Lexan * XHT Resins

No. 1
L’innovation dans les thermoplastiques techniques à
haute tenue en température
CFP, les plastiques très techniques
June 19 th , DIJON
Norberto Robalo
Technical support engineer specialties France
Olivier Pertoldi
Sales developement specialist France
Content
• Sabic Today
1st : part
• Xtrem high temperature polycarbonate technology
• Market segment applications
2nd: part
• high heat polyimide performance technology
• Market segment applications
No. 3
SABIC IN NUMBERS
36 years of growth
2nd largest global
diversified chemical company*
88 B$ total assets
50 B$ annual revenue
33,000 employees
40 countries
* Forbes 2011
No. 4
OUR GLOBAL OPERATIONS
Global Headquarters
Application centers (3)
Distribution, storage facilities
and logistic hubs (46)
International subsidiaries
and sales offices (87)
Manufacturing and compounding
companies (60)
Corporate research
and innovation center (1)
Technology centers (14)
No. 5
SIX STRATEGIC BUSINESS UNITS
Chemicals
Performance
Chemicals
Olefins,
oxygenates
and aromatics
Specialty
automotive
Metals
Long steel
and flat
steel
Catalysts
Chemical
intermediates &
industrial gases
Rubber chemicals
Specialty
polymers
Polymer additives
Aluminum
joint
ventures
Fertilizers
Ammonia
Urea
compounds
Phosphate
Liquid fertilizers
Polymers
Polyolefines
PVC and
polyester
rubber
chemicals
Specialty
polymers
and polymer
additives
Innovative
Plastics
Engineered
thermoplastics:
PC, ABS, PBT,
PPO, PEI
Specialty
compounds
Sheet & film
Polymershapes
No. 6
PRODUCTION HAS MULTIPLIED BY 6 IN 20 YEARS
A high rate of growth…
…reaching 67M metric tons in 2010
70
67
Innovative Plastics
Production (million tons)
1.231
60
0.458
Metals
47
50
5.191
Fertilizers
40
28
30
22
20
10
Performance Chemicals
6
13
7.043
Polymers
10.667
Chemicals
0
1985 1990 1995 2000 2005 2010
42.268
No. 7
WE RANK AMONG THE TOP PRODUCERS WORLDWIDE
#1
#2
#3
Mono-ethylene glycol
Methanol
Polyethylene
MTBE
Polypropylene
Polycarbonate
Polybutylene terephtalate
Polyphenylene
Engineering plastics
and its compounding
Polyether imide
Granular urea
No. 8
OUR HERITAGE IN INNOVATION
Extem*
Producing Plastics since 1935
Our company created:
‒ Polycarbonate (Lexan* resin) in 1953
‒ PPO (Noryl* resin) in 1961
‒ Polyetherimide (Ultem* resin) in 1982
‒ Amorphous thermoplastic polyimide (Extem* resin) in
2006
Lexan* XHT
Flex Noryl*
Lexan* SLX
Geloy*
1950
Noryl*
1960
FILM /
SHEET
1970
Engineering
Structural
Foam
product portfolio size
Noryl PPX*
Xenoy*
Since 1950, we have over 5,000 patents issued and in force
Lexan*
Supec*
Valox*
1980
1990
2000
Ultem*
Cycolac*
*
CycoloyNoryl
GTX*
2010
Lexan* EXL
Xylex*
LNP*
Valox* iQ
Lexan* DMX
No. 9
INNOVATIVE PLASTICS IN THE ENGINEERING
THERMOPLASTICS INDUSTRY
High
Price
Performance
PI
PPSU
Extem* (PI)
Ultem* (PEI)
Lexan* (PC)
Noryl* (PPO)
Cycoloy* (PC/ABS)
Geloy* (ASA)
Cycolac* (ABS)
Polystyrene
Polyvinyl chloride
Low
AMORPHOUS
Clarity, colorability,
impact strength
* Trademark of SABIC Innovative Plastics IP BV
PEEK
LCP
HTN
Xenoy* (PBT/PC)
