Kaneka North America LLC

Transcription

1 Feipur Feiplar 2014

2 Advantage of MS POLYMER Global network Three plants in Europe, Japan, and US continue producing high quality products to supply the world leading sealant companies. Four technical centers in Shanghai, Europe, Japan, and US are supporting customer s development. A new center will start in Kuala-Lumpur this autumn.

3 KANEKA BELGIUM Production T/S center KANEKA INDIA office KANEKA MS POLYMER TM MS POLYMER Global Network KANEKA SHANGHAI T/S center KANEKA KOREA office KANEKA MALAYSIA T/S center KANEKA JAPAN Production T/S center KANEKA NORTH AMERICA Production T/S center KANEKA SOUTH AMERICA Office

4 MS Chemical Structure and Characteristics CH 3 (CH 3 O) 2 Si O CH 3 CH 3 CHCH 2 O n Si(OCH 3 ) 2 Good chemical stability without catalyst * Low viscosity * Good compatibility with various additives (SP value = 8 9) A wide variety of formulations providing a broad based platform to address coating, adhesives, and sealant needs A Wide Variety of Applications Coatings, Construction, General Industry, Automotive etc.

5 Curing Mechanism of MS Polymers TM CH 3 CH 3 CH 3 CH 3 (CH 3 O) 2 Si-(CH 2 ) 3 -O-(-CH-CH 2 -O-) n -(CH 2 ) 3 -Si(OCH 3 ) 2 = R-Si(OCH 3 ) 2 CH 3 CH 3 CH 3 +cat H 2 O R-Si-OCH 3 + H 2 O > R-Si-OH > R-Si-OH -CH 3 OH -CH 3 OH OCH 3 OCH 3 OH [Step 1: HYDROLYSIS] -CH 3 OH + R -Si(OH) 2 (CH 3 ) -H 2 O +cat CH 3 CH 3 R-Si-O-Si-R OH OH [Step 2: CONDENSATION] The residual Si-OH groups can then further condense with other Si-OH or Si-OCH3 groups to form a 3D network.

6 MS Polymer TM Blending Regimes Single most important aspect in the blending processes is to dry the components (and/or the final formulation) MS Polymers + water = stable MS Polymers + catalyst = stable BUT MS Polymers + catalyst + water = rapid polymerization (hydrolysis + condensation)

7 MS Polymer -Application Technology One Component: Typical MS curing chemistry One Component w/booster Faster curing 1K MS Two Component Equally divided ingredients into 2 parts Part A contains catalyst, part B contains water Two component MS/Epoxy Part A MS Part B epoxy

8 Typical MS Adhesive/Sealant Formulation Plasticizer Filler Thixitrope Pigment CH 3 (CH 3 O) 2 Si O CH 3 CH 3 CHCH 2 O n Si(OCH 3 ) 2 MS Polymer Stabilizer Dehydrator Adhesion Promotors Catalyst

9 Typical Ingredients and Effect Type of Additive Plasticizers Fillers Recommended Examples Phthalates, PPG Talc; Fumed Silica Calcium Carbonate Key Functions Rheological control; Viscosity reducer Modulus reducer; Tg suppressor Provides body ; Reinforces formulation UV and light stabilizers Hindered phenols Anti oxidants, HALS Enhances photooxidation resistance Provides weathering resistance; Improves service life. Catalysts U220H (Sn(IV)) Accelerates cure Moisture Scavengers Adhesion Promoters Pigment Vinyl silanes Amino/epoxysilanes TiO2; Carbon Black Provides storage stability Promotes adhesion to a range of substrates Colorant; Modulus enhancer Thixitrope agents Polyamide waxes Allows extrusion

10 General Adhesive/Sealant Product Formulation Properties (NF-1105) Component Grade NF-1105 Viscosity 1 rpm 1900 MS Polymer S203H 30 S303H 70 Plasticizer DIDP 90 Calcium carbonate Ultra Pflex 160 Q3T 54 Titanium Dioxide Ti-Pure R Thixotropic agent Disparlon # Antioxidant Tinuvin UV absorber Tinuvin Dehydration agent A Adhesion promoter A Hardening catalyst U Total 436 by rheometer 2 rpm Pa s rpm 320 Tack free time min 22 Curability in depth after 1day 3.5 after 3days mm 5.9 after 7days 8.7 Hardness Shore A - 29 Tensile strength M100 MPa 0.52 by dumbbell shape TB Cx7days EB % 630 Adhesion in peel by hand non-primer 23 Cx7days Glass UPC Anodized Aluminum CF CF CF

11 MS BENEFITS Durability MS based products have superior durability, excellent weather resistance and high elasticity. Adhesion MS based products show good adhesion without primer on various substrates. Including PVC, EPDM, Glass, Wood, Stone, and others. Paintability MS based products can be painted with various kinds of paints within specified application windows Non-stone staining MS based products has excellent non-staining characteristics against stones, tiles, plates. Quick cure MS based products cure quickly even at low temperatures due to self producing moisture in curing mechanism. Easy handling MS based products viscosity is stable over a wide range of temperatures. Its extrudability is excellent even at cold temperature. Non-isocyanate MS based products are isocyanate free; ensuring an environmentally and worker friendly product. Solvent Free MS products are solvent free meeting the rigorous standards of California and other environmentally conscious states and provinces. As well as near zero voc levels.

