Korporacja KGL S.A. RTP Company. Dobór odpowiedniego tworzywa do wymogów aplikacji. An Engineer s Guide to Specifying the Right Thermoplastic

Transcription

1 Korporacja KGL S.A. przy współpracy z / in cooperation with RTP Company przedstawia / presents Dobór odpowiedniego tworzywa do wymogów aplikacji An Engineer s Guide to Specifying the Right Thermoplastic

2 THERM0PLASTIC ELASTOMERS STRUCTURAL WEAR CONDUCTIVE COLOR FLAME RETARDANT An Engineer s Guide to Specifying the Right Thermoplastic Steve Maki Vice President Technology RTP Company

3 Agenda Plastic Resin Selection Process Application Case Studies Compounding for Performance Engineering High Strength Composites

4 THERM0PLASTIC ELASTOMERS STRUCTURAL WEAR CONDUCTIVE COLOR FLAME RETARDANT Resin Selection

5 The Dilemma 60 Thermoplastic Resins Additives = 1000 s of Potential Compounds Which 1 Do I Choose For My Application????

6 Plastic Selection Process Step 1 -- Use Resin Morphology Step 2 -- Use Thermal & Cost Requirements Step 3 -- Fine Tune & Special Features

7 Morphology The form and structure the molecules of a polymer take upon solidification Amorphous Semi-Crystalline

8 Morphology Amorphous Semi-Crystalline Compare Molecular Packing (Shrinkage) Chemical Bonds (Chemical/Abrasion Resistance) Melting Characteristics (Flow) Light Refraction (Opacity)

9 Morphology Characteristics Low Shrinkage Low Warpage Tight Tolerances Transparency Mold Flow Ease Chemical Resistance Wear Resistance Amorphous Semi-Crystalline

10 Morphology Characteristics Amorphous Semi-Crystalline Low Shrinkage Low Warpage Tight Tolerances Transparency Mold Flow Ease Chemical Resistance Wear Resistance Lens? Fuel Float? Lamp Housing? Tool Housing? Pulley? Precision Printer Chassis? Intake Manifold? Grease Fitting? Laptop Cover?

11 Morphology Of Thermoplastics Amorphous Polyetherimide (PEI) Polyethersulfone (PES) Polysulfone (PSU) Amorphous Nylon Polycarbonate (PC) Acrylonitrile Butadiene Styrene (ABS) Styrene Acrylonitrile (SAN) Polystyrene (PS) High Impact Polystyrene (HIPS) Acrylic (PMMA) Semi-Crystalline Polyetheretherketone (PEEK) Polyphenylene Sulfide (PPS) Polyphthalamide (PPA) Polyamide (PA/Nylons) Polyethylene Terephthalate (PET) Polybutylene Terephthalate (PBT) Acetal (POM) Polylactic Acid (PLA) Polypropylene (PP) Polyethylene (HDPE, LDPE)

12 Plastic Selection Process Step 1 -- Use Resin Morphology Step 2 -- Use Thermal & Cost Requirements Step 3 -- Fine Tune & Special Features

13 Amorphous Polyetherimide (PEI) Polyethersulfone (PES) Polysulfone (PSU) Amorphous Nylon Polycarbonate (PC) Acrylonitrile Butadiene Styrene (ABS) Styrene Acrylonitrile (SAN) Polystyrene (PS) High Impact Polystyrene (HIPS) Acrylic (PMMA) Morphology Vs Thermal/Cost Thermal & Cost Increases Semi-Crystalline Polyetheretherketone (PEEK) Polyphenylene Sulfide (PPS) Polyphthalamide (PPA) Polyamide (PA/Nylons) Polyethylene Terephthalate (PET) Polybutylene Terephthalate (PBT) Acetal (POM) Polylactic Acid (PLA) Polypropylene (PP) Polyethylene (HDPE, LDPE, LLDPE) Commodity (<$1.50) Engineered ($1.50-$4.00) High Performance (>$4.00) Commodity (< 2.50/kg) Engineered ( /kg) High Performance (> 6.50/kg)