Valox* (PBT)
Nylon
Polyethylene
Polypropylene
CRYSTALLINE
High
performance
polymers
Engineering
polymers
and blends
Bulk
polymers
Family
Chemical resistance,
flow, electrical properties
No. 10
A new family of truly high heat polycarbonate resins
Lexan* XHT
Resins
Heat
resistance
Lexan* Specialty Resins Bring Value to Customers
• Advanced Technology
Specialty Copolymers
• Expanded Property Space
• Greater Value for Customers
• Leverages Core Expertise
Functionality
Polymer blends
Functionalization
through additives
Addition of new building
blocks yields Lexan PC
resins with new properties
Polymer
• Standard Technology
• Established Properties
Process Technology
No. 12
EXPANDING HIGH HEAT SOLUTIONS – FILLING A NEED
among all high heat resins…
Lexan* XHT
Resins
PBI
Heat
PI
PAI
High heat Polycarbonate
PEEK
• Glass like clarity
• Long term use temperatures
- Robust Metallization/plating
- Stable clarity/color
- 150oC RTI UL Rating
• Heat/flow/ductility balance
PEI
XHT
PAR
HHPC
PMMI
PPSU
PES
PA46
PPS
PSU
Amorphous
PTFE
PPA
LCP
Crystalline
Chemical Resistance
True high heat performance between 140oC and 185oC w/
Glass Clarity, Metallization, Thin wall & Mechanical advantages
No. 13
Why another high heat PC?
True heat performance 
Lexan* XHT
Resins
Competitive
HHPC Resins
Standard PC
Flow / Processing 
No. 14
Lexan* XHT resins – Automotive applications
Heat
resistance
High heat resistance
•
•
•
•
Clarity
Metallization aesthetics & aging
Color stability on heat aging
Improved flow/impact compared to
other high heat PCs
Auto bezels, Lens covers, Reflectors
Superior
Flow
No. 15
Lexan* XHT resins – Industrial applications
High heat resistance
• Color stability
Heat
resistance
• Higher RTI rating
• Flame retardant – clear V0 down to 2mm
and 5V down to 3mm possible
• Two shot molding with other materials
• Excellent flow for thin wall parts
• Single use medical devices
• Electrical applications at high use temp
XHT4143 resin:
Spot Light Lens
XHT4141 resin:
Face Shield
XHT4141 resin:
Mobile Phone Cover
Housings, Industrial lighting, Electrical
components, Flashlights, Fuses, Face
shields
Competitive material
Lighting
XHT4141 resin:
Mobile Phone
Battery housing
XHT4141 resin: Heater Pads
As molded
After use
No. 16
Lexan* XHT resins – Opaque Metalizable
Where?
Why?
• Metallized
components
• Range of Tg available – 155oC to 185oC
• Higher use temperature at equivalent
HDT
• Better resistance to blistering and microcracking
Failure modes
during use:
170oC
175oC
Pass
Lexan* XHT
Resin 
Hazing
Competitive
High Heat PC
Resin 
Blistering
No. 17
Lexan* XHT resins – Opaque Metallizable
Video of failure mode with temperature for Lexan* XHT
resin (Tg=185oC) and competitive high heat PC resin of
higher heat (Tg=205oC)
Lexan* XHT resin
Competitive HHPC
True
Haze
Blisters
before
Haze
170
18
175
180
185
Temperature (ºC)
190
LEXAN* XHT RESINS – TRANSPARENT –
COLOR STABILITY ON HEAT AGING
Heat Aging against Comp PC at 140oC
BPI PC
Control
BPI PC
250h
BPI PC
500h
BPI PC
750h
BPI PC
1000h
Comp PC
