The Possible Possible Automotive Applications Automotive Applications of Glass Microspheres of Glass...
-
Upload
fjnovaes454 -
Category
Documents
-
view
42 -
download
1
Transcript of The Possible Possible Automotive Applications Automotive Applications of Glass Microspheres of Glass...
4 case 4 case studies to discoverstudies to discoverthe the possible possible automotive applications automotive applications of glass microspheresof glass microspheres
Frédéric JuprelleBusiness Unit ManagerTechnical Products
SPE ANTEC® 2014 / 151
I. General introduction about glass beads
II. Case studies
1. How does BMW improve aesthetic & dimensional stability of PA - 30% glass
fibers?
2. How to improve aesthetic and scratch resistance in PP in PSA application?
3. How does LG enhance dimensional stability & surface resistance in ABS – 20%
AgendaAgenda
3. How does LG enhance dimensional stability & surface resistance in ABS – 20%
glass fibers?
4. What can the new E-glass grade bring to Polycarbonate resin producers?
III. Conclusion
2
SPE ANTEC® 2014 / 152
I. General introduction about glass beads
II. Case studies
1. How does BMW improve aesthetic & dimensional stability of PA - 30% glass
fibers?
2. How to improve aesthetic and scratch resistance in PP in PSA application?
3. How does LG enhance dimensional stability & surface resistance in ABS – 20%
AgendaAgenda
3. How does LG enhance dimensional stability & surface resistance in ABS – 20%
glass fibers?
4. What can the new E-glass grade bring to Polycarbonate resin producers?
III. Conclusion
3
SPE ANTEC® 2014 / 153
Sovitec in FiguresSovitec in Figures
#1 solid glass beads producer in Europe#1 solid glass beads producer in Europe
1954 1954 –– 58 years of experience58 years of experience
5 production sites 5 production sites –– 100,000 T capacity100,000 T capacity
160 employees160 employees
4
Charleroi - BE
Buenos Aires - AG
Berlin - GE
Barcelona - ES
Metz - FR
SPE ANTEC® 2014 / 154
• Road Marking: 400 – 2,000µm
• Blasting: 50 – 500µm
• Functional filler in plastics and coatings: 1 – 50µm
� Efficient Coupling Agents for a wide resin portfolio:PA, PUR, Epoxy, PBT, PET, Polyester, Vinylester, PE, PPand now Styrenics & Polycarbonate
Sovitec portfolio and field of expertiseSovitec portfolio and field of expertise
and now Styrenics & Polycarbonate
� Processing mastery for well controlled particle sizeMicroperl®: 20 to 40µm
Omicron®: 3 to 5µm – unique GB producer to produce this particle size
5
SPE ANTEC® 2014 / 155
Sovitec’sSovitec’s Glass BeadsGlass Beads
6
Raw Material = Recycled glass
SPE ANTEC® 2014 / 156
I. General introduction about glass beads
II. Case studies
1. How does BMW improve aesthetic & dimensional stability of PA - 30% glass
fibers?
2. How to improve aesthetic and scratch resistance in PP in PSA application?
3. How does LG enhance dimensional stability & surface resistance in ABS – 20%
AgendaAgenda
3. How does LG enhance dimensional stability & surface resistance in ABS – 20%
glass fibers?
