Novel Vinyl Hybrid resin technology meet demanding performance and environmental requirements in Automotive
27Pages

Novel Vinyl Hybrid resin technology meet demanding performance and environmental requirements in Automotive Jim Bono JEC Paris, March 12th, 2014

Background • Advanced Material Market • Styrenated Systems are Unacceptable – Governmental Regulations – Control Technologies Needed – Minimize Capital Investment • Development Need for Reactive Diluent Free Thermoset Resin Systems – Cost Effective – Improved Dry/ Wet Tg – Improved Production Rates- approach 3 minute cycle

Nomenclature Styrene Free Resins Reactive Diluent Free Solids: “Pre-preg Monomer Free Hot Melt Vinyl Hybrids” Alternative Reactive Diluents Liquids: Reactive Oligomers “Vinyl Hybrid Liquid Resins” VT • Acrylates • Others

Chemistry Description: Vinyl Hybrids • ADVALITE™ – Monomer Free Hot Melts • ADVALITE™ – Vinyl Hybrid Liquid Resins

Application Overview Process Applications: • Infusion • RTM • Closed Mold • Filament Winding • Pultrusion Uses standard catalysts and initiators – processes the same as UPR and Vinyl Ester resins.

2014 Automotive Composite Floorboard Sandwich Construction: • Glass Mat/Plastic Foam Core • ADVALITE™ – Liquid Vinyl Hybrid Resin • Process: Liquid molding with heated steel tool

Composite Floorboards

Automotive Composite Floorboard Development Criteria for Floorboard: • New material and formulated resin development were needed • Minimal VOC emissions due to part placement under passenger compartment • Low Temperature curing process to maintain structure of polymeric core for weight reduction • ADVALITE™ vinyl hybrid resin reinforced with a coarse structural glass mat to form a final part

Comparison of Cast Resin Properties ADVALITETM Liquid Vinyl Hybrid Resins Property Flex Strength Flex Modulus Tensile Strength Tensile Modulus Tensile Elongation Heat Distortion Temperature Water Absorption 48 hours @ 100°C

GM 2014 Spark Electrical Vehicle Battery Tray • Electric Battery Tray Program – Component – Composite Battery Tray – – Prepreg by Cytec Molded by CSP – Produced using ADVALITE™ Vinyl Hybrid Hot Melt resin • with continuous fiberglass pre-preg • 30° off set barrier, side impact and rear barrier crash testing • Post crash package integrity • 3-meter drop test (bottom /end) • 1-meter water submersion test – Zero VOC Emissions off cured prepreg battery assembly

ADVALITE™ Vinyl Hybrid Prepreg Mechanical Properties of Fiberglass Prepreg Units ADVALITETM Composite Tensile Strength Tensile Modulus Short Beam Shear Flexural Strength Flexural Modulus Fiberglass Content

Automotive Market Evolution • Global OEM cycle plans call for light weighting vehicles. – BMW i3 Electric Vehicle Example • High fuel prices and CAFE increases necessitate lighter vehicles. • Market and regulation are merging into the same trend. • Current approach is through RTM. – OEMs looking for alternative solution – Current Method is an Epoxy RTM ADVALITETM Vinyl Hybrid Prepregs offer the opportunity for higher productivity rates and excellent mechanical properties. – The question remainsHow does one overcome the need for pre-preg automation?

Transportation Market Requirements • Automotive Market Needs: – – – – Fast cure: 2 minutes E-Coat Capable HDT: > 160 C. Automation Capable: Pre-preg Format Room Temperature Storage • ADVALITE™ can meet the market needs. Requirement Fast Cure HDT Pre-preg Storage Temp/Time

ADVALITE™ Vinyl Hybrid System Dielectric Cure Analysis Advalite™ Prepreg Composite Percent Cure-

Process Step Formation of Prepreg Input • ADVALITE™ Vinyl Hybrid Hot Melt Pre-Pregs – Impregnate fibers (woven/uni-directional) at elevated temperature with resin/initiator in liquid state – Cool to ambient temperature – resin is solid with adjustable tack at ambient – Long shelf life (> 1 year) at ambient Resin/Initiator Woven Fiber/ UD Carrier Film Heated Rollers Cooling Rolls

Automation Solutions: Tape/Pre-preg Lay-up Small Flat Tape Layer - added productivity and increased through-put – Hood inner reinforcement charge in an estimated 3 minutes – Net or Near Net Shape Cutting – Equipment Designed by Fives: JEC Booth S43 – Hall 7/2

Automation: Form and Cure Solution Continuous Fiber Form and Cure Prototype Line: Maximum Charge Dimension: 1.5 m x 2.1 m Equipment Supplier: FIVES - JEC Booth S43 – Hall 7/2 Forming Process Material Tension Cassette Hood Inner Indexing Conveyor

Continuous Fiber Inner

Pre-Preg Value Added Automotive OEM Weight Savings: • High Strength Steel: 7 – 10% • Aluminum: 30 – 50% • Cast Magnesium: 50 – 60% • SMC: 10 – 25% • Carbon Fiber (Epoxy RTM): 40 – 70% • ADVALITE™/FG Pre-Preg: 45 – 55%

Mechanical Properties Goal: Meet or Exceed Epoxy Performance Mechanical Property Comparison (0/90 Fabrics) Property Fiber Fraction Tensile Strength (Max Load) • Same glass type and supplier • Epoxy – Bis A system

ADVALITE™ Vinyl Hybrid Hot Melt Resins Clear Cast Properties Property Flexural Strength Flexural Modulus Tensile Strength Tensile Modulus Water Absorption

Glass Transition Temperature Comparisons Vinyl Hybrid Resin Systems- Liquid and Prepreg Applications ADVALITE™ Vinyl Hybrid Hot Melt Resin Systems ADVALITE™ Vinyl Hybrid Liquid Resin Systems 35065-00

Value Added Versus Epoxy Competitive Advantages vs. Epoxy: – Hot/Wet Tg: Traditional Epoxy Systems absorbs more water in comparison to Vinyl Hybrid Systems. – Cure Flexibility: Vinyl Hybrids use standard initiator/inhibitor packages that allow flexibility in gel and cure. – Faster Cure: ADVALITE™ exotherms significantly less than epoxy allowing faster curing of thick laminates. – Robust Stoichiometry: Two component epoxies can be sensitive to mix ratio vs. free radical cure. – Head space analysis: No off-gassing for monomer free hot melts. – Material Storage Conditions/ Shelf Life: For...