Latest Trends in Engineering Polymers

Transcription

1 Latest Trends in Engineering Polymers S. Senthil Kumar Manager - Developments

2 2 Agenda About us Industry trends DuPont Engineering Polymers New Generation Polymers & its features Case studies Question & Answer

3 3

4 4 DuPont Worldwide Today s DuPont The world s leading science Company unlocking the secrets of nature to make the world a better, safer & healthier place using all the sciences at our disposal chemistry, biology, information science t o m e e t h u m a n n e e d s

5 DuPont Worldwide Corporate Slogan 5

6 6

7 7 Market Trends & Challenges: Handheld devices/mobile phones were Imported earlier. In 2006, leading manufacturer setup plants in India. ROHS and Non halogen grades are the recent trends. Shift to lead free soldering hence requirement of High temperature materials. Blister resistant material for RF soldering. India considered as Quality and cost effective hub for manufacturing. Euro Norms in Automotive. ELV certification New developments like : Electrically Conductive Polymers Thermally Conductive Polymers Bio based polymers. Structural Polymers - Metal to Plastics replacements Wear & Friction resistant Polymers - Material with superiortribological properties.

8 Automotive Industry trends ( Polymer opportunities ) 8 FUEL Efficient Cars ( Light weight needed ). Emission Norms ( Fuel tubes to move to multilayer ). Re-cyclability ( Move from Thermosets ). Green Plastic materials ( moving to bio based polymers ). Increased Warranty Periods. ( eg CVJ boots )

9 9 Market Trends Auto India produces close to 1 million cars. India to emerge as the global small car manufacturing hub. Growth YOY is 22%. (2005, 2006) High Export and Domestic potential. ( encl. report)

10 10 Why Use Plastics Corrosion resistant ( water areas,pipelines etc ) Light weight ( In Auto Fuel efficiency ) Economical versus metals ( Faster production cycles, less energy spent ) Good thermal & electrical insulators ( Used widely for connectors in white goods etc ) Accepts wide range of modifiers ( Glass/ Teflon/Kevlar etc) Complex Shapes can be Molded.

11 11 Why Use Plastics High strength/weight ratio ( Auto component replacements ) Design flexibility through molding ( component integration ) Easy to fabricate into intricate shapes ( Reduction of operations ) Colorable ( Color coding is possible, Railway liners etc ) Can be transparent ( Roof sheets for lighting, FRP sheets, PCsheets etc ) Mass production ( multicavity tools with very fast cycle times) Recycling of Thermoplastics possible.

12 DuPont Engineering Polymers World Wide Market Position #.1 in Nylon #.1 in TEEE #.1 in Polyimide #.2 in Acetal #.2 in PET/PBT LCP LCP Liquid Liquid Crystal Crystal Polymers Polymers Zenite Zenite PI PI Polyimide Polyimide Vespel Vespel PPA PPA Polyphthalamide Polyphthalamide Zytel HTN Zytel HTN HPPA HPPA High High Performance Performance Polyamide Polyamide Zytel HTN Zytel HTN PA PA Polyamide Polyamide (Nylon) (Nylon) Zytel, Zytel, Minlon Minlon PET PET Polyester (PET) Polyester Rynite (PET) Rynite PBT PBT Polyester (PBT) Polyester Crastin (PBT) Crastin POM POM Polyacetal (POM) Polyacetal Delrin (POM) Delrin PCT PCT Polyester (PCT) Polyester Thermx (PCT) Thermx 12 #.2 in LCP s TEEE TEEE Thermoplastic Thermoplastic Elastomer (TEEE) Elastomer Hytrel (TEEE) Hytrel TVR TVR Thermoplastic Thermoplastic Rubber Rubber Dupont Dupont ETPV ETPV High performance engineering polymers Engineering polymers PEI PES PAR PSU PC MPPO PEK PPS LCP PI HTN PET TPE PBT NYLON ACETAL Standard polymers ABS SMA PS PVC AMORPHOUS PMMA SAN PP LDPE HDPE SEMI-CRYSTALLINE

13 Nylon resin 13 Polyamide was invented by Wallace Hume Carothers from the DuPont Company in , 1935, and was introduced to the public as Nylon in 1938.

14 14 Nylon (PA) Different Types PA 46 PA 6 PA 66/6 HPPA PA 66 PA 11 PA 12 PA 612 Specialty Grades

15 Nylon Key Properties 15 Strong, tough Chemical resistant Thermal resistant Ease of processibility

16 16 Nylon Modifications Heat stabilizers Nucleating agents UV-stabilizers Hydrolysis stabilizers Tougheners Flame retardants Lubricants Reinforcement: Glass fiber Mineral Minlon Kevlar fiber

17 Nylon & it compounds Automotive Applications 17 Radiators Air intake manifolds Rocker covers Wheel covers Fans / shrouds Cooling Fans

18 Acetal resin 18 Delrin acetal resin was invented by DuPont in the end of the 1950 s.

19 Acetal - Properties 19 Advantages: Stiffness without reinforcement Toughness over wide temperature range Wide range of service temperature Fatigue resistance Creep resistance Dimensional stability, low moisture pickup Chemical and fuel resistance Low friction and wear - lubricity FDA grades available Interior UV stability available Bright colors available Potential Limitations: Max continuous service temp <90; intermittent to 120 C Flame retardant impossible Hydrolysis resistance (hot water) Notch sensitivity Resistance to strong acids and bases Replaces: Metals (weight, friction, corrosion resistance) Polyamide (dimensional stability)

20 20 Engineering thermoplastic elastomer (TPEE) TPEE is a thermoplastic ether ester elastomer with properties like rubber and mechanical performance of plastics. Its ease of processing leads to a unique combination of properties providing cost reduction, performance, and design flexibility.

