super structural plastics continue to push the frontier of ... · pdf filesuper structural...

Super Structural Plastics Continue to Push the Frontier of Metal Replacement

Hyundai FairJune 27 - 29, 2006

2

Super Structural Plastics Continue to Push the Frontier of Metal Replacement

AGENDA

Brief history Current State of TechnologyFocus on high productivity manufacture– Injection MoldingStructural, load-bearing applicationsFuture Technology Trends/Challenges

3

Brief history1930’s

Polymers: Nylon, Polystyrene, Polyethylene, AcrylicsGlass Fibers: Commercial manufacturing process

1940’sMilitary: Glass fiber reinforced resins for Aircraft parts

Reinforced plastic boat hullsConsumer: Fishing rods, Serving trays, Pleasure boats

(All Thermosets)1950’s

Injection molding process Corvette fiberglass body

1960’sIntroduction and growth of reinforced thermoplastics

1970’sOptimization of manufacturing and molding processesCommercial carbon fibers developed

Reinforced Engineering Thermoplastics

‘53-’55 Corvette

‘35 Carothers

‘47 Thunderbird

4


Reinforced vs. Unreinforced

020406080

100120140160180200

PA66 PA66 30%GF

PA66 40%MR

PBT PBT 30%GF

Tens

ile S

tren

gth,

MPa

0

2

4

6

8

10

12

PA66 PA66 30%GF

PA66 40%MR

PBT PBT 30% GF

Mod

ulus

, MPa

5

Glass fiber reinforcementCoupling agent – Bonding fibers to polymer

0

10

20

30

40

50

60

70

80

Resin +30% GF +30% GF Coupled

Tens

ile S

tren

gth,

MP

a

0

1

2

3

4

5

6

Resin +30% GF +30% GF Coupled

Mod

ulus

, MP

a

Uncoupled Coupled

6

Current state of technology

Primary ReinforcementsFiber Platelet SphericalGlass Glass Glass (solid, hollow)Carbon Mineral MineralMineralAramideMetals

Current technical advancesBetter coupling agents – Chemical ResistanceLong glass fiber reinforcementsNanocompositesCombinations of reinforcementsHigh performance polymersIn-line compounding/molding

7

Metal Replacement - How close are we?

Unreinforced

Tens

ile S

tren

gth

Tensile Modulus

Standard Reinforced Engineering Polymers

Steel

ZnAl

Future

Structural Reinforced Engineering

Polymers

8

Benefits Through Light Weight Strength

Specific Tensile Strength (MPa/s.g.)

0 50 100 150 200

Zinc

Mild Steel

Aluminum Alloy

Magnesium Alloy

Superstructural Polymers

versus Aluminum = >40%

weight savings with

comparable strength !

up to 163

133

95

52

34

9

Metal / PPS Replacement

with Zytel® HTN

10

Thermostat HousingThermostat Housing

• End User: Honda / Accord• Grade: Zytel® HTN51G

Requirements:• High heat resistance • LLC resistance• Creep resistance

Electric Water Pump & Valve HousingElectric Water Pump & Valve Housing

End User: Toyota / PriusGrade: Zytel® HTN51G

Requirements:• LLC resistance • Easy assembly with vibration welding

Thermal ManagementThermal Management

Rad

iato

r

Thermostat

MechanicalWater Pump

Engine

Heater core

Elc. Water pump(HTN51G35HSL)

At the time of an engine drive

At the time of an idling stop(At the time of a hybrid motor drive)At the time of an idling stop(At the time of a hybrid motor drive)

It runs at the time of an engine drive.It stops at the time of a hybrid motor drive.It stops at the time of a hybrid motor drive.

11

♦ End-user: Honda♦ Grade: Zytel ® HTN (GR/MR40%)♦ Model : Accord (US model)

Requirements:• Dimensional Stability• Ultrasonic welding• Fuel resistance• High temp. resistance

Fuel Integrated ValveFuel Integrated Valve

Fuel SystemFuel System

Fuel InjectorFuel Injector• End User: Honda• Grade: HTN51G

Requirements:• Cost Reduction• Low SG• Recycle-ability• Process-ability (No flash)• Faster cycle time

Primary　Bobbin HTN51G35HSL

12

♦ Grade: Zytel ® HTN 51G♦ Model : Camry 4WD, Estima, etc.

