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Jörgen Kemps - SABIC

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  • 1. SURFACE EFFECTS OFLEXAN* (CO-) POLYMERSThemadag Kunststof oppervlaktetechniekLüdenscheid, 12 April 2012Jörgen Kemps
  • 2. SURFACE EFFECTS OF LEXAN* (CO-) POLYMERSCONTENTInfluence of additives on surface effectsPolycarbonate Co-Polymers (Lexan* DMX,SLX,HFD)Surface of Glass filled Polycarbonate Modification by Material and ProcessColor Technology - Visual fx examples Diffusion colorsOptical Film – surface technology* Trademark of SABIC Innovative Plastics IP BV No. 1
  • 3. THE INFLUENCE OFADDITIVES ON THESURFACE
  • 4. POLYCARBONATE ADDITIVES• Pigment & Dyes – Transparent, Translucent and Opaque colors• Special effect colors, sparkle, flake, marble, metal….• Fiber glass for modulus & strength with reduced impact• Sulfonate salts to improve flammability resistance• Mold release for easy de-molding• Anti-oxidants for better melt stability and heat aging Additives• UV-absorbers for longer weathering• PTFE for wear resistance (opaque)• Impact modifiers for low temperature ductility Plastic• Blends with other polymers for flow and chemical resistance No. 3
  • 5. SPECIAL ADDITIVES LIKE ANTI DUSTPolycarbonate Anti Dust : Lexan AD143•Fast surface static charge decay•Non permanent (so no surface wiping)•Reduced dust attraction during molding•Less contamination during secondary op’s • Lens coating • Metallization Static dissipation • Painting Static decay as f(time)•Reduced dust attraction during fabrication, 12000 10000transportation, application life time Discharge voltage (V) 8000•~>88% light transmission 6000 Vt=V0 *e -t/RC•Good balance of heat, flow and impact 4000 2000 0 0 100 200 300 400 -2000 t½ Tim e (sec)Surface resistivity Static decay test:EMI/RFI Conductive Static Anti-Stat Anti-dust Isolator • t½ >150sec: isolator Dissipative • t½ >1-150sec: anti-dustShielding 103 104 105 106 107 108 109 1010 1011 1012 1013 1014 1015 1016 1017 • t½ >0-1sec: anti-stat • t½ =0sec: static dissipative No. 4
  • 6. ANTIDUST + HIGH REFLECTIONExample: Requirements Luminaries: • High reflectivity >97%LED Luminaire •Anti-dust performance •Mechanical properties •Processability Anti Dust - high gloss white Aluminum High Reflection Anti-dust Antidust Lexan* for durable high reflectivity No. 5
  • 7. LEXAN *COPOLYMERS
  • 8. LEXAN* SPECIALTY RESINS • Advanced Technology Specialty Copolymers • Expanded Property Space • Greater Value for Customers • Leverages Core Expertise Addition of new building Polymer blends blocks yields Lexan PCFunctionality resins with new properties Functionalization through additives Polymer • Standard Technology • Established Properties Process Technology No. 7
  • 9. LEXAN COPOLYMERS – PORTFOLIO EXL XHT + +Low Temp Heat Impact Resistance + FST + DMX Flame Smoke Scratch Toxicity Clarity Impact Colors Resistance HFD SLX CFR + + +Superior Weatherable Clear Flow Flame Resistance No. 8
  • 10. LEXAN* DMX
  • 11. LEXAN* DMX RESINS Scratch resistance • Surface hardness > PC • H2O & O2 barrier properties Scratch Barrier Chemical Colorability • Drug Efficacyresistance properties resistance • Ammonia resistance • Eliminates hard coating/paint 25 Scratch Depth @6N (mu) 20 15 •Bezels, display/touch 10 screens, keypads •Auto interior knobs 5 0 PC Lexan* PMMA DMX No. 10
  • 12. ERICSSON SCRATCH MEASUREMENTTesting Method (ISO 1518) Apparatus: Ericsson Scratchtester Type 413 Sample: Molded part Stylus Load applied: 6N Test temperature: 23C Load weight Pencil used: 0.01mm conical stylus Profiling: Dektak 6MDektak 6M Typical scratch profiles in microns 24 Lexan* DMX 18 Std PC 12 6 0 -6 -12 -18 -24 No. 11
