Trends and Challenges in Your Market PLUS Potential...

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

2

Part I

Opportunities for Higher Heat

Materials at Horizon 2012-2016

Raphaël Mestanza – SpecialChem's Chief Plastics Expert

3

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

4

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

5

6

“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.

7

“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…



Q2: Impact of trends on material requirements

8

“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,


Q3a: Pressure to use higher Heat Material

9

73% of Total Respondents report Huge/Strong Pressure

No split226 respondents

1. Dimensional Stability2. 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

10

No split226 respondents

1. Existing Apps2. 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

11

Market% Huge

pressure

% Huge +

strong

pressure

Top 3 performances Top 3 Reasons

Automotive

Under the hood42% 76%

Dimensional Stab.

Heat Aging

Peak T° Resistance

Stronger Heat Requirements

Metal Replacement

More part close to the engine

Automotive

Lighting+other19% 64%

Peak T° Resistance

Max. Continuous. Serv. T°

Dimensional Stab.


Metal Replacement

Better product reliability

E&E 22% 69% Ret. Mechanical. Perf.


Dimensional Stab. Industrial 23% 60%

Medical &

Healthcare12% 39%

Peak T° Resistance

Ret. Chemical Resist.

Ret. Mechanical Perf.

Aerospace &

Defense21% 63%


Ret. Electrical Perf.

Peak T° ResistanceWiring & Cable 5% 51%

Better product reliability


Thermosets / Composites

Replacement

Q4 Average Heat Improvements Required

12

Peak and Maximum Continuous Service temperatureNo split226 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

13

43%

30%

Amorphous Semi-crystalline

15%

12%

PA6617%

PPA13%

PBT/PET11%

PC10%

PPS9%

PEEK8%

Polysulfone7%

PEI6%

PA 4,65%

POM5%

PI4%

PA122%

PAI2%

LCP1%

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

14

18%

18%

Amorphous Semi-crystalline

38%

18%

0%

PC8% HHPC

8%

PA669%

PEI17%

PET/PBT9%

PPS9%

PEEK9%

PI9%

PSU13%

PPA9%

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….

15



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

16

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

18

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

19

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

PAIPI

PPS

LCPPTFE

PEEK

HH PCPSU

PESULTEM*

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

UPEXTEM

VH

Closing the Gap to the Top!

21

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 Compoundsfor

- Lubrification - Carbon Fibers

22

Performance offerings

23

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 350Temperature [°C]

Mo

du

lus [

MP

a]

ULTEM*

resin

PEEK

PPS

Tailorable Tg

Tailorable Modulus

EXTEM* UH resin

EXTEM XH

DMA curves for unfilled resins

24

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

0

20

40

60

80

100

120

140

160

23ºC 150ºC 200ºC 250ºC

Fle

x S

tren

gth

[M

Pa] PEEK

UP1004

UP1007

0

20

40

60

80

100

120

140

160

23ºC 150ºC 200ºC 250ºC

Fle

x S

tren

gth

[M

Pa] PEEK

UP1004

UP1007

Looking for strength up to high Temperatures?

25

Looking for stiffness and strength up to high T’s?

The Positive Effect May Stay With Reinforcements

40

50

60

70

80

90

100

0 5000 10000 15000 20000 25000

Tensile Modulus [MPa]

Ten

sil

e S

tren

gth

[M

Pa]

PPS

PEEK

PEI

Extem UP blend

Extem UH resin

30% CF-Filled - Tensile Properties at 200°C

26

Specific Tensile strength of Extem XH1005 may outperform some Die Cast Aluminum’s at >170°C

Add Extem XH2315 data

and newdata

Looking for strength up to high Temperatures?

Aluminum/EXTEM* XH resin Comparison

Specific Tensile Strength

0

10

20

30

40

50

60

70

80

0 50 100 150 200 250 300

Temp °C

Sp

ecif

ic T

en

sile S

tren

gth

(M

Pa c

m3/

g)

EXTEM XH1005 resin

Aluminum 6063-T5

Aluminum 1100-H18

27

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

0 50 100 150 200 250

Temperature °C

Dim

en

sio

n C

han

ge [

%]

PEEK

UP1004

UP1007

Extem

D 50%

0.0

0.5

1.0

1.5

2.0

2.5

3.0

0 50 100 150 200 250

Dim

en

sio

n C

han

ge [

%]

PEEK

UP1004

UP1007

EXTEM* resin

D 50%

28

0

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]

Str

ain

[%

]

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?

