Introduction to SkyPURA 2015. 6.
Contents [Session #1] [Session #2] [Session #3] [Session #4] [Session #5] Introduction to SkyPURA (PCT) LED applications EP applications V-0 Flammability, Physical Properties Alloy 1 1
Session I. Introduction to SkyPURA (PCT) PCT(Polycyclohexylenedimethylene Terephthalate) 2
Price, Performance Thermal Stability SkyPURA - Introduction SkyPURA PCT is a high performance engineering plastic with excellent thermal stability, toughness and fast crystallization half time. SkyPURA PCT has outstanding thermal resistance property that can tolerate high temperature of SMT reflow process. PEEK PES PEI PA46 PPS PSU PCT 270 289 Ecozen PS/PPE PC/PET PC/ABS PMMA PET PA66 TPE PA6 PBT POM SMT, Reflow temp. zone 245 260 260 PETG ABS PP 224 PS HIPS LLDPE HDPE PVC LDPE PET Nylon66 PCT PPS PPA LCP Amorphous Semicrystalline HDT for engineering plastics 3
SkyPURA - Introduction SkyPURA PCT base resin is produced by reacting TPA and CHDM (1,4-cyclohexane dimethanol). SK Chemicals is the only vertically integrated company that produces PCT using captive TPA and CHDM in Korea. Film Electrical Electronic TPA Fiber Automotive CHDM PCT Base Resin Home Application PCT Compound Food Contact SkyPURA Main Properties High Reflectivity and Durability Long Term Heat Resistance Low Moisture Absorption Reflow and Lead-free Soldering Capable Resin TPA Chemical Resistance Cleanliness : Free of Particles, Low Oligomers Excellent metal adhesive Obtain out-of-mold surfaces with high gloss, metal effect and specialty colors Lightweight CHDM 4
SkyPURA - Product Grades SK Chemicals commercialized PCT in 2012, with the current application of LED reflectors and engineering plastics. SK chemicals currently provides 3 different grades of PCT base resin. 1 standard grade 0302, 2 high strength grade 0502, 3 high crystalline grade 0502HC. New PCT grades are now being developed for film & fiber applications, utilizing PCT s intrinsic properties & benefits at each application. Grade 1631 2631 3631 0302 0502 0502HC 3302 3502 Remark Target Applications Film (Transparent) Fiber Alloy with PC LED Reflector EP compound & Alloy Intrinsic Viscosity (dl/g) 0.80 0.80 0.80 0.65 0.75 0.75 0.65 0.75 Mn(kg/mol) 25 25 25 22.5±3 28.0±3 28.0±3 22.5±3 28.0±3 GPC, reference Polydispersity (Mw/Mn) 2.20 2.20 2.20 2.15 2.20 2.20 2.15 2.20 PS with X- PS column Melting point (Tm( )) 280 280 280 286±3 286±3 295±2 286±3 286±3 Crystallization temperature under cooling (Tmc( )) Glass transition temperature (Tg( )) 215 215 215 235±5 235±5 258±5 235±5 235±5 89 89 89 89 89 89 89 89 DSC scan r ate 10 /min Color-L* Color-a* 88±4 0±3 - - 88±4 0±3 88±4 0±3 90±4 0±0.3 90±4 0±3 - - - - After crystallizati on @ Color-b* b* < 6 - b* < 6 b* < 6 b* < 6 b* < 6 - - 150, 1hour 5
SkyPURA - Applications and Characteristics SkyPURA PCT is suitable for LED reflectors because of its high stability towards heat, moisture and light SkyPURA PCT has Good electrical properties also make it possible for PCT to be used for connectors for LED Reflector High Reflectivity and Durability Long Term Heat Resistance Low Moisture Absorption for Connectors Reflow and Lead-free Soldering Capable Resin Long Term Heat Resistance Good Electrical Properties Low Moisture Absorption 6
