Reduction of Styrene Evolution from Thermoset Polyester Resin Composites

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Toby Christian Hill
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1 Reduction of Styrene Evolution from Thermoset Polyester Resin Composites Douglas Denton Chrysler LLC Harry Weinhaus ASC Incorporated Bruce Carpenter SPE Automotive Composites Conference & Exposition September 11 13, 2007 Troy, Michigan

Weinhaus ASC Incorporated Bruce Carpenter SPE Automotive

2 Styrene Odor in Cars and Trucks! From residual styrene in polyester resin composites! Can be an nuisance in passenger compartment! Detectable at very low levels ( ppm)! Persistent slow diffusion through polymer network

3 Chrysler Vehicle Development Program! Conversion of convertible sports car into a coupe with goal of acceptable styrene odor level! Known styrene odor issue with trunk pan of convertible! Unknown quantitative concentration target! No defined materials standards or vehicle level tests

4 Thermoset Polyester/Vinylester Parts SMC LMC

5 VOC Test Method ApproacA pproaches Dynamic Inert Gas To VOC Trap For Analysis Static Sample Held in Sealed Volume Air Sampled at Designated Time(s)

6 Static Tests Conducted at Material, Component, and Vehicle Levels

7 Static Tests: Styrene Concentration with Time

8 Static Tests: Styrene Concentration with Log (Time)

9 Effect of Time on Styrene Evolution Rate

10 Effect of Temperature on Styrene Evolution Rate

11 Trunk Pan Formulation Experiments! Variables examined: Resin type, thermoplastic additive, initiator, inhibitor, promoter, filler level, glass bead content! Screening experiments, formulation experiments, confirming experiments! Best formulation gelled too fast for production! Formulation change adequate for convertible

promoter, filler level, glass bead content!

12 Rate of Styrene Evolution from Trunk Pan Formulations

13 Effect of Post Bake on Rate of Styrene Evolution on a Trunk Pan Formulation

14 Effect of Post Bake on Rate of Styrene Evolution from Trunk Pan Formulations

15 Results of Trunk Pan Assembly Studies! Commercialized new resin paste formulation! Implemented a post bake for coupe trunk pans! Achieved more than 95% reduction of styrene evolution rate in coupe trunk pan assemblies

16 Effect of Cure and Post Bake (163 C) Times on Roof and Liftgate SMC Formulations

17 Effective Use of Coatings and Design! Paint systems known to act as styrene barrier! Full paint system on underside of roof cost effective counter-measure for coupe! Sealed holes in inner panels! Vent channels outside of passenger compartment

18 Styrene Testing at Vehicle Level! Static Test - sealed passenger compartment! Vehicle held at 49 C (120 F) for 66 hours! VOC collected on Tenax tube for gc/ms analysis! Subjective evaluation of odor by jury

19 Results of Vehicle Level Testing! Target of 0.15 ppm developed in iterative process! Final prototype vehicle measured at 0.10 ppm! Vehicle judged to be commercially acceptable by jury before production

20 Summary of Results! Developed simple tests at material, component and vehicle levels -- identified time-temperature effects! Results of designed experiments used to optimize resin paste formulations and part processing! Used coatings and design to contain styrene emission! Successfully met vehicle design goal of acceptable level of styrene odor in passenger compartment

21 Acknowledgements Chrysler ASC MFG AOC Saad Abouzahr,, Stephen Perrot, Mike Mordarski,, Rick Muntz Eric Deweese Gary Gill Ashland Chemical Jet Moulding Compounds Meridian Automotive Systems

Lightweighting: How Adhesive Tapes Contribute to Weight Reduction in Automotive Production Processes

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