PLASTICS WORKSHOP ENGINEERED. Learn About Thermoplastics Connect with Experts COLORADO / UTAH

Transcription

1 ENGINEERED PLASTICS WORKSHOP Learn About Thermoplastics Connect with Experts 2016 COLORADO / UTAH YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS

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3 RTP Company PDF copies of the presentations from today s workshop can be downloaded from our website at 3

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5 Schedule Time Presentation Info Presenter Pg # 8:00 a.m. Registration 8:40 a.m. Introduction to RTP Company Start the day with a brief overview of RTP Company who we are, where we are, and how we can help you! Jason Werginz Sales Engineer 7 9:00 a.m. An Engineer s Guide to Specifying the Right Thermoplastics Steve will explain how to use resin morphology, temperature performance, and cost to choose the right polymer, followed by a discussion on additives and how they can overcome some polymer deficiencies. Steve s case studies will test your knowledge. Steve Maki VP of Technology 15 10:00 a.m. Wear in the World of Plastics Ben will help you make sense of wear and friction principles that affect plastics. He ll cover the common additive solutions beyond traditional PTFE, review test methods, and share information about products to meet demanding wear conditions. Ben Gerjets Product Development Engineer 33 11:00 a.m. Tough or Strong? Short or Long? Dialing in Mechanical Properties Karl will give an overview of additive technologies that can be used to change mechanical properties in thermoplastics. Technologies include alloying and impact modification, as well as short and long fiber reinforcements. Karl Hoppe Senior Product Development Engineer 51 Noon Complimentary lunch 1:00 p.m. Answers to Your Burning Questions: Flame Retardants and Regulations Jesse will provide an overview of the mechanisms for making plastic flame retardant and the process for getting a UL listing. There will also be an introduction of the Hospital Cleaner Damage Resistant technology for flame retardant housings used in the healthcare industry. Jesse Dulek Product Development Engineer 65 1:45 p.m. Color More than Meets the Eye RTP Company Color Engineers do more than match colors they manipulate light! Anna will review how RTP Company communicates and evaluates color, and will discuss how RTP Company modifies materials that are intended for laser marking or laser welding processes. Anna Kreofsky Color R&D Engineer 79 2:30 p.m. Break 2:45 p.m. Taking Charge of Resistivity: An Introduction to Conductive Plastics Technology David will provide an extensive review of technologies for making thermoplastics electrically and/or thermally conductive. Examples will demonstrate the appropriate selection of a technology to achieve desired performance. David Gregerson Product Development Engineer 93 3:30 p.m. Plastic Cures for Common Healthcare Hurdles Karl will talk about the additional challenges that exist in selecting materials for healthcare applications, such as raw material selection, sterilization, and formulation control. In addition, specific technologies used in supporting healthcare applications will be covered especially TPE compounds. Karl Hoppe Senior Product Development Engineer 107 4:15 p.m. Thank you and Door Prizes

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7 Introduction to RTP Company: Your Global Compounder of Custom Engineered Thermoplastics Jason Werginz Sales Engineer (262) :40 a.m. 7

8 3/31/2016 ABOUT RTP COMPANY RTP Company Your Global Compounder of Custom Engineered Thermoplastics RTP Company is an independent, privately owned thermoplastics compounder with global manufacturing, engineering support, and sales representation. 1,500+ employees $500+ million annual sales rtpcompany.com ABOUT RTP COMPANY CUSTOM SOLUTIONS High-Tech Compounds to Unfilled Resins 60+ resins 100s of modifiers Broadest range of competitive compounds (From talc polypropylene to nanotube PEEK) Annual Production 6,000+ commercial products 1,750+ new products per year Intro to RTP Company: Your Global Compounder of Custom Engineered Thermoplastics - Jason Werginz 8 1

9 3/31/2016 GLOBAL MANUFACTURING GLOBAL MANUFACTURING RTP Company operates 18 production plants and has sales offices in major commerce centers around the world. RTP Company is a global compounder of custom engineered thermoplastics. ALLOY POLYMERS LOCATIONS WIMAN LOCATIONS Alloy Polymers, a division of RTP Company, provides contract manufacturing and high volume processes. Wiman Corporation, a wholly-owned subsidiary of RTP Company, produces customized, high quality plastic films and film laminates. Intro to RTP Company: Your Global Compounder of Custom Engineered Thermoplastics - Jason Werginz 9 2

10 3/31/2016 ESP TM LOCATIONS RESMART LOCATION Engineered Sheet Products (ESP ), a division of RTP Company, manufactures specialty engineered sheet. RTP Company partners with ResMart, a distributor of off-the-shelf, unfilled resins. OUR GOAL FLEXIBLE VOLUMES Bags to Bulk Our goal is to satisfy our customers with solutions, providing Technology Flexibility Speed RTP Company offers the most competitive lead times in the industry. Intro to RTP Company: Your Global Compounder of Custom Engineered Thermoplastics - Jason Werginz 10 3

11 3/31/2016 OUR CULTURE WE ARE INDEPENDENT Our culture can be described as A close-knit organization Generational/long term thinkers Entrepreneurial High spirited with a sense of urgency Bureaucracy-less Our independence allows us to be objective in Raw materials Formulations Solutions GLOBAL SUPPORT PRODUCT DEVELOPMENT / R&D RTP Company has 100+ sales & support employees worldwide: Americas Canada, United States, Mexico, Brazil Asia/Pacific Rim China, Korea, Singapore, Japan, Taiwan, India Europe Austria, Netherlands, France, Germany, United Kingdom RTP Company has 50+ development engineers worldwide, including regional engineers for local support. At RTP Company, our development engineers: apply the most current research aggressively seek new resins and additives have a passion for creating the best solution for you Intro to RTP Company: Your Global Compounder of Custom Engineered Thermoplastics - Jason Werginz 11 4

12 3/31/2016 PRODUCT DEVELOPMENT / R&D TECHNICAL SERVICE Our development services are available in each region of the world, and include: RTP Company has 20+ Technical Service Engineers and Specialists worldwide, that provide: Application development Product development Process development CAE support Pilot Plant production Plastic processing trials Injection, extrusion, compression, film, and blow molding trials Process optimization Problem resolution Customer trials and samples CUSTOMER SERVICE GLOBAL COMPOUNDING RTP Company has 30+ Customer Service Representatives worldwide, who are dedicated to serving you. Regionally located, experienced representatives for real-time service Deliver personalized attention to each order Dedicated to your account, serving as an extension of your team We develop it anywhere make it anywhere and support it everywhere! Scalability: Develop your solution on a small scale and produce your solution in large quantities Plant-to-plant consistency ISO: 9001:2008 registered facilities Each year, RTP Company measures how satisfied customers are with the accessibility and helpfulness of their RTP Company Customer Service Representative. In 2015, 96% of respondents indicated that they were satisfied with the service they received. Intro to RTP Company: Your Global Compounder of Custom Engineered Thermoplastics - Jason Werginz 12 5

13 3/31/2016 PRODUCT FAMILIES RESMART Compounds formulated to meet performance requirements, from one property to multiple technologies Color Conductive Flame Retardant Thermoplastic Elastomers Structural Wear Resistant Film - Wiman Sheet - ESP Looking for unfilled plastic resins? We partner with ResMart to fulfill your needs! ResMart Resins: Ultra, Plus, and Utility grades: Polypropylene Nylon 6, 6/6 Clear Nylon (Amorphous Nylon) Polycarbonate SAN ABS Polystyrene Clear ABS (MABS) ACETAL PBT Polypropylene ASA Black Masterbatch TPU Specialty grades: Solvay Udel PSU Solvay Radel PPSU Solvay Ketaspire PEEK MARKETS YOUR GLOBAL COMPOUNDER RTP Company is your global compounder of custom engineered thermoplastics and much more! Appliances Automotive Business & Cash Machines Construction & Agriculture Consumer Defense & Aerospace Energy Electrical/Electronics Electronic Packaging & Data Storage Industrial Medical Sports & Leisure Intro to RTP Company: Your Global Compounder of Custom Engineered Thermoplastics - Jason Werginz 13 6

14 3/31/2016 Thank You! rtpcompany.com Intro to RTP Company: Your Global Compounder of Custom Engineered Thermoplastics - Jason Werginz 14 7

15 An Engineer s Guide to Specifying the Right Thermoplastic Steve Maki VP of Technology [email protected] (507) :00 a.m. 15

16 4/4/2016 AGENDA An Engineer s Guide to Specify the Right Thermoplastic Steve Maki Vice President Technology [email protected] 1. Define Compounding 2. Plastic Resin Selection Process 3. Application Case Studies 4. Compounding To Enhance Performance 5. New RTP Technologies rtpcompany.com [email protected] INDEPENDENT SPECIALTY COMPOUNDER COMPOUNDING PROCESS Compounder We blend thermoplastic resins with fillers, additives, and modifiers Raw Materials Finished Product Specialty We create engineered formulations Independent We are unbiased in our selection of raw materials Blender Extruder Cooling Pelletizer Classifier An Engineer s Guide to Specifying the Right Thermoplastic - Steve Maki 16 1

17 4/4/2016 COMPOUNDING OBJECTIVES COMPOUNDING EXTRUDERS Mixing Dispersive Distributive Agglomerates Dispersion Distribution Single Screw Twin Screw Co-Kneader PUTTING COMPOUNDING INTO PERSPECTIVE Resin Selection Conductive carbon black surface area = 130 m 2 /gram 34 grams carbon black = surface area of football field (4460m 2 ) Dispersing a 20% carbon black compound is similar to evenly coating a football field with 136 grams of plastic! An Engineer s Guide to Specifying the Right Thermoplastic - Steve Maki 17 2

18 4/4/2016 THE DILEMMA PLASTIC SELECTION PROCESS 60 thermoplastic resins additives = 1000 s of potential compounds Step 1: Use Resin Morphology Step 2: Use Thermal & Cost Requirements Step 3: Fine Tune & Special Features Which ONE Do I Choose For My Application??? PLASTIC SELECTION PROCESS MORPHOLOGY Step 1: Use Resin Morphology The form and structure the molecules of a polymer take upon solidification Step 2: Use Thermal & Cost Requirements Step 3: Fine Tune & Special Features Amorphous Semi-Crystalline An Engineer s Guide to Specifying the Right Thermoplastic - Steve Maki 18 3

19 4/4/2016 MORPHOLOGY MORPHOLOGY CHARACTERISTICS Amorphous Semi-Crystalline Low Shrinkage Compare Amorphous Semi-Crystalline Low Warpage Tight Tolerances Transparency Molecular packing (shrinkage) Resistance to molecular disentanglement (chemical/abrasion resistance) Melting characteristics (flow) Light refraction (opacity) Mold Flow Ease Chemical Resistance Wear Resistance MORPHOLOGY CHARACTERISTICS MORPHOLOGY OF THERMOPLASTICS Lens? Fuel Float? Precision Printer Chassis? Tool Housing? Multiple Pin Connector? Pulley? Grease Fitting? Laptop Cover? Low Shrinkage Low Warpage Tight Tolerances Transparency Mold Flow Ease Chemical Resistance Amorphous Semi-Crystalline Amorphous Polyetherimide (PEI) Polyethersulfone (PES) Polysulfone (PSU) Amorphous Nylon Polycarbonate (PC) Acrylic (PMMA) Acrylonitrile Butadiene Styrene (ABS) Styrene Acrylonitrile (SAN) High Impact Polystyrene (HIPS) Polystyrene (PS) Semi-Crystalline Polyetheretherketone (PEEK) Polyphenylene Sulfide (PPS) Polyphthalamide (PPA) Polyamide (PA/Nylons) Polybutylene Terephthalate (PBT) Polyethylene Terephthalate (PET) Acetal (POM) Polylactic Acid (PLA) Polypropylene (PP) Polyethylene (HDPE, LDPE, LLDPE) Wear Resistance An Engineer s Guide to Specifying the Right Thermoplastic - Steve Maki 19 4

