A 10

Thermosets: Innovative Applications
„Un Caso di successo“
Gomma Plastica 02/07/2014
SBHPP | High Performance Plastics
Business unit of Sumitomo Bakelite Co.,Ltd.
2
Sumitomo Bakelite Co., Ltd. is
a pioneer in plastics.
Our products are used for a
wide-ranging applications
such as IT components and
material, high performance
plastics and quality-of-life
products.

5,215

1,406M€

3 business segments…
employees worldwide
annual sales (2013)
Quality Of Life
32%
IT Materials
27%
Consolidated
Sales
2013
High Performance
Plastics
41%
Global Plastic Producer
Operations in
10
20
2,000
countries
production
units
people worldwide
200,000
tons sold
in 2012
N1
o
World leader in
Phenolic chemistry
3
Global
Locations
4
æ
æ
GENK PLANT - BELGIUM
N.V. SUMITOMO BAKELITE EUROPE S.A.
GENT PLANT - BELGIUM
VYNCOLIT N.V.
GELTERKINDEN PLANT – SWISS
NEOPREG AG
æ
SHIZUOKA PLANT - JAPAN
SUMITOMO BAKELITE CO., LTD.
AKITA PLANT - JAPAN
AKITA SUMITOMO BAKELITE CO., LTD.
OSAKA PLANT - JAPAN
YAMAROKU KASEI INDUSTRY CO., LTD.
BARCELONA PLANT - SPAIN
SUMITOMO BAKELITE EUROPE (BARCELONA) S.L.U.
æ
FORT-ERIE PLANT - CANADA
æ
KENTON PLANT - USA
DUREZ CANADA CORP.
DUREZ CORP.
NIAGARA FALLS PLANT - USA
DUREZ CORP.
MANCHESTER PLANT - USA
SUMITOMO BAKELITE NORTH AMERICA INC.
Research & Development Site
Resins
Molding compounds
Molded parts
Circuitry materials
DELHI OFFICE- INDIA
SBEI PVT. LTD.
MACAU PLANT - CHINA
SUMITOMO BAKELITE MACAU CO., LTD.
DONGGUAN PLANT - CHINA
æ
SUMITOMO BAKELITE (DONGGUAN) CO., LTD.
BASEC HONG KONG LTD.
HONG KONG OFFICE - CHINA
SUMITOMO BAKELITE HONG KONG CO., LTD.
BASEC HONG KONG LTD.
SINGAPORE PLANT - SINGAPORE
SUMIDUREZ SINGAPORE PTE. LTD.
JOHOR PLANT - MALAYSIA
SNC INDUSTRIAL LAMINATES SDN. BHD.
PROBOLINGGO PLANT - INDONESIA
PT. INDOPHERIN JAYA
SUZHOU PLANT - CHINA
SUMITOMO BAKELITE (SUZHOU) CO., LTD.
NANTONG PLANT - CHINA
SUMITOMO BAKELITE (NANTONG) CO., LTD.
SHANGHAI PLANT - CHINA
SUMITOMO BAKELITE (SHANGHAI) CO., LTD.
5
Global portfolio
our BRANDNAMES
Resins
SUMILITERESIN®
SUMILAC®
SUMIMAC®
DUREZ®
PLYOPHEN®
VARCUM®
METHYLON®
Compounds
SUMIKON®
RX®
EPIALL®
DUREZ®
VYNCOLIT®
VYNTEC®
POROPHEN®
NEONIT®
KINEL®
Circuitry
SUMILITE®
6
Global portfolio
Chemistry
& Forms
Resins
PHENOLIC Novolac
PHENOLIC Resol
EPOXY
POLYESTER Polyol
TERPENE
FURAN
FRICTION Dust
Compounds
PHENOLIC Novolac
PHENOLIC Resol
EPOXY
DIALLYL-PHTHALATE
SILICONE
BIS-MALEIMIDE
Unsaturated POLYESTER
POLYPHENYLENE
SULFIDE
POLYCARBONATE
POLYAMIDE
Circuitry
PHENOLIC
EPOXY
7
SBHPP Divisions
Automotive
Materials
Electrical &
Industrial
Materials
Circuitry
Materials
Applications
Overview
Automotive BrakePistons BrakePads OilPumps
RubberTackifier CoolingManagement ClutchFacing
Pulleys Transmission Intake/ExhaustComponents
Commutators IgnitionCoil FuelManagement
B r u s h H o l d e r s
S h e l l M o l d
Electrical/Electronics PrintedCircuitBoards
Capacitors Varistors Coils Resistors MotorParts
Relays Switches Sensor s CircuitDevices
Industries FrictionMaterials PhotoResist
C u r i n g A g e n t
O t h e r s
Automotive
Aerospace & Transportation
Electronics & Electrical
Oil & Gas
SBHPP |
High Performance Plastics
Business unit of
Building
& Construction
Sumitomo
Bakelite
Co.,Ltd.