14 Plastic Selection Process Step 1 -- Use Resin Morphology Step 2 -- Use Thermal & Cost Requirements Step 3 -- Fine Tune & Special Features

15 Engineered & Commodity Resins Amorphous Amorphous Nylon Polycarbonate (PC) Acrylonitrile Butadiene Styrene (ABS) Styrene Acrylonitrile (SAN) Polystyrene (PS) High Impact Polystyrene (HIPS) Acrylic (PMMA) Semi-Crystalline Polyamide (PA/Nylons) Polyethylene Terephthalate (PET) Polybutylene Terephthalate (PBT) Acetal (POM) Polylactic Acid (PLA) Polypropylene (PP) Polyethylene (HDPE, LDPE, LLDPE) Commodity (<$1.50/lb) Engineering ($ $4.00/lb) Commodity (< 2.50/kg) Engineering ( /kg)

16 Styrenic Features Morphology Features -- Low Shrink, Low Warp, Tight Dimensional Tolerances, Transparent (except HIPS & ABS) PS Brittle, Good Low Cost HIPS -- Moderate Impact Low Cost SAN -- Brittle, Low Cost, Good Transparency & Moderate Chemical Resistance ABS -- Good Thermal, Low-Moderate Cost, Excellent Impact Resistance & Gloss

17 Acrylic Features Morphology Features -- Low Shrink, Low Warp, Tight Dimensional Tolerances, Transparent PMMA -- Brittle, Low Cost, Optical Quality Transparency, Excellent UV Stability

18 Polycarbonate Features Morphology Features -- Low Shrink, Low Warp, Tight Dimensional Tolerances, Transparent PC -- Moderate Cost, Optical Quality Transparency, High Impact Resistance

19 Olefin Features Morphology Features -- Excellent Chemical Resistance, Excellent Abrasion Resistance, Good Flow in Thin Mold Sections PP Low Temperatures, Low Cost, Low Density, Reasonable Thermal Resistance, Living Hinge Capable HDPE -- Low Cost, Low Density, Good Low Temp Impact Performance [Tg = -77 C vs -9 C for PP (-107 F vs +16 F)]

20 Polyamide Features Morphology Features -- Excellent Chemical Resistance, Excellent Abrasion Resistance, Good Flow in Thin Mold Sections (Except Amorphous Nylon) Nylon 6 -- Moderate Cost, Strong/Stiff (But Humidity Dependent), Good Surface Finish Even When Reinforced Nylon Moderate Cost, Strong/Stiff (But Humidity Dependent), Higher HDT Nylon 6/12, 11, 12, etc. High Cost, Less Sensitive to Humidity

21 Amorphous Nylon Features Morphology Features -- Low Shrink, Low Warp, Tight Dimensional Tolerances, Transparent Amorphous Nylon High Cost, Good Chemical Resistance for Amorphous Morphology

22 Polyester Features Morphology Features -- Excellent Chemical Resistance, Excellent Abrasion Resistance, Good Flow in Thin Mold Sections PET -- Moderate Cost, Difficult to Mold (Poor Nucleation & Hydrolysis), Good Electrical Resistance PBT -- Moderate Cost, Easy to Mold, Good Electrical Resistance, Properties & Dimensions Do Not Fluctuate With Humidity (Same For PET) PLA Difficult to Mold (Poor Nucleation & Hydrolysis), Poor Impact, Poor Heat Resistance, Low Cost, Green Polymer

23 Polyoxymethylene (Acetal) Features Morphology Features -- Excellent Chemical Resistance, Excellent Abrasion Resistance, Good Flow in Thin Mold Sections Acetal -- Moderate Cost, Excellent Resiliency & Fatigue Endurance, Low Friction & Wear