21 Thermoplastic polyester elastomer 21 Soft segment (polyether) Hard segment (polyester) Hytrel : thermoplastic-ether-ester elastomer From Shore D30 flexural modulus 4,000 psi To Shore D82 flexural modulus 175,000 psi A tailor-made molecule that fits your needs

22 22 TPEE- Properties Advantages: Bridges the gap between rubber and rigid plastics Offering with broad range of physical properties Processing versatility & ease Post processing ease High impact strength Excellent fatigue resistance Broad use temp. range Excellent (hydrocarbon) fluids resistance Potential Limitations: UV resistance Resistance to polar fluids Lower scratch resistance Replaces: Rubber (process ease, recycling, system cost reduction, performance) TPU (process ease) Metals (component integration)

23 23 Zytel HTN Key Benefits Zytel HTN high performance polyamides are partially aromatic copolymers, and most fall within a narrower family known as PPA. They cost effectively bridge the performance gap between conventional engineering resins and high-end specialty polymers such as LCP & PEI. Zytel HTN withstands demanding environments Stays strong Retains stiffness Hangs tough Maintains dimensions and offers higher performance in typical, ambient conditions.

24 Zytel HTN The Ultimate Choice The ZYTEL HTN resins show a unique combination of properties: Low effect of moisture Excellent retention of properties Good dimensional stability 2. Good high temperature properties High melting point (up to 310 C) Elevated glass transition temperature (Tg up to140 C DAM) High heat deflection temperature (HDT up to 288 C) 3. Chemical resistance Motor, transmission and transformer oils Fuels Glycols Water, steam 4. Surface Mount (SMT) compatibility, ZYTEL HTN the material of choice in several SMT connector applications 5. Excellent electrical properties High tracking Index CTI: 600 V for the HB grades and 525 V for most FR (flame retardant) grades Retention of dielectric strength over a wide temperature range 6. Dimensional stability Minimized warpage Low coefficient of linear expansion (CLTE)

25 25 DuPont Zytel HTN Positioning within the Polymers Market LCP PERFORMANCE PA 66, 6, PC, PBT, PET, POM PPS PA46 Zytel HTN, PPA PCT PEI POLY- OLEFINS RESIN PRICE

26 What Does DuPont Zytel HTN51 Offer? 26 Zytel HTN vs. PPA - Melt Stability - Higher Flow - Higher Tg - Electricals - Chemical Resistance - Creep Resistance Zytel HTN vs. PA46 - Dimensional Stability - Property Retention with Moisture - Electricals - Surface Appearance - Chemical Resistance PPA PA46 Zytel HTN PPS PEI Zytel HTN vs. PPS - Toughness - Weldline Strength - Longer Tool Life - No Deflashing - Lower Density Zytel HTN vs. PEI - Lower Price - Higher Flow - Higher Yields - Faster Cycle - Lower Density

27 Zytel HTN -- Water Outlet Valve 27 Customer Requirement: Wanted to replace aluminum with a material offering excellent resistance to longlife coolants and moisture. Zytel HTN Benefits: * Excellent resistance to long-life coolants * Hydrolysis and high heat resistance * Cost savings due to lighter weight Zytel HTN51G35HSL -- 35% glass-reinforced, heat stabilized, lubricated resin

28 28 Zytel HTN -- Boiler Diverting Valve Customer Requirement: Searching for a material with hydrolysis resistance, low warpage and high dimensional stability. Zytel HTN Benefits: * Hydrolysis resistance * Low moisture pickup * Dimensional stability Zytel HTN51G35HSLR -- 35% glass-reinforced, heat stabilized, hydrolysis resistant, lubricated resin

29 29 Zytel HTN -- Hot Water Heater Pipe Fitting Customer Requirement: Looking for a material to eliminate a cracking problem experienced when using PPS. Zytel HTN Benefits: * Hydrolysis resistance * Easy processing * Thinner design --Allowed design to go from 8MM to 4MM Zytel HTN51G35HSLR -- 35% glass-reinforced, heat stabilized, hydrolysis resistant, lubricated resin

30 Highly Reinforced Engineering Polymers for Structural and Metal Replacement Applications 30

31 Introduction 31 DuPont has redefined the word STRUCTURE

32 Building upon the key properties of the widest range of high performance semi crystalline engineering polymers Rynite PET Zenite Delrin Acetal LCP Thermx PCT Strong Tough Rigidity Unique frictional properties Cost saving Thermal resistance UV capability Resistance to fatigue Ease of processing Crastin PBT Zytel 66 Nylon Zytel 6 Nylon Zytel HTN

33 33 The use of innovative reinforcement technology... combined with high performance polymer platforms... leads to significant improvement of structural properties.