Examples of automotive
innovative applications…and more
Water Pumps
H Fuel Pump
H Oil Pump
H Valve Block
H Brake Piston
H Pulley & VVT Camshaft Sprocket
H Turbo compressor wheel (POC development)
H Bracket (development)
H Behavior under temperature &load
H Ecological Footprint & Recycling of thermosets
H The TM-Concept
H New development for thermoset/metal hybrid solutions
H
Water Pumps
Water Pumps
Tensile Modulus @ High Temperature
Property Retention (%)
120
100
80
60
40
20
0
0
20
40
60
80
100
120
Temperature (°C)
140
160
180
200
Fuel Pump
Chemical resistance in E100
▬ Vyncolit® X7320 ▬ Vyncolit® X6952 ▬ Vyncolit® BXE7345 ▬ Vyncolit® BXE7670, ▬ Vyncolit® X659, ▬ Vyncolit® X620/1,
▬ Vyncolit® X655M
post-cured up to 240°C and aged in E100 @ 80°C
Flexural Strength
Flexural E-modulus
275
E-modulus (GPa)
Strength (MPa)
325
225
175
125
75
0
500
1000
1500
2000
Time (hours)
2500
30
20
10
3000
0
Weight Change
1500
2000
Time (hours)
2500
3000
25
1
0
0
500
1000
1500
2000
-1
2500
3000
Strength (kJ/m²)
Weight change (%)
1000
Charpy Impact Strength unnotched
2
-2
500
20
15
10
5
0
Time (hours)
0
500
1000
1500
2000
Time (hours)
Test specimens: MPTS bars according to ISO 3167, post-cured up to 240°C
Dimensional change measured on MPTS bars on the width (10mm) of the test bar
2500
3000
Oil Pump
Oil Pump
Valve Block
Valve Block
350
300
250
200
g
150
100
50
0
X6952
Aluminum
Part Weight
100
90
80
70
%
60
50
40
30
Total
Reduction
Source: CTI Transmission Symposium
The control unti of VW‘s new DCT
X6952
Aluminum
Part Price
Valve Block
Tensile Creep @1 20°C (load 50 MPa)
1,6
1,4
Elongation (%)
1,2
1,0
Bolt holes
0,8
0,6
0,4
0,2
0,0
0,01
0,1
1
Time (hours)
10
100
1000
▬ Vyncolit® X6952
▬ Vyncolit® X655RB
▬ PPS GF40
▬ PPA GF35
Positioning
Pins
Brake Piston
Pulley
Sprocket
Sandboxtest
Turbo Wheel (poc Project)
“Blow-by“ VW PV3936 test is a succession of 20 cycles (total 480
hours). The duration of each
cycle is 24 hours and comprises 3 separated stages of immersion;
1. Nitric acid solution (1M, pH=0.02) for 4 hours at 60°C
2. Engine oil (SAE 15W40) for 18 hours at 135°C
3. Diesel fuel for 30 minutes at room
temperature
Bracket (Project)
part N°124
part N°131
20°C
180°C
Mechanical vs. Temperature (high)
Thermal aging in Air @ 150°C
▬ Vyncolit® X6952
Flexural Strength
250
Tensile Strength
150
Strength (MPa)
Strength (MPa)
200
150
100
50
100
50
0
0
0
500
1000
Time (h)
1500
2000
0
2500
500
Flexural Modulus
1500
2000
2500
2000
2500
Tensile Modulus
35
30
30
E-Modulus (GPa)
E-Modulus (GPa)
1000
Time (h)
25
20
15
10
5
0
0
500
1000
1500
Time (h)
2000
2500
25
20
15
10
5
0
0
Test specimens:
MPTS bars according to ISO 3167, post-cured up to 220°C
500
1000
Time (h)
1500
Mechanical vs. Temperature (high)
Thermo mecanical properties in Air
Flexural Strength
Tensile Strength
150
Tensile Strength (MPa)
Strength (MPa)
250
200
150
100
50
100
50
0
0
0
50
100
150
200
250
0
Temperature (°C)
50
Flexural Modulus
100
150
Temperature (C°)
200
250
200
250
Tensile Modulus
35
30
30
E-Modulus (GPa)
E-Modulus (GPa)
▬ Vyncolit® X6952
25
20
15
10
5
0
25
20
15
10
5
0
0
50
100
150
Temperature C°)
200
250
0
Test specimens:
MPTS bars according to ISO 3167, post-cured up to 220°C
