for Multifunctional Plastics

Transcription

1 Carbon Nanostructure Enhanced Reinforcements for Multifunctional Plastics November 22nd, 2012 Philippe Pardo INNOV DAYS _ Dijon(France) LES NANOMATERIAUX EN PLASTURGIE

2 Owens Corning at a Glance Founded in sales: $5.3 billion 15,000 employees in 28 countries FORTUNE 500 company for 58 consecutive years NYSE: OC Component of the Dow Jones Sustainability World Index Global Leader Composites Glass Fiber Reinforcements Engineered Solutions Leading North American Market Positions Residential Insulation Commercial & Industrial Insulation Residential Shingles Roofing Asphalts 11/16 2

3 EMC Thermoplastic Applications Carbon Enhanced Reinforcements (CER) Ruslan Ivantsov / shutterstock.com Consumer Electronic emel82 / shutterstock.com Maksim Toome / shutterstock.com Minerva Studio / shutterstock.com Automotive Electronics Industrial Controls ATEX (explosive All other electronics environment) Tablet PCs Laptops Cameras Cellular phones Handheld devices Panels PLCs Sensors Transformers Power supplies Navigation systems Bluetooth modules Engine controls Electric vehicle battery housing Wire harness assembles Production equipment for fuel Mining Oil, chemical, construction industries Aerospace Medical equipment Military electronics Semiconductor manufacturing CER provides an effective EMI/ESD solution for a wide range of products 3

4 Conductive Thermoplastics Application Drivers and Needs Drivers Increased electronics use, circuit density and processor speed Expansion of wireless communication methods, frequencies, and availability Enhanced electronics in automobiles and appliances Light weighting Part consolidation Needs Reduce signal propagation and cross talk Aesthetics (design freedom and appearance) Thermal management System cost reduction Metal replacement 4

5 Our Solution Carbon Enhanced Reinforcements Carbon Enhanced Reinforcements (CER) Carbon structures grown directly onto glass or carbon fibers in a continuous, in-line production process Takes advantage of Owens Corning s strength in glass fiber technology Proprietary technologydeveloped in conjunction with Applied NanoStructured Solutions LLC, a Lockheed Martin company A new class of conductive additive providing the following enhanced attributes: Electrical conductivity (EMI/RFI, Anti static) Mechanical properties CER Chopped Strand Glass Fiber Roving CER Roving Pre Manufacturing Notice from the American Environment Protection Agency_EPA Eng.PlastCER reinf. Cell phone bodies with CER 11/16 5

6 Carbon Enhanced Reinforcement (CER) Product Forms with Multifunctional Properties Product Forms CER thermoplastic pellets Fiber tow and chopped fiber Tunable Properties Physical Density, thickness Mechanical Toughness, isotropy Thermal Control heat stability and conductivity Electrical Shielding, storing, directing, absorbing Durability Corrosion, wear, fatigue resistance Product forms provided per customer requirements 6

7 What is CER? CNS grown on fiber As manufactured glass fiber spool (left) CER glass fiber spool (right) As manufactured carbon fiber spool (left) CER carbon fiber spool (right) CNS grown directly on fiber surfaces of tow a continuous, production scalable process for glass or carbon fiber 7

8 SEM Analysis of CER Hybrid Fibers CNS on Glass Fiber Surface CNS branched and entangled network delivers a built-in percolated structure 8

9 TGA and Raman Analysis of CER CNS Composition Thermogravimetric Analysis Raman Spectrum Analysis Infused CER CNS CNTs Infused CER CNS CNTs CNS characterization show favorable quality assessment 9

10 Conductivity Basis Conductivity Classification by Surface Resistance Isolating Antistatic Dissipative Conductive Plastics ohms/sq & up ohms/sq ohms/sq ohms/sq ohms/sq EMI Products ohms/sq Metal ohms/sq Housing for electronic products are often made with engineering plastics. However plastics are known to be isolator, thus a major issue for applications requiring EMI Shielding effectiveness. Filling the engineering plastics with a small volume fraction of conductive fillers, can overcome the above hurdle,and allow the keep traditional plastics manufacturing technology to make components enclosure. Well known conductive fillers are Carbon Black, Carbon fibers, Nickel Coated fibers, Stainless Steel fiber, and CNT. CER is part of new Nano Technology for conductive fillers providing outstanding electrical conductive performances, and system cost reduction. 10

11 CER Volume Resistivity in PC/ABS Percolation at low CNS loading 1,00E+14 1,00E+12 Volume Resistivity (Ω*cm) 1,00E+10 1,00E+08 1,00E+06 1,00E+04 1,00E+02 1,00E+00 1,00E Conductive Filler (%) CNS SSF* CB* CF* CNT* CER is a more efficient conductive reinforcement 11 *Ref: Li, et.al. Nano Letters 6 (2006)

