High Heat Materials: Trends and Challenges in Your Market PLUS - - PowerPoint PPT Presentation

April 15th, 2011

High Heat Materials: Trends and Challenges in Your Market PLUS Potential Solutions to Meet Performance Requirements while Reducing Costs!

 Part I:

Opportunities for Higher Heat Materials at Horizon 2012-2016

Raphaël Mestanza – SpecialChem's Chief Plastics Expert

 Part II:

Extreme Heat Solutions with TPI Blends From SABIC Innovative Plastics

Peter Catsman, Global PMM High Heat resins , SABIC Kapil Sheth, Global Product Technology Manager, SABIC

Agenda

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Part I

Opportunities for Higher Heat Materials at Horizon 2012-2016

Raphaël Mestanza – SpecialChem's Chief Plastics Expert

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Key questions we will try to answer today:

Q1: Main Market trends in the coming 2-3 years. Q2: Q4 : Type of material improvement needed to fullfill future requirements Q3 : How strong is the pressure to use higher heat materials in the coming 3- years? and main reasons. Q4 : What are the average levels of « heat » improvement expected? Q5 What materials will be considered for these Higher heat applications? Q6 : Type of materials considered for metal repals

Part I - Agenda

Trends in High Heat Materials

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 Analysis of Omnexus.com members behavior  Interviews with key OEMs, Raw material suppliers and Experts  Market Surveys

Metal replacement Opportunities in the coming 3-5 Years (233 respondents, Jan 2011) Opportunities for Higher Heat plastics at the horizon 2014-2016 (225 respondents, Nov. 2011)

Where the answer are coming from

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“Please rank the top 3 trends you see in your market in the 3 coming years.”

Scale from 0 to 5

Q1 : Main trends in the coming 3 years

Lower weight, Lower System Cost, More Compact design…

Source: Metal replacement opportunities Specialchem market survey, 235 respondants, 45% OEMs, 55% polymer suppliers, Jan 2010.

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“Please rank the top 3 trends you see in your market in the 3 coming years.”

Q1 : Main trends in the coming 3 years

Lower weight, Lower System Cost, More Compact design…

Source: Metal replacement opportunities Specialchem market survey, 235 respondants, 45% OEMs, 55% polymer suppliers, Jan 2010.

Q2: Impact of trends on material requirements

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“What are the 3 main improvements needed for plastics to fulfill these trends?”

Higher Stiffness/Impact, Dimensional Stability and Perf. at HT

Source: Metal replacement opportunities SpecialChem market survey, 235 respondants, 45% OEMs, 55% polymer suppliers, Jan 2010.

Q3a: Pressure to use higher Heat Material

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73% of Total Respondents report Huge/Strong Pressure

No split 226 respondents

• 1. Dimensional Stability
• 2. Higher Max CST
• 3. Mechanical Perf.

Source: SpecialChem Market Survey based on 226 plastics professionals 50% Specifiers / 50% Material supplier, Nov 2010.

Q3b: Why do they have pressure?

Existing Application Demands, Product Reliability, metal replacement

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No split 226 respondents

• 1. Existing Apps
• 2. Superior Reliability
• 3. Metal Replacement

Source: SpecialChem Market Survey based on 226 plastics professionals 50% Specifiers / 50% Material supplier, Nov 2010.

Q3: Pressure by market

Automotive and Industrial have the highest pressure

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Market % Huge pressure % Huge + strong pressure Top 3 performances Top 3 Reasons Automotive Under the hood

42% 76% Dimensional Stab. Heat Aging Peak T° Resistance Stronger Heat Requirements Metal Replacement More part close to the engine

Automotive Lighting+other

19% 64% Peak T° Resistance

• Max. Continuous. Serv. T°

Dimensional Stab. Stronger Heat Requirements Metal Replacement Better product reliability

E&E

22% 69%

• Ret. Mechanical. Perf.
• Max. Continuous. Serv. T°

Dimensional Stab.