  • 13. LEXAN* DMX RESINS – TYPICAL SCRATCH DATA 12 4H Pencil hardness 3H 11 10 2H 9H 8F Improved HB 7 6 B pencil 5 2B 3B 4 hardness 4B 3 5Bperformance 2 6B 1 0 Ericsson scratch, micron 25 20 15 Improved scratch 10performance 5 0 No. 12
  • 14. LEXAN* DMX RESINS – 5 FINGER SCRATCH PERFORMANCE Five finger scratch test 18 16 14 Weight (N) 12 10 8 6 4 2 0 Finger# Weight Lexan* DMX Std PC • 1mm tip 1 18N resin• Visible scratch caused by 2 13Nlowest weight recorded and 3 8Nassigned a severity number 4 3N 5 0.6N Lexan* DMX resin shows good five finger scratch performance No. 13
  • 15. LEXAN* DMX RESINS – BARRIER PROPERTIES Oxygen Barrier Oxygen Barrier @23oC cc.cm/(m2.day.atm) Polystyrene 16.6 Polypropylene 8.0 Polycarbonate 9.3 Lexan* DMX/PC blend 2.1 Lexan* DMX resin 0.5 PET 0.2 Moisture Barrier Shelf Life H20 Barrier @38oC, 100%RH Shelf life @23 C (1 mm thick) g.mm/(m2.day) (years to 10% weight loss in bottles) Polycarbonate 4.4 Polycarbonate 0.3 Lexan* DMX resin 0.88 Lexan* DMX resin 1.5 PET 0.58 Lexan* DMX resin@2mm 3 Polypropylene 0.22 Polypropylene 6 Where? Why? • Packaging – Medical, vials • Reduced oxygen and moisture • Oxygen sensitive dyes, additives permeability No. 14
  • 16. LEXAN* SLX
  • 17. WEATHERINGWhat causes weathering (& what does weathering cause) on polymers ?UV radiation & visible light > spectral distribution, & intensity > season, exposure angle, & latitudeHeat & thermal cycling > temperature excursions & “soaks” > also, potential for thermo-elastic stressesMoisture > condensation, precipitation & humidityBiological attack > mildew … •Chain scission •Polymer oxidation - embrittlement Light, O2, H20 Material •Hydrolysis - erosion •Colorant degradation •Yellowing •Colorant fade/shift No. 16
  • 18. THE INFLUENCE OF UV ADDITIVE Florida outdoor weathering Xenon 1200 artificial weathering 50 Lexan 101R 16 45 Lexan 103R 141R 14 40 Lexan 141R 143R 12 35 Lexan 143RColor Shift, dYI 10 Color Shift, DYI 30 25 8 20 6 15 4 10 2 5 0 0 0 500 1000 1500 0 10 20 30 40 Exposure time (months) Exposure time (hours) Under defined conditions, artificial tests predicts outdoor weathering No. 17
  • 19. LEXAN* SLX VS. UV STABILIZED PC RESIN UV stabilized PC Lexan SLX resin No. 18
  • 20. LEXAN* SLX RESINS As molded: UVweathering In hot chamber for 2900 hours: 175W MH lamp UV light 120oC on the refractor 55 oC ambient UV PROTECTIVE LAYER Lexan* SLX resin UV PC resin Lexan SLX resin Potential Applications:UV weathering Outdoor / Street Lighting• Clarity, color and gloss Industrial meters, outdoor displays• Toughness• Chemical resistance• Eliminates UV coating• Diffuse lighting No. 19
  • 21. LEXAN* SLX VS. UV STABILZED PC RESIN 80 UV PC Ductile Impact Energy (J) 60 Lexan SLX25x1T 40 Brittle Lexan SLX resin Lexan* UV-stab 20 PC resin 0 0 10000 20000 30000 Exposure energy (kJ/m2) Xenon Arc Exposure Modified G26 protocol 3000 kJ/m2 = ~1 year Florida exposure Lexan SLX Resin: Better Retention of Colour, Transparency, Ductility than standard UV PC Resin20 No. 20
  • 22. XENON ARC WEATHERING: YI AND HAZELEXAN* SLX RESINS LOWER HAZE AND YELLOWNESS AFTER UV EXPOSURE 10 25 8 20 Haze (%)Delta YI 6 15 4 10 2 5 0 0 0 2000 4000 0 2000 4000 Hours Hours Lexan* UV PC resin ISO-4892-2A protocol Lexan* SLX resin T3 (SLXxy7zT) ~1800 hours = 1 yr Florida exposure Black Standard Temperature : 65 DegC This information should be used as indicative only. The Chamber Temperature : 40 DegC true performance can only be determined under conditions Relative Humidity : 50% as in the final application. Irradiance at 340nm : 0.5 W/sq.m No. 21