SkyPURA - Applications and Characteristics SkyPURA PCT is expected to expand its application to film and fiber fields mainly due to the good thermal and hydrolytic stabilities. SkyPURA PCT also can be used for oven trays because of its long-term heat resistance and FDA approval for Film for Fiber for Oven Tray Good thermal, Color, Hydrolytic Stability Good Electrical Properties Low Moisture Absorption Good laundry durability at high temperature Excellent chemical resistance/ hydrolytic stability Shape/performance stability and durability Long Term Heat Resistance FDA Approval 7
Session II. LED Applications PCT (Polycyclohexylenedimethylene Terephthalate) 8
SkyPURA - Advantage for LED reflector SkyPURA PCT offers comprehensive initial reflectance and reflectance stability required in light-emitting diode(led) packages found in display backlight and general lighting SkyPURA PCT is applied for middle watt (0.5~1.5W) as main material and extended toward high watt market by customers [Wattage/PKG] Consumption [ 14] (compound) Ceramics SMC 2,000 MT 1.5 EMC PCT 4,000 MT 0.5 PA9T PA10T PA6T 10,000 MT 2,000 MT 7,000 MT Total 25,000 MT 9
% - LED Application : Whiteness & Light Stability of PCT Compound SkyPURA PCT has better color and reflectance stability than PA9T (200 Oven aging). It retains 90% of its original optical property, while other plastics show drastic degradation in properties. Color L Color b 0 hr 2 hr 4 hr 8 hr 12 hr 24 hr PCT PA9T 100 97.7 97.6 96.4 15 95 90 85 80 85.4 10 5 75 PCT PA9T 0 0 hr 2 hr 4 hr 8 hr 12 hr 24 hr 100 Reflectance(450nm) 0 hr 12 hr 100.0 100.0 96.0 68.7 50 0 PCT PA9T 10
Session III. Engineering Plastic Applications PCT (Polycyclohexylenedimethylene Terephthalate) 11
- EP Application : Properties SkyPURA PCT features in the engineering plastic application are - the highest HDT among polyester EP materials - good electric insulation with high value of Comparative Tracking Index Properties of PCT GF-compound as compared to those of other engineering plastics Properties PCT 30%GF PCT 40%GF PBT 40%GF PET 43%GF PPS 40%GF Nylon 6 40%GF DRY/WET Specific gravity (g/cc) 1.45 1.63 1.65 1.79 1.61 1.5 Shrinkage X-flow (%) 0.8 0.8 0.8 0.6 0.2 ~ 0.06 1.1 Shrinkage with flow (%) 0.2 0.2 0.6 0.1 0.1~0.3 0.1 Tensile Modulus (MPa) 8,700 10,800 10,000 17,000 13,000 14,000 / 8,200 Tensile Strength(MPa) 113 114 125 130 150 165 / 105 Tensile Elongation (%) 1.6 1.5 2 1.8 1.1 4 / 5.5 Charpy Unnotched Impact 23 (kj/m 2 ) 58 45 50 43 10 70 / 80 HDT unannealed at 0.45 MPa ( ) 270 270 220 240 > 260 200 / 190 HDT unannealed at 1.8 MPa ( ) 260 260 195 225 > 260 205 / 200 Surface Resistivity (ohm / sq) 1.05 10 15 1.05 10 15 1.0 10 15 1.0 10 15 > 1.0 10 15 1.0 10 12 Volume Resistivity (ohm m) > 1.0 10 15 > 1.0 10 15 1.0 10 15 1.0 10 15 1.0 10 13 1.0 10 12 Comparative Tracking Index (V) - 440 175 250 150 525 Electrical Strength (kv/mm) 32 33 22 28 20
- EP Application : Hydrolytic Stability SkyPURA PCT has better hydrolytic stability than PA6T and PBT (85, 85% humidity) It retains 90% of its original tensile strength to 1200hrs, while other plastics show drastic degradation in the properties. Tensile Strength(kgf/cm 2 ) 0 hr 24 hr 168 hr 720 hr 1200 hr 2000 1500 1000 500 0 PCT-GF30 PA6T-GF30 PBT-GF30 Retention of Tensile Strength(%) 0 hr 24 hr 168 hr 720 hr 1200 hr 100.0 50.0 0.0 PCT-GF30 PA6T-GF30 PBT-GF30 13
- EP Application : Low Moisture Absorption SkyPURA PCT shows lower moisture absorption(0.25%) than PA6T and PBT Important for dimensional stability and hydrolytic stability. 3.0 Moisture Absorption(85, 85%) 72 hr 168 hr 336 hr 1200 hr 5000 hr 2.5 2.53 2.0 1.5 1.0 0.5 0.25 0.50 0.0 PCT-GF30% PA6T-GF30% PBT-GF30% 14