Requirements:• Dimensional stability• Ultrasonic welding• Chemical resistance （Gasoline）• High temp. resistance

FUEL CUT OFF VALVE

Fuel SystemFuel System

13

Brake Guide PistonBrake Guide PistonEnd User: ToyotaGrade: HTN 51G

Requirement:• Chemical resistance (Brake oil)

at elevated temp. • Weld line strength• Good quality for product

liability

Chasis Chasis / / PowertrainPowertrain

Throttle Valve GearThrottle Valve GearEnd User: HondaModel: CivicGrade: HTNWRF51G

Requirements:• Dimensional stability / Low moisture pick up• Low wear / low friction• High temp. resistance

14

Motor Brush HolderMotor Brush Holder• End User: Honda• Grade: HTN 51G

Requirements:• Heat resistance at an elevated temp.• Dimensional stability / low moisture

pick up• Cost Reduction• Recycle-ability

Auto E/E / ExteriorAuto E/E / Exterior

Sunroof Guide BracketSunroof Guide Bracket• End User: Toyota, GM• Grade: HTN GR/MR50%

Requirements:• Low wear / low abrasion• Dimensional stability / low moisture

pick up• Part strength during roll over• Weight reduction• Cost downHUMMEROpa,Cardina

15

Summary

• There is still significant opportunity for metal-replacement by using our SuperStructural resins in monolithic parts - and where they work, they will almost always be the most cost-effective solutions v.s. hybrid structures.

16

StructuralProduct offerings

DuPont Engineering Polymers

Rynite® PET Polyester Polymers

Zytel® Nylon Polymers

Zytel® HTN PPA Polymers

Crastin® PBT Polyester Polymers

Delrin® Acetal Polymers

Hytrel® Thermoplastic Polyester Elastomers

18

Back Up Charts

19

Extending Properties for Reinforced Engineering Polymers

Polymer Matrix MaterialsPrimary function:

Stabilize fibersTransfer stress between fibers Provide a barrier against adverse environmental effects

Important Properties:ModulusStrengthChemical ResistanceResistance to end use environment (Tg, thermal stability)

20

Properties:High, consistent stiffness and strength capabilityImpact performanceCreep resistanceStructural performance at elevated temperatures

Materials:PPA high performance polyamide technology Long glass fiber reinforced PPA and PA66 resinsGlass-reinforced polyester

Extending Properties for Reinforced Engineering Polymers

21

Superstructural Key Grades

75LG60HSL60

75LG50HSL50

75LG40HSL40Long Length

70G60HSL60

Rynite® 555 (55% glass)54G50HSLR53G50HSLR50

Rynite® 54552G45HSL51G45HSL45Standard Fiber Length

Rynite®

PETZytel®PA66

Zytel®HTN54

Zytel®HTN53

Zytel®HTN52

Zytel®HTN51

Filler Level

Reinforcement Type

51LG50HSL

22

Key Features of the Zytel® HTN Product Families

Good toughness

High burst pressure and knit line strength

Retention of propertieswith moisture

Retains high level of stiffness up to 110°C

Water heated tools

PPA resin

Highest stiffness/strength at ambient temperatures

Good toughness

Outstanding surface finish

Water heated tools

Highest melting point and deflection temperature

Moldable in water heated tools

PPA resin

Outstanding retention of properties with moisture

Improved dimensionalstability

Retains high level of stiffness up to 140°C

PPA resin

HTN54 SeriesHTN53 SeriesHTN52 SeriesHTN51 Series

Superstructural – Ultra Stiff– High Strength– Excellent Creep Resistance

23

High Strength and StiffnessSt

ress

at B

reak

(MPa

)

ISO

527

Tensile Modulus DAM (GPa) ISO 527

260

240

220

200

180

160

140

120

100

8 10 12 14 16 18 20

PA46 50% GF PA66 43% GF PPS 40% GF

PBT 50% GF

Short Glass fiber reinforced engineering polymers Polyamides conditioned to 50% RH

24


ress

at B

reak

(MPa

)

ISO

527


260

240

220

200

180

160

140

120

100

8 10 12 14 16 18 20

PA46 50% GF PA66 43% GF PPS 40% GF

PBT 50% GF

Polyamides conditioned to 50% RH

Higher Performance short glass fiber reinforced PPA1 45% GF

PPA3 50% GF

PPA2 45% GF

PET 45% GFPA66 60% GFPET 55% GF

PPA4 50% GF

Short Glass fiber reinforced engineering polymers

25


ress

at B

reak

(MPa

)

IS

O 5

27


260

240

220

200

180

160

140

120

100

8 10 12 14 16 18 20

PA46 50% GF PA66 43% GF PPS 40% GFPPS 50% LFRT

PP 50% LFRT

PBT 50% GF


Long glass fiber reinforced

PA66 40% LFRT

PA66 50% LFRT

PPA1 50% LFRT

PA66 60% LFRT

PPA1 45% GF

PPA3 50% GF

PPA2 45% GF

PET 45% GFPA66 60% GFPET 55% GF

PPA4 50% GF

Higher Performance short glass fiber reinforced


26

High Notched Impact Strength and ModulusN

otch

ed C

harp

yIm

pact

Str

engt

h (k

J/m

2 )

