The Possible Possible Automotive Applications Automotive Applications of Glass Microspheres of Glass...

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4 case 4 case studies to discover studies to discover the the possible possible automotive applications automotive applications of glass microspheres of glass microspheres Frédéric Juprelle Business Unit Manager Technical Products SPE ANTEC ® 2014 / 151

Transcript of The Possible Possible Automotive Applications Automotive Applications of Glass Microspheres of Glass...

Page 1: The Possible Possible Automotive Applications Automotive Applications of Glass Microspheres of Glass Microspheres

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

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Page 2: The Possible Possible Automotive Applications Automotive Applications of Glass Microspheres of Glass Microspheres

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

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Page 3: The Possible Possible Automotive Applications Automotive Applications of Glass Microspheres of Glass Microspheres

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

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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

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Charleroi - BE

Buenos Aires - AG

Berlin - GE

Barcelona - ES

Metz - FR

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• 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

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Sovitec’sSovitec’s Glass BeadsGlass Beads

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Raw Material = Recycled glass

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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

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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

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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

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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

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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%

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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

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Tensile Modulus MPa ISO 527-2 3200 9200 8700

Elongation at break % ISO 527-2 4,5 3 4

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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

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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

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Page 13: The Possible Possible Automotive Applications Automotive Applications of Glass Microspheres of Glass Microspheres

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

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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

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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

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Previous PP grade New PP grade

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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

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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

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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

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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

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Page 18: The Possible Possible Automotive Applications Automotive Applications of Glass Microspheres of Glass Microspheres

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

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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

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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

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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

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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

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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

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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

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Case Study 3: Case Study 3: ABSABS--GF GF –– Technical DataTechnical Data

� Additional Benefits measured

� Higher production output

60

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90

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120

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rqu

e ABS + 20% GF

ABS + 20%GF + 10%GB

ABS + 20% GB

At same torque ���� higher production output

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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%)

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60

750 800 850 900 950 1000

Speed (kg/h)

ABS + 20% GB

10 to 22% shorter cycle time measured

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Page 24: The Possible Possible Automotive Applications Automotive Applications of Glass Microspheres of Glass Microspheres

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

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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

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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

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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

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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

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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

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0

20

40

60

80

100

120

140

PC PC + 15% GF PC + 15% GB

Warpage (%)

- 55%

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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

� …

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Thank you for your attentionThank you for your attention

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