Thermoplastic elastomers in extreme environments Chris Newman

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1 Thermoplastic elastomers in extreme environments Chris Newman MPG Rubber Conference th May 2016 Lancashire County Cricket Ground

2 Characteristics of TPEs Advantages of TPEs: - low-cost and easy processing (injection moulding, extrusion or extrusion blow moulding) - high dimensional requirements can be met - excellent elastomeric properties (shore A5 to D75) - easy to colour, transparent TPEs are also available - can be modified with standard additives (such as UV and FR stabiliser), - recyclable - form secure polar bonds with a wide range of thermoplastic (PP, PA, PC, ABS, PA6, SAN, ASA, PMMA, PBT, PET, POM) and metal materials Extreme environments include: - a wide temperature range (hot and cold), - performance under high and repeated mechanical loads, - good resistance to chemicals, hydrolysis, swelling in oil and water and microbes. 2

3 ALBIS UK DISTRIBUTION TPU OWN COMPOUNDS TPV DESMOPAN TPE-SEBS TPC-ET EVOPRENE SOLPLAST A specialist in engineering thermoplastic raw material supply with technical knowhow in application development 3

4 Thermoset rubbers set the bar high Thermoset rubbers set the bar high; thermoplastic elastomers generally come into consideration when factors such as compromised requirements, design and manufacturability permit. Vehicle tyre Not a candidate for TPEs anytime soon - Wear resistance - UV Light resistance - Mechanical demands - Thermal demands 4

5 TPE & Thermoset rubber: essential difference (1/2) Thermoset rubber The thermoset elastomeric nature arises principally from the 3D network generated from vulcanisation. Mutliblock copolymer TPEs Elastomeic properties are achieved with from rubbery domains formed from soft segments within the block copolymer structure when the material cools from the melt. In the case of Blend TPEs (including TPVs) the microstructure possesses fine scale rubbery domains which may or may not be cross-linked. 5

6 TPE & Thermoset rubber: essential difference (2/2) Other Key Differences Vulcanisation permits retention of mechanical properties over a large temperature range. Also with thermosets, chemical resistance can be enhanced. Mass production With TPEs the absence of a vulcanisation step permits the use of high volume processing techniques (injection moulding, extrusion). However, design needs to fit within process constraints. Eg Thermoset thick-sections possible. TPEs impractical. TPEs capability is generally tuned at a reactor stage and not through formulation design. 6

7 Desmopan TPU Key characteristics No plasticisers variety of chemistries to suit application (ester, ether-ester, ether, carbonates, aliphatics) Shore A 60 to D75 Injection moulding, extrusion, blow moulding Flexible high-performance thermoplastic material Excellent abrasion and wear resistance Good hydrolysis resistance High mechanical strength, high stiffness Highly transparent grades 2K on PC, PC/ABS, ABS, PA, PC blends, Nice dry touch Grades with improved microbial resistance Temperature range: -40 C to 120 C, dependent on grade 7

8 TPU case study: automotive suspension component Automotive Extrusion blow moulded grades Desmopan Ester type Benefits Resists buckling and needs wear resistance under high dynamic loads Oil / Grease resistance over service temperature -30 C to 120 C 8

9 TPU Case study: Elevator and timing belts Building and Construction Elevator and Timing belts Desmopan grades (ester and carbonate series) consist of TPU and high strength steel vs Aramid fibres DP.3392A, DP.3395A, 392 and 790 Benefits 2x lifecycle compared to steel rope Corrosion free Longer maintenance interval Outstanding bonding to metals Less wear with optimised bearing pairs Low noise level Very high tensile strength 9

10 TPV properties PP+EPDM Shore A35 to D50 Natural, black, coloured Temperature range -40 C to 125 C (short term to 150 C) Good resistance to grease, oil, acids, solvents Good ozone, UV and weathering resistance Processable by injection moulding, extrusion, blow moulding Easy flow grades available very good flow properties and UV resistance Tailor-made compounds available Nylon 6 and 66 (up to 30% glass filled) bondable grades available Automotive emissions approvals for interior use 10

11 TPV Case Study: High heat under bonnet environment Automotive Blow Moulding application air ducts ALFATER XL D50E 2GP 0000 BLACK Benefits Heat Aging Resistance 160 C for 300 hours and 150 C for 1,000 hours Superior to thermoplastic copolyesters in cyclic loading Clean air intake 11

12 TPV Case Study: High heat under bonnet environment Automotive Blow Moulding application air ducts ALFATER XL D50E 2GP 0000 BLACK 12

13 Case Study: Sipolprene Copolyester Elastomer D35 to D75 Shore Hardness Excellent resistance to mechanical stress Operating temperatures -50 deg C to 150 deg C (Melt temperatures up to 220 deg C) Suitable for compounding feedstock UV, heat and hydrolysis stabilised versions available Low medium and high flow grades available Good chemical resistance Forms secure bonds with PS, ABS, PC, PBT and PVC Power transmission flange 13

14 ALBIS TPEs: table of properties Test Material Properties method ALFATERXL TPV Evoprene TPS (SEBS) Solplast TPS (SEBS) Desmopan TPU Sipolprene TPC Shore Hardness ISO 868 A35 to D50 A5 to D60 A5 to D60 A60 to D75 D27 to D72 Abrasion resistance DIN fair fair fair excellent excellent PC, ABS, PA6, SAN, ASA, ABS, PP, PVC, PA, PA 6, PA, PS, ABS, POM, PC, Bonds to PP, PA PMMA PBT, PET, POM PS, PMMA, POM, EVA PBT, PVC PA, PS, ABS, PC, PET, PBT, PVC, ASA Density ISO g/cm g/cm g/cm g/cm g/cm 3 Flame retardancy / UL Listing UL 94 HB 1.5mm - 3mm V2, HB Hydrolysis resistance excellent excellent excellent Ether grades excellent fair Chemical resistance (Oil / Fat) fair fair fair excellent excellent Chemical resistance (Acids/Cleaning products) excellent excellent excellent fair fair Compression set ISO 815 excellent excellent excellent good good UV stable available available available available available Ozone stable excellent excellent excellent excellent excellent Resistance to hot air / maximum operating temperature 135 C 125 C 125 C 120 C 150 C Minimum operating temperature / freezing conditions -40 C -50 C -50 C -40 C -50 C Low emissions / low fogging available available available available Odour (-free) available available available Recyclability Colourability Microbial resistance excellent excellent excellent excellent fair Transparent materials available? No Yes Yes Yes No 14

15 Thank You Thank You ALBIS UK Ltd Parkgate Industrial Estate, Knutsford, Cheshire, WA16 8XW Tel: +44 (0) Fax +44 (0)