lightweight composites epoxy - matrix materials for faster ... · presentation agenda . 3...
TRANSCRIPT
1
Automotive Solutions
Performance
Passion
Success
LIGHTWEIGHT COMPOSITES Epoxy - Matrix materials for faster RTM processes Tom McKay – Chemical Intermediates, BASF Corporation
2
Introduction
Market Pull, Drivers
Product Attributes
Value Proposition
Questions
Presentation Agenda
3
Introduction - Chemistry
Epoxy resin Amine
Epoxy polymer
H
H
N N R H
H
CH2 CH
O
CH CH2
O
CH2 CH
O
CH2 CH
O
CH2 CH
CH2 CH
CH CH2
CH2 CH N N R
OH OH
OH OH
Epoxy systems are highly cross linked, high Tg systems
2 component system plus IMR
HEAT
4
High pressure injection
Elevated material temperatures
Mold temperatures of 100°C+
Introduction – RTM Process
Source: Fraunhofer ICT
Press / mould
Pumps
Component
B
Component
A
GRP/CRP – preform
Mixing chamber
5
Reduction in fuel consumption in vehicles
Consumption of non-renewable resources
Reduction in pollution, environmental concerns
Reduction of crude oil consumption
Less dependency on Middle East
Consumer cost of energy
$4.00+ per gallon gal prices
Market Drivers
6
A demanding challenge for the automotive industry
Source: Pub.L. 110 - 140
Market Pull – Why the Interest? Time schedule for fleet MPG in the U.S.
A demanding challenge for the automotive industry 2011 2017 1978
Energy Independence &
Security Act 2007: Revised
April 1, 2010 to 34.1 by 2016
MP
G
2025
Pending
Legislation
2017-2025
Sept 30, 2011
notice
Final by July 31,
2012 Light Weighting vehicle is essential to meet 2017 – 2025
scenarios
7
A demanding challenge for the automotive industry
Source: ThyssenKrupp Steel
2008 2009 2010 2011 2012 2014 2013 2015 2020
190
170
150
130
110
90
70
0
130 g/km
95 g/km
EU target
80%
65%
75%
100%
100%
Market Pull – Why the Interest?
Schedule for average CO2 emissions, EU
CO2 emission in [g/km]
165 g/km
"Phase-in" percentage of new vehicle registrations
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Short cycle time
No post-curing/annealing required
Fiber content ≥ 50%
Low viscosity for fast infusion and optimum fiber wetting
Fast curing
High glass transition temperature
Very good mechanical properties
Can conventional chemistry achieve this?
Resin Transfer Molding
Process requirements for medium series
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Can conventional chemistry achieve this?
Product Attributes Current Situation
Customers look for a combination of…
Fast infusion with good fiber wetting through low reactivity
Fast polymerization / vitrification through high reactivity
Fast
Curing
Slow
Slow Infusion Fast
Slow
Curing
Fast
Curing
Customer
need
Latent
Curing
Baxxodur®
10
A lesson learned from the wind turbine market…
Large parts with non-uniform thicknesses and irregular shapes
Unique challenges for conventional chemistry
Product Attributes
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Latent curing
High temperature injection
Excellent fiber wetting
Product Attributes
12
Processing:
Mixing and filling Mixing quality
Compatibility Viscosity A/B mixing ratio
Reactivity Catalysis Gelling Mould filling
Curing Gelling Phase separation Vitrification
Post-curing Final properties
Product Attributes
Processing of reactive resins
Viscosity Modulus
tstart tdemould tgel
Reaction time
Curing Post-curing Filling
Pot life
Gopt
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Product Attributes
Steerable Viscosity Properties
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Product Attributes
Viscosity Profile
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Product Attributes Solution : Latent accelerators
Exothermic
Conventional curing
Curing by latent accelerators
Long open time
Time
16
0
50
100
150
200
250
0 1 2 3 4 5 6
Zeit [min]
Vis
ko
sit
ät
[mP
as
]
0
1000000
2000000
3000000
4000000
5000000
Sp
eic
herm
od
ul [P
a]
Latent Epoxy Systems: longer pot life AND quicker curing!
Standard @ 80°C
Baxxodur @ 110°C
Vis
co
sit
y [
mP
as]
Time [min]
Sto
rag
e m
od
ulu
s [
mP
a]
Product Attributes
Resin Transfer Moulding (RTM)
Potential solution for fast EP systems: Latent accelerators
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Key Material Characteristics
Mixture #1 Mixture #2
Resin/Hardener ratio (w/w)
100 : 9 100 : 13.5
Viscosity at 80 °C Approx. 100 cps Approx. 40 cps
Tg Approx. 150 °C Approx. 130 °C
Cure Temp 100 °C – 120 °C 100 °C – 120 °C
Infusion Time 30 – 90 secs, depends on many things
30 – 90 secs, depends on many things
Cure Time 2 – 5 mins, depends on part size, mold temp
2 – 5 mins, depends on part size, mold temp
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Mechanical Properties
Mixture #1 Mixture #2
Resin/Hardener ratio (w/w)
100 : 9 100 : 13.5
Flexural Strength (MPa) 95 116
Elongation at Max Strength (%)
5.4 >6.1
E Modulus (MPa) 2850 3100
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RTM / RIM processes for medium-volume production need shorter cycle times.
Shorter cycle times require faster matrix systems.
BASF is working on fast RTM systems with enhanced properties based on epoxy resin
Processing technology for EP is established
There is no such thing as "the" matrix material, the specification, application and cost will dictate the material.
BASF is the cooperation partner for developing epoxy, polyurethane
and polyamide systems.
Lightweight Composites
Summary and outlook
BASF - Innovations for an Energy-
Efficient and Sustainable Mobility