4. What can the new E-glass grade bring to Polycarbonate resin producers?
III. Conclusion
7
SPE ANTEC® 2014 / 157
Case Study 1: PA6Case Study 1: PA6--GF GF –– Starting pointStarting point
Company: BMW
Market: Automotive
Material: PA6 + 30% glass fibers
Processing mode: Twin-screw extrusion and injection molding
Requirements:Requirements:
� Improve surface aspect and dimensional stability
� white powdered surface due to fibers
� unstable shrinkage and warpage
� Maintain good mechanical properties
8
SPE ANTEC® 2014 / 158
Case Study 1: Case Study 1: PA6PA6--GF GF –– Solution & BenefitsSolution & Benefits
Solution: substitute 1/3 of glass fibers by solid glass beads
Initial material: PA6 + 30% glass fibers
Final material: PA6 + 20% glass fiber + 10% Microperl® 050-20-215 (20µm)
Benefits:
� Surface improvement � no white powder on the surface anymore� Surface improvement � no white powder on the surface anymore
� Good Dimensional stability � warpage and shrinkage are now more stable
� Mechanical performance brought by glass fibers are retained
Additional benefits:
� Higher production output
� Cost reduction
� Improved abrasion resistance
9
SPE ANTEC® 2014 / 159
Case Study 1: Case Study 1: PA6PA6--GF GF –– Technical DataTechnical Data
� Surface improvement
PA + 20% GF + 10% GBPA + 30% GF Glass fibers are dispersedLeading to powdered surface
Beads align the fibers,leading to clean surface
� Better dimensional stability
10
GB influence on Warpage
0
20
40
60
80
100
120
140
160
PA PA + 30%
GF
PA +
30%GB/GF
PA +
30%GB
Flo
w- 47%
GB influence on Shrinkage
0
0,05
0,1
0,15
0,2
0,25
0,3
0,35
0,4
FLOW TRANSVERSAL
pe
rce
nta
ge PA6
30% GF
30% GB/GF
30% GB
- 33%- 25%
SPE ANTEC® 2014 / 160
Case Study 1: Case Study 1: PA6PA6--GF GF –– Technical DataTechnical Data
� Keep good mechanical properties
Property Units Method PA6 30% GF 30% GB/GF
Izod Impact (unnotched)
kJ/m² ISO 180/1U n.b. 90 75
Izod Impact (notched)
kJ/m² ISO 180/1A 8 6 6
Flexural Modulus MPa ISO 178 2900 8000 7400
Flexural Strength MPa ISO 178 125 155 145
11
Tensile Modulus MPa ISO 527-2 3200 9200 8700
Elongation at break % ISO 527-2 4,5 3 4
SPE ANTEC® 2014 / 161
Case Study 1: Case Study 1: PA6PA6--GF GF –– Technical DataTechnical Data
� Additional Benefits measured
� Higher production output
� -14% on cycle time
� Cost reduction
-2,4% on raw material cost
50
60
70
80
90
100
110
750 800 850 900 950 1000
To
rqu
e
Production output (kg/h)
Production outputPA 6.6 + 30% GF
PA 6.6 + 20% GF + 10% GB
PA 6.6 + 10% GF + 20% GB
PA 6.6 + 30% GB
Compound RM cost
PA6 + 30%GF 2680 €/T� -2,4% on raw material cost
� Improved abrasion resistance
� +1,5% on weight retained
12
98,5
98
99,5
99,9
97
97,5
98
98,5
99
99,5
100
100,5
PA6 30% GF 30% GB/GF 30% GB
Weight retained after testing (%)
+1,5%
PA6 + 30%GF 2680 €/T
PA6+20%GF+10%GB 2615 €/T
SPE ANTEC® 2014 / 162
I. General introduction about glass beads
II. Case studies
1. How does BMW improve aesthetic & dimensional stability of PA - 30% glass
fibers?
2. How to improve aesthetic and scratch resistance in PP in PSA application?
3. How does LG enhance dimensional stability & surface resistance in ABS – 20%
AgendaAgenda
3. How does LG enhance dimensional stability & surface resistance in ABS – 20%
glass fibers?
4. What can the new E-glass grade bring to Polycarbonate resin producers?
III. Conclusion
13
SPE ANTEC® 2014 / 163
Case Study Case Study 2: PP 2: PP –– Starting pointStarting point
Company: PSA
Market: Door handles, dashboard, …
Material: PP + 30% Talcum
Processing mode: Twin-screw extrusion and injection molding
Requirements
� Improve dimensional stability
� Improve abrasion and scratch resistance
� Improve aesthetic
14
SPE ANTEC® 2014 / 164
Case Study Case Study 2: PP 2: PP –– Solution & BenefitsSolution & Benefits
Solution: Sovitec developed a new family of coupling agent giving both the link with glass and polyolefin resin.