Lexan* XHT
0h
Lexan* XHT
250h
Lexan* XHT
500h
Lexan* XHT
750h
Lexan* XHT
1000h
Lexan* XHT
High use temperatures (140oC+)
+
Clarity
+
Color stability
= Lexan* XHT resins
No. 19
COLOR STABILITY ON UV WEATHERING
PAR
PAR
XHT
XHT
High heat + Clarity + Low color shift on UV weathering = Lexan* XHT
resins
PAR - Polyarylate
No. 20
LEXAN* XHT RESINS : MECHANICAL PROPERTIES
RELATIVE THERMAL INDEX (UL RTI)
Impact Strength Retention at 150oC
120%
120%
Lexan* XHT resin
100%
80%
60%
40%
Std PC
20%
0%
1000
2000
3000
4000
5000
Time of exposure (hrs)
Comp HHPC
6000
7000
Impact Strength Retention
Tensile Strength Retention
Tensile strength retention at 150oC
100%
Lexan* XHT resin
80%
60%
40%
Std PC
20%
0%
1000
2000
Comp HHPC
3000
4000
5000
Time of exposure (hrs)
6000
7000
HIGHEST RTI + Clarity = Lexan* XHT resins
PMMI PAR
Std PC
125oC
130oC
HH PC – High Heat Polycarbonate,
Competitive
HHPC
135oC
140oC
Lexan* XHT
resins
145oC
150oC
No. 21
LEXAN* XHT RESINS – PROCESSING AND FLOW
Spiral Flow Length (cm)
70
Competitive HHPC
Lexan* XHT resin (HDT 155oC)
60
50
40
XHT4141 resin:
Mobile Phone
Battery housing
0.8 mm thickness
30
20
300
325
Temperature (oC)
When?
350
Why?
• Lexan* XHT resins demonstrate
~30% improvement in flow length
compared to competitive high heat
PC
• Lexan* XHT resins offer better
release
High heat + Clarity + Processability (flow, release)
= Lexan* XHT resins
• When molding productivity is desired
• When design flexibility is desired
No. 22
ARE LEXAN* XHT RESINS WHAT YOU NEED?
Lexan* XHT resin features
Your Benefits
High Flow 
Enables Thinner walls with lower mass, faster cycle
times and Lower cost
High Heat 
Reduced Failures and broader design windows
Direct Metallizable 
Recyclable 
Eliminate Lacquering cost and scrap
Reduced scrap, high yield, lower net cost
No. 23
Lexan* XHT Resins
LEXAN* XHT RESINS – PRODUCT PORTFOLIO
Notes:
HDT†
(oC)
MFI‡
(g/10 min)
165
26
XHT4141
XHT4143
156
33
XHT3141
XHT3143
XHT3146
145
48
XHT2141
XHT2143
XHT2146
135
70
XHT1141
XHT1143
Standard
UV
Stabilized High Release
† 1.8MPa, 3.2mm
‡ 330oC/2.16kg
No. 24
Lexan Copolymers – Portfolio Look
Unique Product Attributes expand Polycarbonate Performance to New Applications
+
EXL
+
Low Temp
Impact
+
Heat
Resistance
FST
Flame
Smoke
Toxicity
+
Superior
Flow
2
5
XHT
+
Clarity
HFD
Impact
+
Weatherable
SLX
Colors
DMX
Scratch
Resistance
+
CFR
Clear
Flame
Resistance
No. 25
CONTACT US
Rob de Jong
Product Marketing Manager
Lexan* Copolymers
SABIC Innovative Plastics BV
Plasticslaan 1
PO Box 117
4600 AC Bergen op Zoom
T:
+31 (0)164 292256
F:
+31 (0)20 7948191
M:
+31 (0)6 5185 2519
[email protected]
www.sabic-ip.com
Robert van de Grampel SABIC Innovative Plastics BV
Product Technology Leader Plasticslaan 1
Lexan* Copolymers
PO Box 117
4600 AC Bergen op Zoom
T:
+31 (0)164 291947
F:
+31 (0)164 291686
M:
+31 (6) 8186 8270
robert.vande [email protected]
www.sabic-ip.com
No. 26
EXTEM
High Heat solution
19th June 2012
1.
Introduction
2.
The Extreme Polymer landscape
3.
EXTEM XH resins
4.
EXTEM UH resins
5.
