronic housings RTP 2000 HC FR A IR Reflecting Colors Allows Dark Colored Plastics To Remain Cool When Exposed To Sunlight Patio Furniture Decking/Pavers Roofs/Siding Auto Interiors NEW TECHNOLOGIES (FR) NEW TECHNOLOGIES (WEAR) FR Compounds for Plenum Applications (UL 2043) Low Heat/Smoke Release Grades FR PP Grades (Glass Fiber, Mineral, Unfilled) FR Nylon (Glass Fiber) Opportunities Wireless Access Points Speaker Housings Vent Diffusers Abrasion Resistant Compounds To Compete With UHMWPE (Not Moldable) Injection Moldable Polyolefin Alloy Similar Abrasion Resistance To UHMWPE Gears Cams Slides Wear Liners Cable Racks Light Housings 15
16 NEW TECH (HIGH TEMPERATURE) REVIEW Specialty Torlon Compounds RTP has a license agreement with Solvay Specialty Polymers to manufacture specialty compounds based on Torlon polyamide-imide Custom Fiber Reinforced Custom Wear Formulas Automotive Aerospace Industrial Intro To Compounding The Dilemma Resin Selection Procedure Resin Morphology Resin Cost & Thermal Performance Unique Resin Features Application Case Studies Compounding in Performance Overcoming Resin Deficiencies Introduction To New Technologies Questions? Thank you! Steve Maki Vice President Technology smaki@rtpcompany.com rtpcompany.com rtp@rtpcompany.com 16
An Engineer s Guide to Specify the Right Thermoplastic
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