34 Remarkable improvement in strength and stiffness 34 Strength (23 C) Stiffness (23 C) Delrin Acetal - the best structural properties of any unreinforced polymer 20 Tensile stress at break (MPa) % Tensile Modulus (GPa) % DuPont EP structural polymers range DuPont EP unreinforced polymers range DuPont EP structural polymers range DuPont EP unreinforced polymers range

35 Customer requirements for structural applications 35 Customer requirements Automotive Appliance Telecom Industrial Aerospace Ability of DuPont structural polymers to meet requirements High rigidity Good toughness Light weight Chemical resistance Hot water resistance Corrosion resistance Opportunity to reduce costs versus traditional materials Opportunity to produce innovative designs

36 36 DuPont structural polymers offer many major benefits versus metals - let s s remember the key advantages.

37 Major weight savings opportunities 37 Kg s per litre 9 COPPER BRASS STEEL CAST IRON Lighter weight provides savings in many different ways: 5 DIECAST ZINC & ZA ALLOYS Easier handling of parts 4 3 ALUMINIUM ALLOYS Reduced shipping costs Increasing weight per component 2 1 MAGNESIUM ALLOYS DUPONT EP STRUCTURAL POLYMERS Automotive fuel efficiency 0

38 Time & cost saving through reduced number of processing steps 38 6 Steps 6 Steps Diecasting Sheet metal construction Granules Injection Moulding Finished Part Finished part Metal Ingots Finished part Sheet metal Painting Meltdown - cold chamber Injection moulding Painting Stamping Finishing Moulding Only Assembly Drilling Cutting Bending 3 Steps

39 Additional requirements to maximise benefits 39 Conceptual & detailed design skills. Expertise in material selection. Intensive knowledge of mould tool design and processing. Part optimisation skills. DuPont has over 70 years experience in this area!

40 The properties of the DuPont structural polymers are interesting 40 but I would also like: Low density There are a number of lower glass filled variants available with correspondingly reduced density levels. Best possible surface finish Look at some of the high glass grades that are on offer such as Crastin SK9230, Rynite 530CS or Zytel70GHSLA variants. Very low levels of distortion Consider low warp options such as Minlon, Crastin LW grades, Rynite 935 or 940 etc. Optimum toughness Think about the array of toughened variants, such as Zytel 80G series, Crastin T variants or Rynite SST products. Improved flame retardency There are flame retardant variants available in all products apart from Delrin Acetal. Indeed Zenite is inherently flame retardant.

41 41 Tough/SuperTough Advantage Product Line ZYTEL ADVANTAGE RESINS Supertough Advantage ST801A Classic Supertough Advantage. Heat-stabilized and weatherable grades available. DMXST601AH Moisture-stable Supertough Advantage. ST901 High-stiffness, toughest Supertough nylon. ST811HS Flexible, extrudable Supertough nylon. Toughened Advantage MT409A Classic Toughened Advantage. Heat-stabilized and weatherable grades available. DMXMT609AH Moisture-stable, Toughened Advantage.

42 Solutions in Zytel Zytel FR nylon

43 Flame-retardant Nylons 43 Variety of V-0 grades Zytel unreinforced, glass- and mineral-reinforced, Zytel HTN Key Markets: Electrical/electronic parts: coil forms, connectors, relays, motor parts, branching & control; thermoset replacement Part of broad E/E offering Rynite PET, Crastin PBT, Zenite LCP

44 44 Zytel FR - Connector Customer Requirement: Temperature resistance and high mold flow were key requirements necessary for this application. Zytel HTN Benefits: * Excellent temperature resistance * High mold flow allowing for very thin walls * Excellent balance of properties Zytel HTNFR52G30BL -- 30% glass-reinforced, flame retardant, lubricated resin

45 45 Zytel - Industrial Socket Customer Requirement: Looking for a flame-proof material for a surface box for sockets. Zytel Benefits: * Excellent mechanical strength and dimensional stability * UV resistance, plus anti-static and electrical insulation properties

46 DuPont Engineering Polymers: From Concept to Commercialization and Regions to Global 46 DuPont can help brainstorm on problems Loads Constraints Thermal Concerns Chemical Resistance Economic Constraints Design Validated for Process Via CAE. Mold Filling Optimized Cycle Time Minimized DuPont s material knowledge can help with gating. DuPont can help with any phase of your system or component development. We Start With Customer s Need We Help Determine Application Feasibility Concepts Requirements Analysis Design Feasibility Process Feasibility Prototypes Productio n Part DuPont uses state of the art plastics design and CAE.. Design Constraints Best Practice Part Design Design Integration Computer Modeling Structural Analysis DuPont Molding Facility Process Optimization DuPont s molding experts can help with prototypes.