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Welcome to Helvoet Rubber & Plastic Technologies
26-09-2018, Veldhoven
Hybrid Precision Parts: Bonding Various Materials in Critical Applications
Ing. J.W. (Hans) van der Meer
THERMOSET THERMOPLAST RUBBER & LSR ASSEMBLY
Topics
Introduction
What is a hybrid part?
Material combinations
Types of bonding
Mechanical bonding
Chemical bonding Applying bonding agents
Direct bonding & 2K
Hybrid parts in critical applications
Testing of the bonding strength
Product examples
Introduction
Personal introduction
Hans van der Meer
HLO chemistry (specialisation in environmental chemistry)
Weiterbildungsstudium Kautschuktechnologie Leibniz Universität Hanover
4 year at Cabot Leiden Technical Centre (supporting Rubber Blacks)
11 years at Helvoet Rubber & Plastic Technologies B.V.
A stable partner on your side
About us
General FiguresFounded in 1939
~ 750 employees
6 manufacturing locations
world wide customer base
Member of Hydratec industries (Listed on Euronext Amsterdam)
Production Figures
> 200 injection moulding and rubber processing machines
> 100 machines for post-processes
> 30 automated assembly lines
> 1 billion components produced per year
> 4.300 tons yearly material consumption of thermoplastics, thermosets, rubber & LSR
Helvoet locations
Global service, local care
MUNICH
Thermoset, Thermoplastic
ISO 9001, 14001
Simulations, Insert-Moulding
PUNE
Thermoset, Thermoplastic, (LSR)
ISO 14001, IATF 16949
Lapping, Assembly
LOMMEL
Thermoset, Thermoplastic
ISO 14001, IATF 16949
Finishing processes, High volumes
TILBURG
Thermoplastic
ISO 9001, 14001, 13485, OHSAS18001, FDA 21 CFR 820
Assembly lines, Cleanroom
HELLEVOETSLUIS
Thermoplastic, Rubber, LSR
ISO 9001, IATF 16949, ISO 22000, 13485, DVGW
Assembly lines, Compounding
Kaniow
Rubber
ISO 9001, IATF 16949
Assembly and inspection
US Michigan & California
Engineering & Sales
NAFTA and Mercosur markets
Spain Alicante
Engineering & Sales
Extensive material range to fulfill your needs
Material toolbox
Thermoset
Phenolic, BMC
Special treatments / coatings
similar thermal extension as metal
resistant against aggressive media
good thermal insulation
lightweight
Thermoplastic
Commodities
PP, PS, PE
High performance plastics
ABS, PC, PPS, PEEK,
PBT, COC, COP,
TPE, PA66, PBT,
PPA
LSR
Excellent light
transmittance
Superior tensile
strength, elongation,
tear strength, and
compression
Rubber
Own compounding
Customized recipes
NBR, HNBR, EPDM,
FKM, VAMAC,
Bonding with other
materials
Our customer base
Topics
Introduction
What is a hybrid part?
Material combinations
Types of bonding
Mechanical bonding
Chemical bonding Applying bonding agents
Direct bonding & 2K
Hybrid parts in critical applications
Testing of the bonding strength
Product examples
What is a hybrid part?
With a hybrid part we mean a product that consists of two different materials which are fixed together by either mechanical or chemical bonding.
In most cases it is a combination of a hard material and a softer material.
The softer material often has a sealing or damping function.
The hard and soft component can be made in one mould (2k) or in two separate moulds (k+k).
Topics
Introduction
What is a hybrid part?
Material combinations
Types of bonding
Mechanical bonding
Chemical bonding
Applying bonding agents
Direct bonding & 2K
Hybrid parts in critical applications
Testing of the bonding strength
Product examples
Material combinations
Hard / soft combinations:• Metal / Plastic
⁻ Stainless steel with PC
⁻ Stainless steel and PA
⁻ ..
• Metal / Rubber⁻ i.e. magnetic stainless steel with NBR
⁻ Brass and HNBR
⁻ Aluminium with FKM
⁻ Stainless steel with LSR (VMQ)
⁻ ..
• Plastic / Rubber⁻ PPA with AEM rubber
⁻ PPS with FKM
⁻ PA with LSR (VMQ)
⁻ ..
• Plastic / TPE⁻ PP with SEBS
⁻ ..
Topics
Introduction
What is a hybrid part?
Material combinations
Types of bonding
Mechanical bonding
Chemical bonding Applying bonding agents
Direct bonding & 2K
Hybrid parts in critical applications
Testing of the bonding strength
Product examples
Types of bonding
Bonding type
Mechanical Chemical
Bonding agents(use of adhesives)
Direct bonding(without bonding agents)
Topics
Introduction
What is a hybrid part?