  • 23. LEXAN* SLX RESINS – OPAQUE Lexan* SLX resin ~ 1 year outdoor UV stabilized PC 3-4 months outdoor Lexan* SLX resin Where? Why? • Outdoor vehicles – industrial, • Lower colour shift after UV weathering agricultural, marine • Better gloss retention after UV weathering • Outdoor automotive • Better ductility and impact retention after UV• Paint cost elimination/reduction weathering • Better chemical resistance than standard PC No. 22
  • 24. LEXAN* HFD
  • 25. LEXAN* HFD RESINSSuperior flow & ductility• Improved toughness• Optical clarity Superior Flow• Low birefringence• Low temperature processing• High gloss filled surfaces• High surface replication• Bio/green content Camera lenses, Medical housings,Safety/specialty eyewear, Consumer electronics, Bezels, Appliances Impact Clarity Sustainability resistance No. 24
  • 26. LEXAN* HFD RESINS – DUCTILITY ADVANTAGES When? 65 MFI 65 MFI • When you like the MFI of standard PC resin, Lexan HFD resin Standard PC but need better impact Ductile 23oC Brittle 23oC • When you like the impact of standard PC but need better flow Notched Izod Ductile/Brittle Temp vs MFR 15 10 • Standard PCD/B transition temp (C) • HFD - PC EXRL0672 / 0 HFD1810 HFD1810 -10 HFD1711 / EXRL0681 HFD1711 -20 EXRL0682 / HFD1212 HFD1212 Why? FLOW EXRL0683 / HFD vs. For a given melt flow, Lexan HFD -30 HFD1413 standard HFD1413 PC resin has 10-15 oC better IMPACT -40 HFD1014/ EXRL0684 HFD1014 Ductile/Brittle (D/B) transition -45 5 10 15 25 40 temperature compared to standard MFR (g/10min, 300C/1.2kg) PC resins No. 25
  • 27. LEXAN* HFD RESINS – BETTER PROCESSING 800000 Lexan* HFD resin Effective Viscosity 600000 Standard PC resin 400000 200000 0 0.2 0.4 0.6 0.8 1 1.2 Shear Rate (1/Fill Time)Moulding and processing 700• Up to 40% lower injection pressures 600 1 Deg. Core Draft Ejector Force• Up to 75% reduction in ejector force 500• Reduced thermal instability or shear 400 sensitivity 300• Reduced gate blush or splay 200• Long residence time and abusive 100 conditions handled well 0 Lexan Standard HFD resin PC resin No. 26
  • 28. LEXAN* HFD RESINS – OPTICAL PROPERTIES What? • Std PC clarity • Lower molded in stress • Lower birefringence Standard PC HFD of same MW Where? • Thin wall displays • Functional optics No. 27
  • 29. SURFACE OF GLASSFILLED POLYCARBONATE
  • 30. SURFACE OF GF PCGlass in Polycarbonate GF Increase stiffness / modulus – Reduces strain and impactNegative Surface effects:Glass Fibers in Amorphous Polymers increase roughness and decrease glossFibers and flow patterns visible on surfaceLight colors are used to hide stain effect (e.g. Electrical housings) No. 29
  • 31. LEXAN* HFD RESINS – CLASS A SURFACE WITH FILLERS 100 Lexan HFD resin PC resin 60 degree Gloss 80 60 40 20 10% 20% 30% 40% Glass Fiber ContentWhat? Where?• Up to 50% improved gloss with • High modulus aesthetic glass ibers/mineral fillers applications• Similar mechanical properties as GF PC (only non-FR) No. 30
  • 32. LEXAN* HFD RESINS – CLASS A SURFACE WITH FILLERS 10% glass reinforced 10% glass reinforced HFD plaque standard PC plaque Exposed glass fibers HFD surface 50x PC surface 50x magnification magnification Glass-filled HFD surface shows reduction in exposed glass fibers = higher surface gloss No. 31
  • 33. PROCESSING INFLUENCE ON SURFACEEffect of Molding Parameterson roughness and glossHigher Temp = Higher GlossHigher Speed = Higher Gloss30% GF PolycarbonateSource: SABIC brochure Improving the surface finish of reinforced thermoplastics No. 32
  • 34. HEAT & COOL TECHNOLOGYRaise and Lower the tool temp within the molding cycle Better Heat & Cool can allow:SurfaceQuality -Improved surface finishing and “weldline free” molding -Less sensitivity to surface defectsWorseSurface -Smooth surface finishing with filled mat.Quality -High Gloss -Less residual stress on parts -Improved flow for thinwall Painted As Molded with Painted As Molded with Conventional Molding Heat and Cool No. 33