24 THERM0PLASTIC ELASTOMERS STRUCTURAL WEAR CONDUCTIVE COLOR FLAME RETARDANT Application Case Studies

25 Putting It All Together Step 1 -- Use Resin Morphology Step 2 -- Use Thermal & Cost Requirements Step 3 -- Fine Tune & Special Features Test Your Knowledge With Application Examples

26 Case Study CD Jewel Case PS Transparent Flat & Dimensionally Stable Low Cost

27 Case Study Gas Tank Good Chemical Resistance Good Low Temperature Impact Low Cost HDPE

28 Case Study Auto Tail Lamp Cover Transparent Colors Dimensionally Stable Excellent UV Low Cost PMMA

29 Case Study Plastic Glass Tumblers Transparent Reasonable Thermal & Chemical Resistance (Dishwasher Cycles) Low Cost SAN

30 Case Study Sump Pump Housing Chemical & Moisture Resistance Moderate Thermal Resistance & Stiffness Low Cost PP + Glass Fiber

31 Case Study Safety Glasses PC Optical Transparency High Impact Moderate Cost OK

32 Case Study Truck Wheel Odometer Lens Transparent Good Chemical Resistance Moderate Cost OK Amorphous Nylon (Polyamide)

33 Case Study Chemical Beakers Transparent Excellent Chemical Resistance Low Cost?????????

34 Case Study Nail Gun Housing Good Chemical Resistance Excellent Strength, Stiffness & Impact Good Surface Finish When Reinforced Moderate Cost OK (Polyamide) Nylon 6 + Glass Fiber

35 Case Study Automotive Intake Manifold Chemical Resistance Excellent Strength, Stiffness & Impact Good Heat Resistance Moderate Cost OK (Polyamide) Nylon 6/6 + Glass Fiber

36 Case Study Oil Pan Chemical Resistance Excellent Strength, Stiffness & Impact Good Heat Resistance Moderate Cost OK Extremely Tight Dimensions & Flat?????????

37 Case Study Electrical Connectors Good Flow in Thin Walls Excellent Electrical Properties Dimensionally Stable in Humidity Moderate Cost OK PBT (PET) + Glass Fiber + Flame Retardant

38 Case Study Conveyor Rollers Good Abrasion Resistance Low Wear & Friction Moderate Cost OK Acetal

39 Case Study Printer Gears Good Abrasion Resistance Low Wear & Friction Moderate Cost OK Extremely Tight Dimensions?????????

40 Case Study Lawn Tractor Hood Chemical Resistance Good Mold Flow Moderate Cost OK Tight Dimensions & Low Warp?????????

41 THERM0PLASTIC ELASTOMERS STRUCTURAL WEAR CONDUCTIVE COLOR FLAME RETARDANT Overcoming Morphology Deficiencies via Compounding

42 Independent Specialty Compounder Compounder = We blend thermoplastic resins with fillers, additives, and modifiers Specialty = We create engineered formulations Independent = We are unbiased in our selection of raw materials

43 Compounding Process Raw Materials Finished Product Blender Extruder Cooling Pelletizer Classifier

44 Morphology Deficiencies Amorphous Semi-Crystalline Low Shrinkage D Low Warpage D Tight Tolerances D Transparency D Mold Flow Ease D Chemical Resistance D Wear Resistance D

45 Dimensional Stability Can We Reduce Shrink Rate, Improve Dimensional Stability & Flatness of Semi-Crystalline Resins?

46 Fiber Reduces Shrink Shrink Rate X Shrink Rate Y Warp

47 Warp Control Shrink Rate X = Shrink Rate Y But Low Strength! Flat Part

48 Strength & Warp Control Common Loading = 15% Glass Fiber & 25% Mineral or Beads

49 Case Study Oil Pan Chemical Resistance Excellent Strength, Stiffness & Impact Good Heat Resistance Moderate Cost OK Extremely Tight Dimensions & Flat (Polyamide) Nylon 6/6 + 15% Glass Fiber + 25% Mineral