20 4/4/2016 PLASTIC SELECTION PROCESS MORPHOLOGY VS. THERMAL/COST Step 1: Use Resin Morphology Step 2: Use Thermal & Cost Requirements Step 3: Fine Tune & Special Features Amorphous Polyetherimide (PEI) Polyethersulfone (PES) Polysulfone (PSU) Amorphous Nylon Polycarbonate (PC) Acrylic (PMMA) Acrylonitrile Butadiene Styrene (ABS) Styrene Acrylonitrile (SAN) High Impact Polystyrene (HIPS) Polystyrene (PS) Thermal & Cost Increases Semi-Crystalline Polyetheretherketone (PEEK) Polyphenylene Sulfide (PPS) Polyphthalamide (PPA) Polyamide (PA/Nylons) Polybutylene Terephthalate (PBT) Polyethylene Terephthalate (PET) Acetal (POM) Polylactic Acid (PLA) Polypropylene (PP) Polyethylene (HDPE, LDPE, LLDPE) Commodity (<$1.50) Engineered ($1.50-$4.00) High Performance (>$4.00) PLASTIC SELECTION PROCESS ENGINEERED & COMMODITY RESINS Step 1: Use Resin Morphology Step 2: Use Thermal & Cost Requirements Step 3: Fine Tune & Special Features Amorphous Amorphous Nylon Polycarbonate (PC) Acrylic (PMMA) Acrylonitrile Butadiene Styrene (ABS) Styrene Acrylonitrile (SAN) High Impact Polystyrene (HIPS) Polystyrene (PS) Semi-Crystalline Polyamide (PA/Nylons) Polybutylene Terephthalate (PBT) Polyethylene Terephthalate (PET) Acetal (POM) Polylactic Acid (PLA) Polypropylene (PP) Polyethylene (HDPE, LDPE, LLDPE) Commodity (<$1.50) Engineering ($1.50-$4.00) An Engineer s Guide to Specifying the Right Thermoplastic - Steve Maki 20 5

21 4/4/2016 AMORPHOUS RESINS SEMI-CRYSTALLINE RESIN Morphology Features -- Low Shrink, Low Warp, Tight Dimensional Tolerances, Transparent (except HIPS & ABS), Poor Chemical & Abrasion, Poor Flow in Thin Mold Sections Amorphous Amorphous Nylon Polycarbonate (PC) Acrylic (PMMA) Acrylonitrile Butadiene Styrene (ABS) Styrene Acrylonitrile (SAN) High Impact Polystyrene (HIPS) Polystyrene (PS) Special Features Transparent/good chem. resistance Optical transparency/high impact Optical transparency/uv stable High impact/high gloss/opaque Transparent/mod. chem. resistance Moderate impact/opaque Transparent/brittle Commodity (<$1.50) Engineering ($1.50-$4.00) Morphology Features -- Excellent Chemical Resistance, Excellent Abrasion Resistance, Good Flow in Thin Mold Sections, Poor Dimensions, Opaque Semi-Crystalline Special Features Nylon 6/12 Less Sensitive to humidity vs. 6&6/6 Nylon 6/6 Better thermal vs. 6/humidity Dep Nylon 6 Hides GF/strong but humidity Dep Polybutylene Terephthalate (PBT) Good electricals/easier to mold Polyethylene Terephthalate (PET) Good electricals/difficult to mold Acetal (POM) Low wear & friction/high fatigue Polylactic Acid (PLA) Green/Low impact & thermal Polypropylene (PP) Poor low temp impact/mod thermal Polyethylene (HDPE, LDPE, LLDPE) Good low temp impact Commodity (<$1.50) Engineering ($1.50-$4.00) PUTTING IT ALL TOGETHER CASE STUDY Step 1: Use Resin Morphology Step 2: Use Thermal & Cost Requirements Step 3: Fine Tune & Special Features CD Jewel Case Transparent Flat & Dimensionally Stable Low Cost Test Your Knowledge With Application Examples PS An Engineer s Guide to Specifying the Right Thermoplastic - Steve Maki 21 6

22 4/4/2016 CASE STUDY CASE STUDY Gas Tank Good chemical resistance Good low temperature impact Low cost Auto Tail Lamp Cover Transparent Colors Dimensionally Stable Excellent UV Low Cost HDPE PMMA CASE STUDY CASE STUDY Plastic Glass Tumblers Transparent Reasonable Thermal & Chemical Resistance (Dishwasher Cycles) Sump Pump Housing Chemical resistance Reasonable thermal resistance Low cost Low Cost SAN PP + GF An Engineer s Guide to Specifying the Right Thermoplastic - Steve Maki 22 7

23 4/4/2016 CASE STUDY CASE STUDY Safety Glasses Optical transparency High impact Moderate cost OK Hub Odometer Lens Transparent Good Chemical Resistance Moderate-High Cost OK PC Amorphous Nylon CASE STUDY CASE STUDY Chemical Beakers Excellent chemical resistance Low Cost Transparent????????? Nail Gun Housing Good chemical resistance Excellent strength, stiffness & impact Good surface finish when reinforced Moderate cost OK Nylon 6 + GF An Engineer s Guide to Specifying the Right Thermoplastic - Steve Maki 23 8

24 4/4/2016 CASE STUDY CASE STUDY Automotive Intake Manifold Chemical resistance Excellent strength, stiffness & impact Moderate heat resistance Moderate cost OK Nylon 66 + GF Oil Pan Chemical resistance Excellent strength, stiffness & impact Moderate heat resistance Moderate cost OK Extremely tight dimensions & flat????????? CASE STUDY CASE STUDY Electrical Connectors Good flow in thin walls Excellent electrical properties Dimensionally stable in humidity Moderate cost OK Conveyor Rollers Good abrasion resistance Low wear & friction Moderate cost OK PBT (PET) + GF + FR Acetal An Engineer s Guide to Specifying the Right Thermoplastic - Steve Maki 24 9

25 4/4/2016 CASE STUDY CASE STUDY Lawn Tractor Hood Tight dimensions & low warp Moderate cost OK Printer Gears Extremely tight dimensions Moderate cost OK Good abrasion resistance Low wear & friction????????? Chemical resistance Good mold flow????????? MORPHOLOGY DEFICIENCIES Overcoming Resin Deficiencies Via Compounding Amorphous Semi-Crystalline Low Shrinkage D Low Warpage D Tight Tolerances D Transparency D Mold Flow Ease D Chemical Resistance D Wear Resistance D An Engineer s Guide to Specifying the Right Thermoplastic - Steve Maki 25 10

26 4/4/2016 DIMENSIONAL STABILITY FIBER REDUCES SHRINK Can We Reduce Shrink Rate & Improve Dimensional Stability of Semi-Crystalline Resins? Y X Shrink Rate X Shrink Rate Y Warp WARP CONTROL STRENGTH & WARP CONTROL Y X Y X Shrink Rate X = Shrink Rate Y But Low Strength! Flat Part Common Loading = 15% Glass Fiber & 25% Mineral or Beads An Engineer s Guide to Specifying the Right Thermoplastic - Steve Maki 26 11

27 4/4/2016 CASE STUDY TRANSPARENCY Oil Pan Can We Make A Semi-Crystalline Resin Transparent? Chemical resistance Excellent strength, stiffness & impact Moderate heat resistance Moderate cost OK Extremely tight dimensions & flat Nylon % GF + 25% Mineral NUCLEATION/CLARIFICATION CASE STUDY Compounding nucleator into PP or PE controls crystal size to less than wavelength of light = Transparency Melt Phase Nucleation Phase Semi-Crystalline Phase Chemical Beakers Excellent chemical resistance Low Cost Transparent Normal PP Opaque PP PP + Nucleator PP + Nucleator Clarified PP An Engineer s Guide to Specifying the Right Thermoplastic - Steve Maki 27 12

28 4/4/2016 CHEMICAL RESISTANCE/MOLD FLOW ALLOYING Can We Improve Chemical Resistance & Mold Flow of Amorphous Resins? Alloy PC with ABS RTP 2500 A Series PC PC/ABS Tensile Strength, psi Flexural Mod, E6 psi Izod Impact, ft lb/in psi, 0 F Fuel Resistance Poor Poor Melt Flow, gm/10 min Clarity Transparent Opaque ALLOYING CASE STUDY Alloy PC With Polyester (PBT or PET) RTP 2099 X B PC PC/PBT Tensile Strength, psi Flexural Mod, E6 psi Izod Impact, ft lb/in psi, 0 F Fuel Resistance Poor Fair Melt Flow, gm/10 min Clarity Transparent Opaque Lawn Tractor Hood Tight dimensions & low warp Moderate cost OK Chemical resistance Good mold flow PC/PBT Alloy An Engineer s Guide to Specifying the Right Thermoplastic - Steve Maki 28 13

29 4/4/2016 WEAR RESISTANCE PTFE LUBRICATED Can We Make An Amorphous Resin Wear Resistant? Compound PTFE Into PC RTP 300 TFE 15 PC PC/15 PTFE Acetal Wear Factor Dynamic Coef. of Friction CASE STUDY WHAT S NEW? New Technologies Printer Gears Extremely tight dimensions Moderate cost OK Good abrasion resistance Low wear & friction PC + PTFE An Engineer s Guide to Specifying the Right Thermoplastic - Steve Maki 29 14

30 4/4/2016 NEW TECH (HEALTHCARE) RTP 2000 HC Series Increased chemical resistance to healthcare cleaners vs PC, ABS, PC/ABS Good dimensional stability with shrinkage similar to above resins Flame retardant grade for electronic housings RTP 2000 HC FR A NEW TECHNOLOGIES (COLOR) IR Reflecting Colors Allows Dark Colored Plastics To Remain Cool When Exposed To Sunlight Patio Furniture Decking/Pavers Roofs/Siding Auto Interiors NEW TECHNOLOGIES (FR) NEW TECHNOLOGIES (WEAR) FR Compounds for Plenum Applications (UL 2043) Low Heat/Smoke Release Grades FR PP Grades (Glass Fiber, Mineral, Unfilled) FR Nylon (Glass Fiber) Opportunities Wireless Access Points Speaker Housings Vent Diffusers Abrasion Resistant Compounds To Compete With UHMWPE (Not Moldable) Injection Moldable Polyolefin Alloy Similar Abrasion Resistance To UHMWPE Gears Cams Slides Wear Liners Cable Racks Light Housings An Engineer s Guide to Specifying the Right Thermoplastic - Steve Maki 30 15

31 4/4/2016 NEW TECH (HIGH TEMPERATURE) REVIEW Specialty Torlon Compounds RTP has a license agreement with Solvay Specialty Polymers to manufacture specialty compounds based on Torlon polyamide-imide Custom Fiber Reinforced Custom Wear Formulas Automotive Aerospace Industrial Intro To Compounding The Dilemma Resin Selection Procedure Resin Morphology Resin Cost & Thermal Performance Unique Resin Features Application Case Studies Compounding in Performance Overcoming Resin Deficiencies Introduction To New Technologies Questions? Thank you! Steve Maki Vice President Technology [email protected] rtpcompany.com [email protected] An Engineer s Guide to Specifying the Right Thermoplastic - Steve Maki 31 16

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33 Wear in the World of Plastics Ben Gerjets Product Development Engineer (507) :00 a.m. 33

34 4/5/2016 WEAR AND FRICTION Wear in the World of Plastics Ben Gerjets Product Development Engineer, Wear and Friction Products? My application is wearing out! Fatigue? Abrasion?? Chemical Attack?? rtpcompany.com Weather/UV Resistance? WEAR AND FRICTION WEAR AND FRICTION Be Specific! Wear Sliding wear of thermoplastic compounds against a contact surface (steel, aluminum, other thermoplastics, etc.) Friction Reducing/controlling the friction in a sliding or moving system Internally Lubricated Thermoplastics Wear in the World of Plastics - Ben Gerjets 34 1

35 4/5/2016 AGENDA WEAR DEFINITIONS I. Wear Definitions & Test Methods II. Friction Definitions & Test Methods III. Additive Technologies IV. Application Examples Tribology: The Science of the mechanisms of friction, lubrication, and wear of interacting surfaces that are in relative motion V. Extreme Conditions Ultra Wear WEAR DEFINITIONS WEAR DEFINITIONS Adhesive Wear Mechanism Recall: Sliding surfaces The primary mechanism for thermoplastic wear Characterized by transfer of material from one part to the other caused by frictional heat Wear = Loss of material over time Wear in the World of Plastics - Ben Gerjets 35 2