Material combinations
Types of bonding
Mechanical bonding
Chemical bonding Applying bonding agents
Direct bonding & 2K
Hybrid parts in critical applications
Testing of the bonding strength
Product examples
Mechanical bonding
Soft component
Hard component
+ All material combinations possible - Limited design freedom
- Limited functional integration
- Tensions in the soft material
- Less fatigue resistant
- No adhesive bond between soft and hard component!!
Sealing area
Topics
Introduction
What is a hybrid part?
Material combinations
Types of bonding
Mechanical bonding
Chemical bonding Applying bonding agents
Direct bonding & 2K
Hybrid parts in critical applications
Testing of the bonding strength
Product examples
Chemical bonding
Soft component
Hard component
+ Maximum design freedom
+ Maximum functional intergration
+ Material saving
+ Less tension concentrations
+ Better fatigue resistance
+ Sealability
+ Adhesive bond between soft and hard component
- Not possible for all substrate combinations
Sealing area
Chemical bonding
Important principles to obtain a chemical bond:
• Wetting- A high surface area gives a better wettability (polar bonding agents)
• Diffusion- Inter diffusion of different polymeric chains
- Entanglements of chains in the boundary surface
• Reaction⁻ Physical reactions: i.e. hydrogen bonds
⁻ Chemical reactions: i.e. functional groups, crosslinking
Chemical bonding
Diffusion:
Inter diffusion of different polymeric
chains
Entanglements of chains (mechanical adhesions)
Chemical bonding
Reaction:
Combination of physical “reaction” ie. Hydrogen
bonds (Y-X) and Chemical reaction via functional groups and crosslinking
resulting in ionic bonds (X)
xxx
xx
x
xxx
Y
Y
Y
Chemical bonding – use of bonding agents
Rubber
TopcoatPrimer
Substrate
Adsorption / mechanical anchoring
Chemical bonding / mechanical inter diffusion
Schematic example using a bonding system:
Bonding system
Chemical bonding – use of bonding agents
What is a bonding agent:
- Dispersion/suspension of various materials:- Polymers
CSM, CR, Chlorinated NR, phenol- / Epoxy resins
- Fillers, Pigments Carbon black, Silica's, Metal oxides, metal
- Cross linkers Isocyanates, Silanes, rubber accelerators
- Solvents Ketones, Aromatic hydrocarbons, Alcohols, water
Topics
Introduction
What is a hybrid part?
Material combinations
Types of bonding
Mechanical bonding
Chemical bonding Applying bonding agents
Direct bonding & 2K
Hybrid parts in critical applications
Testing of the bonding strength
Product examples
Chemical bonding – use of bonding agents
Process steps:
Met
al
Pla
stic
Cleaning
Degreasing (washing)
Drying Activation
Cleaning
Plasma treatment
Blasting
Various blasting materials
Apply bonding agent
Primer (optional)
Topcoat / one-coat
Apply bonding agent
Primer (optional)
Topcoat / one-coat
Vu
lcan
isat
ion
+ Proven technology- The use of bonding agents require a lot of sensitive process steps
Dry
ing
Dry
ing
Dry
ing
Dry
ing
Sto
rage
Chemical bonding – use of bonding agents
Methods for applying the bonding agents:
• Dipping• 10 to 50% dilution with solvent
• Brushing• Use undiluted• For large parts
• Spraying• 50-200% dilution with solvent
• Best system for applying a precise layer thickness.
Applications & Impressions: Hellevoetsluis, bonding technology
Important parameters
Surface energy of cleaned and activated parts
Correct surface roughness (metal parts) after blasting
Applying primer in correct layer thickness (micron level)
Applying topcoat in correct layer thickness (micron level)
Correct drying times for bonding agents
Correct packaging of coated parts to prevent contamination of bonding layer
Bonding rubber/metal and rubber/plastic hybrid parts
Applications & Impressions: Hellevoetsluis, bonding technology
Automated cleaning
Automated blasting
Automated spraying with bonding agents
Drum coating machine
Clean environment according latest industry requirements
Bonding rubber/metal and rubber/plastic hybrid parts
Topics
Introduction
What is a hybrid part?
Material combinations
Types of bonding
Mechanical bonding
Chemical bonding Applying bonding agents
Direct bonding K+K & 2K
Hybrid parts in critical applications
Testing of the bonding strength
Product examples
Bonding 2 materials together without the use of bonding agents.