Industrial

23% 60%

Medical & Healthcare

12% 39% Peak T° Resistance

• Ret. Chemical Resist.
• Ret. Mechanical Perf.

Aerospace & Defense

21% 63%

• Max. Continuous. Serv. T°
• Ret. Electrical Perf.

Peak T° Resistance

Wiring & Cable

5% 51% Better product reliability Stronger Heat Requirements Thermosets / Composites Replacement

Q4 Average Heat Improvements Required

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Peak and Maximum Continuous Service temperature

No split 226 respondents

24% need +10 to +20°C 20% need +25 to +35°C 38% need more than 35°C 23% need +10 to +20°C 24% need +25 to +35°C 34% need more than 35°C

Source: SpecialChem Market Survey based on 226 plastics professionals 50% Specifiers / 50% Material supplier, Nov 2010.

Q5: Polymer considered for higher heat applications

Engineering plastics users

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43% 30%

Amorphous Semi-crystalline

15% 12%

PA66 17% PPA 13% PBT/PET 11% PC 10% PPS 9% PEEK 8% Polysulfone 7% PEI 6% PA 4,6 5% POM 5% PI 4% PA12 2% PAI 2% LCP 1%

0% 15% of applications could switch to HH amorphous materials

Commodities

• Eng. Plastics

High perf. Plastics Specialties

Source: SpecialChem Market Survey based on 226 plastics professionals 50% Specifiers / 50% Material supplier, Nov 2010.

Q5: Polymer considered for higher heat applications

Amorphous High Heat Polymer users

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18% 18%

Amorphous Semi-crystalline

38% 18% 0%

PC 8% HHPC 8% PA66 9% PEI 17% PET/PBT 9% PPS 9% PEEK 9% PI 9% PSU 13% PPA 9%

8%

Commodities

• Eng. Plastics

High perf. Plastics Specialties

Source: SpecialChem Market Survey based on 226 plastics professionals 50% Specifiers / 50% Material supplier, Nov 2010.

18% of applications could switch to HH amorphous materials

Q6: Material considered to replace metal

Many High Heat Plastics will be considered….

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Source: Metal replacement opportunities Specialchem market survey, 235 respondants, 45% OEMs, 55% polymer suppliers, Jan 2010.

 Strong trends for weight saving, system cost reduction and more compact design will drive…  Demand for materials with Higher heat performances and higher stiffness/impact balance.  Stronger pressure in Automotive under-the-hood , E&E, Industrial and Aerospace seeking average improvements of 20 to 25°C (peak, RTI…)  These trends will also drive demand for extreme heat resistant materials  There is room for materials with intermediate performances between PEEK, PI and High Heat polymers.

Conclusion

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Part II Extreme Heat Solutions From SABIC Innovative Plastics E-Seminar, April 15, 2011 In Special Cooperation with SpecialChem

Presenters: Peter Catsman, Global PMM High Heat resins Kapil Sheth, Global Product Technology Manager

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1. Introduction 2. High Heat – What are you looking for.. 3. Case studies - Market and Value offerings 4. Wrap-up 5. Questions Today’s Agenda

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High Heat… your challenges?

Short Term Heat Resistance? Long Term Heat Resistance? Additional Factors:

• dimension stability
• mechanical load
• chemical environment

EXTEM* TPI Resins:

• Melt Processable, Extreme

Environment Thermoplastics

• Based on proprietary amines

and anhydrides

• Proprietary blend technology

with e.g., PEEK resin

Heat

High Perf. Amorphous:

v Modulus at elevated

temperature

v Dimensional

stability

v Creep resistance

High Perf. Crystalline:

v Continuous use temp. v Chemical resistance v Wear resistance

Amorphous Crystalline

PBI PAI PI PPS LCP PTFE PEEK HH PC PSU PES ULTEM* PEI resin PPSU PA46 PPA Chemical Resistance

Ultra High Performance:

v High temp. load bearing v Low & stable CTE . vTypically must have

imidization step

The top of the Pyramid

XH UH UP

EXTEM

VH

Closing the Gap to the Top!