� Now it is possible to achieve similar results shown on PA in reinforced PP
Initial material: PP + 30% Talcum
Final material: PP + 15% Talcum and 15% Microperl® 050-20-223 (20µm)
Benefits:
� Better dimensional stability � lower and isotropic shrinkage
� Better abrasion and scratch resistance � more durable surface aspect
� Better surface aspect
15
Previous PP grade New PP grade
SPE ANTEC® 2014 / 165
Case Study Case Study 2: PP 2: PP –– Technical DataTechnical Data
� Better Dimensional Stability : Shrinkage properties
0,5
1
1,5
2
%
PP
30%
TALCUM
30% GB
223
� Better abrasion resistance
16
Taber Test CS10 – 1kg
PP + 30% Talcum(weight lost)
PC + 15% Talcum + 15% GB(weight lost)
1000 cycles 48 mg 24 mg
5000 cycles 230 mg 95 mg
10000 cycles Destroyed 160 mg
0
0,5
FLOW TRANSVERSAL
15%
Talcum &
15% GB223
SPE ANTEC® 2014 / 166
Case Study Case Study 2: PP 2: PP –– Technical DataTechnical Data
� Higher scratch resistance
20
40
60
80
100
PP
30% Talcum
30% GB 223
15% Talcum &
15% GB223
� Aesthetic
17
0
20
ISO1518 (2 kg)
100 = no visible scratch 80 = low scratch 60 = medium scratch 40 = depth scratch 20 = very depth scratch
PP + 30% Talcum PP + 15% Talcum + 15% GB
SPE ANTEC® 2014 / 167
I. General introduction about glass beads
II. Case studies
1. How does BMW improve aesthetic & dimensional stability of PA - 30% glass
fibers?
2. How to improve aesthetic and scratch resistance in PP in PSA application?
3. How does LG enhance dimensional stability & surface resistance in ABS – 20%
AgendaAgenda
3. How does LG enhance dimensional stability & surface resistance in ABS – 20%
glass fibers?
4. What can the new E-glass grade bring to Polycarbonate resin producers?
III. Conclusion
18
SPE ANTEC® 2014 / 168
Case Study 3: ABSCase Study 3: ABS--GF GF –– Starting pointStarting point
Company: LG
Market: Electronic device housing
Material: ABS + 20% GF
Processing mode: Twin-screw extrusion and injection molding
Requirements
� Improve dimensional stability
� Improve abrasion and scratch resistance
� Improve surface aspect
� Maintain mechanical properties
19
SPE ANTEC® 2014 / 169
Case Study 3: Case Study 3: ABSABS--GF GF –– Solution & BenefitsSolution & Benefits
Solution: add 10% of glass microspheres
Initial material: ABS + 20% GF
Final material: ABS + 20% GF + 10% Microperl® 050-20-215 (20µm)
Benefits:
� Better dimensional stability � lower and isotropic shrinkage� Better dimensional stability � lower and isotropic shrinkage
� Better abrasion and scratch resistance � more durable surface aspect
� Surface aspect � glass fibers/glass beads dispersion improved
� Similar mechanical performance
Additional benefits:
� Higher production output
20
SPE ANTEC® 2014 / 170
Case Study 3: ABSCase Study 3: ABS--GFGF–– Technical DataTechnical Data
� Lower and isotropic shrinkage
� Better scratch resistance
Sample ABS ABS + 20% GF ABS + 20% GF + 10% GB ABS + 20% GB
Shrinkage (parallel) 0,80 % 0,50 % 0,40 % 0,20 %
Shrinkage (perpendicular) 1,00 % 0,70 % 0,40 % 0,20 %
ABS + 20% GF + 10% GBABS + 20% GF
� Better abrasion resistance
21
Scratch done with a Clemen, 2kg Weight, Tungsten bead
ABS ABS + 20% GF ABS + 20% GF + 10% GB ABS + 20% GB
Weight lost (%) 2,3 2,8 1,7 0,9
Abrasion done with an abrasive paper 40, 10000 cycles
SPE ANTEC® 2014 / 171
Case Study 3: Case Study 3: ABSABS--GF GF –– Technical DataTechnical Data
� Better Surface aspect
ABS+20%GF+10% GB
ABS+20%GF
Clean surface aspect due the dispersion of
glass fiber
� Mechanical performance are retained
22
Property Units Method ABS 20% GF 20% GF 10% GB
Charpy Impact (unnotched) kJ/m² ISO 180/1U n.a. 22 22
Charpy Impact (notched) kJ/m² ISO 180/1A 12 12 10
Flexural Modulus MPa ISO 178 2370 5000 5200
Flexural Strength MPa ISO 178 62 125 125
Tensile Strength MPa ISO 527-2 38 90 95
Elongation at break % ISO 527-2 15 4 8
SPE ANTEC® 2014 / 172
Case Study 3: Case Study 3: ABSABS--GF GF –– Technical DataTechnical Data
� Additional Benefits measured
� Higher production output
60
70
80
90
100
110
120
To
rqu
e ABS + 20% GF
ABS + 20%GF + 10%GB
ABS + 20% GB
At same torque ���� higher production output
23
ABS + 20% GF ABS + 20% GF + 10% GB ABS + 20% GB
Cycle Time 50 seconds 45 seconds 39 seconds
Saving 5 seconds (10%) 11 seconds (22%)
50
60
750 800 850 900 950 1000
Speed (kg/h)
ABS + 20% GB
10 to 22% shorter cycle time measured
SPE ANTEC® 2014 / 173
I. General introduction about glass beads
II. Case studies
1. How does BMW improve aesthetic & dimensional stability of PA - 30% glass
fibers?
