wim van de velde
TRANSCRIPT
Wim Van de Velde, Director of Marketing, Plastic Additives
May 2014, Wards Interior Automotive
conference, Dearborn,MI
Light Weight Automotive TPOs with
Improved Aesthetics, an additive
approach
1
©2013 Milliken & Company
Confidential
Agenda
• Milliken & Company
• Hyperform®HPR-803i:
What is it?
How does it perform?
Commercial interior case studies
2
©2012 Milliken, Private & Confidential
Milliken & Company
3
©2014 Milliken & Company
Confidential
Milliken & Company
H
H Headquarter
Technical center
• Founded in 1865. Headquartered in
Spartanburg, SC, USA
• 7,000+ associates
• Global presence- 45 facilities around
the world
Technical Innovation
• Community of
innovators
• More than 5.000
patents
©2014 Milliken & Company
Confidential
Milliken & Company
Floor CoveringBeautifying offices, hotels, airports,
homes, and commercial
environments around the world
Performance MaterialsCustom-engineered textiles for a variety of
industrial markets including automotive
(hoses, airbags, interlinings, tires)
Apparel & Specialty FabricsFabrics for industrial applications
such as healthcare, hospitality,
table linens, office interiors, labels,
and much more
Performance SolutionsAssisting organizations to become safer and
more competitive in the marketplace
©2014 Milliken & Company
Confidential
Milliken Chemical: innovation
Silicone chemistry
Performance plastic
additives
Polymeric bound
chemistry
Silicone
Performance plastic additives
R & D projects
Colorants for Clear PPColorants for PU
Colorants for detergents
Hyperform HPN
Nucleating agentMillad NX 8000 Clarifying agent
Hyperform HPR
Reinforcing agent
Stiffness/impact balance
Scratch resistance
Crystallization speed
Crystallization orientation
Barrier
Opticals
©2012 Milliken, Private & Confidential
Hyperform®HPR-803i: what is it?
7
©2013 Milliken & Company
Confidential 8
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.
©2012 Milliken, Private & Confidential
Hyperform®HPR-803i: how does it
perform?
9
©2013 Milliken & Company
Confidential
Easy-to-implement reinforcing technology
10
Hyperform HPR-803i reinforced PP
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
Confidential
Different filler types for PP with class A surface finish
11
Reinforcing efficiency
Modulu
s
Filler loading
Molders and compounders can realize high-performance, reduced density materials and parts
with HPR-803i in filled PP and TPO applications
Ratio Exposed
Surface / Volumex 2x 3,5
Hyperform
HPR 803i
Calcium-
carbonate
Fine talcs
Coarse talcs
TalcCaCO3
©2013 Milliken & Company
Confidential
Using HPR-803i hybrids for interior and exterior parts
12
Weight and density reduction
Talc filled
Part density > 1.0 Kg/dm3
HPR-803i hybrid
Part density
between 0.95 and 0.99 Kg/dm3
©2013 Milliken & Company
Confidential
Lower compound viscosity enables easier processing
290
300
310
320
330
340
350
360
20% Talc 13% HPR-803i/talc
9% HPR-803i/talc 7% HPR-803i
Filling length
(m
m)
Flow length
Flow length
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Ease of processing
Higher weld line
strengthFaster cycle time
Lower extrusion
temperature
Easier filling of
the mold
Spiral flow sample( = injection point)
©2013 Milliken & Company
Confidential
Reducing the filler content and a harder surface result in better scratch
14
Scratch resistance
2.27
3.62
1.17
1.53
0
1
2
3
4
5
6
7
Fine grain (VW K31) Coarse grain (VW K3A)
Delt
a L
valu
e
10N Erichsen scratch
15% Talc 6% HPR-803i
Talc HPR-803i Talc HPR-803i
©2013 Milliken & Company
Confidential
Applications for HPR-803i containing PP compounds
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Hyperform®HPR-803i
©2012 Milliken, Private & Confidential
Commercial interior case studies
16
©2012 Milliken, Private & Confidential
Lightweighting & foaming
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©2014 Milliken & Company
Confidential
Lightweight foamed parts
Case Study – foamed parts
Engine cover - typical
foamed application
Challenge – evaluate the performance of
Hyperform® HPR-803i in chemical and mechanical
(gas inject) foaming applications
Mechanical foaming material – 20% 2µ talc filled
Chemical foaming material – 20% 1µ talc filled
Reduce part weight
Evaluate stiffness
Evaluate impact
Targ
ets
©2014 Milliken & Company
Confidential
Lightweight Foam Technology
19
Case Study – foamed parts
Mechanical Foam
N2 or CO2 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
Special equipment
incorporates the gas
into polymer
Chemical foaming
agent added to polymer
Chemical Foam
©2014 Milliken & Company
Confidential
Mechanical foaming
20
Case Study – foamed parts
12%
3%
0%
2%
4%
6%
8%
10%
12%
14%
Talc HPR-803iSti
ffness
loss
wit
h f
oam
ing
45.4
41.3
52.9
47.249.9
44.948.5
43.9
0
10
20
30
40
50
60
Un-foamed Foamed
Part
weig
ht
(g)
No f
ille
r
20% t
alc
fille
d
10% t
alc
+ 3
% H
PR
10% H
PR-8
03i
No f
ille
r
20% t
alc
fille
d
10% t
alc
+ 3
% H
PR
10% H
PR-8
03i
11% 7%
Materials: 35 mfr impact coploymer, 2µ talc
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
©2014 Milliken & Company
Confidential
Chemical foaming
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Case Study
13%
4%
0%
2%
4%
6%
8%
10%
12%
14%
Talc HPR-803iSti
ffness
loss
wit
h f
oam
ing
215
185
245
215230
205
225
195
0
50
100
150
200
250
300
Un-foamed Foamed
Part
weig
ht
(g)
No f
ille
r
20% t
alc
fille
d
10% t
alc
+ 3
% H
PR
10% H
PR-8
03i
No f
ille
r
20% t
alc
fille
d
10% t
alc
+ 3
% H
PR
10% H
PR-8
03i
12% 9%
Materials: 18 mfr medium impact coploymer, 2µ talc
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
©2014 Milliken & Company
Confidential
Foaming and Impact Strenght
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Case Study
32%
25%
0%
5%
10%
15%
20%
25%
30%
35%
Talc HPR-803i
Impact
loss
wit
h f
oam
ing
Materials: 18 mfr medium ICP, 1µ talc
84%
52%
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
Talc HPR-803i
Impact
loss
wit
h f
oam
ing
Multi-Axial Impact, 23°C, 2.2 m/s Notched Charpy impact , 23°C
Materials: 35 mfr impact coploymer, 2µ talc
Mechanical Foam Chemical Foam
Foaming is known to negatively affect impact
strength. However in some interior
applications this is not of major concern.