K+K: first the hard component is moulded (i.e. plastic).
The soft component is over moulded onto the hard component.
The process takes place in two different moulds.
2K: first the hard component is moulded (plastic).
The soft component is over moulded in a second step, but in the same mould.
Applications & Impressions: Hellevoetsluis, bonding technologySelf bonding Rubber possibilities
Self bonding Rubber possibilities
Process steps:
Pla
stic
K
+K
Pla
stic
2
K
Optional plasma treatment
Molding of plastic part + moulding Soft component
(Rubber/TPE) in one mould
+ Proven technology+ Few process steps- Higher costs of 2K moulds with complex temperature demands (especially for rubber)- More limited material combinations
Moulding of soft component (Rubber/TPE in
separate mould
Packaging
Examples:
Self-adhesive LSR (VMQ) to metal, PBT, PA and other materials.
FKM to PA612, PA4-6
AEM (Vamac) to PPA
HNBR to PA 6-3-T
SEBS to PP
Applications & Impressions: Hellevoetsluis, bonding technologySelf bonding Rubber possibilities
Applications & Impressions: Hellevoetsluis, bonding technologySelf bonding Rubber possibilities
AEM – Vamac – rubber (two sides)Plastic (PPA)No bonding agentsStrong bonds
Topics
Introduction
What is a hybrid part?
Material combinations
Types of bonding
Mechanical bonding
Chemical bonding Applying bonding agents
Direct bonding & 2K
Hybrid parts in critical applications
Testing of the bonding strength
Product examples
Selection of materials:
• In order to select the correct hard and soft materials it is important to understand the proposed function of the product:
• Temperature range (low and high)
• Mechanical forces on the product
• Contact media
• Food contact
• If this information is know, we can investigate if there is a good combination possible as all used materials should be suitable for the environment.
Applications & Impressions: Hellevoetsluis, bonding technologyHybrid parts in critical applications
Bond strength:
• A good bond strength makes failing on the interface of the soft and hard component impossible.
• The failure takes place in the weakest part, normally the soft component.
• A good bond strength is stronger than the strength of the soft component.
Applications & Impressions: Hellevoetsluis, bonding technologyHybrid parts in critical applications
Topics
Introduction
What is a hybrid part?
Material combinations
Types of bonding
Mechanical bonding
Chemical bonding Applying bonding agents
Direct bonding & 2K
Hybrid parts in critical applications
Testing of the bonding strength
Product examples
Testing of the bond strength:
• As it is difficult to test the bond quality of parts in a consistent way, it is important to evaluate the capability of the bonding during the development of the part.
• Standardized tests can help to obtain objective data on the strength of the bond.
Applications & Impressions: Hellevoetsluis, bonding technology Testing
Testing of the bond strength:
Based on ISO 5600
Applications & Impressions: Hellevoetsluis, bonding technology Testing
Conical shaped substrate parts (various metals or plastics)
Soft elastic component
Yes/No bonding agent(s)
Testing of the bond strength:
Applications & Impressions: Hellevoetsluis, bonding technology Testing
Good bonding is a 100% rubber break
Failure modes:1. Separation between substrate surface and soft
component (i.e. rubber).
When using bonding agents:1. Separation between substrate surface and primer2. Separation between primer and topcoat.3. Separation between bonding agent (topcoat) and
soft component (i.e. rubber).
Testing of the bond strength (example Brass, one-coat system and HNBR):
Applications & Impressions: Hellevoetsluis, bonding technology Testing
Failure between bondingsystemand substrate
Failure between bondingsystem
and rubber
Partial failure between bonding system and rubber and partial rubber
break
100% thick rubber break
Break force 350 Newton
Break force 680 Newton
Break force 840 Newton
Break force 900 Newton
Testing of the bond strength:
Applications & Impressions: Hellevoetsluis, bonding technology Testing
Bonding strength and type of failure can be determined after:
1. Moulding2. Ageing in air3. Ageing in various application liquids (oil, fuels, AdBlue, water etc..)4. Ageing in plasticizers5. Ageing in hot distilled water6. Ageing in salt water7. Ageing in acid environments
Topics
Introduction
What is a hybrid part?
Material combinations
Types of bonding
Mechanical bonding
Chemical bonding Applying bonding agents
Direct bonding & 2K
Hybrid parts in critical applications
Testing of the bonding strength
Product examples
Manufacturing your competitive advantage
Hans van der Meer
Rubber Technologist & Materials engineer
Helvoet Rubber & Plastic Technologies
Tel.: +31 (0) 181331324
Email: [email protected]
www.helvoet.com
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