Xc Time (sec) - EP Application : Crystallization Half-Time(Base Resin) The crystallization half-time(t 1/2 ) is defined as the time at which the extent of crystallization is completed 50% The shorter the half-time, the faster the crystallization rate. SkyPURA PCT has fast crystallization rate, compared with PET which gives better processability at injection or extrusion molding step, due to short cycle time than PET Crystallization Half-Times (t 1/2 ) Crystallization Half-Times (t 1/2 ) PCT PET PCT PET 100 1000 80 800 60 600 40 20 @ Tc - 20 PCT : 220 PET : 150 400 200 0 0 100 200 300 400 500 600 700 800 Time (sec) 0 120 140 160 180 200 220 240 260 Temperature ( ) Isothermal Temp. n log k t 1/2 PCT Tc-20 2.0-3.6 47.3 PET Tc-20 1.9-4.7 238.1 Avrami Equation : X t = 1 exp( -k t n ) X t : the relative crystallinity at different crystallization times n : constant depending on the mechanism of nucleation and the form of crystal growth k : crystallization rate constant related to nucleation and growth parameters 15
kg/cm2 kg/cm2 kg/cm2 % - EP Application : Blend Results(Compounding) is a thermoplastic alloy of amorphous polycarbonate and semi-crystalline PCT that provides a combination of mechanical strength, melt flow, and chemical resistance Flexural Strength & Modulus Blend Tensile strength & Elongation Blend Flexural Strength Flexural Modulus Tensile Strength Elongation 1,200 1,000 800 600 400 200 0 100/0 90/10 70/30 50/50 30/70 10/90 0/100 25,000 20,000 15,000 10,000 5,000 0 800 700 600 500 400 300 200 100 0 100/0 90/10 70/30 50/50 30/70 10/90 0/100 900 800 700 600 500 400 300 200 100 0 16
Appendix.
Time (sec) - EP Application : Blend Results(Compounding) SkyPURA PCT has good melt flow properties, compared with PC Melt Flow Idnex of blend was increased to 83 g/10min with PCT 90 wt.% It has fast crystallization which gives better processability at injection or extrusion molding Melt Flow Index (300, 1.835kg) 100/0 90/10 70/30 50/50 30/70 10/90 0/100 M.F.I g/10min 5.9 21.6 39.1 52.7 70.0 83.2 55.0 Crystallization Half-time (190 ) 700 Crystallization Half-time (t 1/2 ) 600 500 400 300 200 100 0 100/0 90/10 70/30 50/50 30/70 10/90 0/100 18
- V-0 Flammability and Surface Characteristics Flame retardant grade (UL-94 grade) of PCT neat resin is V-2 V-0 grade can be made by compounding with Non-Halogen Flame retardant(op 1240, 8~10phr) and synergist(melamine cyanurate, 6~8phr). The thickness of specimen is 0.8 mm The surface of PCT is clean Surface condition depends on types of flame retardants and process condition though Aluminum diethyl Phosphinate (EXOILT OP1240, Clariant) Melamine cyanurate (MC) 19
- Physical Properties Properties Unit SKYPURA 3302 3502 3631 Comment IV dl/g 0.65±0.04 0.75±0.05 0.80 MI g/10min 33 (GF 30wt.%) 21 (GF 30wt.%) 55 (neat resin) 300, 1.83kg Crystallinity % ~10 ~50 Calculated from density Ρ a : 1.18, Ρ c : 1.265 Moisture absorption ppm 4,000 2,500 2,500 85, 85% Humidity Izod Impact Str. J/m 13 34 50 Flexural Strength kgf/cm2 620 1,020 980 Flexural Modulus kgf/cm2 21,300 23,200 19,900 SKYPURA samples : treated for 1 hour at 140 20
Flowability (Shear Rate - Shear Viscosity @ 300 ) Data were measured in a plate-plate rheometer
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