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EXTEM* product families

Extem UH resins

• Glass transition > 300ºC
• Chemical resistance
• High continuous use Temp.
• RTI up to 260°C

Extem XH resins

• Glass transition ~ 267ºC
• High temperature creep
• High flow for thin wall
• Lead-free solderable

Extem UP – PEEK blends

• Strength/Stiffness/Creep at Temp.
• Outstanding Chemical Resistance
• High Flow
• RTI of 240ºC

Extem VH resins

• Glass transition ~ 247ºC
• Metalizable
• High flow for thin wall
• Cost/performance

LNP Specialty Compounds

for

• Lubrification
• Carbon Fibers

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Performance offerings

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• EXTEM XH/UH maintain stiffness up to Temp’s as High as ~280°C
• EXTEM UP blends offer 5-8x more stiffness vs. PEEK and PPS at high Temp’s

Looking for stiffness up to high Temperatures?

EXTEM UP

10 100 1000 10000

50 100 150 200 250 300 350 Temperature [°C]

Modulus [MPa]

ULTEM* resin PEEK PPS

Tailorable Tg Tailorable Modulus

EXTEM* UH resin EXTEM XH

DMA curves for unfilled resins

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Extem UP Blends offer significantly higher strength at >150°C vs. PEEK

20 40 60 80 100 120 140 160 23ºC 150ºC 200ºC 250ºC Flex Strength [MPa] PEEK UP1004 UP1007 20 40 60 80 100 120 140 160 23ºC 150ºC 200ºC 250ºC Flex Strength [MPa] PEEK UP1004 UP1007

Looking for strength up to high Temperatures?

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Looking for stiffness and strength up to high T’s? The Positive Effect May Stay With Reinforcements

40 50 60 70 80 90 100 5000 10000 15000 20000 25000 Tensile Modulus [MPa] Tensile Strength [MPa]

PPS PEEK PEI

Extem UP blend Extem UH resin 30% CF-Filled - Tensile Properties at 200°C

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Specific Tensile strength of Extem XH1005 may

• utperform some Die Cast Aluminum’s at >170°C

Add Extem XH2315 data and new data

Looking for strength up to high Temperatures?

Aluminum/EXTEM* XH resin Comparison Specific Tensile Strength

10 20 30 40 50 60 70 80 50 100 150 200 250 300

Temp °C Specific Tensile Strength (MPa cm

3/g)

EXTEM XH1005 resin Aluminum 6063-T5 Aluminum 1100-H18

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Looking for dimension control up to high T’s? Extem UH resin and UP blends may offer 30-50% lower dimension change at 200ºC versus PEEK resin

0.0 0.5 1.0 1.5 2.0 2.5 3.0 50 100 150 200 250

Temperature °C Dimension Change [%]

PEEK UP1004 UP1007 Extem

D 50% 0.0 0.5 1.0 1.5 2.0 2.5 3.0 50 100 150 200 250

Dimension Change [%]

PEEK UP1004 UP1007 EXTEM* resin

D 50%

28 0.1 0.2 0.3 0.4 0.5 0.6 0.7 1.E+01 1.E+02 1.E+03 1.E+04 1.E+05 1.E+06 Time [s] Strain [%] Extem* UP blend Extem UH resin PEEK PPS

30% Carbon Fiber Reinf. - Creep @ 150°C/25MPa

High Temperature Creep may be less for Amorphous materials Looking for low creep up to high T’s?

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• RTI according UL746B is a long term temp. rating for electrical equipment.
• Temp at which 50% of tensile -, electrical strength are retained after 100khrs = 11 yrs exposure

Are you looking for High Continuous Use Temp.?