IS

O 1

79

Tensile Modulus (GPa) ISO 527

70

60

50

40

30

20

10

0


PA46 50% GF

PA66 43% GF

PPS 40%GF

6 10 12 14 16 18 208


27

High Notched Impact Strength and ModulusN

otch

ed C

harp

yIm

pact

Str

engt

h (k

J/m

2 )

IS

O 1

79


70

60

50

40

30

20

10

0


PA46 50% GF

PA66 43% GF

PPS 40%GF

PPA1 45% GF

PPA3 50% GF

PPA4 50% GFPET 45% GF

PA66 60% GF

PET 55% GF

6 10 12 14 16 18 208

Higher Performance short glass fiber reinforced


28

Not

ched

Cha

rpy

Impa

ct S

tren

gth

(kJ/

m2 )

I

SO

179


70

60

50

40

30

20

10

0

6 10 12 14 16 18 20


8

PA46 50% GF

PA66 43% GF

PPS 40%GF

PP 50% Long glass

Zytel® HTN 51G45HSL

Zytel® HTN53G50HSLR

Zytel® HTN54G50HSLRRynite® 545

Zytel® 70G60HSL

Rynite® 555

Glass fiber reinforced engineering polymers

DuPont EP Superstructural standard glass fiber reinforced products

DuPont EP Superstructural long glass fiber reinforced products

Zytel® 75LG40HSL

Zytel® 75LG50HSL

Zytel® 75LG60HSL

Zytel® HTN51LG50HSL

High Notched Impact Strength and Modulus

29

LFRT - Long Fiber Reinforced Thermoplastics

Fiber length in granules 8-12 mmFiber length in molded parts are typically 3–4 mm versus 0.3 mm for standard glass fiber resinsComponent design plus processing conditions governaverage fiber length and therefore part performance

Standard pellet compounding

LFRT pellets from pultrusionprocess

Pellet Dimensions: Standard vs. LFRT pellets

30

LFRT - Increased Multiaxial Impact Performance

0

5

10

15

20

25

PA66 50% GR BK Zytel® 75LG50L NC010

Energy to Max Load Total Energy

Joul

es

PA66 50% GF PA66 50% LFRT

DAMISO 6633 mm Disc

Energy to max load Total energy

31

Properties of PPA 50% LFRT vs. PPA 45% GF

100001100012000130001400015000160001700018000

DAM 50%RH

Flexural Modulus, M

Pa Long Glass vs. Short Glass PPA:5% Higher Tensile Strength10-20% Higher Modulus4-7X Higher Notched Impact Strength

Notched Charpy Impact, kJ/m^2

01020304050607080

DAM 50%RH

50% LFRT 45% GF

120140160180200220240260280

DAM 50%RH

Stress at Break, MPa

32

Creep Resistance at High TemperaturesPPA 50% LFRT vs. PPA 45% GF

DMA Accelerated Flexural Creepat 28 MPa, 150C

PPA 50% LFRT vs. PPA 45% GF

00.10.20.30.40.50.60.70.80.9

1

0 1 10 100 1000 10000 100000 1000000

hrs

Tota

l Stra

in, %

DAM

Long Glass vs.Short Glass PPA:Better Creep resistance at load and

temperature extremes

33

Modulus vs TemperaturePPA 50% LFRT vs. PPA 45% GF

Long Glass vs.Short Glass PPA:Higher Stiffness throughout temperature rangeSimilar retention of properties at 50%RH conditions

Tensile Modulus vs. Temperature PPA 50% LFRT vs. PPA 45% GF

0

4000

8000

12000

16000

20000

24000

-40C 23C 80C 100C 130C 150C 175C 200C

Temperature, C

Tens

ile M

odul

us, M

pa

DAM

Tensile Modulus vs. TemperaturePPA 50% LFRT vs. PPA 45% GF

0

4000

8000

12000

16000

20000

24000

23C 80C 100C 130C 150C

Temperature, C

Tens

ile M

odul

us,

MPa

50%RH

34


Current and Future Technology TrendsHigh performance matrix polymersLonger glass fiber lengthExpanded use of carbon fiberThermoplastic nanocompositesPolymeric fibers and self-reinforced polymersHigh strength, reinforced polymer fibersCombined multi-material reinforcementsMetal–plastic hybrid systemsEngineered fiber/fabric composites, laminates and hybrids Bio-derived polymer matricesNatural fiber composites

35


Current and Future ChallengesHigh volume, consistent supply of advanced reinforcementsPolymer manufacture/compoundingOptimum molding processes High productivity molding/forming processesRecycle-abilityPainting and finishingJoining multi-materials systemsMaterial property databases and end-user materials knowledgeFire and low temperature performancePart repair strategies

super structural plastics continue to push the frontier of ... · pdf filesuper structural...

Documents