12 MS BENEFITS-Weather Resistance Period (days) Irradiation (Lannqley x10 3 ) Corresponding years in Japan Initial ,201 1, MS PU

13 Dimension of Sliced Specimens ~ Sampling Sealant ~ SURFACE SLICE 2 SLICE 1 SLICE 0 DEPTH FROM SURFACE BACK SIDE SIZE OF TEST SPECIMENS 10mm x 45mm x 1mm

14 Tensile Strength at 100% Elongation (MPa) and Tensile Strength at Break (MPa) Elongation at Break (%) Mechanical Properties with Different Depth ~ 10 years old 1 part MS sealant ~ MS-1 after 10 years EB 700% 600% % TB M % 300% 200% 100% Surface Depth from Surface (mm) 0% Fig. Tensile Test Results of MS-1 Sealant after 10 Years

15 MS BENEFITS- Cold Weather Application

16 MS BENEFITS- Cold Weather Application

17 Adhesion on Various Substrates

18 Paintability on Cured Sealant Water based paint MS sealant Silicone sealant

19 Types of Stone Staining Migration Staining Dirt Streaking Hydrophobic Staining MS Construction formulation Less Non Non MS Non-staining formulation Non Non Non Non-staining SR Non??? NG Normal SR NG NG NG

20 Mechanism of Dirt Streaking

21 Outdoor Staining Test Granite (Out door exposure for 6 years) MS SR SR* PS PU Artificial Marble (Out door exposure for 4 years) Remarks; SR* : One Part Type Others : Two part Type MS SR SR* PS

22 Sealants and Adhesives Multiple Applications

23 Industrial Multiple Applications

24 Coatings Multiple Applications

25 Multiple Applications Weather Barriers

26 Spray apply Multiple Applications

27 Panel bonding & flooring Multiple Applications

28 Multiple Applications Sealant (paint) Demonstrating good paintability

29 Multiple Applications Sealant (different substrate) Good for sealing different types of substrate

30 Marin use Multiple Applications

31 Conclusion: Construction MS strong points are resistance to movements, paintability, low risk of staining, weatherability, universal sealant and easy handling expansion and connection joints in the building industry. sealing of joints in prefabricated buildings. movement joints in high rise constructions. sealing between window- and doorframes. exposed movement joints on all usual building substrates

32 Conclusion: Industry MS strong points are primerless adhesion, solvent and isocyanate free, paintability, high hardness, early grab. structural bonding which require elasticity and high strength structural bonding in vibrating constructions elastic bonding of panels supple bonding in carbodies, caravans and containers, ship and boat building

33 Advantage of MS POLYMER Proven and trusted brand 40 years history with widespread application in the world Long term storage stability Excellent adhesion Low viscosity

34 Advantage of MS POLYMER Various properties with easy production process Many types of grades to prepare soft to rigid products For each practical application, no limitation to mix each other

35 KANEKA MS POLYMER TM CH 3 OSi - CH ( 3 - CH 2 CH O - )n - Si OCH 3 Unique polymer design by own polymerization Kaneka s polymer synthesis technology enables the best design for sealant and adhesive. No urethane bond MS POLYMER is non solvent and low viscosity, and does not contain urethane bond. Heat resistance and durability issues by degradation of urethane bond can never happen.

36 SiPU (Silyl terminated polyurethane) CH 3 OSi - - Si OCH 3 Silane Commercial Urethane coupling agent PPG Urethane Commercial PPG Urethane Silane coupling agent Most of silane modified polymers are silane terminated polyurethane structures, which are modifications of polyurethane technology. Therefore they have similar disadvantages to PU, such as heat resistance and durability.

37 SiPU (Silyl terminated polyurethane) The reactive silane group of most of SiPU polymers is an unstable type, which causes stability issue. Especially with water, viscosity increase and gelation issue can occur. Also this type of silane causes high modulus and low elongation. Catalyst for silane can accelerate degradation of urethane bond. Since SiPU has been in the market for only a short time, the impact of long time usage is unknown.