36 4/5/2016 WEAR DEFINITIONS WEAR TESTING Adhesive Wear Mechanism Caused by a hard material scraping or abrading away at a softer material Characterized by grooves cut or gouged into the surface Three body Question: How do you simulate an application and test a material for long-term wear resistance? Answer: RTP uses ASTM D-3702 wear test to quantify the amount of material a sample loses over time under specific conditions (pressure, speed, temperature) WEAR TESTING WEAR TESTING ASTM D-3702 Thrust Washer Wear Test Adjustable: Counter-surface (thrust washer) Pressure Velocity Temperature Torque Load Rotating Molded or machined sample Stationary Thrust washer (steel, aluminum, plastic, etc.) RTP Company has six thrust washer wear testing machines in our wear lab located in Winona, MN Equipment is available to perform customer requested testing A test isn t always just a test Conditions matter! The best use of this test is to perform comparative screening of multiple candidate materials Wear in the World of Plastics - Ben Gerjets 36 3

37 4/5/2016 WEAR TESTING WEAR TESTING Wear factor (K): Used to quantify wear resistance Lower Value = Better Wear Resistance! K = W/(F x V x T) K = Wear Factor: (in 3 -min/ft-lb-hr) or (mm 3 /N-m) 10-8 W = Volume wear: in 3 or mm 3 F = Force: lb or N V = Velocity: ft/min or m/sec T = Elapsed time: hr or sec 100 Hour Test! Standard Conditions: Steel thrust washer 40 psi 50 ft/min Ambient temp 100 hour test PV = (Pressure Velocity) Conditions often used together to characterize severity of a wear environment 2,000 PV = (40 psi 50 ft/min) Typical testing done at 2,000 to 10,000 PV WEAR TESTING WEAR TESTING RTP Wear Brochure PV (psi*ft./min) Wear Factor (K) Question: Does an equivalent PV always result in the same data? Nylon 6/6 (RTP 200 Series) Load (lb) Speed (ft/min) PV PV (SI) Wear Factor (K) RTP (70) 901 (1811) 0.66 RTP (175) 95 (191) 0.91 RTP (350) 191 (384) 0.60 RTP 0200 SI (70) 639 (1284) 0.54 RTP 0200 SI (175) 181 (364) 0.78 RTP 0200 SI (350) 85 (171) 0.77 RTP 0200 TFE (70) 957 (1924) 0.61 RTP 0200 TFE (175) 427 (858) 0.77 RTP 0200 TFE (350) 76 (153) 0.59 RTP 0200 TFE (70) 341 (685) 0.31 RTP 0200 TFE (175) 171 (344) 0.28 RTP 0200 TFE (350) 156 (314) 0.29 RTP 0200 TFE 18 SI (70) 11 (22) 0.20 RTP 0200 TFE 18 SI (175) 59 (119) 0.36 RTP 0200 TFE 18 SI (350) 18 (36) 0.19 Excellent Wear Resistance (K= < 75) Good Wear Resistance (K = ) Fair Wear Resistance (K = ) K (SI) µk Standard Conditions: PV = 2,000 P = 40psi V = 200 ft./min Non-Standard Conditions: PV = 2,000 P = 10psi V = 200 ft./min Answer: No Wear factor will change based on individual conditions Wear Factor (in 3 -min/ft-lb-hr) 10E-10 POM + 20% PTFE Steel Countersurface (40 psi 50 ft/min) (10 psi 200 ft/min) Wear in the World of Plastics - Ben Gerjets 37 4

38 4/5/2016 WEAR TESTING AGENDA Question: What happens when PV is increased? Does Wear Factor (K) also increase? I. Wear Definitions & Test Methods Wear Factor (in 3 -min/ft-lb-hr) 10E POM POM + 20% PTFE PV (lb-ft/in 2 -min) II. Friction Definitions & Test Methods III. Additive Technologies IV. Application Examples V. Extreme Conditions Ultra Wear Wear per ASTM D 3702 against C1018 Steel FRICTION DEFINITIONS FRICTION DEFINITIONS Coefficient of Friction (µ) Ratio of the force of friction between two bodies and the force pressing them together µ=f/n Coefficient of Friction (µ) Static coefficient of friction (µ s ) = Fx/Fy Fx = Force to initiate motion Fy = Normal force holding surfaces together F W P Dynamic coefficient of friction (µ k ) = Fx/Fy Fx = Force to sustain motion Fy = Normal force holding surfaces tog N Wear in the World of Plastics - Ben Gerjets 38 5

39 4/5/2016 FRICTION DEFINITIONS FRICTION TESTING In most non-plastic materials µ s >µ k Thermoplastics are somewhat unique ASTM D 1894 sled test Coefficient of friction testing Does not determine wear resistance Can show slip/stick µ k >µ s May cause slip/stick Glide Factor SM If µ k >>µ s you may have squeaking FRICTION TESTING TESTING REVIEW RTP Modified ASTM D3702 Friction Test Oscillating motion used to measure Friction coefficients and Glide Factor SM Glide Factor SM is used to quantify the difference between µ s and µ k in order to reduce/eliminate stick/slip Used to generate friction data for optimal material selection in medical devices Torque Load Molded test Specimen Thrust washer Question: How does RTP measure wear resistance? Answer: ASTM D3702 Thrust Washer wear test; Wear Factor (K) Question: How does RTP measure Friction? Answer 1: ASTM D1894 Sled Test (Static and Dynamic Coefficient of Friction) Answer 2: Modified ASTM D3702 Thrust washer friction test. (Glide Factor SM ) Wear in the World of Plastics - Ben Gerjets 39 6

40 4/5/2016 AGENDA ADDITIVE TECHNOLOGIES I. Wear Definitions & Test Methods PTFE Silicone PFPE II. III. IV. Friction Definitions & Test Methods Additive Technologies Application Examples Graphite MoS 2 Fibers V. Extreme Conditions Ultra Wear ADDITIVE TECHNOLOGIES ADDITIVE TECHNOLOGIES PTFE Polytetrafluoroethylene (5-20%) Workhorse additive solid white powder Compatible with nearly all thermoplastic resins PTFE Wear Mechanism Base Polymer Layer Exposed PTFE PTFE Layer Limitations: Fluorine content Die plate-out Relatively high loadings Cost fluctuation Part As Molded Part After break-in period Exposed PTFE shears to form layer Wear in the World of Plastics - Ben Gerjets 40 7

41 4/5/2016 ADDITIVE TECHNOLOGIES APPLICATION EXAMPLE Wear Factor E-10(in 3 min/ft lb hr) Unfilled vs. PTFE Wear Factor Unfilled 20% PTFE PC POM PA 6/6 Wear factor against Steel; PV = 2000 Laser Printer Fuser Gears Requirements: High Operating Temperatures Good wear Resistance Solution: Glass fiber reinforced and PTFE lubricated PPS Structural Wear ADDITIVE TECHNOLOGIES ADDITIVE TECHNOLOGIES PTFE Silicone Silicone Polydimethylsiloxane (1-3%) Boundary lubricant which migrates to the surface over time Migration rate is viscosity dependent Excellent friction reducer Best in high speed/low load applications Limitations: Limited use in decorated parts Poor adhesion of paint or print inks Bad for electrical applications Can foul contacts Wear in the World of Plastics - Ben Gerjets 41 8

42 4/5/2016 ADDITIVE TECHNOLOGIES ADDITIVE TECHNOLOGIES PTFE + Silicone Wear Mechanism SI Present as Molded Exposed PTFE SI + PTFE Layer Part As Molded Part After break-in period Wear Factor E-10(in 3 min/ft lb hr) Wear Resistance with PTFE and Silicone Unfilled 2% Silicone 20% PTFE PC POM PA 6/6 100 ADDITIVE TECHNOLOGIES ADDITIVE TECHNOLOGIES Friction Reduction with PTFE and Silicone Specific Gravity Differences with PTFE and Silicone Dynamic µ Unfilled 2% Silicone 20% PTFE PC POM PA 6/6 Specific Gravity Unfilled 2% Silicone 20% PTFE PC POM PA 6/6 Wear in the World of Plastics - Ben Gerjets 42 9

43 4/5/2016 ADDITIVE TECHNOLOGIES ADDITIVE TECHNOLOGIES Tensile Strength (psi) Tensile Strength with PTFE and Silicone Unfilled 2% Silicone 20% PTFE 14,000 12,000 12,000 11,000 10,000 8,500 9,500 8,500 8,700 7,800 8,000 7,000 6,500 6,000 4,000 2,000 0 PC POM PA 6/6 Specific Gravity Tensile Strength (psi) Flexural Modulus (psi) Notched Impact (ft-lb/in) Unfilled PC PA 6/6 POM PTFE (20%) Silicone (2%) Unfilled PTFE (20%) Silicone (2%) Unfilled PTFE (20%) Silicone (2%) ,500 7,000 8,500 12,000 9,500 11,000 8,700 6,500 7, , , , , , , , , , APPLICATION EXAMPLE APPLICATION EXAMPLE Garage Door Opener Limit Switch Requirements Dimensional stability Good strength and stiffness Solution Silicone lubricated PC Drug Delivery Pen Components Requirements Good strength, dimensional stability, eliminate secondary lubricant application and no slip/stick Solution(s) Optimal Plastic Friction Pairs with low Glide Factor SM Fiber reinforced and internally lubricated PC or PBT Structural Medical Wear Structural Wear Not Transparent! More on this later Internally lubricated POM or PBT Wear in the World of Plastics - Ben Gerjets 43 10

44 4/5/2016 ADDITIVE TECHNOLOGIES ADDITIVE TECHNOLOGIES PTFE Silicone PFPE PFPE Perfluoropolyether Oil (< 1%) Thermally stable up to PEEK processing temps Differentiates RTP Company from others Synergy with PTFE Specific gravity benefits Limitations: Limited effectiveness in amorphous resins Needs PTFE kick to deliver optimum friction reduction APPLICATION EXAMPLE APPLICATION EXAMPLE Agricultural Pump Requirements Chemical and Wear Resistance Solution PFPE lubricated PP Universal Conveyor Roller Requirements Strength, conductivity and wear resistance (must be silicone-free) Solution Carbon fiber reinforced and PTFE/ PFPE lubricated PPS Wear Wear Structural Structural Conductive Wear in the World of Plastics - Ben Gerjets 44 11

45 4/5/2016 ADDITIVE TECHNOLOGIES ADDITIVE TECHNOLOGIES Additives Reduce Clarity! PTFE Silicone PFPE PC with APWA+ PC with PTFE PC with PFPE PC with Silicone Graphite MoS 2 Natural PC ADDITIVE TECHNOLOGIES APPLICATION EXAMPLE Graphite Powder (5-30%) Aqueous environments Excellent temperature resistance Black color Molybdenum Disulfide MoS 2 (1-5%) Nucleating agent in nylons: creates harder surface High affinity to metal: Smoother mating metal surface = lower wear Limitations: Limited use Dark color limits colorability Sloughing type additives Water Meter Valve Requirements Dimensional stability, potable water contact - NSF listed Solution Graphite lubricated PS and SAN Structural Wear Wear in the World of Plastics - Ben Gerjets 45 12

46 4/5/2016 ADDITIVE TECHNOLOGIES ADDITIVE TECHNOLOGIES PTFE Silicone PFPE Reinforcing Fibers and Wear Resistance Glass Fiber Carbon Fiber Aramid Fiber Graphite MoS 2 Fibers Improved bearing capabilities/wear resistance Very abrasive Higher bearing capabilities Excellent thermal resistance Conductive Less abrasive Little strength improvement Very gentle to mating surface ADDITIVE TECHNOLOGIES APPLICATION EXAMPLE Fibers protect the polymer, but may be abrasive against the mating material Copier Bushings Requirements High HDT and good wear resistance Solution Aramid fiber reinforced and PTFE lubricated PPA Wear Glass Carbon Aluminum Contact Surface Aramid Structural High Temp Wear in the World of Plastics - Ben Gerjets 46 13

47 4/5/2016 ADDITIVE TECHNOLOGIES ADDITIVE TECHNOLOGIES APWA PLUS : All Polymeric Wear Alloy A Unique Polymer Alloy Technology Offering: Improved wear and friction performance Especially effective in plastic vs. plastic wear Good retention of base resin physical properties Lower specific gravity than PTFE Reduction/Elimination of plate-out associated with PTFE ADDITIVE TECHNOLOGIES AGENDA 10/10/10 Carbon Fiber/Graphite Powder/PTFE Typical additive package for high load bearing/high temp. applications Aramid Fiber/PTFE Excellent wear package that is gentle on the mating surface Carbon Fiber/Ceramic Additive Non-PTFE solution, good for very demanding conditions Additive Synergies I. Wear Definitions & Test Methods II. Friction Definitions & Test Methods III. Additive Technologies IV. Application Examples V. Extreme Conditions Ultra Wear Wear in the World of Plastics - Ben Gerjets 47 14

