QUESTRA Auto Presentation 12 99

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Information about QUESTRA Auto Presentation 12 99
Education

Published on January 11, 2008

Author: Raulo

Source: authorstream.com

Slide1:  MEH 4/98 * Trademark of The Dow Chemical Company Automotive Applications Introduction:  Introduction What are QUESTRA Crystalline Polymers Where are QUESTRA Crystalline Polymers manufactured Why are QUESTRA Crystalline Polymers exceptional How performance can meet design requirements with QUESTRA Crystalline Polymers What are QUESTRACrystalline Polymers?:  What are QUESTRACrystalline Polymers? QUESTRA Crystalline Polymers are: a new family of semi-crystalline engineering thermoplastics polymerized from styrene monomer using a metallocene catalyst system in a new polymerization process. QUESTRA Crystalline Polymers Chemistry:  • Syndiotactic Polystyrene Molecular Structure  Atactic (Random)         Syndiotactic (Ordered) • Semi-Crystalline Morphology QUESTRA Crystalline Polymers Chemistry Crystalline Region Amorphous Region Manufacturing Facilities for QUESTRA Crystalline Polymers:  Manufacturing Facilities for QUESTRA Crystalline Polymers Polymer Commercial Plant -4th Quarter 1999 in Leipzig, Germany with capacity to produce 80MM lbs/year (37,000 MT) of neat polymer Compounding DH Compounding – Clinton, TN Terneuzen - The Netherlands Materials QUESTRA Competes With...:  Materials QUESTRA Competes With... Glass Reinforced Polyphenylene Sulfide (PPS) Ryton (Philips) Fortron (Ticona) Glass Reinforced Polybutylene Terephthalate (PBT) Valox (GE) Celanex (Ticona) Pocan (Bayer) Arnite (DSM) Glass Reinforced Polyethylene Terephthalate (PET) Rynite Glass Reinforced PA 6,6 Zytel (Dupont) Akulon (DSM) Materials QUESTRA Competes With (continued):  Materials QUESTRA Competes With (continued) Glass Reinforced Polyphthalamide (PPA) Amodel (Amoco) HTN (Dupont) Glass Reinforced PA 4,6 Stanyl (DSM) Glass Reinforced LCP Zydar (Amoco) Vectra (Ticona) Zenite (Dupont) QUESTRA Crystalline Polymers for Automotive Applications:  QUESTRA Crystalline Polymers for Automotive Applications Why are QUESTRA Crystalline Polymers Unique:  Why are QUESTRA Crystalline Polymers Unique A Combination of: High Heat Performance Excellent Processability Excellent Dimensional Stability Excellent Electrical Properties Comparable Mold Shrinkage Low Specific Gravity QUESTRA Crystalline Polymers - Harnessing the Heat Performance :  QUESTRA Crystalline Polymers - Harnessing the Heat Performance Unfilled QUESTRA: Glass Reinforced QUESTRA: Crystalline Region Amorphous Region Crystalline Region Amorphous Region Glass Fiber QUESTRA Crystalline Polymers - Melting Point Comparison:  QUESTRA Crystalline Polymers - Melting Point Comparison 310 280 270 255 245 230 127 88 100 50 52 52 IR-Reflow Study Conducted by Dow:  IR-Reflow Study Conducted by Dow Heat Distortion of High Temperature Automotive Materials:  Heat Distortion of High Temperature Automotive Materials QUESTRA WA 552 30% GF PCT 30% GF PPA 40% GF PPS 30% GF LCP Heat Distortion Temperature (C) QUESTRA WA 206 Heat Distortion Temperature (F) Heat Distortion Temperature of Moderate Heat Automotive Materials:  Heat Distortion Temperature of Moderate Heat Automotive Materials DTUL (°F) at 264 psi HDT (°C) at 1.8 MPa 230 220 210 200 190 180 QUESTRA WA 208 30% GF PBT #1 30% GF PBT #2 30% GF PBT #3 QUESTRA WA 204 Heat Distortion Temperature of Moderate Heat Automotive Materials:  Heat Distortion Temperature of Moderate Heat Automotive Materials DTUL (°F) at 66 psi HDT (°C) at 0.45 MPa 260 250 240 230 220 210 QUESTRA WA 208 30% GF PBT #1 30% GF PBT #2 30% GF PBT #3 QUESTRA WA 204 Why are QUESTRA Crystalline Polymers Unique:  Why are QUESTRA Crystalline Polymers Unique A Combination of: High Heat Performance Excellent Processability Excellent Dimensional Stability Excellent Electrical Properties Comparable Mold Shrinkage Low Specific Gravity Processing of QUESTRA Crystalline Polymers:  Processing of QUESTRA Crystalline Polymers Drying is not typically required Extremely low viscosity at processing conditions Low hydraulic pressures required to fill complex parts Less flash Water Absorption of Glass Filled Polymers:  Water Absorption of Glass Filled Polymers Water Absorption after 24 hours (50% RH, Room Temperature) Percent 0 QUESTRA WA 552 QUESTRA WA 206 ~ ~ Reactivity with Moisture :  Reactivity with Moisture QUESTRA Crystalline Polymers are an addition