50 Transparency Can We Make A Semi-Crystalline Resin Transparent?

51 Nucleation/Clarification Compounding nucleator into PP or PE controls crystal size to less than wavelength of light = Transparency Courtesy Milliken Chemical

52 Case Study Chemical Beakers Transparent Excellent Chemical Resistance Low Cost PP + Nucleator

53 Chemical Resistance/Mold Flow Can We Improve Chemical Resistance & Mold Flow of Amorphous Resins?

54 Alloy PC with ABS RTP 2500 A Series Alloying PC PC/ABS Tensile Strength, psi (MPa) 9000 (62) 8900 (61) Flexural Mod, E6 psi (MPa) 0.34 (2340) 0.40 (2760) Izod Impact, ft lb/in (J/m) 15 (800) 13 (700) 264 psi, F ( C) 270 (130) 210 (100) Fuel Resistance Poor Poor Melt Flow, gm/10 min Clarity Transparent Opaque

55 Alloying Alloy PC With Polyester (PBT or PET) RTP 2099 X B PC PC/PBT Tensile Strength, psi (Mpa) 9000 (62) 8700 (60) Flexural Mod, E6 psi (MPa) 0.34 (2340) 0.35 (2410) Izod Impact, ft lb/in (J/m) 15 (800) 15 (800) 264 psi, F ( C) 270 (130) 250 (120) Fuel Resistance Poor Fair Melt Flow, gm/10 min Clarity Transparent Opaque

56 Case Study Lawn Tractor Hood Chemical Resistance Good Mold Flow Moderate Cost OK Tight Dimensions & Low Warp PC/PBT Alloy

57 Case Study GPS Housing Good Mold Flow Tight Dimensions & Flat High Impact Moderate Cost OK PC/ABS or PC/PBT Alloy Want Sustainability PC/PLA Alloy (30% Bio) Want More Sustainability Recycled (PCR) PC/PLA Alloy (30%Bio + 60% PCR = 90% Sustainable)

58 Wear Resistance Can We Make An Amorphous Resin Wear Resistant?

59 PTFE Lubricated Compound PTFE Into PC RTP 300 TFE 15 PC PC/15 PTFE Acetal Wear Factor * Dynamic Coef. of Friction * (in 3 min/ft/lb/hr) E-10

60 Case Study Printer Gears Good Abrasion Resistance Low Wear & Friction Moderate Cost OK Extremely Tight Dimensions PC + PTFE

61 THERM0PLASTIC ELASTOMERS STRUCTURAL WEAR CONDUCTIVE COLOR FLAME RETARDANT Engineering High Strength Composites The Theory of Reinforcement

62 Additive Aspect Ratio Aspect Ratio = L/D

63 Filler/Reinforcement Classification Additive Geometry Aspect Ratio Classification Glass Beads Spherical 1 Filler Clay Platy 1-3 Filler Calcium Carbonate Talc Platy Platy Filler Filler Wollastonite Acicular 5-20 Transition Mica Flake Transition Milled Glass Fibrous Transition Glass Fiber Carbon Fiber Fibrous Fibrous Reinforcement Reinforcement

64 Filler vs. Reinforcement F iller Reinforcement Shrink Control + ++ Strength 0 ++ Modulus + ++ Impact Resistance -- * Heat Distortion + ++ * Reinforcements Tend to Make Brittle Resins Tough and Tough Resins Brittle

65 Filler vs. Reinforcement RTP 200 Nylon 6-6 Unfilled RTP 227 Nylon % Filler RTP 207 Nylon % Reinforcement Mold Shrinkage, in/in (cm/cm) Tensile Strength, psi 11,000 11,000 32,000 MPa Flexural Modulus, psi E MPa Notched Izod Impact, ft lb/in J/m psi, F kpa, C Filler = Talc Reinforcement = Chopped/Short Glass Fiber