48 4/5/2016 EXTREME CONDITIONS EXTREME CONDITIONS What happens when your application has a PV higher than 10,000? Ultra Wear Products Developed for Demanding applications High Temperature High Loads (500+ psi) High Speeds Chemical Resistance Excellent Mechanical Properties Injection Molded Parts Transmission Seal High Load Thrust Washers Pipe Gaskets Off-Shore Drilling Construction Vehicles Oil and Gas Industry 100 ft/min tests 200 ft/min tests 10,000 PV: 100 psi 10,000 PV: 50 psi 25,000 PV: 250 psi 25,000 PV: 125 psi 50,000 PV: 500 psi 50,000 PV: 250 psi EXTREME CONDITIONS EXTREME CONDITIONS 1. Develop a series of high performance RTP products ideal for Ultra testing PEE K Resins PPS PPA Carbon Fiber Graphite Aramid Fiber Additives PTFE Ceramic MoS 2 2. Compare RTP Ultra Products with industry leading wear resistant materials Rulon J Rulon LR Torlon 4301 Torlon 4630 Vespel SP-21 Vespel SP-211 Stanyl TW371 Wear Factor (in 3 -min/ft-lb-hr)*e-10 Compound PTFE 1 Not Melt Processable Extensive Post Curing Process Melt Processable Thermoplastic PTFE 2 PAI 1 Wear Factor (in 3 min/ft lb hr)*e 10 PEEK-CF/Ceramic Dynamic µ PTFE PTFE PAI PEEK-CF/Ceramic TS-PI TS-PI PPS-CF/Proprietary Wear PEEK-CF/GRPH/TFE PAI PEEK-AF/TFE PEEK-CF/GRPH/TFE (CGP) PV=50, ft/min) TS-PI 1 43 Compound TS-PI 2 Wear per ASTM D-3702 against Steel 58 PPS-CF/Proprietary Wear PEEK-CF/GRPH/TFE Wear Factor (in 3 min/ft lb hr)*e 10 Dynamic µ PPS-CF/TFE PPS-AF/TFE Wear Limit NA PPS-GF/TFE Wear Limit NA PEEK-CF/TFE Wear Limit NA PEEK-CF/AF/TFE Wear Limit NA PEEK-CF/GRPH/TFE/PFPE Wear Limit NA PEEK-CF/PFPE Wear Limit NA PPA-CF/TFE Wear Limit NA PPA-CF/Proprietary Wear Wear Limit NA PPA-CF/AF/TFE/SI Wear Limit NA PA 46 - TFE Wear Limit NA Wear in the World of Plastics - Ben Gerjets 48 15

49 4/5/2016 EXTREME CONDITIONS EXTREME CONDITIONS Wear Factor (in 3 -min/ft-lb-hr)*e Not Melt Processable Melt Processable Thermoplastic Torlon 4301 (PAI) Vespel SP 21 (TS PI) Manufacturer Solvay DuPont Rulon J (PTFE) St. Gobain Stanyl TW371 (PA46) RTP 1300 AR 15 TFE 15 (PPS) RTP 4085 TFE 15 (PPA) RTP 2285 HF TFE 15 (PEEK) RTP 2299 X A (PEEK) DSM RTP RTP RTP RTP Polymer PAI TS PI PTFE PA 4/6 PPS PPA PEEK PEEK Generic Description PTFE/Grph Grph PI Pwdr PTFE AF/PTFE CF/PTFE CF/PTFE CF/Ceramic Strength G G P F F E E G PEEK-CF/Ceramic TS-PI 1 TS-PI 2 Stiffness G G P P F E E G ~ Cont. Use >500 F >600 F ~550 F ~350 F ~400 F ~375 F ~475 F ~475 F Temperature (260 C) (316 C) (290 C) (177 C) (205 C) (190 C) (246 C) (246 C) Chem. Resistance E E E P E G E E Wear Factor Dynamic Disc Material (in 3 min/ft lb hr)*e 10 µ PEEK-CF/Ceramic TS-PI TS-PI PTFE 1 Wear Limit NA PAI 1 Wear Limit NA PPS-CF/Proprietary Wear Wear Limit NA Wear per ASTM D-3702 against Steel at 400 F; PV = 100,000 Parts Parts Processing 17 Day Cure G G G G G Only Only Friction G G E G E F G G Wear resistance E E E G G G G E Moisture sensitivity P G E P E G G G APPLICATION EXAMPLE APPLICATION EXAMPLE AC Compressor Scroll Seal Requirements High temperature, chemical and wear resistance Solution Carbon fiber reinforced and PTFE/Graphite lubricated PEEK Transmission Seal Rings/Thrust Washers Requirements Ability to survive extremely high PV conditions with external lubrication Solution Carbon fiber reinforced, internally lubricated PEEK Structural Wear High Temp Wear Structural High Temp Wear in the World of Plastics - Ben Gerjets 49 16

50 4/5/2016 WEAR AND FRICTION ADDITIONAL INFORMATION Wear Factor (K) and friction coefficient (µ K ) for common tribological compounds: Thank You! Ben Gerjets [email protected] (507) rtpcompany.com [email protected] Wear in the World of Plastics - Ben Gerjets 50 17

51 Tough or Strong? Short or Long? Dialing in Mechanical Properties Karl Hoppe Senior Product Development Engineer (507) :00 a.m. 51

52 3/31/2016 STRENGTH Tough or Strong? Short or Long? Dialing in Mechanical Performance Karl Hoppe Senior Product Development Engineer rtpcompany.com STIFFNESS IMPACT Tough or Strong? Short or Long? Dialing in Mechanical Properties - Karl Hoppe 52 1

53 3/31/2016 THE FORMULA THE FOUNDATION Resin Additives Change in Properties THE ADDITIVES TOOLBOX MODIFIERS Polymer blends Impact modifiers Modifiers Fillers Tough or Strong? Short or Long? Dialing in Mechanical Properties - Karl Hoppe 53 2

54 3/31/2016 POLYMER BLENDS POLYMER BLENDS PC/ABS Nylon/PP PC/PBT ABS brings Improved flow Chemical resistance Cost reduction PP brings Improved flow Chemical resistance Cost reduction PBT brings Improved flow Chemical Resistance ABS/PC PP/Nylon PBT/PC PC brings Toughness Strength Nylon brings Strength Stiffness PC brings Toughness Dimensional stability POLYMER BLENDS POLYMER BLENDS PC PC/ABS (RTP 2500 A) ABS Specific Gravity Tensile Strength (MPa) Notched Izod Impact (J/m) Housing for Hearing Tester Problem: Solution: Benefits: Toughness and chemical resistance Polycarbonate/ABS Alloy Strength and toughness of PC with the added chemical resistance of ABS Tough or Strong? Short or Long? Dialing in Mechanical Properties - Karl Hoppe 54 3

55 3/31/2016 MODIFIERS IMPACT MODIFIERS Impact properties PA 6/6 Impact Modified PA 6/6 Specific Gravity Impact Modifiers Notched Izod Impact (J/m) Tensile Strength (MPa) Flexural Modulus (GPa) (Stiffness) Strength/stiffness IMPACT MODIFIERS IMPACT MODIFIERS ATV Wheel Bead Lock Ring Problem: Low ductility Solution: Impact Modified Nylon 6/6 with fiber reinforcement Benefits: Retain some stiffness of reinforced Nylon Improved ductility for high strain rate loads Limitations Base resin Environment Lose Performance Temperature Chemical Resistance UV Resistance Tough or Strong? Short or Long? Dialing in Mechanical Properties - Karl Hoppe 55 4

56 3/31/2016 THE ADDITIVES TOOLBOX FILLERS Modifiers Fillers Beads (Glass) Minerals (Talc) Fibers (Glass) Photo: Potters, Inc. ASPECT RATIO LOW ASPECT RATIO Property change determined by: Aspect Ratio = L/D Specific Gravity PC PC + 10% PC + 30% Glass Beads Glass Beads D L Beads (Glass) Photo: Potters, Inc. Tensile Strength (MPa) Notched Izod Impact (J/m) Aspect Ratio = 1 Flexural Modulus (GPa) Aspect Ratio Reinforcing Tough or Strong? Short or Long? Dialing in Mechanical Properties - Karl Hoppe 56 5

57 3/31/2016 LOW ASPECT RATIO LOW ASPECT RATIO PC PC + 20% Talc PC + 40% Talc Specific Gravity Minerals (Talc) Tensile Strength (MPa) Notched Izod Impact (J/m) Y X Aspect Ratio = 2-50 Flexural Modulus (GPa) Shrink Rate X = Shrink Rate Y Flat Part LOW ASPECT RATIO HIGH ASPECT RATIO Reusable Handling Container Problem: Warpage prevented smooth operation Specific Gravity PC PC + 30% Glass Beads PC + 30% Glass Fiber Solution: Benefits: Mineral filled Polypropylene Reduced warpage Improved functionality Fibers (Glass) Aspect Ratio = Tensile Strength (MPa) Notched Izod Impact (J/m) Flexural Modulus (GPa) Tough or Strong? Short or Long? Dialing in Mechanical Properties - Karl Hoppe 57 6

58 3/31/2016 HIGH ASPECT RATIO HIGH ASPECT RATIO Fibers (Glass) Aspect Ratio = Specific Gravity Tensile Strength (MPa) Notched Izod Impact (J/m) Flexural Modulus (GPa) PP PP + 40% Talc PP + 40% Fiber Surgery Drill Guide Problem: Solution: Benefits: Stiffness and dimensional stability Glass fiber reinforced Polycarbonate Rigidity Tight tolerances HIGH ASPECT RATIO - WARP HIGH ASPECT RATIO - FLAT Y1 Y1 X1 X2 X3 X1 X2 X3 Shrinkage X1 & X2 X3 Warp Shrinkage X1 = X2 = X3 Flat Part Tough or Strong? Short or Long? Dialing in Mechanical Properties - Karl Hoppe 58 7

59 3/31/2016 EXTREME ASPECT RATIO - VLF EXTREME ASPECT RATIO - VLF Fiber Extruder/Die Puller Pelletizer Short Fiber Fiber length: ~ 1-2 mm Long Fiber Fiber length: 12 mm EXTREME ASPECT RATIO -VLF EXTREME ASPECT RATIO - VLF Long Glass Fiber Aspect Ratio = 300+ Specific Gravity Tensile Strength (MPa) Notched Izod Impact (J/m) Flexural Modulus (GPa) PP + 40% Short Glass PP + 40% Long Glass Tough or Strong? Short or Long? Dialing in Mechanical Properties - Karl Hoppe 59 8

60 3/31/2016 EXTREME ASPECT RATIO - VLF IMPROVEMENTS IN SGF PP PA % VLF Seat Belt Tensioner Housing % Glass PP Tensile Strength (MPa) Short Glass extra Performance Long Glass (VLF) IMPROVEMENTS IN SGF PP IMPROVEMENTS IN SGF PP 40% Glass PP 40% Glass PP Flexural Modulus (MPa) Impact Strength (kj/m2) Short Glass extra Performance Long Glass (VLF) Short Glass extra Performance Long Glass (VLF) Tough or Strong? Short or Long? Dialing in Mechanical Properties - Karl Hoppe 60 9

61 3/31/2016 HIGH ASPECT RATIO FIBER COMPARISON- PP PEEK PEEK + 40% Glass Fiber PEEK + 40% Carbon Fiber PP 40% GF PP 40% VLF PP 30% CF Specific Gravity Flexural Modulus (MPa) Carbon Fibers Aspect Ratio = Tensile Strength (MPa) Notched Izod Impact (J/m) Flexural Modulus (GPa) Tensile Strength (MPa) Notched Izod Impact (kj/m 2 ) Specific Gravity FIBER COMPARISON PA 6/6 FIBER COMPARISON PPS PA 6/6 60% VLF (Long Fiber) PA 6/6 35% Carbon Fiber Flexural Modulus (MPa) Tensile Strength (MPa) Tensile Elongation (%) Specific Gravity PPS 40% Glass PPS 20% Carbon Flexural Modulus (MPa) Tensile Strength (MPa) Tensile Elongation (%) Specific Gravity Tough or Strong? Short or Long? Dialing in Mechanical Properties - Karl Hoppe 61 10