polymer, it does not pick up moisture and it does not react with moisture PBT and other condensation polymers typically react with moisture during processing and in actual use Hydrolytic Stability in Use:  Hydrolytic Stability in Use USCAR stands for the United States Council for Automotive Research USCAR was formed to standardize automotive components which are not considered competitive advantages Standard number PF-1 covers the test conditions and procedures for connectors USCAR Connector Standard:  USCAR Connector Standard Contains 4 classes of environmental exposure conditions Each class calls out different test conditions USCAR Connector Class Testing :  USCAR Connector Class Testing 40 cycles of exposure to the following temperature/humidity sequence Class 1,2 and 3 have lower temperature exposures USCAR Test Results - Class 4:  USCAR Test Results - Class 4 Benefits of QUESTRA’s Moisture Insensitivity:  Benefits of QUESTRA’s Moisture Insensitivity Save Time, Energy and Money Drying prior to processing is not typically required Consistent Processing No loss of molecular weight during molding due to moisture Consistent Physical Properties No loss of molecular weight during molding due to moisture No change in properties due to moisture during shipping and handling Less effect of moisture on physical properties in actual use Consistent IR Reflow Performance for High Heat Grade No blistering Capillary Melt Viscosity of Automotive Materials:  Capillary Melt Viscosity of Automotive Materials True shear Rate (1/sec) True Viscosity (poise) Processing Comparison :  Processing Comparison Capillary Melt Viscosity of PBT & QUESTRA EA 522:  Capillary Melt Viscosity of PBT & QUESTRA EA 522 MOLD FILLING SIMULATION:  MOLD FILLING SIMULATION Materials Compared QUESTRA WA 550, 30% GF Compared to: 30% GF PBT, 30% GF LCP, 30% GF IM PBT, 40% GF PPS Part Geometry - 4 Cavity Tool Flow length 65 mm (2.6 in) Wall thickness 1.3 mm (.051 in) Part volume 4.2 cm3 (.26 in3) Processing Temperature; Manufacturers recommended values Mould Filling Simulation Comparing QUESTRA to other materials:  Mould Filling Simulation Comparing QUESTRA to other materials Runner Volume (cm^3) 40% 46% 48% 58% Mould Filling Simulation Comparing QUESTRA to other materials:  Mould Filling Simulation Comparing QUESTRA to other materials Runner Part Cooling Time (sec) 24% 51% 15% 60% 20% 53% 81% 53% Mould Filling Simulation Comparing QUESTRA to other materials:  Mould Filling Simulation Comparing QUESTRA to other materials Cavity Pressure (Mpa) 44% 45% 50% 44% Lower Melt Viscosity Benefits:  Lower Melt Viscosity Benefits Mold at lower fill pressures Easier to fill multiple cavity tools Design with thinner walls and greater flow lengths Design with smaller runners resulting in less scrap and less regrind and shorter cycle times Reduced overall cycle time Why QUESTRA Crystalline Polymers are Unique:  Why QUESTRA Crystalline Polymers are Unique A Combination of: High Heat Performance Excellent Processability Excellent Dimensional Stability Excellent Electrical Properties Comparable Mold Shrinkage Low Specific Gravity Crystal Density of Thermoplastic Materials:  Crystal Density of Thermoplastic Materials RESIN PRODUCT CRYSTALLINE DENSITY gm/cc AMORPHOUS DENSITY gm/cc QUESTRA Crystalline Polymers Poly(pheneylene) sulphide (PPS) Poly(butylene) terepthalate (PBT) HBN/HNA copoylmer (VECTRA) HBN/TA/Bis A terpolymer (XYDAR) Nylon 6 Nylon 4,6 % CHANGE 1.05 1.05 1.28 1.08 1.08 1.23 1.43 1.32 1.28 1.41 0 15.6 12.2 7.7 9.2 N/A N/A 0 0 Benefit of Similar Crystal Density:  Benefit of Similar Crystal Density When crystalline, the SPS molecule has similar density to the amorphous phase Little part stress resulting from crystallization Post mould crystallization results in little dimensional changes Why QUESTRA Crystalline Polymers are Unique:  Why QUESTRA Crystalline Polymers are Unique A Combination of: High Heat Performance Excellent Processability Excellent Dimensional Stability Excellent Electrical Properties Comparable Mold Shrinkage Low Specific Gravity Dielectric Constant of Ignition Resistant Materials at 1 MHz:  Dielectric Constant of Ignition Resistant Materials at 1 MHz Why QUESTRA Crystalline Polymers are Unique:  Why QUESTRA Crystalline Polymers are Unique A Combination of: High Heat Performance Excellent Processability Excellent Dimensional Stability Excellent Electrical Properties Low Specific Gravity Comparable Mold Shrinkage