2. How to improve aesthetic and scratch resistance in PP in PSA application?
3. How does LG enhance dimensional stability & surface resistance in ABS – 20%
AgendaAgenda
3. How does LG enhance dimensional stability & surface resistance in ABS – 20%
glass fibers?
4. What can the new E-glass grade bring to Polycarbonate resin producers?
III. Conclusion
24
SPE ANTEC® 2014 / 174
Case Study 4: New grade for PC Case Study 4: New grade for PC –– Starting pointStarting point
Company: -
Market: Various applications – Suitcases, Cars, electronic, …
Material: PC
Processing mode: Twin-screw extrusion and injection molding
Requirements
� Improve dimensional stability
� Improve abrasion and scratch resistance
� Improve processing
25
SPE ANTEC® 2014 / 175
Case Study 4: New grade for Case Study 4: New grade for PC PC –– Solution & BenefitsSolution & Benefits
Solution: Sovitec developed a new glass composition to answer OEM customer request
The chemical structure of E-glass naturally leads to higher compatibility between the
resins and the beads.
Initial material: PC
Final material: PC + 15% of Microperl® 050-20-EG (20µm)
Benefits:
� Better dimensional stability � lower and isotropic shrinkage
� Better abrasion and scratch resistance � more durable surface aspect
� Easier processing
26
SPE ANTEC® 2014 / 176
Case Study 4: New grade for Case Study 4: New grade for PC PC –– Technical DataTechnical Data
� Easier processing
� The addition of glass beads clearly improve the extrusion and injection of PC compounds : ball bearing
effect, less defects, …
To produce 500 pieces within specifications
Formulation Cycle TimeNb of injected
piecesTotal time for this
production
PC 44s 512 375 min
PC + 15% GF 48s 552 442 min
� Better abrasion resistance
27
PC + 15% GF 48s 552 442 min
PC + 15% GB 36s 501 300 min
Taber Test CS10 – 1kg
PC (weight lost)
PC + 15% GB(weight lost)
1000 cycles 30 mg 5 mg
5000 cycles 180 mg 30 mg
10000 cycles Destroyed 65 mg
64% more resistant than PC for 2x cycles
SPE ANTEC® 2014 / 177
Case Study 4: New grade for Case Study 4: New grade for PC PC –– Technical DataTechnical Data
� Higher scratch resistance
PC + 15% GBPC
� Better dimensional stability
28
0
20
40
60
80
100
120
140
PC PC + 15% GF PC + 15% GB
Warpage (%)
- 55%
SPE ANTEC® 2014 / 178
Benefits of Glass Benefits of Glass Beads Beads -- ConclusionConclusion
Glass microspheres offer a wide set of technical and economic advantages, alone or blend to your current solution.
By substituting a portion of GF, or replacing silica by microspheres into several thermoplastic resins (PA / PP / PO / PBT / Styrenics / PC…), we improve the following properties :
� Dimensional Stability: warpage, shrinkage and isotropic behavior
� Surface aesthetic: uniform color and aspect
� Scratch & Abrasion resistance: shallower scratch & excellent abrasion resistance
� Processing speed: production output (extrusion, injection, film, …) & less waste
� Cost reduction: cost-savings
� …
29
SPE ANTEC® 2014 / 179
Thank you for your attentionThank you for your attention
SPE ANTEC® 2014 / 180