62 3/31/2016 CARBON FIBER APPLICATION HIGH TEMPERATURE POLYMERS Brake Rotor Measuring Probe Amorphous Semi-Crystalline Problem: Solution: Benefits: Casting replacement Carbon fiber reinforced PPA High strength High stiffness Polyetherimide (PEI) Polyethersulfone (PES) Polysulfone (PSU) Amorphous Nylon Polycarbonate (PC) Acrylic (PMMA) Acrylonitrile Butadiene Styrene (ABS) Styrene Acrylonitrile (SAN) High Impact Polystyrene (HIPS) Polystyrene (PS) Thermal & Cost Increases Polyetheretherketone (PEEK) Polyphenylene Sulfide (PPS) Polyphthalamide (PPA) Polyamide (PA/Nylons) Polybutylene Terephthalate (PBT) Polyethylene Terephthalate (PET) Acetal (POM) Polylactic Acid (PLA) Polypropylene (PP) Polyethylene (HDPE, LDPE, LLDPE) Commodity Engineered High Performance CHEMICAL STRUCTURE AMORPHOUS MATERIALS Flexural Modulus Vs. Temperature Polyethylene Tg -5 F C C C C C C C n N O C C O Polyimide Tg 482 F O C C O N R n Flexural Modulus, MPa % GF PSU 40% GF PES % GF PEI Temperature, F Tough or Strong? Short or Long? Dialing in Mechanical Properties - Karl Hoppe 62 11

63 3/31/2016 SEMI-CRYSTALLINE MATERIALS ELEVATED TEMP PROPERTIES Flexural Modulus, MPa Flexural Modulus Vs. Temperature 40% GF PPA 40% GF HTN 40% GF PEEK 40% GF PPS 40% GF TPI Temperature, F Stress - MPa Multiple Temperature Tensile Stress/Strain 40% Glass fiber filled Polypropylene Typical -40 C Typical 23 C Typical 65 C Typical 107 C % Glass fiber filled Nylon 6/6 0 Typical DAM, -40 C Tyical DAM, 23 C Typical DAM, 65 C Typical DAM, 121 C Strain mm/mm % Glass fiber filled PPA Typical DAM, -40 C Typical DAM, 23 C Typical DAM, 65 C Typical DAM, 176 C ULTRA PERFORMANCE PRODUCTS HIGH TEMPERATURE APPLICATION Tensile Strength (MPa) % GF 50% VLF 40% CF 40% UP CF Surgical Head Restraint Problem: Solution: Benefits: Stable under MRI/CT energy Carbon fiber reinforced PEEK High stiffness Creep resistance Resistance to autoclave 0 PEI PPS PPA PEEK High Temp Resins Tough or Strong? Short or Long? Dialing in Mechanical Properties - Karl Hoppe 63 12

64 3/31/2016 SUMMARY Modifiers Polymer Blends - overcome morphology deficiencies Impact Modifiers - increase impact but reduction in strength/stiffness Thank You! Fillers Performance driven by aspect ratio High Temperature Range of polymers offer array of performance Overall: Combinations of technologies result in balancing of properties and requirements rtpcompany.com [email protected] Tough or Strong? Short or Long? Dialing in Mechanical Properties - Karl Hoppe 64 13

65 Answers to Your Burning Questions: Flame Retardants and Regulations Jesse Dulek Product Development Engineer (507) :00 p.m. 65

66 3/31/2016 FLAME RETARDANT (FR) MATERIALS Answers to Your Burning Questions: Flame Retardants and Regulations Jesse Dulek Product Development Engineer, Flame Retardant Products Definition Materials that do not ignite readily or propagate flames under small to moderate fire exposures Materials are combustible Fire retardants reduce the intensity and spread of fire Reduces smoke and toxic by-products of combustion Fuel rtpcompany.com Fire Triangle GOALS OF FLAME RETARDANT COMPOUNDS Increase resistance to ignition Reduce rate of flame spread Reduce rate of heat release Reduce smoke emission End Goal: Meet FR specifications Make the world a safer place! MARKETS FOR FR THERMOPLASTICS Segmentation of FR Consumption by Value Textil: Adhesive: Coating 15% Transportation 12% Electrical Parts Electronic Enclosures Wire and Cable Building 34% E&E 39% Appliances Transportation Building and Construction Answers to Your Burning Questions: Flame Retardants and Regulations - Jesse Dulek 66 1

67 3/31/2016 OVERVIEW THERMOPLASTIC RESIN FLAMMABILITY Thermoplastic Flammability Flame Retardant Additive Chemistries and Mechanisms Flammable Inherently Flame Resistant Regulatory Landscape Testing Standards Case studies Hospital Cleaner Resistant Technology Polyolefins Nylons Polycarbonate Polyesters Styrenics TPEs Polysulfones Polyphenylene Sulfide Polyetheretherketone Polyetherimide Flouropolymers CHALLENGES OF FLAME RETARDING PLASTICS COMMON TYPES OF FR ADDITIVES Limiting Oxygen Index Halogenated FR s Flame Retardant Additive Usage, 2011 Acetal Cotton PE PP ABS PMMA SAN PET PBT Nylon 6/6 PC PSU TPI PVDF PVC Brominated Chlorinated Halogen Free FR s Metal hydroxides Phosphorous Based Melamine Based Inorganics 44% Other 6% Bromine 22% Chlorine 12% Phosphorus 16% PTFE LOI % Answers to Your Burning Questions: Flame Retardants and Regulations - Jesse Dulek 67 2

68 3/31/2016 HALOGENATED FR MECHANISM NON-HALOGEN MECHANISMS Halogenated technology inhibits the chemical reaction in the gas/vapor phase Phosphorous Hydrated Minerals Melamine Cyanurate Various molecules that efficiently get large amounts of free radicals to the gas phase Additive Type Higher Halogen Content Lower Loadings High Thermal Stability Polymeric Type Melt Blendable Less effect on physical properties Enhanced Flow Various forms Contributes to the condensed phase char formation Produce water during combustion process, dilute flammable vapors Insulative char formation Resin Systems Endothermic decomposition Physical removal of flame from surface Halogenated flame retardants are compatible in most resin systems with the exception of Acetal Polyolefins, Polyamides, Polyesters, Polycarbonate and alloys Polyolefins, Polyamides Polyamides, used as a synergist for other Phosphorous technologies HALOGEN VS. HALOGEN-FREE CHOOSING A FR SYSTEM Halogenated Lower Cost Better Processing Better Efficiency Better Physical Properties Halogen Free Evolving Economics Improved Processability Wide Variety of Products Low Smoke Lower Toxicity Less Corrosive Lower Specific Gravity How do we decide which FR mechanism to use? Resins System FR Specification Part Function Fillers/Additives Regulatory Concerns Halogen, RoHS, etc Answers to Your Burning Questions: Flame Retardants and Regulations - Jesse Dulek 68 3

69 3/31/2016 OVERVIEW ROHS DIRECTIVE Thermoplastic Flammability Flame Retardant Additive Chemistries and Mechanisms Regulatory Landscape Testing Standards Case studies Hospital Cleaner Resistant Technology Restriction of Hazardous Substances (RoHS) EU Directive in effect as of July 2006 Banned Substances Lead (Pb) Mercury (Hg) Cadmium (Cd) Hexavalent Chromium (CrVI) Polybrominated Biphenyls (PBB) and Polybrominated Diphenyl Ethers (PBDE) Flame Retardants and Pigments Does not need to be Halogen Free! IMPACT OF ROHS EVOLUTION OF HALOGEN-FREE TECHNOLOGIES How does RoHS compliance affect material selection? Drop in replacements available Identical Properties Physical, Flow, Heat Resistance, Processability Cost Premium More self-policing /customer driven bans New FR standards Green Movement More Effective/Economical FR Chemicals Increased Performance Competition in the Market Answers to Your Burning Questions: Flame Retardants and Regulations - Jesse Dulek 69 4

70 3/31/2016 HALOGEN RESTRICTIONS IMPACT OF HALOGEN-FREE OEM Driven Ban on Halogenated Chemicals HP, DELL, IBM etc. Eco Labels Blue Angel, White Swan, Ecolabel etc. Resin Limitations Physical Properties Strength/Impact Flow Heat Resistance Resin Dependent Flammability Cost Reduction in Specific Gravity 30% GF NYLON 6/6 OVERVIEW Mechanical Properties RTP 205 FR RTP 205 FR Halogen Free Tensile Strength, psi Tensile Modulus, psi E Tensile Elongation, % 2-4% 2-4% Flexural Strength, psi Flexural Modulus, psi E Impact Notched, ft-lb/in Impact Un-notched, ft-lb/in psi Specific Gravity Flammability 1/32 1/32 Thermoplastic Flammability Flame Retardant Additive Chemistries and Mechanisms Regulatory Landscape Testing Standards Case studies Hospital Cleaner Resistant Technology Answers to Your Burning Questions: Flame Retardants and Regulations - Jesse Dulek 70 5

71 3/31/2016 INDUSTRY AND MARKET DRIVEN RTP COMPANY UL CERTIFICATION Electrical and Electronics (E&E) UL 94 V, 5V, HB UL 746 HAI, HWI, CTI RTP Company has 600+ UL Yellowcards Continuous expansion of UL listed products UL Certified Laboratory under Client Test Data Program (CTDP) Short term properties to UL94 Long term thermal aging (RTI) RTP Company offers custom UL certifications to achieve full commercialization Quick turnaround Compress your Time to Market! UL94 - HB UL94 - VB Horizontal burning test for HB classification mm Classification Criteria V-0 V-1 V mm Specimen Number of bar specimens mm Specimen mm Wire Gauze mm Wire Gauze Maximum flame time per specimen per flame application, sec Burner mm Classification Criterion Maximum total flame time 5 specimens, 2 ignitions, sec Specimen drips, ignites cotton NO NO YES Cotton 6 mm max. 3.0 mm to 13.0 mm thickness slower than 40 mm/minute or combustion ceases prematurely < 3.0 mm thickness slower than 75 mm/minute or combustion ceases prematurely Maximum afterglow time per specimen, sec Burn to holding clamp NO NO NO ** In general most thermoplastics meet this criteria** Thickness dependent ratings Answers to Your Burning Questions: Flame Retardants and Regulations - Jesse Dulek 71 6

72 3/31/2016 UL94 VERTICAL BURN DEMO AEROSPACE Flame Retardant V-0 Non- Flame Retardant No Rating FAR Flammability: 15-Second Horizontal Burn 12-Second Vertical Burn 60-Second Vertical Burn Smoke Density: <200 ABD0031 or BSS 7238 or ASTM E-662 OEM Driven Requirements Toxic Gas Emission: Varies by OEM ABD0031 or BSS 7239 Ohio State University Heat Release: Calorimetry Test Measures Peak and Total Heat Release <100/100, <65/65, & <55/55 are common Requirements vary by part size and location BUILDING / INDUSTRIAL RECAP Requirements focus on: Low Smoke, Heat Release, Burn Rate, Flame Spread Various standard that apply: UL2043, UL723/ASTM E84, ASTM E1354, NFPA 701, FM 4996, CAL TB133 Applications: Wall coverings, Furniture, Plenum, Pallets, Storage systems, Roofing, Floor coverings, Ventilation Designing for an FR application Regulatory Landscape RoHS, Halogen Restrictions Specifications UL94, FAR, ASTM, etc. Part Function Performance Requirements, Application Environment, etc. Economics Price is a Property Answers to Your Burning Questions: Flame Retardants and Regulations - Jesse Dulek 72 7

73 3/31/2016 OVERVIEW FR MEETS TRANSPARENCY Thermoplastic Flammability Flame Retardant Additive Chemistries and Mechanisms Regulatory Landscape Testing Standards Case studies Hospital Cleaner Resistant Technology LED Lens Cover Market: Problem: Solution: Benefits: Consumer UL 94 V-0, High Light Transmission, UV, Light Diffusion, RoHS Compliance PC Transparent, Flame retardant, Specialty pigment package Provided ample diffusion of high powered LED lights with a proprietary pigment technology while achieving the required flame performance FR MEETS OUTDOORS / UV FR BREAKS THROUGH THE CEILING Marine Connector Speaker Unit Market: Consumer Market: Industrial Problem: Solution: Benefits: Strength/impact, UV resistance, specialty color, UL94 V-0, F1 PC/PBT Glass reinforced, UV stabilized, Flame Retardant Product was able to pass the required drop impact testing and stringent UL outdoor and flammability ratings Problem: Solution: Benefits: Plenum location, UL 2043, UL94 5VA, Rigidity Polypropylene Glass fiber reinforced, Halogen free Flame Retardant Provided structural requirements needed for function and stringent UL flame resistance Answers to Your Burning Questions: Flame Retardants and Regulations - Jesse Dulek 73 8