EXTEM UP resins
6.
LNP Specialty compounds with EXTEM resins
No. 28
INTRODUCTION
29
No. 29
WHAT IS EXTEM*
Extreme Environment Thermoplastics (up to 300°c)
•
Melt Processable suitable for Thermoplastic processes (injection,
extrusion,.)
•
Based on proprietary amines and anhydrides
+
•
Thermoplas
tic
PolyImide
Proprietary blend technology with e.g., PEEK resin
No. 30
THE EXTREME POLYMER LANDSCAPE
31
No. 31
The top of the Pyramid
Ultra High Performance
v
High temp. load bearing
v Low & stable CTE
v Typically must have imidization step
PBI
PI
PAI
UH
High Performance Amorphous
XH
v Modulus at elevated temperature
v Dimensional stability
ULTEM*
PEI resin
v Creep resistance
EXTEM
PES
UP
High Performance Crystalline
v Continuous use temperature
v Chemical resistance
v Wear resistance
PEEK
PPS
PA46
PPSU
PPA
PSU
HH PC
Heat
Amorphous
PTFE
LCP
Crystalline
Chemical Resistance
No. 32
THE EXTEM* PORTFOLIO
EXTEM
XH
•
Amorphous
•
Amorphous
•
Tg up to 267°C
•
Tg up to > 300°C
•
LOI = 45%
•
Excellent chemical
•
UP
UH
resistance
Amber transparent
•
RTI Listing up to 260ºC
•
Amber translucent /
amber transparent
•
*
•
Amorphous/SemiCrystalline blends (Extem
/PEEK Blend)
•
Tg ~ 145/300°C, Tm ~
343°C
•
Outstanding chemical
resistance
•
RTI Listing up to 240ºC
•
LOI ~ 42%
•
Opaque
No. 33
EXTEM XH FAMILY
High
Temp.
Resist.
High
Strength
FST
Perf.
34
No. 34
35
EXTEM* XH – DMA’s
10000
Modulus [MPa]
Tailorable Tg
1000
PPS
100
ULTEM* 1000
EXTEM XH
10
50
100
150
200
250
300
350
Temperature [°C]
No. 35
EXTEM* XH – Specific strength & fst
Aluminum/EXTEM XH Comparison
Specific Tensile Strength
Limiting Oxygen Index (LOI) & UL94
80
LOI (%) UL-V0 (mm)
EXTEM XH1005
Specific Tensile Strength
(MPa cm3/g)
70
Aluminum 6063-T5
60
Aluminum 1100-H18
Ultem PEI resin
45
1.6
PEEK
35
1.6
PAI
45
1.2
Extem XH1005
45
0.4
50
40
30
20
10
Aircraft Flammability
0
0
50
100
150
200
Temp (deg C)
Specific Tensile strength
outperforms some DCAL’s at T°
250
300
Aircraft
Verticle burn OSU heat
Smoke Density Smoke Toxicity
FAR and OEM
release
Ds, 4min
Draeger tube
Specs
FAR 25853 FAR 25.853 ASTM F814/E662
ABD0031
ABD0031
BSS7238
BSS7238
Extem UH1006
a(60s), pass
0/21
<50, pass
Pass
Extem XH1005
a(60s), pass
3/41
<50, pass
Pass
Ultem 1000
a(60s), pass
35/65
<50, pass
Pass
Ultem 9085
a(60s), pass
20/40
<50, pass
Pass
No. 36
EXTEM XH POTENTIAL APPLICATIONS
Semicon
Offering:
• Chip Trays
•
Cleanliness
• Pick up systems
•
Dimension stability
•Test Sockets
•
Strength/Creep resistance at high T’s
•
Thin wall
Food Service
Offering:
• Baking Trays
•
Baking temperature up to 250°C
• Oven components
•
Low Staining
•
Durability
•
Thin Wall
Agency’s Food-contact:
- EFSA approved per 1/1/2010
No. 37
EXTEM XH POTENTIAL APPLICATIONS
Automotive
• Main beam/fog- light Reflectors
• Turbochargers
E&E/Lighting
• Defense, Aerospace Connectors
• LED Substrates
• FO Lenses and Connectors
• Industrial/Domestic lighting
Agency’s:
Offering:
• Direct Metallization
•
Haze Onset ~250oC
•
Transparency for near IR
light
•
Dimension stability
•
System Cost
Offering:
• Dimension Stability
• Strength at high temperatures
• Lead-free soldering
• Direct metallization
• Transparency in visible light &
near IR light
• System Cost
- UL Yellow Card for unfilled
No. 38
EXTEM UH FAMILY
Superior
Temp. Resist
Chemical
Perf.
