Light Weight Automotive TPOs with Improved Aesthetics, an additive approach Wim Van de Velde, Director of Marketing, Plastic Additives May 2014, Wards Interior Automotive conference, Dearborn,MI 1
Agenda Milliken & Company Hyperform HPR-803i: What is it? How does it perform? Commercial interior case studies 2013 Milliken & Company 2
Milliken & Company 3 2012 Milliken, Private &
Milliken & Company Founded in 1865. Headquartered in Spartanburg, SC, USA 7,000+ associates Global presence- 45 facilities around the world H Technical Innovation Community of innovators More than 5.000 patents H Headquarter Technical center 2014 Milliken & Company
Milliken & Company Performance Materials Custom-engineered textiles for a variety of industrial markets including automotive (hoses, airbags, interlinings, tires) Apparel & Specialty Fabrics Fabrics for industrial applications such as healthcare, hospitality, table linens, office interiors, labels, and much more Floor Covering Beautifying offices, hotels, airports, homes, and commercial environments around the world 2014 Milliken & Company Performance Solutions Assisting organizations to become safer and more competitive in the marketplace
Milliken Chemical: innovation Colorants for Clear PP Colorants for PU Silicone Polymeric bound chemistry Silicone chemistry Colorants for detergents Performance plastic additives Hyperform HPR Reinforcing agent Millad NX 8000 Clarifying agent Performance plastic additives R & D projects Hyperform HPN Nucleating agent Stiffness/impact balance Crystallization speed Barrier Scratch resistance Crystallization orientation 2014 Milliken & Company Opticals
Hyperform HPR-803i: what is it? 7 2012 Milliken, Private &
HPR-803i Technology Reinforcing Agent for Automotive PP Compounds HPR offers a drop-in solution for OEM s to light weight vehicle PP; low-cost, low-hanging fruit solution. Brings additional scratch resistance and colorability value. Hyperform HPR-803i is a synthetic mineral-based reinforcing additive Fiber length = 20 microns Fiber diameter = 0.5 micron Mohs hardness = 2.5 (Talc = 1.0 ; glass fiber = 6 to 7) Density = 2.3 (Talc = 2.7; glass fiber = 2.6) Testing performed in 35MFR interior grade Medium impact copolymer. 2013 Milliken & Company 8
Hyperform HPR-803i: how does it perform? 9 2012 Milliken, Private &
Hyperform HPR-803i reinforced PP Easy-to-implement reinforcing technology HPR-803i in the Market 5 to 15 % Weight reduction Scratch improvement Runs on conventional IM equipment Easier to process compounds Recycled PP performance booster Meeting increasing lightweight demands in automotive 2013 Milliken & Company 10
Reinforcing efficiency Modulus Different filler types for PP with class A surface finish Fine talcs Coarse talcs Calciumcarbonate Hyperform HPR 803i Talc CaCO3 Filler loading Ratio Exposed Surface / Volume x 3,5 x 2 Molders and compounders can realize high-performance, reduced density materials and parts with HPR-803i in filled PP and TPO applications 2013 Milliken & Company 11
Weight and density reduction Using HPR-803i hybrids for interior and exterior parts HPR-803i hybrid Talc filled Part density between 0.95 and 0.99 Kg/dm3 Part density > 1.0 Kg/dm3 2013 Milliken & Company 12
Ease of processing Filling length (mm) Lower compound viscosity enables easier processing 360 Flow length 350 Spiral flow sample ( = injection point) 340 330 320 310 300 290 20% Talc 13% HPR- 803i/talc Flow length 9% HPR-803i/talc 7% HPR-803i Higher weld line strength Faster cycle time Lower extrusion temperature Easier filling of the mold 2013 Milliken & Company 13
Delta L value Scratch resistance Reducing the filler content and a harder surface result in better scratch 7 10N Erichsen scratch 6 5 Talc HPR-803i Talc HPR-803i 4 3.62 3 2 1 2.27 1.17 1.53 0 Fine grain (VW K31) 15% Talc 6% HPR-803i Coarse grain (VW K3A) 2013 Milliken & Company 14
Hyperform HPR-803i Applications for HPR-803i containing PP compounds 2013 Milliken & Company 15
Commercial interior case studies 16 2012 Milliken, Private &
Lightweighting & foaming 17 2012 Milliken, Private &
Case Study foamed parts Lightweight foamed parts Challenge evaluate the performance of Hyperform HPR-803i in chemical and mechanical (gas inject) foaming applications Engine cover - typical foamed application Mechanical foaming material 20% 2µ talc filled Chemical foaming material 20% 1µ talc filled Reduce part weight Evaluate stiffness Evaluate impact Targets 2014 Milliken & Company
Case Study foamed parts Lightweight Foam Technology Mechanical Foam Chemical Foam Special equipment incorporates the gas into polymer Chemical foaming agent added to polymer N 2 or CO 2 added to polymer Creates small, uniform voids Gas displaces polymer Equipment changes necessary Foaming agent added to polymer Creates small, uniform voids Gas displaces polymer May leave residual chemicals 2014 Milliken & Company 19