29

• 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

300P

EI

TP

I

PE

S

TP

I/P

EE

K

PE

EK

PP

S

PP

A

PA

4,6

PA

6,6

RT

I [

°C]

unfilled

30%GF

30

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%

o-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

32

Are you looking for simple thermoplastic processing?

MoldedParts

PartInspection

LoadOvens

Part Inspection

PartInspection

Low YieldOverall

(40-60%)~95% Yield

Overall

PAI*

EXTEM* resins

several days

UnusableLosses

ReusableLoss

UnloadOvens

CUREParts

Processing simplicity

May provide easy processing

May provide as molded properties

Potential High yields

* Customer feedback

ReusableLoss

33

Molding # 2

Sprue/RunnerRegrind

Virgin Resin

Molding # 1

Molding # 4

Sprue/RunnerRegrind

Sprue/RunnerRegrind

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

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%

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%

Izod Impact 100% 77% 103% 104%

Viscosity 100% 104% 105% 101%

34

Processing techniques

Extem* resins can be processed with different techniques

35

Looking for Ultrafine Powders?

Volu

me %

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

37

High Temperature Performance(Strength, Creep, Dimensional Stability)

Th

erm

op

lasti

c B

en

efi

ts(M

elt P

rocessin

g,

Regrind,

Recycle

, M

old

ing)

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

38

Case Studies - Market look and value offering

39

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

40

Potential features:

Dimension Stability

Strength at high temperatures

Direct metallization

Transparency

- visible

- near IR light

Lead-free soldering

System Cost


• 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% GFdevelopm

ent

Portfolio:

41

Automotive

Portfolio:

Potential features:

Direct Metallization

Haze Onset ~250oC

Transparency for near IR light

Dimension stability

System Cost


• 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

42

Potential features:

Strength/Creep resistance at high temp

Dimension stability at high temp

High Continuous Use Temperature

Chemical resistance

Thin wall


• 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+

LubricatedCrystallineExtem Blend

CF/Graphite/PTFEor CF/PTFE

Graphite/PTFE

Structural/Conductive 30% CF

ESD

CrystallineExtem Blend

AmorphousExtem Blend

30% CF

LNP portfolio:

43

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


• 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

*

44

High Temperature Performance(Strength, Creep, Dimensional Stability)

Th

erm

op

lasti

c B

en

efi

ts(M

elt P

rocessin

g,

Regrind,

Recycle

, M

old

ing)

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

45

Disclaimer:

THE MATERIALS, PRODUCTS AND SERVICES OF SABIC INNOVATIVE PLASTICS HOLDING BV, ITS

SUBSIDIARIES AND AFFILIATES (“SELLER”), ARE SOLD SUBJECT TO SELLER’S STANDARD CONDITIONS OF

SALE, WHICH CAN BE FOUND AT http://www.sabic-ip.com. AND ARE AVAILABLE UPON REQUEST. ALTHOUGH

ANY INFORMATION OR RECOMMENDATION CONTAINED HEREIN IS GIVEN IN GOOD FAITH, SELLER MAKES

NO WARRANTY OR GUARANTEE, EXPRESS OR IMPLIED, (i) THAT THE RESULTS DESCRIBED HEREIN WILL

BE OBTAINED UNDER END-USE CONDITIONS, OR (ii) AS TO THE EFFECTIVENESS OR SAFETY OF ANY

DESIGN INCORPORATING SELLER’S PRODUCTS, SERVICES OR RECOMMENDATIONS. EXCEPT AS

PROVIDED IN SELLER’S STANDARD CONDITIONS OF SALE, SELLER SHALL NOT BE RESPONSIBLE FOR ANY

LOSS RESULTING FROM ANY USE OF ITS PRODUCTS OR SERVICES DESCRIBED HEREIN. Each user is

responsible for making its own determination as to the suitability of Seller’s products, services or recommendations for

the user’s particular use through appropriate end-use testing and analysis. Nothing in any document or oral statement

shall be deemed to alter or waive any provision of Seller’s Standard Conditions of Sale or this Disclaimer, unless it is

specifically agreed to in a writing signed by Seller. No statement by Seller concerning a possible use of any product,

service or design is intended, or should be construed, to grant any license under any patent or other intellectual

property right of Seller or as a recommendation for the use of such product, service or design in a manner that

infringes any patent or other intellectual property right.

SABIC Innovative Plastics is a trademark of SABIC Holding Europe BV

* Trademark of SABIC Innovative Plastics IP BV

http://www.sabic-ip.com/



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