High
RTI
39
No. 39
EXTEM UH MECHANICAL RESISTANCE
Dimensional Stability
Continuous Use – Aging for 1,000 Hr
2
Strength Retention [%]
Dim Change [%]
2.5
Extem UH1006
PEEK
1.5
1
0.5
120%
100%
80%
60%
40%
20%
0%
0
0
50
100
150
200
250
200
220
240
Aging Temp [ºC]
260
Temp [°C]
•
Linear, low expansion up to 240°C
•
High continuous use temperatures
No. 40
EXTEM UH CHEMICAL RESISTANCE
23°C, 7 day, Immersion
% Strength Retention
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%
High Strength Retention
No. 41
EXTEM UH POTENTIAL APPLICATIONS
Semicon
• Chip Trays
• Pick up systems
Offering:
Electrical
• Connectors
• Wire and cable
• Film
• Speaker cones
• Electrical/thermal insulation
Agency’s:
- UL Yellow Card for unfilled
•
Cleanliness
•
Tg > 300°C/572°F
•
UL94 V0 @ 0.4mm
•
Dimension stability
•
Strength/Creep resistance at high T’s
Offering:
•
Strength/Creep resistance at high
temp
•
Dimension stability at high temp
•
High continuous use/thermal class
•
High cut through temperature
•
Chemical resistance
- UL RTI for EXEM0025 @ 260°C!!
No. 42
EXTEM UP FAMILY
High
Temp. Resist
High
Chemical
Perf.
High
RTI
43
No. 43
EXTEM UP PERFORMANCE
Performance over 150-300ºC
• Mechanical strength
• Low Creep
• Dimensional stability
• Chemical resistance
PEEK
200
150
Chemical
Wear
100
UP1007
PBIPEEK
Performance
Mechanical
50
PEK
0
Extem UP
Blends
PEK
™
PEEK
PEEK
polymer
UP1004
PBI-PEEK
Cost
Expanding PEEK performance over 150ºC
No. 44
EXTEM UP DMA
Modulus [ MPa ]
10000
Increasing
EXTEM resin content
EXTEM resin
1000
UP1007
UP1004
PEEK
100
50
100
150
200
Temp [ °C]
250
300
Up to ~5-10 times higher stiffness at 200ºC
No. 45
EXTEM UP POTENTIAL APPLICATIONS
Transportation/Aerospace
• Connectors
• Cable wraps/holders/fixations
• Composites
Industrial
• Pump/valve linings/seats
• Seals
• Bearings
• Gears
• Bushings
• Composites
Offering:
•
Strength/Creep resistance at high
temp
•
Dimension stability at high temp
•
Chemical resistance
•
Excellent FR and low heat release
Offering:
•
Strength/Creep resistance at high
temp
•
Dimension stability at high temp
•
High Continuous Use Temperature
•
Chemical resistance
•
Thin wall
No. 46
LNP COMPOUND FAMILY
Many available effects with
Glass Fibre
Carbon Fibre
Mineral Filler
Additives (lubricant)
47
MERCI !
Q&A
No. 48
Global Disclaimer
THE MATERIALS, PRODUCTS AND SERVICES OF SABIC INNOVATIVE PLASTICS
HOLDING B.V. 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 is a trademark of SABIC Holding Europe BV
* Trademark of SABIC Innovative Plastics IP BV
No. 49