74 3/31/2016 OVERVIEW PROBLEM STATEMENT Thermoplastic Flammability Flame Retardant Additive Chemistries and Mechanisms Regulatory Landscape Testing Standards Hospital Acquired Infections 2,000,000 new cases per year (USA) 100,000 deaths per year (USA) $11 Billion additional cost (USA) Global trend Costs have been driven back to healthcare providers Case studies Hospital Cleaner Resistant Technology PROBLEM STATEMENT RISING TO THE CHALLENGE Added costs have led to an increase in cleaner usage and frequency Harsh chemicals causing failures in plastic housings Product Development Criteria Increased chemical resistance to healthcare cleaners vs. traditional housing materials PC/ABS, PC/PBT, ABS, PC, PC/ASA High Impact/Ductility Good dimensional stability with shrinkage similar to PC/ABS Colorable Flame retardant grade for electronic housings Answers to Your Burning Questions: Flame Retardants and Regulations - Jesse Dulek 74 9

75 3/31/2016 TEST METHOD EVALUATION TEST METHODOLOGY 1% strain Patch method Saturate patch every 24 hours Air dry Test physical properties after exposure (96 hours) Nine day soak test showed no change in physical properties Most field failures are seen in areas where stress is applied Need a test method that replicates field failures Test replicated field failures and relative resistance CHEMICAL CLASSES CHEMICAL CLASSES STUDIED Wide variety of chemical cleaners used to help avoid the spread of hospital acquired infections: Alcohols Aldehydes Quaternary compounds Alkylamine derivatives Chlorine releasing compounds Acidic / Basic solutions Etc. Base Chemical Class Alkylamine Glutaraldehyde Glucoprotamin Phenol Quaternary compound Chlorine releasing compound Alcohol Typical Brand Names T-Spray II Cidex Plus Incidin Plus Birex Sani-Cloth AF3 Sani-Cloth Active Sani-Cloth Bleach Clorox CaviCide 1 Super Sani-Cloth Sani-Cloth Plus Incides N Incidin Pro Disinfectant Examples: Wipes/cloth Liquid sprays RTP Continues Testing Provide a sample Will report results Answers to Your Burning Questions: Flame Retardants and Regulations - Jesse Dulek 75 10

76 3/31/2016 CHEMICALS TESTED DEVELOPMENT Cleaning Agent Birex CaviCide 1 Cidex Plus Incides N Incidin Plus Incidin Pro Sani-Cloth Active Sani-Cloth Bleach Sani-Cloth Plus Super Sani-Cloth T-Spray II Base Chemical Class Phenol Isopropanol / Ethanol Glutaraldehyde Propanol Glucoprotamin / Ethanol Alkylamine / Ethanol Quaternary compound Chlorine releasing compound Isopropanol / Ethanol Isopropanol Alkylamine Numerous compositions screened for physical property and chemical resistance Over a dozen polymers tested Extensive alloy testing Proprietary polyester alloy was proven as best performer Alloy was optimized for physicals, chemical resistance and flame performance Introducing RTP 2000 HC series: PASS/FAIL CRITERIA TENSILE STRENGTH Tensile Strength 75% retention or greater Cleaner RTP 2000 HC FR A FR PC/ABS FR PC/PBT T-Spray II Cidex Plus Incidin Plus Birex Tensile Elongation Minimum 10% tensile elongation Sani-Cloth Active Sani-Cloth Bleach CaviCide 1 Super Sani-Cloth Sani-Cloth Plus Incides N Incidin Pro Answers to Your Burning Questions: Flame Retardants and Regulations - Jesse Dulek 76 11

77 3/31/2016 TENSILE ELONGATION CASE STUDY Cleaner RTP 2000 HC FR A FR PC/ABS FR PC/PBT T-Spray II Cidex Plus Incidin Plus Birex Sani-Cloth Active Electronic Control Housing Sani-Cloth Bleach CaviCide 1 Super Sani-Cloth Sani-Cloth Plus Incides N Incidin Pro Market: Problem: Solution: Benefits: Medical Experiencing field failures and all commercially available housing materials were failing chemical testing RTP 2000 HC FR A Provided required cleaner resistance, utilizing the existing tooling CONCLUSIONS RTP 2000 HC offers resistance to healthcare cleaners Available in UL94 V-0/5VA grade Physical properties well suited for housings Dimensional stability Similar molding conditions in existing tooling (PC/ABS, PC/PBT, ABS, PC, PC/ASA) Fully colorable Available for immediate sampling/testing Thank You! Jesse Dulek [email protected] (507) rtpcompany.com [email protected] Answers to Your Burning Questions: Flame Retardants and Regulations - Jesse Dulek 77 12

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79 Color More than Meets the Eye Anna Kreofsky Color R&D Engineer (507) :45 p.m. 79

80 3/31/2016 TOPICS Color More than meets the Eye Anna Kreofsky Color R&D Engineer Brief introduction to RTP Company Color Division Color Fundamentals Three Sciences of Color Colorant Types & Limitations Evaluation & Control Effective Color Communication rtpcompany.com Beyond Visible Light Near Infrared Attenuation Laser Welding Laser Marking Questions RTP COMPANY COLOR DIVISION GLOBAL COLOR CONSISTENCY Color virtually all resins Engineering resins Styrenic resins Polyolefin resins Color in multiple formats Masterbatches Precolored resins Cube blends Advanced Color Development Custom colors Multiple light sources Regulatory knowledge UL, FDA, USP, RoHS, etc. 8 Color Labs USA, France, China, Singapore, Mexico Color Control Consistent raw materials Consistent hardware Consistent software Global database Speed Fast color matching service Transfers across regions Global color palette RTP Color 2008 Color More than Meets the Eye - Anna Kreofsky 80 1

81 3/31/2016 COLORING OPTIONS PRODUCT FAMILIES Masterbatches Concentrated formulation of colorants and/or additives dispersed in a polymer carrier Usage defined by let-down ratio or percentage Most widely used form to color commodity resins Master batch Resin Compounds formulated to meet performance requirements, from one property to multiple technologies Precolor Colorants are added to the polymer and extruded Ready to use as-is Color Conductive Flame Retardant Thermoplastic Elastomers Cube blend Masterbatch is blended with resin (two or more pellet solution) Your Color Your Way Structural Wear Resistant Film - Wiman Sheet - ESP TOPICS COLOR SCIENCE Brief introduction to RTP Company Color Division Color Fundamentals Three Sciences of Color Colorant Types & Limitations Evaluation & Control Effective Color Communication Beyond Visible Light Near Infrared Attenuation Laser Welding Laser Marking Biology Physics Color perception Light interactions Chemistry Colorants Questions Color More than Meets the Eye - Anna Kreofsky 81 2

82 3/31/2016 BIOLOGY BIOLOGY How do we see color? Two types of Photoreceptors - Detector Rods Vision at low lights levels Observer Cones Sensitive to three colors Light Source Optical nerve sends signal to brain for decoding Object PHYSICS ART OF COLOR Light behaves like a wave Color More than Meets the Eye - Anna Kreofsky 82 3

83 3/31/2016 PHYSICS SPECTRAL REFLECTANCE White light is made up of all wavelengths of visible light. It is separated into individual colors when light passes through a glass prism. Blue Reflected Color Green Reflected Color Red Reflected Color Appears blue Appears black Blue object Black object Spectral reflectance curves produced by spectrophotometer Graph shows light reflected from an object at each wavelength Each color has a unique spectral curve CHEMISTRY - COLORANT TYPES ORGANIC VS. INORGANIC Inorganic Pigments: Pigments from various metals or other substances from nature Organic Pigments: Pigments made synthetically Dyes: Synthetic substances that are soluble Organic Pigments: Small particle size Difficult to disperse Limited heat stability (300 C max) High color strength Light fastness Evaluated on individual basis Inorganic Pigments: Large particle size Easy to disperse Heat stable Weak color strength Improved light fastness Color More than Meets the Eye - Anna Kreofsky 83 4

84 3/31/2016 DYES COLOR EVALUATION & CONTROL Soluble Migration concerns High color strength Transparent Commonly used in: Styrenic Resins Engineering Resins Visual Color Evaluation Confirmed color vision Color standards for reference Controlled light Agreed upon color space Instrumental Color Evaluation Calibrated instruments Color standards for reference Controlled temperature Agreed upon color space RTP Color 2008 ENVIRONMENTAL FACTORS Observer Each person sees color uniquely Light Source Different spectral distributions (D65, CWF, Incandescent) Background Contrast difference makes colors appear different Viewing Angle Most common 45º Keep viewing conditions CONSTANT SPECIFICATION & TOLERANCES Numeric Color Modeling Numeric model provides 3 dimensional color space Quantify colors numerically Can be used for specification, identification, comparison Several Color Spaces CIE 1931 Yxy CIE L*a*b* 1976 CIE LCh CMC l:c 1984 Color More than Meets the Eye - Anna Kreofsky 84 5

85 3/31/2016 COMMON COLOR TERMS COLOR SPACE Hue Color perceived Chroma (Saturation) Vividness of a color Lightness Measure of brightness (think about gray scale) Tint: Hue has been lightened Pink is a tint of red Shade: Hue has been darkened Maroon is shade of red Chroma CIE 1931 Yxy Uses numeric values Yxy Y - Luminance x,y - Chromaticity values Only x,y chromaticity values shown Hue changes around color gamut Chroma increases from center towards edge Non-Uniform Color Scale COLOR SPACE COLOR SPACE CIE L*a*b* Model (Traditional X-Y-Z coordinate system) Developed in 1976 Most popular color space Uniform color space Identified by numeric values L* = lightness to darkness (0-100) a* = redness to greenness b* = yellowness to blueness E* = total color shift (dimensionless) RTP Color 2008 LCh Model (cylindrical coordinates r, Ф, z) RTP Color 2008 ) Color More than Meets the Eye - Anna Kreofsky 85 6

86 3/31/2016 COLOR SPACE TOLERANCES CMC l:c (1984) Used for tolerancing l:c (lightness:chromaticity) values are typically 2:1 Provides better agreement between visual and instrumental assessment Allows user to vary ellipse tolerance per application Tolerances developed around variation in raw materials, processing, customer goals for visual appearance * Asymmetrical color tolerances are perfectly acceptable to use l:c = 2:1 l:c = 1.5:1 COLOR COMMUNICATION APPLICATION REQUIREMENTS/TARGET Application Requirements: Resin/Compound Regulatory Restrictions Processing Method Secondary Operations Color Target: Grass Green Pantone: 347 L* = 43 a* = b* = It s important to specify all targets through color communication Physical Color Color Reference Color Space Values Color More than Meets the Eye - Anna Kreofsky 86 7

87 3/31/2016 SATISFYING EXPECTATIONS TOPICS Color nomenclature: Identifies both regulatory and formulation commitment Lot control: Ingredient traceability Process control: Defined manufacturing specifications Engineering review during development and continuous improvement Contributes to consistency Color quality control: Color meets defined requirements Physical properties Composition consistency Brief introduction to RTP Company Color Division Color Fundamentals Three Sciences of Color Colorant Types & Limitations Evaluation & Control Effective Color Communication Beyond Visible Light Near Infrared Attenuation Laser Welding Laser Marking Questions BEYOND VISIBLE LIGHT - IR/NIR TRANSMITTANCE Active nm range Combination of light controlling attributes Transparent or opaque at specific wavelengths Commonly used in: Fiber optics Transmitters/receivers % Transmission Visible Infrared Unfilled Polycarbonate RTP 0300 SC IR BLACK RTP 0300 SC BLACK EC RTP 0399 X mm NS EC IR ABSORBER Wavelength (nm) Sample Thickness = 1.5 mm Color More than Meets the Eye - Anna Kreofsky 87 8