12 Electrical Percolation of CER CNS Dispersion and Concentration Dependent 1.E+14 1.E+12 CER Resistivity (ohm*cm) 1.E+10 1.E+08 1.E+06 1.E+04 1.E+02 1.E+00 1.E % CNS (wt.%) CNS Glass Fiber *Test method: ASTM D257 silver paint method for values up to 1x10 2 ohm*cm and concentric ring method for values above 1x10 6 ohm*cm PA-6,6 PC/ABS Percolation in PC, PC/ABS, PP at ~0.8 wt% CNS and ~2.5 wt% CNS in PA-6,6 PP PC CER wt% CNS wt% Glass Fiber % % % Weight % in polymer 12

13 Goal Keep unwanted electrical signals either in or out Electromagnetic Shielding (EMI) Basics EMI Shielding Results by Thickness Shield Shield Electronic circuits must be protected from other devices, as well as encased to limit Electromagnetic Interference (EMI) emissions. Electronic Device Antenna Antenna Electronic Device EMI shields greatly reduce the strength of the EM waves using two mechanisms : Reflection Absorption SE = R + A + db db db M db Reflection Absorption Multiple Reflections 13

14 EMI Shielding Effectiveness of CER Concentration Dependent Shielding Effectiveness (db) PC/ABS PP PC PA-6, CER Loading (wt.%) *EMI Shielding per ASTM D4935. Values reported at 1.5 GHz for 3 mm thick injection molded plates. EMI Shielding at concentrations above the CNS percolation threshold 14

15 EMI Shielding Effectiveness of CER Polymer Dependent Shielding Effectiveness (db) Frequency (GHz) PP PC/ABS PC PA66 *EMI Shielding per ASTM D4935. Samples were 3mm thick. EMI Shielding up to 65 db at 1.5 GHz for 3mm thick plate with 30 wt% CER 15

16 EMI Shielding Effectiveness of CER Frequency Dependent 120 EMI Shielding Effectiveness (db) % CER in PC/ABS 15% NiCF in PC/ABS Aluminum Frequency (GHz) *EMI Shielding per SAE IEEE 299 samples were 3mm thick. CER EMI Shielding increases at higher frequency 16

17 Thermal Conductivity of CER Polymer and Concentration Dependent 0.6 Thermal Conductivity (W/mK) PA-6,6 PC/ABS PC PP CER Loading (wt.%) *Thermal conductivity per ASTM E1530 measured perpendicular to the flow. Thermal conductivity is higher for the semi-crystalline PA-6,6 17

18 Mechanical Properties of CER Injection Molded Coupon Properties Mechanical Property PC/ABS - neat 30 wt% CER PC/ABS Tensile Strength, MPa Tensile Modulus, GPa Tensile Strain, % Flexural Strength, MPa Flexural Modulus, GPa Mechanical property trends are similar to fiber reinforcements: Increased strength and modulus with a decrease in strain to failure 18

19 Injection Molded Properties of CER Multiple Source Testing Property (in PC/ABS) Units Typical Range Test Standard CER Weight Content % ASTM D792 CNS Weight Content % ASTM D792 Specific Gravity ASTM D792 Tensile Strength MPa ASTM D638 Tensile Modulus GPa ASTM D638 Flexural Strength MPa ASTM D790 Flexural Modulus GPa ASTM D790 Un-notched Izod Impact kj/m ASTM D4812 Notched Izod Impact kj/m ASTM D256 Heat Distortion Temperature 0 C ASTM D648 Coefficient Thermal Expansion 10-6 / 0 C ASTM E228 Thermal Conductivity normal to flow W/m.K ASTM E1530 Mold Shrinkage parallel to flow % ASTM D955 Flammability for 3.1mm V0 UL 94 Surface Resistance Ohm ASTM D257 EMI Shielding at 1 GHz for 3.1mm db ASTM D

20 New Enabler for Advanced EMC Designs Carbon Enhanced Reinforcements (CER) A Lightweight Solution! Form a Faraday cage throughout the part for EMI shielding Higher modulus for effective design of complex part sections Metal-like shielding effectiveness Availability and Consistency! Continuous, modular process scalable to meet customer demands Offer better dispersion and process ability than other carbon nano-forms Validated performance using existing process equipment An Affordable Solution! Improve manufacturing yields and costs by eliminating secondary coating operations Enable part consolidation Provide excellent electrical, mechanical and cost performance versus competing conductive materials Enable reduced design and system cost EDHAR / shutterstock.com 20

21 Thank You! Questions? Carbon Enhanced Reinforcements (CER) A New Multifunctional Reinforcements for Today s EMC Applications Contact Information: philippe.pardo@owenscorning.com CER@owenscorning.com 21