Introduction to Liquid Silicone Rubber (LSR) Opportunities of 2k-Injection Moulding

Transcription

1 CREATING TOMORROW`S SOLUTIONS (LSR) Opportunities of 2k-Injection Moulding Procureur Yann, Innov Days, 15 th June

2 Disclaimer The information contained in this presentation is for background purposes only and is subject to amendment, revision and updating. Certain statements and information contained in this presentation may relate to future expectations and other forward-looking statements that are based on management's current views and assumptions and involve known and unknown risks and uncertainties. In addition to statements which are forward-looking by reason of context, including without limitation, statements referring to risk limitations, operational profitability, financial strength, performance targets, profitable growth opportunities, and risk adequate pricing, as well as the words may, will, should, expects, plans, intends, anticipates, believes, estimates, predicts, or continue, potential, future, or further, and similar expressions identify forward-looking statements. By their nature, forward-looking statements involve a number of risks, uncertainties and assumptions which could cause actual results or events to differ materially from those expressed or implied by the forward-looking statements. These include, among other factors, changing business or other market conditions and the prospects for growth anticipated by the Company's management. These and other factors could adversely affect the outcome and financial effects of the plans and events described herein. Statements contained in this presentation regarding past trends or activities should not be taken as a representation that such trends or activities will continue in the future. The Company does not undertake any obligation to update or revise any statements contained in this presentation, whether as a result of new information, future events or otherwise. In particular, you should not place undue reliance on forward-looking statements, which speak only as of the date of this presentation. 1

3 Agenda Wacker Silicones Silicone & Silicone Elastomers Processing of Liquid Silicone Rubber Self-adhesive to realize Hard-soft Composites 2

4 WACKER SILICONES Over 100 Years of Success #2 Market Position 2,001 million Sales % Growth 4,236 Employees 3,000 Silicone Products 15 Technical Centers 12 Production Sites 3 Integrated Production Sites Silicones: An essential product or process material in nearly all industries all figures

5 Agenda Wacker Silicones Silicone & Silicone Elastomers Processing of Liquid Silicone Rubber Self-adhesive to realize Hard-soft Composites 4

6 What are Silicones? Generic name for a class of synthetic polymers with Si-O links made from silicon metal R R Si R R R R Si R R O Si O Si O R R R Si R Quartz Silicon metal Silane Polydimethylsiloxane 5

7 What are Silicone Elastomers? Essential Raw Materials are Polymer and Silica R R Si O R R Si O Si O Si R R R R R Si Si O R R R Si Si O O Si R R R R R R Si Si O O O Si R R R R Structural similarity of silicone polymer and silica filler (Si-O) and low particle size of primary particles SiO 2 translucent Elastomeric, rubber-like polymers with a combination of very unique properties 6

8 Silicone Elastomers Properties qualify for wide range of applications Chemical properties Thermal stability up to 180 C, with heat stabilizers up to 300 C Chemical inertness Sterilizability for single and multiple use Good media resistance against a variety of solvents and chemicals Good weathering, UV and ageing resistance Physical properties Constant mechanical and electrical properties over a wide temperature range Low temperature flexibility down to -50 C (T g = -125 C) Hydrophobicity, low surface tension High gas permeability 7

9 Silicone Elastomers Bring into your Articles nearly every Color ELASTOSIL COLOR PASTES FL F F F F ELASTOSIL COLOR PASTES FL that can be used as heat stabilizers F IVORY 1014 RED-BROWN 2001 RED IRON OXIDE 3013 DEEP BLACK 9005 BLACK 9005 F Recommendation for long-term applications in hot air at T > 160 C Typical dosing 2 % Improvement of compression set 8

10 Silicone Elastomers comply with relevant regulatory Requirements Food contact FDA CFR Rubber articles intended for repeated use BfR XV. Silicone, section III. Silicone elastomers Biocompatibility United States Pharmacopoeia <88> Biological reactivity tests, In vivo, Class VI ISO Biological Evaluation of Medical devices Pharmaceutical applications European Pharmacopoeia Silicone elastomers for closures and tubing Others Free of phthalates and other organic softeners (EU directive 2007/19/EC) Free of nitrosamines (EU directive 93/11/EEC) Free of latex and plant proteins, animalderived products, organic stabilizers 9

