Introduction to SkyPURA

2015. 6.

1

Contents

[Session #1] Introduction to SkyPURA (PCT)

[Session #3] EP applications

1

[Session #2] LED applications

[Session #4] V-0 Flammability, Physical Properties

[Session #5] PC/PCT Alloy

2

PCT(Polycyclohexylenedimethylene Terephthalate)

Session I.

Introduction to SkyPURA (PCT)

3

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.

SkyPURA - Introduction

PPS

PETG

PET Ecozen

Price

, Perf

orm

ance

PCT

224

245

260

289

PET Nylon66 PCT LCP

260

270

PPS PPA

SMT, Reflow temp. zone

HDT for engineering plastics

Therm

al Sta

bility

PEEK

HDPE

LDPE

LLDPE PS

PVC

HIPS

ABS

Amorphous Semicrystalline

PA66

PA6

TPE

PBT

PP

POM PMMA

PES

PSU

PEI PA46

PC/ABS

PC/PET PS/PPE

4

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.

SkyPURA Main Properties

High Reflectivity and Durability

Long Term Heat Resistance

Low Moisture Absorption

Reflow and Lead-free Soldering Capable Resin

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

TPA CHDM

PCT Compound

Fiber

TPA

CHDM

Film

Food Contact

Home Application

Automotive

Electrical Electronic

PCT Base Resin

5

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 PS with X-PS column

Polydispersity (Mw/Mn) ≥ 2.20 ≥ 2.20 ≥ 2.20 2.15 2.20 2.20 2.15 2.20

Melting point (Tm(℃)) ≤ 280 ≤ 280 ≤ 280 286±3 286±3 295±2 286±3 286±3

DSC scan r

ate 10℃/min

Crystallization temperature under cooling (Tmc(℃))

≤ 215 ≤ 215 ≤ 215 235±5 235±5 258±5 235±5 235±5

Glass transition temperature (Tg(℃))

≤ 89 ≤ 89 ≤ 89 89 89 89 89 89

Color-L* 88±4 - 88±4 88±4 90±4 90±4 - - After crystallization @ 150℃, 1hour

Color-a* 0±3 - 0±3 0±3 0±0.3 0±3 - -

Color-b* b* < 6 - b* < 6 b* < 6 b* < 6 b* < 6 - -

High Reflectivity and Durability

Long Term Heat Resistance

Low Moisture Absorption

for LED Reflector

for Connectors

Reflow and Lead-free Soldering Capable Resin

Long Term Heat Resistance

Good Electrical Properties

Low Moisture Absorption

SkyPURA - Applications and Characteristics

6

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

SkyPURA - Applications and Characteristics

7

Good thermal, Color, Hydrolytic Stability

Good Electrical Properties

Low Moisture Absorption

for Film

Good laundry durability at high temperature

Excellent chemical resistance/ hydrolytic stability

Shape/performance stability and durability

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 Oven Tray

Long Term Heat Resistance

FDA Approval

for Fiber

8

PCT (Polycyclohexylenedimethylene Terephthalate)

Session II.

LED Applications

9

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]

Ceramics

SMC

EMC

PCT

PA9T

PA10T

PA6T

1.5

0.5

4,000 MT

10,000 MT

7,000 MT

2,000 MT

2,000 MT

Consumption [’14]

(compound)

Total 25,000 MT

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.

10

- LED Application : Whiteness & Light Stability of PCT Compound

75

80

85

90

95

100

PCT PA9T

97.7 97.6 96.4

85.4

Color L

0 hr 2 hr 4 hr 8 hr 12 hr 24 hr

0

50

100

PCT PA9T

100.0 100.0 96.0

68.7

%

Reflectance(450nm)

0 hr 12 hr

0

5

10

15

0 hr 2 hr 4 hr 8 hr 12 hr 24 hr

Color b

PCT PA9T

11

PCT (Polycyclohexylenedimethylene Terephthalate)

Session III.