©2014 Milliken & Company
Confidential
Outcome
23
Case Study - foaming
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
Targ
ets
Part weight reduced ~8%
Stiffness & impact requirement met
©2012 Milliken, Private & Confidential
Decreasing Weight, Increasing Recycled
PP, and Improving Scratch Resistance
24
Luxus/Nissan Case Study
©2013 Milliken & Company
Confidential 25
The Strength of Partnership
• Development of PP compounds containing new reinforcing agent
• Validation of the PP compounds and trims
• Reinforcing fiber supplier
©2013 Milliken & Company
Confidential 26
PP Weight Reduction and Recycled Content
258 278
226232
16157
0
100
200
300
400
500
600
700
Talc Talc/HPR Hybrid
We
igh
t (g
)
Molded Part component split (g)
Filler
Virgin PP & Additives
Recycled PP 40
49
35
41
25
10
0
10
20
30
40
50
60
70
80
90
100
Talc Talc/HPR Hybrid
(%)
Material recipe component split (% in weight)
12% lighter part combined with increased recycled PP content
645 g 568 g
-77g 12% weight reduction
9 % increased recycled PP
©2013 Milliken & Company
Confidential 27
Luxus TDS – Door panel application
12% weight reduction
©2013 Milliken & Company
Confidential 28
Scratch Resistance
Improved scratch resistance AND higher recycled PP
HPR/Talc
Talc
5.80
1.4
0.0
1.0
2.0
3.0
4.0
5.0
6.0
7.0
25% Talc Talc-HPR
Delt
a L
valu
e
10N Erichsen scratch
©2013 Milliken & Company
Confidential 29
Dimensional Properties
New compound on existing moulds :
Dimensions within specifications
©2012 Milliken, Private & Confidential
Weight Reduction & Scratch Resistance
Improvement
30
Grupo Antolin Door Panel Case Study
©2013 Milliken & Company
Confidential
Doorpanel Grupo Antolin
Case study HPR-803i
429
403
390
395
400
405
410
415
420
425
430
435
16 % Talc 9 % mineral filler (HPR/Talchybrid)
Weig
ht
(g)
Weight reduction
0.5
0.8
0.4 0.4
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
Fine grain (K31) Coarse grain (K3A)
Delt
a L
Scratch resistance16 % Talc 9 % mineral filler (HPR/Talc hybrid)
Polypropylene compound with Hyperform HPR-803i
enables 6% weight reduction and scratch improvement
©2013 Milliken & Company
Confidential
Doorpanel Grupo Antolin
Case study HPR-803i
Polypropylene compound with Hyperform HPR-803i
enables 6% weight reduction and CO2 emission reduction
Wei
ght
Red
uct
ion • 52 g saved per car
for 2 rear doors
• 7,8 tons/y lessmaterial (1)
C0
2 e
mis
sio
n r
edu
ctio
n • 462 g CO2/car saved
• 111 tons CO2/y saved(2)
(1) For production of 150.000 cars/year
(2) Average single car mileage of 30.000 km per car
©2012 Milliken, Private & Confidential
Lighter weight, improved scratch,
reduced color, improved flow, and
improved weld strength compound
33
Inno-Comp Case Study
©2013 Milliken & Company
Confidential
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
Compound reformulation
34
Case study on HPR-803i
Stiffness = meets OEM specs
Impact = meets OEM specs
Density = >1.0 g/cc
281
262
230
250
270
290
20% Talc 13% mineral filler(HPR/Talc Hybrid)
Weig
ht
(g)
0
20
40
60
80
100
20% talc 13% mineral filler(HPR/Talc Hybrid)C
om
posi
tion b
y w
eig
ht,
%
PP Total filler
©2013 Milliken & Company
Confidential 35
Inno-Comp TDS – Application in B-pillar
7% weight reduction
©2013 Milliken & Company
Confidential
Using HPR-803i hybrids for interior and exterior parts
36
Weight and density reduction
Talc filled
Part density > 1.0 Kg/dm3
HPR-803i hybrid
Part density
between 0.95 and 0.99 Kg/dm3
Thank you! Questions?
3
7
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