Part weight (g) Case Study foamed parts No filler 20% talc filled 10% talc + 3% HPR 10% HPR-803i No filler 20% talc filled 10% talc + 3% HPR 10% HPR-803i Stiffness loss with foaming Mechanical foaming Gas foaming allowed for 11% weight reduction over control, and HPR-803i allows another 7% weight reduction over talc HPR-803i maintains higher stiffness than talc 60 11% 7% 14% 50 40 30 20 45.4 52.9 49.9 48.5 41.3 47.2 44.9 43.9 12% 10% 8% 6% 4% 12% 10 2% 3% 0 Un-foamed Foamed 0% Talc HPR-803i Materials: 35 mfr impact coploymer, 2µ talc 2014 Milliken & Company 20
Part weight (g) Case Study No filler 20% talc filled 10% talc + 3% HPR 10% HPR-803i No filler 20% talc filled 10% talc + 3% HPR 10% HPR-803i Stiffness loss with foaming Chemical foaming Chemical foaming allows for 12% weight reduction over control, and HPR-803i allows another 9% weight reduction over talc HPR-803i maintains higher stiffness than talc 300 12% 9% 14% 250 200 150 100 50 215 245 230 225 185 215 205 195 12% 10% 8% 6% 4% 2% 13% 4% 0 Un-foamed Foamed 0% Talc HPR-803i Materials: 18 mfr medium impact coploymer, 2µ talc 2014 Milliken & Company 21
Case Study Impact loss with foaming Impact loss with foaming Foaming and Impact Strenght Mechanical Foam Chemical Foam 90% 80% 70% 60% 50% 40% 30% 20% 10% 0% 2014 Milliken & Company 84% Talc 52% 35% 30% 25% 20% 5% 0% 32% Foaming is known to negatively affect 15% impact strength. However in some interior applications this is not of major 10% concern. HPR-803i Talc 25% HPR-803i Multi-Axial Impact, 23 C, 2.2 m/s Notched Charpy impact, 23 C Materials: 35 mfr impact coploymer, 2µ talc Materials: 18 mfr medium ICP, 1µ talc 22
Case Study - foaming Outcome Hyperform HPR-803i allowed for additional weight reduction with reduced filler content and lower density More tests needed to understand the effect of HPR- 803i particle size on the formation of foam structure using either technologies Part weight reduced ~8% Stiffness & impact requirement met Targets 2014 Milliken & Company 23
Decreasing Weight, Increasing Recycled PP, and Improving Scratch Resistance Luxus/Nissan Case Study 24 2012 Milliken, Private &
The Strength of Partnership Development of PP compounds containing new reinforcing agent Reinforcing fiber supplier Validation of the PP compounds and trims 2013 Milliken & Company 25
PP Weight Reduction and Recycled Content Weight (g) (%) 700 600 500 Molded Part component split (g) 645 g 568 g -77g 12% weight reduction 161 57 100 90 80 70 Material recipe component split (% in weight) 25 10 41 60 400 232 35 226 50 300 200 100 258 278 40 Filler Virgin PP & Additives Recycled PP 30 20 40 10 9 % increased recycled PP 49 0 Talc Talc/HPR Hybrid 0 Talc Talc/HPR Hybrid 12% lighter part combined with increased recycled PP content 2013 Milliken & Company 26
Luxus TDS Door panel application 12% weight reduction 2013 Milliken & Company 27
Delta L value Scratch Resistance 7.0 10N Erichsen scratch 6.0 5.80 5.0 4.0 3.0 HPR/Talc 2.0 1.4 1.0 0.0 25% Talc Talc-HPR Improved scratch resistance AND higher recycled PP Talc 2013 Milliken & Company 28
Dimensional Properties New compound on existing moulds : Dimensions within specifications 2013 Milliken & Company 29
Weight Reduction & Scratch Resistance Improvement Grupo Antolin Door Panel Case Study 30 2012 Milliken, Private &
Case study HPR-803i Delta L Weight (g) Doorpanel Grupo Antolin 0.9 0.8 0.7 0.6 0.5 0.4 0.3 0.2 0.1 0 435 430 425 420 415 410 405 400 395 390 Weight reduction 0.5 429 403 16 % Talc 9 % mineral filler (HPR/Talc hybrid) Scratch resistance 16 % Talc 9 % mineral filler (HPR/Talc hybrid) Fine grain (K31) 0.8 0.4 0.4 Coarse grain (K3A) Polypropylene compound with Hyperform HPR-803i enables 6% weight reduction and scratch improvement 2013 Milliken & Company
Case study HPR-803i Weight Reduction C02 emission reduction Doorpanel Grupo Antolin 52 g saved per car for 2 rear doors 462 g CO 2 /car saved 7,8 tons/y less material ( 1 ) 111 tons CO 2 /y saved( 2 ) (1) For production of 150.000 cars/year (2) Average single car mileage of 30.000 km per car Polypropylene compound with Hyperform HPR-803i enables 6% weight reduction and CO 2 emission reduction 2013 Milliken & Company
Lighter weight, improved scratch, reduced color, improved flow, and improved weld strength compound Inno-Comp Case Study 33 2012 Milliken, Private &
Composition by weight, % Case study on HPR-803i Weight (g) Compound reformulation 100 80 60 290 270 281 40 20 250 262 0 20% talc 13% mineral filler (HPR/Talc Hybrid) 230 20% Talc 13% mineral filler (HPR/Talc Hybrid) PP Total filler Stiffness = meets OEM specs Impact = meets OEM specs Density = >1.0 g/cc Stiffness = meets OEM specs Impact = meets OEM specs Density = <1.0 g/cc OEMs get lightweight parts Improved scratch performance Reduced color loading Improved flow properties Improved weld-line strength 2013 Milliken & Company 34
Inno-Comp TDS Application in B-pillar 7% weight reduction 2013 Milliken & Company 35
Weight and density reduction Using HPR-803i hybrids for interior and exterior parts HPR-803i hybrid Talc filled Part density between 0.95 and 0.99 Kg/dm3 Part density > 1.0 Kg/dm3 2013 Milliken & Company 36
3 Thank you! Questions? Wim Van de Velde Marketing Director, Plastic Additives Milliken & Company 920 Milliken Road M-209 Spartanburg,SC 29303 T +1 864 503 6047 / C +1 864 680 7064 wim.vandevelde@milliken.com