Engineering Plastic Applications

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/m2) 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) 1.05×1015 1.05×1015 1.0×1015 1.0×1015 > 1.0×1015 1.0×1012

Volume Resistivity (ohm m) > 1.0×1015 > 1.0×1015 1.0×1015 1.0×1015 1.0×1013 1.0×1012

Comparative Tracking Index (V) - 440 175 250 150 525

Electrical Strength (kV/mm) 32 33 22 28 20

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

- EP Application : Properties

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.

13

- EP Application : Hydrolytic Stability

0

500

1000

1500

2000

PCT-GF30 PA6T-GF30 PBT-GF30

Tensile Strength(kgf/cm2)

0 hr 24 hr 168 hr 720 hr 1200 hr

0.0

50.0

100.0

PCT-GF30 PA6T-GF30 PBT-GF30

Retention of Tensile Strength(%)

0 hr 24 hr 168 hr 720 hr 1200 hr

SkyPURA PCT shows lower moisture absorption(0.25%) than PA6T and PBT

Important for dimensional stability and hydrolytic stability.

14

- EP Application : Low Moisture Absorption

0.0

0.5

1.0

1.5

2.0

2.5

3.0

PCT-GF30% PA6T-GF30% PBT-GF30%

0.25

2.53

0.50

Moisture Absorption(85℃, 85%)

72 hr 168 hr 336 hr 1200 hr 5000 hr

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- EP Application : Crystallization Half-Time(Base Resin)

0

20

40

60

80

100

0 100 200 300 400 500 600 700 800

Xc

Time (sec)

Crystallization Half-Times (t1/2)

PCT PET

@ Tc - 20℃

PCT : 220℃

PET : 150℃

0

200

400

600

800

1000

120 140 160 180 200 220 240 260

Tim

e (s

ec)

Temperature (℃)

Crystallization Half-Times (t1/2)

PCT PET

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 : Xt = 1 – exp( -k • tn )

Xt : 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

The crystallization half-time(t1/2) 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

16

- EP Application : PC/PCT Blend Results(Compounding)

Flexural Strength & Modulus

PC/PCT is a thermoplastic alloy of amorphous polycarbonate and semi-crystalline PCT that provides a combination of mechanical strength, melt flow, and chemical resistance

Tensile strength & Elongation

0

5,000

10,000

15,000

20,000

25,000

0

200

400

600

800

1,000

1,200

PC/PCT100/0

PC/PCT90/10

PC/PCT70/30

PC/PCT50/50

PC/PCT30/70

PC/PCT10/90

PC/PCT0/100

kg/c

m2

kg/c

m2

PC/PCT Blend

Flexural Strength Flexural Modulus

0100200300400500600700800900

0

100

200

300

400

500

600

700

800

PC/PCT100/0

PC/PCT90/10

PC/PCT70/30

PC/PCT50/50

PC/PCT30/70

PC/PCT10/90

PC/PCT0/100

%

kg/c

m2

PC/PCT Blend

Tensile Strength Elongation

Appendix.

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- EP Application : PC/PCT Blend Results(Compounding)

SkyPURA PCT has good melt flow properties, compared with PC

Melt Flow Idnex of PC/PCT 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)

PC/PCT 100/0

PC/PCT 90/10

PC/PCT 70/30

PC/PCT 50/50

PC/PCT 30/70

PC/PCT 10/90

PC/PCT 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℃)

0

100

200

300

400

500

600

700

PC/PCT100/0

PC/PCT90/10

PC/PCT70/30

PC/PCT50/50

PC/PCT30/70

PC/PCT10/90

PC/PCT0/100

Tim

e (

sec)

Crystallization Half-time (t1/2)

- 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

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Aluminum diethyl Phosphinate

(EXOILT OP1240, Clariant) Melamine cyanurate

(MC)

Properties Unit SKYPURA

Comment 3302 3502 3631

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

- Physical Properties

※ SKYPURA samples : treated for 1 hour at 140℃

20

Flowability (Shear Rate - Shear Viscosity @ 300 ℃)

Data were measured in a plate-plate rheometer

686 Sampyeong-dong, Bundang-gu, Seongnam-si, Gyeonggi-do 463-400 Korea

Jae Hwang Cho, Manager / Phone: +82-2-2008-2455 / E-mail: j.h.cho@sk.com Fax: +82-2-2008-2319

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