50
100
150
Temperature (C°)
Mechanical vs. Temperature (high)
Fatique behaviour
▬ Vyncolit® X6952
Tensile Fatigue Strength
Stress level versus number of cycles to failure
120
100
Maximum Stress (MPa)
80
Vyncolit® X6952
23°C
Vyncolit® X6952
120°C
60
40
20
0
1,00E+01
1,00E+02
1,00E+03
1,00E+04
1,00E+05
1,00E+06
Number of cycles
Test specimens: MPTS bars according to ISO 3167, postcured 8h 180°C, Frequency 30Hz
Mechanical vs. Temperature (low)
Flexural Strength
▬ Vyncolit® X6952
300
Strength (MPa)
250
200
150
100
50
0
-60
-40
-20
0
20
40
60
80
100
Temperature (°C)
Flexural E-Modulus
Test specimens:
MPTS bars according to ISO 3167, as molded
E-modulus (GPa)
20
17.5
15
12.5
10
-60
-40
-20
0
20
40
Temperature (°C)
60
80
100
Ecological Footprint
SB Phenolic…
Steel
PVC
Cu
LD-PE
PP
HD-PE
PS
POM
PA66
PA6
Al
-300
-100
100
300
Energy Requirement to produce raw
material (in M J/kg)
Energy to produce component with
equal stiffness than steel (base 100)
Recycling Concept
Chemical decomposition of the linked thermoset.
recycled resin and recycled fillers will be extracted
back with the sharing process.
Supercritical
fluid
Subcritical
Critical
pressure
C(critical point)
liquid
solid
gas
T (triple point)
pressure
industrial
ＰＭ廃材 waste
temperature
Critical
temperature
typical phase diagram
gas like properties
Hohe Diffusionsfähigkeit
recycelt resin
recycelt fillers
liquid like properties
resin
glasfibers
(Hohe Auflösungsfähigkeit für
organische Materialien)
Recycling Concept
Properties of recycled Grade
Summary
H constant
performance over a width
temperature range of combustion engines
H High
chemical restistance against fluid used
in a engine
H High
H No
level of design freedom
cold creep
TM-CONCEPT
PM2-CONCEPT
A COMPREHENSIVE STUDY
ON POLYMER INNOVATION IN
THE AUTOMOTIVE
ENGINE INDUSTRY
Helping CO2 reduction
The information presented
in this document is provided in good faith, but no
warranty is given or is to
be implied regarding its
accuracy or relevance to
any particular application.
Users must satisfy themselves regarding the suitability and safety of their
use of the information and
products
in
the
application
concerned.
Nothing herein is to be
construed as advi-sing or
authorizing the use of any
invention
covered
by
existing patents without
license from the owners
thereof.
33
7/3/2014
Introduction to TM concept
TM is a virtual engine concept which has been developed in cooperation with IAV.
Our goal was to come up with is a small scalable engine architecture with 4, 3 or 2 cylinders while using
SBHPP Compounds and composites materials (short fiber, long fiber, phenolics, epoxies,…). This engine
could be usable as primary engine or as range extender (APU).
- High power density/ downsizing (low weight with high performance)
PM2-CONCEPT
- Maximum integration of functions in the composites parts
- Good Noise, Vibration, and Harshness (NVH) characteristics
- Price/performance
An other important topic is the ecological foot print for making
parts out of SBHPP Compounds. The energy – directly
related to CO² emission - required for making part of equal stiffness
is very favorable for SBHPP compounds.