11 Silicone Elastomers Offer Countless Unique Properties Material Characteristics & Advantages Heat resistant Low temperature flexible Electrically insulating Electrically conductive Constant properties Radiation resistant Weather resistant High damping Highly elastic Low flammability Chemical resistant Pure Biocompatible Sterilizability for multiple use High transparent 10

12 Agenda Wacker Silicones Silicone & Silicone Elastomers Processing of Liquid Silicone Rubber Self-adhesive to realize Hard-soft Composites 11

13 Torque / MPa Liquid Silicone Rubber Processing of ELASTOSIL LR Injection molding / Process technology Processing advantages Short cycle times (low viscosity, high vulcanization speed) A B Fully automated processing Mold with up to 128 cavities No waste in cold runner tool Shear thinning behavior 4000 Curing behavior No mechanical finishing necessary Shear rate / s-1 0,6 0,5 0,4 0,3 0,2 0,1 0 T = 150 C Time / s Combination of hard and soft materials Realization of complex geometries (thin wall thickness with long flow distance) 12

14 Agenda Wacker Silicones Silicone & Silicone Elastomers Processing of Liquid Silicone Rubber Self-adhesive to realize Hard-soft Composites 13

15 Préambule Les pièces multi-composants sont devenues de plus en plus nombreuses ces dernières années. Qu'il soit dans les secteurs automobiles, sanitaires, médicaux ou domestiques par exemple, les systèmes composites s imposent dans les produits novateurs et la production automatisée, économique et fiable. L injection multi-composants comme "le moulage Séquentiel, le Surmoulage, la Co-injection (le moulage de Sandwich), l assemblage dans le moule, les techniques de transfert, de rotation élargissent la portée possible pour la conception créative et la polyvalence des fonctions et de l'application. Les silicones «LSR» sont dorénavant des matières qui répondent aux exigences et aux défis de ces procédés dans la filière plasturgie grâce à des matières aux fonctionnalités variées et polyvalentes. 14

16 Self-adhesive to realize Hard-soft Composites Self adhesive Liquid Silicone Rubber Direct bonding technology Product portfolio Mold Concepts Applications Self-adhesive technology invented by WACKER 15

17 Hard-soft Composites Current technologies LSR Current technologies for hard/soft composites Drawbacks of undercuts, primers and surface treatments Silicone Substrate Undercuts Primer Surface treatment Additional processing steps (cleaning, pre-treatment) Expensive equipment Solvents included Ambitious design Not suitable for complex geometries Time-limited activation of the surface (plasma) 16

18 Self-adhesive LSR offers efficient technique for 2K parts Direct bonding Bonding agent Silicone Substrate Silicone Substrate Benefits self-adhesion technology Adhesion to silicone elastomers, plastics, metals and glass No undercuts, no primer needed No solvents Join and seal in one step Suitable for various designs One-step process (adhesion during cure) High degree of automation, no assembly (2K injection molding) 17

19 The process of self adhesion occurs by chemistry Process of Migration Self adhesion starts with migration adhesion promotors are soluble in the uncured rubber migration occurs during the curing process of the rubber and after rubber is vulcanized Curing process 18

20 Adhesion promotors react at the surface to create new molecules Process of bonding Reaction at the surface give different molecules adhesion promotor react at the surface concentration at the surface layer decreases but silicone matrix pursue to fill the gap (equilibrium state) adhesion promotors will react, etc. in the end almost all promotors (new molecules) is clearly identified at the interface Adhesion improve by time and post curing 19

21 Self-adhesive LSR of WACKER suitable bonding partners ELASTOSIL LR 307x and SILPURAN 6700 for direct bonding on selected thermoplastics PEEK LCP PEI PES (PPS) High performance plastics PC PET PBT PMMA ABS PA POM Engineering plastics PS PP SAN PVC PE-HD PE-LD Commodities good adhesion no direct bonding 20