Specific Gravity Comparison of QUESTRA to Other Automotive Materials:  Specific Gravity Comparison of QUESTRA to Other Automotive Materials 22% 14% 15% 14% 20% 18% Specific Gravity Specific Gravity Comparison of QUESTRA to PBT:  Specific Gravity Comparison of QUESTRA to PBT Arrow Indicates % Reduction of Part Weight Specific Gravity 20% 30% GF PBT QUESTRA WA 208 23% 30% GF PBT QUESTRA WA 204 QUESTRA Crystalline Polymers have a Unique Combination of... :  QUESTRA Crystalline Polymers have a Unique Combination of... Heat IR-Reflow capable Processing Increased productivity No Crystal/Amorphous Dimensional Stability Density Difference Low warp/bow Electrical Properties Greater impedance Low tracking Specific Gravity More parts/kg Comparable Mold Shrink Use existing tooling Physical Properties of Automotive Grades:  Physical Properties of Automotive Grades Thermal Aging of QUESTRA:  Thermal Aging of QUESTRA OEM Approvals for QUESTRA:  OEM Approvals for QUESTRA Chrysler: MSU0484 for Power Distribution Centre. Delphi: M3587 WA552 Header Connectors. In progress for WA204. Fiat: 4 grades included by Central Lab in material tables. Ford: All grades submitted and specifications being prepared. GM: WA552 (Opel) approved for Fan Shroud applications. Renault: FRM # being prepared for WA552. BMW: WA208 submitted for inclusion in approved materials tables. General Chemical Resistance of Semi-Crystalline Materials :  General Chemical Resistance of Semi-Crystalline Materials Chemical QUESTRA PBT PPS Acids XX X XX Bases XX XX XX Glycols (antifreeze) XX XX XX Oils/Under Hood Fluids XX XX XX Chlorinated Hydrocarbons X Aromatic Hydrocarbons X XX Aliphatic Hydrocarbons XX XX XX Gasoline X XX Alcohols XX X XX Salt Solutions XX XX XX Water XX X XX X X       X Good Moderate Poor Cross Reference Chart of Automotive Materials:  Cross Reference Chart of Automotive Materials Multi Directional Interface Connector:  Multi Directional Interface Connector QUESTRA Application Electronics Application Requirement Thin wall moulding High heat solderable Competitive cycle time Withstand blade insertion Lower cost Low warpage Lower Cost, Competitive Processing, Excellent Performance Edge Card Connector:  Edge Card Connector Application Requirement Thin-wall moulding IR reflow solderable for surface mount Competitive processing in moulding Pin stitchable Lower cost Low warp QUESTRA Product Solution Easier flow than PCT IR solderable - no blistering or dimensional change Faster cycle for sized runners Passes pin stitiching and pin retention Lower overall part cost, runs in PCT tools Low warp QUESTRA Application Electronics Lower Cost, Easy Processing, Near Equivalent Performance Automotive Header Connector for Engine Management:  Automotive Header Connector for Engine Management Application Requirement Thin-wall moulding High-heat soldering (palletless) Low solder cling Molten solder resistance in process Pin insertion Low cost OEM specification QUESTRA Product Solution Easier flow than PPA Passes palletless soldering test Exhibited low solder cling Same dimensions after solder dunk Acceptable mechanical performance Cost advantaged Specification active QUESTRA Application Auto Electronics Lower Cost, Acceptable Performance Automotive Power Distribution Center:  Automotive Power Distribution Center Application Requirement Low warpage Higher output Low cost Adequate mechanical and heat performance OEM specification QUESTRA Product Solution Low warpage achieved Faster than PBT Lower overall cost Meets mechanical and heat requirements OEM specification pending QUESTRA Application Auto Electrical Lower Cost, Faster Processing Material Recommendation for Automotive applications:  Material Recommendation for Automotive applications QUESTRA Grade Power Distribution Centers…….. WA 208 Surface mounted connectors……. WA 552 Board mounted connectors……… WA 552 Wire to wire connectors…………. WA 208 Head light connector…………….. WA 212 USCAR Class 4 Connectors…….. WA 212 Evaluate SPS Resin Performance In Your Application:  Evaluate SPS Resin Performance In Your Application Most Electrical Devices and Enclosures Most Electronic Connectors Where Warpage is a Concern For Thin Wall Parts Anything in Contact With Water/Humidity In Challenging Environments (eg. Auto Underhood) When Looking to Reduce Part Weight Where Soldering is Involved When Seeking Alternatives to Reduce Overall Part Cost

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