Recycling is also considered with a patented chemical recycling
technology developed by SBHPP and ongoing
material development with renewable resin resources (Green materials)..
The information presented
in this document is provided in good faith, but no
warranty is given or is to
be implied regarding its
accuracy or relevance to
any particular application.
Users must satisfy themselves regarding the suitability and safety of their
use of the information and
products
in
the
application
concerned.
Nothing herein is to be
construed as advi-sing or
authorizing the use of any
invention
covered
by
existing patents without
license from the owners
thereof.
PM2 presentation
34
7/3/2014
PM2-CONCEPT
SPURRING INNOVATION
1
Innovation
focus
Structural Casing
SBHPP’s Innovative Compounds
and Composites materials has
helped establish more than a
few automotive conventions,
while inspiring designers to
forever challenge the
boundaries of what’s been
done before.
The range and versatility of
performance properties
inherent in our extensive
portfolio of automotive
materials offers solutions for
the most demanding
applications.
35
7/3/2014
Innovation focus
Structural Casing
POROPHEN® long glass fiber reinforced
phenolic (LGFPF) can be molded into thinwall structural parts, enabling reduced
weight with integrated functions.
Main engine
housing
PM2-CONCEPT
Engine
brackets
Lateral engine
cover with
integrated engine
brackets
The information presented
in this document is provided in good faith, but no
warranty is given or is to
be implied regarding its
accuracy or relevance to
any particular application.
Users must satisfy themselves regarding the suitability and safety of their
use of the information and
products
in
the
application
concerned.
Nothing herein is to be
construed as advi-sing or
authorizing the use of any
invention
covered
by
existing patents without
license from the owners
thereof.
36
7/3/2014
PM2-CONCEPT
SPURRING INNOVATION
2
Innovation
focus
Monolythic Valve Cover
SBHPP’s Innovative Plastics and
Composites materials has
helped establish more than a
few automotive conventions,
while inspiring designers to
forever challenge the
boundaries of what’s been
done before.
The range and versatility of
performance properties
inherent in our extensive
portfolio of automotive
materials offers solutions for
the most demanding
applications.
37
7/3/2014
Innovation focus
Monolythic Valve Cover
Innovation Tips
PM2-CONCEPT
Direct camshaft assembly
without bolting elements
This optimized assembling
method is made possible
with SBHPP compounds
thanks to the tight molding
tolerances and the excellent
thermal resistance of the
thermosetting materials
The camshaft (shaft + cam
elements) can be assembly
directly on the valve cover.
The shaft is cooled down at
very low temperature
whereas the cams are heated
up and positioned over the
molded valve cover.
 SUMIKON®, DUREZ®
and VYNCOLIT®
reinforced phenolic
compounds offer
excellent processability,
and provide an
excellent balance of
heat resistance, surface
hardness and finish.
 In combination with the
monolythic valve cover
concept they offer
weight reduction up to
45 percent compared to
die cast aluminum.
 The high creep
resistance allows
designing without insert.
The information presented
in this document is provided in good faith, but no
warranty is given or is to
be implied regarding its
accuracy or relevance to
any particular application.
Users must satisfy themselves regarding the suitability and safety of their
use of the information and
products
in
the
application
concerned.
Nothing herein is to be
construed as advi-sing or
authorizing the use of any
invention
covered
by
existing patents without
license from the owners
thereof.
38
7/3/2014
Innovation focus
Monolythic Valve Cover
E-Modulus at high temperature
Innovation Tips
Property Retention (%)
120
In general, tooling
investment cost for SBHPP
molding compounds
compared to aluminum diecasting is 3 to 5 times lower.
80
60
PPS (GF+MD)65
40
PPA GF33
PF GF+GB45
20
PM2-CONCEPT
PF GF50
0
Function integration
0
50
100
150
200
Temperature (°C)
Tensile creep at 120°C
(load 50 MPa)
2,5
PPS GF40
2
Elongation (%)
The excellent moldability of
the SBHPP thermoset
materials allows for complex
designs with integration of
function’s like the high
pressure direct injection
pump. Due to the excellent
chemical resistance to
several automotive liquids
like engine oil, fuels, cooling
liquid… function integration
is easily feasible and results
in lean design with lower
cost.