22 Adhesion performance depends on substrate and surface functionalities Substrate General Adhesion performance Substrate General Adhesion performance PA PES --- PA PEI --- PA PE / PP --- PA PPE ++ PBT +++ PPS - PET +++ PSU --- PC --- VMQ ++ PEEK ++ PMMA

23 Self-adhesive ELASTOSIL LR Adhesion after press curing (DIN ISO 813) 22

24 Self-adhesive ELASTOSIL LR product range Product portfolio Self adhesive HEALTH CARE Good adhesion to PA+PBT 3070/10-60 Food contact (BfR, FDA), KTW 3071/30-60 Self-adhesive, PET, PBT, (PA) 6700/40-60 Low COF + reduced self-heal. 6760/50 Oil bleeding 3072/30-50 Coolant resistant 3074/60 Oil resistant, npc low CS 3076/50 + /70 Specialties Flame retardant, UL 94 V0 3170/40 Hot water res. (Food, KTW) 3271/45 Self-adhesive technology invented by WACKER Low COF + reduced self-heal. 3671/

25 2k-Injection Mould concepts Transfer system Rotary Table system Index Plate system Others Index Plate system Sliding Split system 24

26 Process developed and promoted for the K2016 show-case R&D Department / Innovation: Patrice JACQUET p.jacquet@pernoud.com 25

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28 Coolant Resistant ELASTOSIL LR products for Radiator Gaskets to keep the engine cool Requirements Good coolant resistance (Glysantin G40, G30 > G48 > G33) Excellent low temperature flexibility down to -50 C Low compression set Self adhesion for the production of 2K parts (LR 3074/60) Grades of choice ELASTOSIL LR 3074/60 (self adhesive) 27

29 Hybrid, Electric and Fuel Cell Vehicles Require Challenging High Voltage System Component Solutions HV Connecting and Contact Systems System Requirements High voltage electrical insulation Very reliable sealing performance Heat resistance & low temp. flexibility High voltage singe wire seals Self-adhesive LSR: Adhesion ensures reliable sealing performance Shielded cables and connectors LSR processing advantages Silicone elastomers for long operating lifetime ELASTOSIL Grades of Choice LR 384x (oil bleeding) LR 3065 (low COF) LR 3070 (self-adhesive) Upper image: courtesy of Rosenberger Hochfrequenztechnik GmbH & Co. KG 28

30 ELASTOSIL LR 3072/50 Completes WACKER s Portfolio of Self-Adhesive and Oil Bleeding LSR Solutions Benefits of LR 3072/50 Soft-hard combination of LSR and PA, PBT New Product Self bonding Reduced COF due to oil film formation Low compression set for excellent sealing 10 %* after 22 h / 125 C Application Single wire seals in addition to connector seals Oil bleeding * Acc. ISO type B method A, non post cured 29

31 Self-Adhesion Technology Can Be Combined with WACKER s Low Coefficient of Friction (COF) Technology Product Benefits Self bonding Low coefficient of friction New Product Food Product of Choice ELASTOSIL LR 3671/ BfR, FDA approved Easier opening of thermos flasks Medical Product of Choice SILPURAN 6760/50 New Product Fine filtering (50 µm) / packaging into clean room* USP class VI, ISO *Class 8 acc. DIN EN ISO

32 Useful link at hptt/. Liquid Silicone Rubber opens up new dimensions at ELASTOSIL Hard-Soft Combinations on the Advance at Wacker - ACEO 3D Printing with Silicones at 31

33 Thank You for Your Attention. 32

34 The impressive success story of Self-adhesive LSR is moving forward Feasible functionalities Sealing, insulating and shielding (single- or multi functionality) Elasticity / rebound (buttons, membranes) Damping / decoupling of vibrations Lighting (diffusor, protector) 33

35 The impressive success story of Self-adhesive LSR is moving forward New trends and opportunities for self adhesive LSR Simplified and safe assembly Downsizing requires Weight reduction Many sealing functions in one part with one shot reduces costs 34