  • 35. COLORXPRESSVISUAL FX
  • 36. SABIC COLOR TECHNOLOGY VISUALFX*SURFACE EFFECTS BY COLOR TECHNOLOGY Flame Illuminate Sparkle Ares Diamond Diffusion Lustre Glass Smoke Frost Golden Porcelain SparklePiano Black Dark Dark Marble Ferrite Alpine Polar Sparkle Light No. 35
  • 37. EXAMPLE METALLIC EFFECTS Paint out – Cost out – Eco solutionHeadlamp Bezel Mercedes SLS Rear lamp Bezel Range RoverSparkle effect Ares effectMatched in Lexan XHT - High heat PC Matched in Cycoloy* PC/ABSSilver effect color – on spot matching No Flow lines due to surface structureExcellent processing – low weld line effect and tool design No. 36
  • 38. YEARLY COLORXPRESS EXPRESSION KIT No. 37
  • 39. DIFFUSION COLORSIN LED
  • 40. LEXAN* DIFFUSION (FXD) RESINS Potential Applications: CFL bulb LED bulb LED tubesDiffusion Distance Variations Combination of Diffuser Loading Variations standard pigments and specially designed diffusers in LEXAN resin A B A B Provides almost limitless options for aesthetic and light management needs D C D CDistance: D > C > B > A Loading: D > C > B > A • Broad spectrum of light management options available • Formulas can be custom designed per application needs • Available in many grade platforms No. 39
  • 41. DESCRIBING TRANSLUCENT & DIFFUSED ARTICLESTransmission: percentage of the incident Diffusivity: measure of light dipersion: sumlight that is transmitted of the luminance measured at 20° and 70° over two times the luminance on 5° (see nextHaze: percentage of the light which page)deviates from the incident beam greaterthan 2.5° on the average Degree of light dispersion: angle at whichClarity: percentage of the light which half of the luminance of the incident light isdeviates from the incident beam smaller observed (see next page)than 2.5° on the average (determines the Translucency Diffusionsee-through quality) Applications typically require: Applications typically require: • Haze • Haze • Hiding power • Hiding powerLuminance: measure of the luminous • Light scattering in all directions • Diffusion through light refraction  also in backward direction  scattering in net forward directionintensity per unit area of light travelling in a • Lower overall light transmittance • Higher overall light transmittance • Causes loss in contrast (haze) • Causes loss in sharpness (clarity)given direction More aesthetics More functionalTranslucent Scattering Narrow Angle Scattering Wide Angle Scattering No. 40
  • 42. DIFFUSIVITY & DEGREE OF LIGHT DISTRIBUTION The luminance of a difussed sample can be measured under different angles  this allows the assessment on the degree of light diffusion Two measures are:  Diffusivity  Degree of Light Dispersion Diffusivity Degree of Light Dispersion 50% LAngle 20° + LAngle 70° Diffusivity = Degree of Light Dispersion = gL = 50% 2  LAngle 5° Larger Values Mean Higher Degree of Light Diffusion4 No. 41
  • 43. DIFFUSIVITY VS. TRANSMISSION – DIFFUSER TECHNOLOGIESDifferent Diffuser Types Wide Angle Scattering Narrow Angle ScatteringDiffuser + Opacifier Higher hiding power Translucent Scattering + Wide Angle Scattering Various Diffusion Effects can be matched in the Lexan* FXD Product Portfolio No. 42
  • 44. OPTICAL FILMS
  • 45. DIFFUSION + SURFACE TECHNOLOGYIlluminex* display films-innovative optical filmsFeatures:Superior scratch resistance versus coated PET filmsNo coating uniformity or flaking issuesNo mismatched CTE, CWE Less thermal wrinklingHigher HDT (>130°C) versus traditional PET films No. 44