88 3/31/2016 LASER WELDING LASER WELDING MECHANISM Requires two types of materials with different behavior in the NIR Method for joining thermoplastic parts by using the power of the laser to bond materials A: Light transmits through upper material and is absorbed by lower material B: Melting pool is created C: Heats upper layer D: Melting pool solidifies under external pressure ADVANTAGES OF LASER WELDING ORGANIC VS. INORGANIC Weld complex parts No flash is produced High-precision joints can be produced (Hermetic seals) Resins of different compositions can be joined No consumables (adhesives, fasteners, etc.) IR Transparent Resin: Amorphous Resins Require the least amount of energy Semi-Crystalline Require more energy due to scattering Welding challenges PEEK, LCP, PPS, etc. Highly crystalline materials have significant scatter IR Absorbing Resin: All resins Amorphous Semi-Crystalline need IR Absorbing colorants Color More than Meets the Eye - Anna Kreofsky 88 9

89 3/31/2016 ORGANIC VS. INORGANIC DEGREE OF COMPLEXITY IR Reducing: Glass fibers, glass beads, colorants Various additives UV stabilizers, heat stabilizers, etc. IR Blocking: Carbon fiber, minerals, metals, etc. RTP Company has experience with pigment/filler combinations, and loading levels, to support successful welding using both Diode and Nd:YAG lasers Color combinations influence complexity of formulation Part thickness and laser frequency also determine material transmissivity LASER MARKING ONE LIGHT TWO MARKS Basic mechanism Laser Laser energy absorbed causing a reaction Charring (dark mark) Foaming (light mark) Ablation (removal of layer, ex. Paint) Charring produces (dark marks) One Light Source Foaming produces (light marks) No Universal Additives Can be combined with other additive technologies Unique colors achievable beam Laser additive Marks vary with resin, additive, and color package Color More than Meets the Eye - Anna Kreofsky 89 10

90 3/31/2016 HIGH CONTRASTING MARKS Black resin color with light marks: PP (Olefins) Nylon ABS (Specific Grades) POM PMMA Possibly more LASER PARAMETERS Different lasers can be used, Nd:YAG (Neodymium doped Yttrium Aluminum Garnet) is the best compromise of Speed Flexibility Marking quality Power (Amps) Marking Speed = Constant Frequency (khz) Laser and marking parameters will influence quality of mark SUMMARY QUESTIONS RTP Company supplies innovative colors and functional additives Color communication is crucial to color matching and tolerancing Light attenuation is the selective control of transmission, either by wavelength, intensity, or both Three main factors for successful welds: material selection, laser source, joint configuration Any Questions??? Dark and light marks can be achieved using same laser source with overall goal of a high contrasting mark Color More than Meets the Eye - Anna Kreofsky 90 11

91 3/31/2016 Thank You! rtpcompany.com Color More than Meets the Eye - Anna Kreofsky 91 12

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93 Taking Charge of Resistivity: An Introduction to Conductive Plastics Technology David Gregerson Product Development Engineer (507) :45 p.m. 93

94 RTP Company Your Global Compounder of Custom Engineered Thermoplastics OVERVIEW Taking Charge of Resistivity: An Introduction to Conductive Plastics Technology David Gregerson Product Development Engineer Conductive Classification and Testing Overview of Conductive Modifiers Migratory Anti-Stats Inherently Dissipative Polymers Carbon (Powder, Fiber, Nanotubes) More Specialized Technologies EMI Shielding Thermal Conductivity rtpcompany.com Wrap Up and Questions CONDUCTIVE CLASSIFICATION STATIC DECAY TESTING Antistatic Cleanliness Prevent Dirt & Dust build up Static Dissipative Protect Delicate Electronics Prevent Explosions Conductive (Current-Carry Devices) Electrical Contacts Electrical Circuits Shielding Provide Protection against RFs Static Decay Rate Measures seconds to decay 5000V to 50V 12% Relative Humidity Standards/Specifications MIL PRF D NFPA 56A Numerous Others 5 k V HIGH VOLTAGE SOURCE ELECTRODES TEST SAMPLE DECAY SIGNAL TO INDICATING OR RECORDING EQUIPMENT Taking Charge of Resistivity: An Introduction to Conductive Plastics Technology - David Gregerson 1 94

95 RTP Company Your Global Compounder of Custom Engineered Thermoplastics SURFACE TESTING SURFACE RESISTIVITY TEST Surface Resistivity (ohms/square) Surface Resistance (ohm) Standards/Specifications ASTM D257 ESD STM11.11 IEC Numerous others Small Samples Irregular Part Shapes In-Field Test Units = ohms/square Voyager SRM-110 SURFACE RESISTIVITY TEST SURFACE RESISTANCE TEST Surface Resistance Meter Point to Point Measuring small & critical areas on part Units = ohm Guarded Ring Electrode Flat Specimen Precise Measurement Units = ohms/square Taking Charge of Resistivity: An Introduction to Conductive Plastics Technology - David Gregerson 2 95

96 RTP Company Your Global Compounder of Custom Engineered Thermoplastics VOLUME RESISTIVITY TEST OVERVIEW Overview of Conductive Modifiers ρ = Volume Resistivity R = Resistance A = Cross-sectional Area = Length Units = ohm-cm ASTM D-257 A Migratory Anti-Stats Inherently Dissipative Polymers Carbon (Powder, Fiber, Nanotubes) More Specialized Technologies EMI Shielding Thermal Conductivity Wrap Up and Questions CONDUCTIVE MODIFIERS PERCOLATION CURVE Migratory Antistats Inherently Dissipative Polymers (IDPs) Carbon Black Carbon Fiber Carbon Nanotubes Metallic Additives Taking Charge of Resistivity: An Introduction to Conductive Plastics Technology - David Gregerson 3 96

97 RTP Company Your Global Compounder of Custom Engineered Thermoplastics MIGRATORY ANTI-STATIC AGENTS INHERENTLY DISSIPATIVE POLYMERS (IDP) Migrating surfactant based not bonded to resin Temperature & humidity dependent Best at room temperature & high humidity Colorable Liquids & semi-solids with low boiling points Compatible only with los-temp resins Olefins, Styrenics, PVC Economical/commodity materials All-polymeric, based on IDP Typically consist of PE oxide Other block dictates compatibility Forms a co-continuous morphology with the base resin Over 20 different resin systems Limited process temps (< 520 ºF) Surface resistivity Standard: to ohm/sq PLUS: 10 8 to 10 9 ohm/sq Static decay rate Standard < 2.0 s PLUS < 0.5 s PermaStat PERMASTAT TECHNOLOGY BENEFITS TYPICAL APPLICATIONS Permanent ESD protection not dependent on migration, humidity or temperature Clean Technology non sloughing with FDA and Biocompatible grades available Transparent grades available and fully colorable Reticle Boxes ABS, PMMA Inhalers ABS, PP, PMMA Base resin properties retained PermaStat PLUS can meet ATEX requirements Gas Cap POM ATEX IBC PE Taking Charge of Resistivity: An Introduction to Conductive Plastics Technology - David Gregerson 4 97

98 RTP Company Your Global Compounder of Custom Engineered Thermoplastics WHAT IS ATEX? ATEX TESTING ATMOSPHERE EXPLOSIVE Potentially explosive environments Began as a European Directive Standardize compliance procedure Now seen in US and other countries (IECEx) Actual requirements defined by customer All tests are on actual parts Tests could include: Surface Resistance (almost always included) Relative Thermal Index (RTI) Chemical Resistance Impact (Low temperature) Ultra Violet (UV) High humidity aging testing Flame Retardant (FR) Need to fully identify all requirements for proper material selection ATEX SURFACE RESISTANCE ATEX MARKETS Specific test Isolation resistance <1 Gohm at 50% R.H. Tested at 500 V Different from the standard surface resistance or resistivity widely used in the plastic industry IEC ASTM D 257 ESD STM11.11 No real correlation Mining Personal protective equipment Food, chemicals, and paint industries Hand-held equipment Industrial equipment (pneumatic, hydraulic, venting systems, pumps) Taking Charge of Resistivity: An Introduction to Conductive Plastics Technology - David Gregerson 5 98

99 RTP Company Your Global Compounder of Custom Engineered Thermoplastics CONDUCTIVE CARBON BLACK CONDUCTIVE CARBON BLACK Characterized by: Structure Size of particles Porosity Surface Chemistry Permanent Black color only Sloughing / Marking / Crayoning Economical Dissipative or conductive SR 10 3 to 10 9 ohm/sq VR 10 0 to 10 6 ohm-cm CARBON BLACK APPLICATIONS CARBON / GRAPHITE FIBER Non-sloughing Colorable Anisotropic shrinkage Electronic device trays PP, PS, PC Pipette tips - PP Reinforcing Chopped Fiber ¼ long bundles Dissipative or conductive SR 10 2 to 10 6 ohm/sq VR 10-1 to 10 4 ohm-cm Milled Fiber pulverized Storage bins & totes - PP Fuel filler tubes - PE Taking Charge of Resistivity: An Introduction to Conductive Plastics Technology - David Gregerson 6 99

100 RTP Company Your Global Compounder of Custom Engineered Thermoplastics CARBON FIBER APPLICATIONS CARBON NANOTUBES (CNT) > 90% graphite Hollow Full Line components PPA, Nylon, Acetal Chip transport/storage trays PC, PSUL, PES Datacard Group, Minnetonka, MN Card printer chassis PC 10 nanometer diameter High L/D ratio CNT SIZE DIFFERENCE PRIMARY BENEFITS OF CNTS Uniform electrical conductivity prevent hot spots and protect sensitive electronics Effective at low loadings clean product with low SG and good surface finish Isotropic Properties non reinforcing, behaves like neat resin A carbon fiber surrounded by CNTs Ability to use regrind maintains conductivity with additional processing Taking Charge of Resistivity: An Introduction to Conductive Plastics Technology - David Gregerson 7 100

101 RTP Company Your Global Compounder of Custom Engineered Thermoplastics ELECTRICAL CONDUCTIVITY HOT SPOTS SEM (2000x) of typical CNT compound Smooth surface finish Uniform shading is a direct result of uniform electrical conductivity SEM (2000x) of typical CF compound Rough surface finish White shading indicates a point of high conductivity - Hot spot Possible conductive particle generation site CNT Fewer Hot Spots Lower Voltage Retention Reduced Tribocharging CF ELECTRONICS INDUSTRY APPLICATIONS OVERVIEW Hard disc drive (HDD) handling components Silicon wafer handling components Semiconductor chip trays ESD shipping trays More Specialized Technologies EMI Shielding Thermal Conductivity Trays Wafer Caddy HDD Wrap Up and Questions Taking Charge of Resistivity: An Introduction to Conductive Plastics Technology - David Gregerson 8 101

102 RTP Company Your Global Compounder of Custom Engineered Thermoplastics EMI SHIELDING EMI IN ACTION ElectroMagnetic Interference = EMI EMI shields protect sensitive devices Emitted from a source or Received by a device Frequency range of 1 khz to 10 GHz Faraday Cage Principle: Barrier that reflects or conducts signals to ground Shielding provides Immunity EMI IN ACTION EMI SHIELDING FILLERS Electrically Conductive modifiers: Carbon Powder Carbon fiber Graphite Stainless steel fiber Nickel-coated carbon fiber Other metallic additives Taking Charge of Resistivity: An Introduction to Conductive Plastics Technology - David Gregerson 9 102

103 RTP Company Your Global Compounder of Custom Engineered Thermoplastics ADDITIVE COMPARISON COAXIAL TRANSMISSION LINE TEST Stainless Steel Fiber Non-Reinforcing Equivalent shrinkage to neat resin Moderate shielding performance Colorable ASTM D 4935 Direct Measurement on Flat Specimens Fast and Repeatable Relative Ranking Frequency range of 30 MHz to 1.5 GHz Units = Decibels of SE Spectrum Analyzer/Tracking Generator Nickel-Coated Carbon Fiber Reinforcing High shielding performance Higher cost Less colorable Test specimen REVIEW OF SHIELDING OPTIONS EMI APPLICATIONS VR is key parameter SR is misleading SE dependent on filler loading and wall thickness Easily Grounded SR key parameter Other surfaces insulative SE depends on coating Conductivity & Thickness Uniform Conductivity SR easily measured Easily grounded Shielding gasket TPO/SS Motor Housing PC/NCCF Care in grounding required Taking Charge of Resistivity: An Introduction to Conductive Plastics Technology - David Gregerson