Relative Thermal Index (UL746B)

A method for continuous use temperature

• EXTEM UH1019 resin has an unparalleled RTI rating of 260°C
• At shorter exposure times higher heat exposures are possible

100 120 140 160 180 200 220 240 260 280 300 PEI TPI PES TPI/PEEK PEEK PPS PPA PA 4,6 PA 6,6 RTI [°C]

unfilled 30%GF

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23°C, 7 day, Immersion Chemical Extem UH1006 Polyamideimide (PAI) Sulfuric Acid (10%) 95% 104% Hydrochloric Acid (20%) 91% 104% Sodium Hydroxide (10%) 93% 98% Methylethey ketone (MEK) 93% 103% Toluene 97% 106%

• -Dichlorobenzene

98% 107% % Strength Retention

Extem UH resins offer excellent chemical resistance Looking for chemical resistance?

31 Aircraft OSU heat FAR and OEM release Specs FAR 25.853 Extem UH1006 0/21 Extem EXEM0025 0/14 Extem UP1017 0/49 Extem XH1005 3/41 Extem VH1003 11/46 Ultem 1000 35/65 Ultem 9085 20/40

Looking for extreme flame retardancy?

Limiting Oxygen Index (LOI) & UL94

Aircraft Flammability:

 FAR25.853, vertical burn a(60s) - PASS  Smoke Density ABD0031/BSS7238 – PASS  Smoke Toxicity ABD0031/BSS7239 – PASS  OSU Heat release 55/55 - PASS

Extreme Flame-Smoke-Tox Performance

 Halogen Free, RoHS compliant  UL94 V0 at extreme thin gauge  Pushing the LOI envelope LOI (%) UL94 V0 (mm) Ultem* PEI resin 45 1.6 PEEK 35 1.6 PAI 45 1.2 Extem* XH1005 resin 45 0.4 Extem UH1006 47 0.4 Extem EXEM0025 53 0.4

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Are you looking for simple thermoplastic processing?

Molded Parts Part Inspection Load Ovens Part Inspection Part Inspection Low Yield Overall (40-60%) ~95% Yield Overall PAI* EXTEM* resins

several days

Unusable Losses Reusable Loss Unload Ovens CURE Parts

Processing simplicity

 May provide easy processing  May provide as molded properties  Potential High yields

* Customer feedback

Reusable Loss

33 Molding # 2 Sprue/Runner Regrind Virgin Resin Molding # 1 Molding # 4 Sprue/Runner Regrind Sprue/Runner Regrind Molding # 3

75% 75% 75% 100% 25% 25% 25%

Extem resins may offer: Sustainable Solutions – Maximized Yield and Re-use Rework Study Extem* UH1016 resin

Izod Impact 100% 77% 103% 104% Viscosity 100% 104% 105% 101% 100% Virgin Resin 25% Regrind, 1 Pass 25% Regrind, 2 Pass 25% Regrind, 3 Pass Flexural Strength 100% 101% 101% 100% Tensile Strength 100% 94% 104% 103% Heat Distortion Temp 100% 100% 100% 100%

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Processing techniques



Extem* resins can be processed with different techniques

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Looking for Ultrafine Powders?

Volume % Particle Size mm)

<45mm

Viable grades: Ultem* 1000 resins Siltem* resins Extem* VH1003, XH1005 resins Expanding the portfolio with Ultrafine Powders Ultrafine Powder Development:

• new technology to create micronised powders
• particle size < 45micron
• larger sample availability as of 5/2011

36  Upfront application/process assessment  Prepare a trial plan  Involve SABIC personnel  Perform the trial  Involve SABIC personnel  Analyze the results  Involve SABIC personnel  Celebrate success (Involve SABIC personnel..)