66 THERM0PLASTIC ELASTOMERS STRUCTURAL WEAR CONDUCTIVE COLOR FLAME RETARDANT Long Fiber Technology

67 The Long Fiber Process Proprietary Pultrusion Process Fiber Roving Impregnation Die Puller Pelletizer * Typical pellet length is (12 mm) and pellet diameter is (3 mm)

68 Short Fiber & VERY LONG FIBER Pellet Length ~1-2 mm 1/32-1/16 Fiber Length 12 mm 1/2

69 Aspect Ratio Comparison Compound Type (Glass Fiber) Typical Aspect Ratio (Prior to Molding) Short Fiber 100 Long Fiber 800

70 The Structural Skeleton PA 6/6 + 60% VLF Seat Belt Tension Housings

71 VLF Expands The Envelope 40% VLF Nylon 6/6

72 THERM0PLASTIC ELASTOMERS STRUCTURAL WEAR CONDUCTIVE COLOR FLAME RETARDANT Case Study Converting Commodity PP to Engineering PP

73 Short Glass PP Versus Nylon Resin PP Nylon 6 Glass Fiber 40% Short 30% Short Humidity DAM DAM Tensile Str, psi MPa Flex Mod (E6),psi MPa Izod Impact, ft lb/in J/m 264, 1820 kpa, C 13, , Spec Gravity

74 VLF PP Versus Short Glass PA Resin PP PP Nylon 6 Glass Fiber 40% Short 40% Long 30% Short Humidity DAM DAM DAM Tensile Str, psi MPa 13, , , Flex Mod (E6), psi MPa Izod Impact,ft lb/in J/m , 1820 kpa, C Spec Gravity

75 VLF PP Versus Short Glass PA Resin PP PP Nylon 6 Nylon 6 Glass Fiber 40% Short 40% Long 30% Short 30% Short Humidity Tensile Str, psi MPa Flex Mod (E6),psi MPa DAM/ 50%RH 13, DAM/50%RH DAM 50% RH 17, , , Izod Impact,ftlb/ in J/m , kpa, C Spec Gravity

76 Case Study Automotive Armrest 30% GF/Nylon 6 Strength, Modulus, and Impact Performance Lighter Weight Lower Cost 40% VLF/PP 12% Lighter Weight Reduced Cost

77 RTP VLF Product Offering RTP Series Resin 100 Polypropylene 200 Nylons (Polyamides) 300 Polycarbonate 400 Polystyrene 600 ABS 700 HDPE 800 POM 1000 PBT 1300 PPS 1400 PES 2100 PEI 2200 PEEK 2300 RTPU 4000 PPA * RTP Ultra Performance Products Coming November 2013

78 Ultra Performance Products Resins PEI PPA PPS PEEK Ultimate Loadings Chopped Glass High Performance Carbon Fiber Long Glass Fiber To Compete with Metals, Ceramics, and Thermosets in Demanding Environments

79 Very Long Fiber PPA Resin PPA PPA PPA Glass Fiber Unfilled 50% Short 50% Long Tensile Strength (psi) MPa Flexural Strength (psi) MPa Flex Mod (E6 psi) MPa Izod Impact (ft lb/in) J/m ( 1820 kpa, C Specific Gravity

80 Review The Dilemma Resin Selection Procedure Resin Morphology Thermal & Cost Rankings Unique Resin Features Application Case Studies Compounding for Additional Performance Overcoming Morphology Deficiencies Engineering High Strength Compounds Maximizing Aspect Ratio

81 Dziękujemy! Thank you! Informacje / Information Korporacja KGL S.A. j.bernard@kgl.pl M: T: ext. 221 Tworzywa nie z tej Ziemi ABS (35 kolorów, transparent, galwanizacja, samogasnący), ASA, SAN, PC, PMMA, PA, PBT, POM, PPS, PS, EPS, PPH, PPC, PPR, PP metalocenowe, LDPE, HDPE, MDPE, PE metalocenowe, TPE: SBS, SEBS, TPV (EPDM/PP), wypełniacze kredowe, PP wypełniany