  • 46. ADVANCED OPTICAL DISPLAY BY MICRO TEXTUREVisibility under ambient light Hiding PowerPrinted Matte finish sample Printed micro-lens sampleExcellent hiding power Top view of matte PC film3x better contrast in un-illuminated display SEM imageconfiguration than matte finish films.3x better ability to transmit light at regions that arenot directly illuminated by the light source. Top view of micro lens PC Film SEM image Improved brightness or energy saving No. 45
  • 47. Thank you ! Questions? No. 46
  • 48. CONTACT INFORMATIONJörgen Kemps SABIC Innovative Plastics BVPC Marketing Plasticslaan 1Sales Development Specialist PO Box 117 4600 AC Bergen op Zoom M: +31 (0)6 4859 2524 T: +31 (0) 46 204 7690 Jorgen.kemps@sabic-ip.com www.sabic-ip.comBenelux:Julian Maasdijk: Sales Development SpecialistT +31 164 29 3566 / M +31 2731 9813Julian.maasdijk@sabic-ip.comJos van Laerhoven: Technical ManagerT +31 164 29 3036 / M +31 651 66 9128Jos.vanlaerhoven@sabic-ip.com No. 47
  • 49. TAC TECHNICAL ANSWER CENTRE EUROPE Contact Data: Tel: (0)0 800 1 238 50 60 or 00 36 1 238 50 60 Fax: 00 36 1 330 9562 E-mail: webinquiries@sabic-ip.comTAC can help with... TAC cannot help with... Supply chain related issues• Technical datasheets (TDS)• Material Safety Datasheets (MSDS, colour specific) • Certificate of conformity (COA) • Customs documents• Certification (colour specific) • Order / delivery related doc/info • UL cards • Access to order system • Fire & Smoke & Toxicity • Price enquiries • REACH, RoHS, Substances, WEEE • ISO certificates • Complaints (order/delivery) • Food contact, biocompatibility Long term supplier declarations • Potable water, Toy • IT issues (access) • EU Directives (Packaging, ELV, shelf life etc.) • SF&S requests • IMDS info • Finance & accounting issues / billing• Brochures & Literature (eg. molding guides) Please contact your local SABIC Innovative• Requests for technical / processing assistance & Plastics Representative for this information information No. 48
  • 50. DISCLAIMERTHE MATERIALS, PRODUCTS AND SERVICES OF SABIC INNOVATIVE PLASTICS HOLDING BV,ITS SUBSIDIARIES AND AFFILIATES (“SELLER”), ARE SOLD SUBJECT TO SELLER’S STANDARDCONDITIONS OF SALE, WHICH CAN BE FOUND AT http://www.sabic-ip.com AND ARE AVAILABLEUPON REQUEST. ALTHOUGH ANY INFORMATION OR RECOMMENDATION CONTAINED HEREINIS GIVEN IN GOOD FAITH, SELLER MAKES NO WARRANTY OR GUARANTEE, EXPRESS ORIMPLIED, (i) THAT THE RESULTS DESCRIBED HEREIN WILL BE OBTAINED UNDER END-USECONDITIONS, OR (ii) AS TO THE EFFECTIVENESS OR SAFETY OF ANY DESIGN INCORPORATINGSELLER’S PRODUCTS, SERVICES OR RECOMMENDATIONS. EXCEPT AS PROVIDED INSELLER’S STANDARD CONDITIONS OF SALE, SELLER SHALL NOT BE RESPONSIBLE FOR ANYLOSS RESULTING FROM ANY USE OF ITS PRODUCTS OR SERVICES DESCRIBED HEREIN. Eachuser is responsible for making its own determination as to the suitability of Seller’s products, services orrecommendations for the user’s particular use through appropriate end-use testing and analysis. Nothingin any document or oral statement shall be deemed to alter or waive any provision of Seller’s StandardConditions of Sale or this Disclaimer, unless it is specifically agreed to in a writing signed by Seller. Nostatement by Seller concerning a possible use of any product, service or design is intended, or should beconstrued, to grant any license under any patent or other intellectual property right of Seller or as arecommendation for the use of such product, service or design in a manner that infringes any patent orother intellectual property right.SABIC Innovative Plastics is a trademark of SABIC Holding Europe BV* Trademark of SABIC Innovative Plastics IP BV No. 49
  • 51. No. 50

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