38 Viscosity of commercial SiPU polymers 23C Viscosity (Pa s) MS POLYMER SiPU S303H S203H S327 SAT010 SiPU1 SiPU2 SiPU Storage stability of commercial SiPU polymers Based on Kaneka formulation 1105 Before test 10rpm(Pa s) 50C 4weeks later 10rpm(Pa s) MS SiPU S303H SiPU1 SiPU2 SiPU

39 Mechanical properties of commercial SiPU polymers One of advantages of MS sealant is toughness. Most of SiPU polymers contain trimethoxysilane, which show high modulus and low elongation. In combination with aminosilane, the trend can be accelerated. Elongation (%) SiPU SiPU 100% Modulus(MPa)

40 Impact of aminesilane Reactivity of silane reaction Silane at MS Silane at SiPU Aminosilane O Si CH 3 OCH 3 OCH 3 O OCH 3 << O N Si OCH 3 = H 2 N H OCH 3 O C H 3 Si O C H 3 O C H 3 Reaction of aminosilane give a big impact to adhesive performance. In MS formulation, aminosilane can show excellent performance such as better adhesive property compared to the other similar technology as well as good storage stability. Since reactivity of silane at SiPU is similar to one of aminosilane, it might be difficult aminosilane can transfer to substrates. Also storage stability issue can happen.

41 Adhesive property of commercial SiPU polymers Hand peel test Based on Kaneka formulation 1105 MS POLYMER SPUR S303H SiPU1 SiPU2 SiPU3 Aluminum CF CF CF CF After 23C 7 days curing Stainless CF CF CF CF Glass CF CF CF CF PVC CF AF AF AF Aluminum CF AF CF CF After 50C 7 days under water Stainless CF CF CF AF Glass CF AF AF AF PVC CF AF AF AF

42 Heat stability of commercial SiPU sealants Commercial sealant MS SPUR MS1 SiPU1 SiPU2 SiPU3 100% Modulus (MPa) Before test Tensile strength (MPa) Elongation (%) After 80C 2 months After 90C 2 months 100% Modulus (MPa) Tensile strength (MPa) Elongation (%) % Modulus (MPa) Tensile strength (MPa) Elongation (%)

43 Heat stability of commercial SiPU sealants SiPU1 SiPU2 SiPU3 Decomposition of PU bond may occur

44 General properties in various Sealant MS (Modified Silicone) SR (Silicone) PU (Polyurethane) SPUR (Silyl-terminated Polyurethane) Durability (movement) Good Excellent Good - Mid Good - Mid UV resistance Good Excellent Good - Mid Good Adhesion property Excellent - good Excellent - good Good - Mid Good Heat resistance Good Excellent Middle Good - Mid Staining Good Poor Good Good Surface pollution Middle Poor Middle Good - Mid Paint ability Good Poor Good Good Cost Good - Mid Good Good Good - Mid Environmental Friendliness Good Middle (oxime) Middle Good - Mid MS has a good balance property, no poor property but no special (excellent) property MS can be used for a lot of application by formulation technology (Technical service)

45 Cross-linking of Acryl-Modified MS / SAT (MA) CH 3 (CH 3 O) 2 Si O CH 3 CH 3 CHCH 2 O Si(OCH 3 ) 2 n Hybrid R 1 R 1 CH 2 -C CH 2 -C C O R 2 O R 3 Si(OCH 3 ) x (CH 3 ) 3-x monomer Tg Mw Functional group MA/SAT Acryl Acryl H 3 C Si O Si CH 3 PPO CH 3 CH 3 Si O Si Acryl PPO O Si O Si CH 3 CH 3 Acryl CH 3 Si O Compatible (Transparent)

46 High Wetherability Sealants Thick Layer Thin Layer hv/h 2 O/heat Stabilizer hv/h 2 O/heat Stabilizer Chalking Filler etc. Blushing around joint of sidig-board Time(hour) until blushing on thin layer part(150μm) :SWM MS MA MS MA KNK#105formulation Time(hour) until cracks on surface (3mm) : SWM

47 Acryl-Modified SAT for Adhesive High Strength Universal Adhesion High Tack Adhesion Tensile Shear Strength SAT200 Normal MS CF AF MA440 Acryl modified Al ABS PC FRP Melami ne Acryl PCl CF10 AF90 CF70 AF30 CF AF AF CF KNK JK-199 Formulation CF10 CF90 CF40 CF CF AF90 AF10 AF60 CF: Cohesion Failure, AF: Adhesive Failure CF

48 Design of SAT / EPX system (for high strength) SAT To introduce high cohesive elements Solubility control EPX A-part SAT Polymer Hardening catalyst for Epoxy Compatibilizer (aminosilane) Cured STPE phase Cured Epoxy particle (+/ mm) TEM B-part Epoxy resin Hardening catalyst for SAT Compatible (Transparent) Hardening Tough elastomer Phase separation (Opaque)