104 RTP Company Your Global Compounder of Custom Engineered Thermoplastics THERMAL CONDUCTIVITY THERMALLY CONDUCTIVE ADDITIVES Improved Thermal Conductivity >0.5W/mK Thermally Conductive and Electrically Insulative Base Resin Standard Compounds 0.2W/mK Lowered Thermal Conductivity <0.2W/mK Thermally and Electrically Conductive Electrically Conductive Carbon based In Plane up to 30 W/mK Through Plane up to 6 W/mK Color limited to Black/Grey Electrically Insulative Ceramic based In Plane up to 10 W/mK Through plane up to 1.5 W/mK Colorable ADDITIVE ORIENTATION METAL REPLACEMENT Convection Limited Systems Higher conductivity of metal often not necessary Limited to what can be dissipated to environment Thermal Conductivity is measured in the direction of flow (in plane) and in the direction normal to the plane of flow (through plane) Increase Surface Area Alignment of particles during molding leads to higher thermal conductivity in the in-plane direction Ribs, fins and pins maximize convection Reduce the bottleneck in thermal transfer Heat is not transported through insulative plastic to be carries away by ambient air. Heat is transported through conductive plastic at the same rate as it can be carried away by ambient air. More heat is transported through metal than can be carried away by ambient air Taking Charge of Resistivity: An Introduction to Conductive Plastics Technology - David Gregerson

105 RTP Company Your Global Compounder of Custom Engineered Thermoplastics BENEFITS THERMALLY CONDUCTIVE APPLICATIONS Much higher thermal conductivity than conventional thermoplastics Ease of manufacturing net shapes compared to metals Significant weight savings even compared to lightweight Al EMI + TCC solutions available for complete metal replacement Electronics Housing LED Heatsinks CONDUCTIVE MODIFIERS: PROS AND CONS Technology Pros Cons Migratory Antistats Inherently Dissipative Polymer PermaStat Economical Permanent Transparent availability Colorable No loss of mechanical properties Non-permanent Process temperature limited Humidity dependent Limited to dissipative range Process temperature limited Thank You! Carbon Black Economical Dissipative or conductive Resists Tribocharging Sloughing Black only Lower impact strength Carbon Fiber Dissipative or conductive Reinforcing Non-sloughing Anisotropy Poor tribocharging Carbon Nanotubes Metallic Additives Dissipative or conductive Superior tribocharging performance Minimal effect on mechanical and viscosity Low LPC EMI/RFI shielding Highly conductive Cost Black only Limited colorability Higher specific gravity rtpcompany.com [email protected] Taking Charge of Resistivity: An Introduction to Conductive Plastics Technology - David Gregerson

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107 Plastic Cures for Common Healthcare Hurdles Karl Hoppe Senior Product Development Engineer (507) :30 p.m 107

108 4/11/2016 THE SITUATION Plastic Cures for Common Healthcare Hurdles Karl Hoppe Senior Product Development Engineer Customer asks for RTP 603 (ABS +20% GF) Evaluate the situation from a non-healthcare perspective Evaluate the situation from a Healthcare perspective rtpcompany.com [email protected] AGENDA WHAT S SPECIAL? What s special about Healthcare? Care in material selection What s so special about Healthcare applications? Nothing! Care in formulation control Hot technologies for Healthcare Common Hurdles TPE Compounds Plastic Cures for Common Healthcare Hurdles - Karl Hoppe 108 1

109 4/11/2016 WHAT S SPECIAL? BREAKING DOWN SPECIAL What s so special about healthcare applications? Everything! Unique requirements for medical devices May touch internal tissues or fluids! Changes can be bad! Not all suppliers support healthcare applications May touch internal tissues or fluids! Changes can be bad! Not all suppliers support healthcare applications Sterilization Biocompatibility Change Control BREAKING DOWN SPECIAL BREAKING DOWN SPECIAL May touch internal tissues or fluids! Changes can be bad! Not all suppliers support healthcare applications May touch internal tissues or fluids! Changes can be bad! Not all suppliers support healthcare applications Sterilization Biocompatibility Change Control Sterilization Biocompatibility Change Control Plastic Cures for Common Healthcare Hurdles - Karl Hoppe 109 2

110 4/11/2016 BREAKING DOWN SPECIAL STERILIZATION May touch internal tissues or fluids! Ethylene Oxide Changes can be bad! Not all suppliers support healthcare applications Radiation Sterilization Biocompatibility Change Control Autoclave (Steam) STERILIZATION STERILIZATION Ethylene Oxide (EtO) Toxic gas Polymers require chemical resistance Most polymers OK for use with EtO CONTAINS ETHYLENE OXIDE CANCER HAZARD AND REPRODUCTIVE HAZARD Radiation Gamma E-beam Damages polymers via: Chain scission Crosslinking Cumulative damage Plastic Cures for Common Healthcare Hurdles - Karl Hoppe 110 3

111 4/11/2016 STERILIZATION STERILIZATION Radiation resistant ABS Sulfones (PSUL, PES, PPSU) PC Yellows with exposure Maintains properties PE Crosslinks upon exposure PP Requires stabilization Not recommended Polyacetal (POM) PTFE FEP Autoclave (Steam) 120ºC to 135ºC with humidity exposure Exposure time from 3 to 15 minutes STERILIZATION BREAKING DOWN SPECIAL Resistance to autoclave Best PEEK PPSU Good PP PA PSUL PC Not recommended Styrenics ABS Polystyrene Polyesters PBT PET Avoid materials with poor resistance to heat/humidity May touch internal tissues or fluids! Changes can be bad! Not all suppliers support healthcare applications Sterilization Biocompatibility Change Control Plastic Cures for Common Healthcare Hurdles - Karl Hoppe 111 4

112 4/11/2016 BIOCOMPATIBILITY BIOCOMPATIBILITY Tissue/Fluid contact suitability often determined by biocompatibility USP Class VI ISO Most common ISO tests Cytotoxicity Evaluate the toxic effects of the material on cells Sensitization Irritation Determine skin or tissue reactions to prolonged exposure of material or extracts Observe local irritation of skin, eye, or mucous membranes QUESTIONS TO CONSIDER BIOCOMPATIBILITY OF INGREDIENTS What are some ways to ensure that a compound will pass part biocompatibility requirements? Specialty medical compounder material selection Biocompatible resins Available in many different polymer systems Is this possible? FDA compliant additives Most additives do not carry biocompatibility Plastic Cures for Common Healthcare Hurdles - Karl Hoppe 112 5

113 4/11/2016 CONFIDENCE IN FORMULATING QUESTIONS TO CONSIDER What other steps can be taken to ensure consistency in performance and long term safety and effectiveness? BREAKING DOWN SPECIAL CHANGE CONTROL May touch internal tissues or fluids! Changes can be bad! Formulation ingredients need to be locked Required changes need to be communicated Not all suppliers support healthcare applications Sterilization Biocompatibility Change Control Plastic Cures for Common Healthcare Hurdles - Karl Hoppe 113 6

114 4/11/2016 THE SITUATION AGENDA Customer asks for RTP 603 (ABS +20% GF) Evaluate the situation from a non-healthcare perspective. Evaluate the situation from a Healthcare perspective. What s special about Healthcare? Care in material selection Care in formulation control Hot technologies for Healthcare Common Hurdles TPE Compounds COMMON HEALTHCARE HURDLES COMMON HEALTHCARE HURDLES Radiopacity: visible using X-ray imaging Barium Sulfate Bismuth minerals Antistatic: For efficient drug delivery Reduce static build up Dry powder drug delivery Clear and colors Tungsten Plastic Cures for Common Healthcare Hurdles - Karl Hoppe 114 7

115 4/11/2016 COMMON HEALTHCARE HURDLES THERMOPLASTIC ELASTOMERS Reinforced Compounds: for patient mobility Bed/chair components Wheelchair components Equipment bases THERMOPLASTIC ELASTOMERS THERMOPLASTIC ELASTOMERS SBS POE TES SEBS TPV TPU COPE PEBA SBS POE TES SEBS TPV TPU COPE PEBA Styrenic Elastomer Attributes Highly Elastic Highly Customizable Design Flexibility Broad Cost Spectrum Great RT Compression Set Vulcanizate TPE Attributes Broad temperature range Improved chemical resistance Easily colorable Broad cost spectrum Great room temp compression set Plastic Cures for Common Healthcare Hurdles - Karl Hoppe 115 8

116 4/11/2016 THERMOPLASTIC ELASTOMERS THERMOPLASTIC ELASTOMERS SBS POE TES SEBS TPV TPU COPE PEBA SBS POE TES SEBS TPV TPU COPE PEBA POE, TPU, COPE, PEBA Variety of performance Low cost to high temperature and performance Base resins available as colors Excellent starters for alloys Standard Compounds common to the market TPE Alloys Combining neat technologies to optimize performance Specialties Incorporating RTP additive expertise STANDARD TPE MD GRADES RTP 2700S MD Materials (Styrenic) Gaskets & Stoppers Certain Plunger Tips Non-slip grips PP Overmolds (soft touch) Buttons & Locators Skin Interface Areas Supported Profiles Dropper Bulbs RTP 6003 MD & 6042 MD Materials (Bondable Alloy) Polar Substrate Overmolds Unique stand-alones Electronic Housings Adhesive elimination Surgical Tool Handles Medical Product Branding Rubber Armor Drug Delivery Device Grips Plastic Cures for Common Healthcare Hurdles - Karl Hoppe 116 9

117 4/11/2016 SPECIALTY ADDITIVE TPE MD GRADES TPE SPECIALTIES MEDICAL TPE + Specialty Additives: Design Attributes TPE + Specialty Additives: Application Areas Biocompatible Color Conductivity Anti-Static / O 2 Environment Color: Branding Radio Opacity/Gravity Anti-Microbial Catheter Tips Color: Identification EMI Shielding Flame Retardant Strain reliefs Sticktion elimination Friction Modified Reinforcement Sensors/Diagnostics High Stability/Stiffness AGENDA What s special about Healthcare? Care in material selection Care in formulation control Thank You! Hot technologies for Healthcare Common Hurdles TPE Compounds rtpcompany.com [email protected] Plastic Cures for Common Healthcare Hurdles - Karl Hoppe

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119 An Engineer s Guide to Specifying the Right Thermoplastic Slide 21 & 22 AMORPHOUS RESINS Morphology Features -- Low Shrink, Low Warp, Tight Dimensional Tolerances, Transparent (except HIPS & ABS), Poor Chemical & Abrasion, Poor Flow in Thin Mold Sections Amorphous Special Features Amorphous Nylon Transparent/good chem. resistance Polycarbonate (PC) Acrylic (PMMA) Optical transparency/high impact Optical transparency/uv stable Acrylonitrile Butadiene Styrene (ABS) High impact/high gloss/opaque Styrene Acrylonitrile (SAN) High Impact Polystyrene (HIPS) Transparent/mod. chem. resistance Moderate impact/opaque Polystyrene (PS) Transparent/brittle Commodity (<$1.50) Engineering ($1.50-$4.00) SEMI-CRYSTALLINE RESIN Semi-Crystalline Nylon 6/12 Nylon 6/6 Nylon 6 Morphology Features -- Excellent Chemical Resistance, Excellent Abrasion Resistance, Good Flow in Thin Mold Sections, Poor Dimensions, Opaque Polybutylene Terephthalate (PBT) Polyethylene Terephthalate (PET) Acetal (POM) Polylactic Acid (PLA) Polypropylene (PP) Polyethylene (HDPE, LDPE, LLDPE) Special Features Less Sensitive to humidity vs. 6&6/6 Better thermal vs. 6/humidity Dep Hides GF/strong but humidity Dep Good electricals/easier to mold Good electricals/difficult to mold Low wear & friction/high fatigue Green/Low impact & thermal Poor low temp impact/mod thermal Good low temp impact Commodity (<$1.50) Engineering ($1.50-$4.00) 4/4/2016

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121 Attendee Survey Which workshop did you attend? Denver Salt Lake City What is your primary responsibility? Engineering/Design Manufacturing Purchasing Management Sales Other How would you describe your company? OEM Molder Design Other How would you rate the overall value of today s workshop? Exceeded my expectations Met my expectations Below my expectations What did you enjoy most about today s workshop? What areas of the workshop need improvement? Please have a representative from RTP Company contact me to address the following need: Name: Phone/ Please add me to the following mailing lists (check all that apply): Newsletter Technical Webinars s address:

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