EXTEM* Resin Processing Trials, recommendations

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High Temperature Performance

(Strength, Creep, Dimensional Stability)

Thermoplastic Benefits

(Melt Processing, Regrind, Recycle, Molding)

Thermoset-like Thermoplastic PI PAI

TPI Resins & Blends

PEI PEEK

Summary

Extem* resins may offer:

 Thermoplastic, as molded properties  Short and Long term Heat performance  Maintained mechanical and dimension stability at high Temp’s  Extreme, halogen free FR performance

Desired

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Case Studies - Market look and value offering

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Potential Applications

• Chip Trays
• Pick up systems
• Vacuum chamber components
• Test Sockets

Potential features:

• Cleanliness (low out gassing and - ionic content)
• UL746C RTI listings up to 260°C
• Dimension stability
• Strength/Creep resistance at high T’s
• High LOI’s up to 53%

Semiconductor Market

Portfolio:

Extem UH, Tg up to 300°C+ Extem UP, Tg = 145/300°C, TM = 345°C

• Std. Flow

UH1016 Unfilled UP1004 Easy Flow UH1026

Highest Heat

EXEM0025 30% GF Dvlpmntl

Portfolio:

PEEK rich Unfilled UP1017 30% GF Dvlpmntl UH rich

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Potential features:

• Dimension Stability
• Strength at high temperatures
• Direct metallization
• Transparency
• visible
• near IR light
• Lead-free soldering
• System Cost

Potential Applications

• Defense, Aerospace Connectors
• LED Substrates
• Wire insulation
• Film
• Industrial/Domestic lighting

E&E + Lighting

Extem XH, Tg = 267°C Extem VH, Tg = 247°C

• Std. Flow

XH1005

• Std. Flow

VH1003 Easy Flow XH1015 30% GF XH2315 30% GF developm ent

Portfolio:

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Automotive

Portfolio:

Potential features:

• Direct Metallization
• Haze Onset ~250oC
• Transparency for near IR light
• Dimension stability
• System Cost

Potential Applications

• Main Beam Reflectors
• Fog light reflectors
• Brackets/housings
• Turbo Chargers

Extem VH, Tg = 247°C

• Std. Flow

VH1003(F) 30% GF development

Extem XH, Tg = 267°C

• Std. Flow

XH1005 Easy Flow XH1015 30% GF XH2315

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Potential features:

• Strength/Creep resistance at high temp
• Dimension stability at high temp
• High Continuous Use Temperature
• Chemical resistance
• Thin wall

Potential Applications

• Pump/valve linings/seats
• Seals
• Bearings
• Gears
• Bushings
• Composites
• Coatings

Industrial

Portfolio:

Extem UP, Tg = 145/300°C, TM = 345°C Extem UH, Tg up to 300°C+

Lubricated

Crystalline Extem Blend CF/Graphite/PTFE

• r CF/PTFE

Graphite/PTFE

Structural/ Conductive

30% CF ESD Crystalline Extem Blend Amorphous Extem Blend 30% CF

LNP portfolio:

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Potential features:

• Baking temps up to 250°C/482°F
• Food Contact Approvals
• Excellent Stain resistance
• Scratch Resistance
• Metal Adhesion
• Durability
• Thin Wall
• (Limited) color availability

Potential Applications

• Bread Baking Trays
• Oven ware
• Oven components
• Binder for PTFE coatings

Extem XH, Tg = 267°C Extem VH, Tg = 247°C

• Std. Flow

XH1005F

• Std. Flow

VH1003F Easy Flow XH1015F 30% GF XH2315F 30% GF Dvlmnt

Portfolio:

Food Service

*

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High Temperature Performance

(Strength, Creep, Dimensional Stability)

Thermoplastic Benefits

(Melt Processing, Regrind, Recycle, Molding)

Thermoset-like Thermoplastic PI PAI

TPI Resins & Blends

PEI PEEK

Summary page

Extem* resins may offer:

 Expanded Range of properties  Opportunities for improvements over current solutions  New opportunities for metal, thermoset or ceramic replacement  Provide lower system cost solutions

Desired

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Disclaimer:

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