100
PPA GF35
PF GF+GB45
1,5
PF GF50
1
0,5
0
0,01
1
100
Time (hours)
10000
The information presented
in this document is provided in good faith, but no
warranty is given or is to
be implied regarding its
accuracy or relevance to
any particular application.
Users must satisfy themselves regarding the suitability and safety of their
use of the information and
products
in
the
application
concerned.
Nothing herein is to be
construed as advi-sing or
authorizing the use of any
invention
covered
by
existing patents without
license from the owners
thereof.
39
7/3/2014
PM2-CONCEPT
OIL SUMP MODULE CONCEPT
3
Innovation
focus
Oil Sump Module
The concept of an composite Oil
Sump Module (OSM) with
integration of several functions like
the oil pump, oil cooler and oil
filter has multiple benefits. Due to
the integration, compact design is
possible resulting in better and
easier control of the oil flow and
oil temperature thus helping to
reduce fuel consumption and thus
lower CO² emissions. Also
significant weight reduction (up to
45%) and cost reduction can be
realized. The concept of the
composite OSM is based on the
use of the SBHPP POROPHEN®
compound for the structural parts
(oil sump) combined with the
SBHPP short fiber Engineering
Thermoset compounds for the
functional applications like the oilpump, -cooler and –filter.
40
7/3/2014
Innovation focus
Innovation Tips
Oil Sump Module
PM2-CONCEPT
Function Integration
SBHPP Engineering Thermoset
compounds are very well suited
to replace sintered metal and
aluminum in oil pumps were
thermal-, mechanical- and
chemical resistance combined
with the need for tight
tolerance are key requirements.
Design flexibility and excellent
moldability allows for new
innovative pump concepts
resulting in lower part cost and
improved performance helping
to reduce fuel consumption
and CO2 emission.
The information presented
in this document is provided in good faith, but no
warranty is given or is to
be implied regarding its
accuracy or relevance to
any particular application.
Users must satisfy themselves regarding the suitability and safety of their
use of the information and
products
in
the
application
concerned.
Nothing herein is to be
construed as advi-sing or
authorizing the use of any
invention
covered
by
existing patents without
license from the owners
thereof.
41
7/3/2014
Combination molding
technology
New development for thermoset/metal
hybrid solutions
SBHPP | High Performance Plastics
Business unit of Sumitomo Bakelite Co.,Ltd.
2014/4/3
Confidential
Concept
Merits
Function of MCs
Function of Metal
Light weight (downsizing)
Strength & Modulus
Electrical insulation
Elctromagnetic shild
Thermal insulation
Air tightness
Reduction of NV
Inertia force
Reduction of parts and
process
Heat conductivity
Multi-functionalization by
combination between
Thermoset MCs and Metal
Range of application
Thermosetting resin：Phenol resin, Epoxy resin, Unsaturated polyester resin etc
Metal
：Aluminum, Al die-cast, SUS, copper
Metal position
：Place on outside position
Molding method ：Transfer, Compression, Injection
Confidential
2014/4/3
Confidential
Shear strength and Flexural strength
No treatment
Rarefaction by chemicals
0-1MPa
27MPa
Shear strength
Image of metal
surface
3-point flexural test
Resin layer :3mm
Aluminum layer：1㎜
Strength：140MPa
Modulus ：15 GPa
Strength：350MPa
Modulus ：23 GPa
(Al layer is low side)
Properties of Phenolic
compound
Strength:125MPa
Modulus :13 GPa
Confidential
2014/4/3
Shear Adhesion strength
金属種
せん断密着強度
Metals
Shear Adhesion Strength
Aluminum(A5052)＋処理A
24～27
Al die-cast(ADC12)＋処理B
14～21
Copper(C1100) ＋処理A
10～15
SUS(SUS304)＋処理A
9～13
Aluminum(A5052)No treatment
0～1
Standard Epoxy Glue
7～9
●金属表面 Metal Sureface：ソ化処理実施 Metal Surface was Refaced by Treatment Companies
処理A Treatment-A：メック株式会社様のアマルファ処理実施
処理B Treatment-B：株式会社京信様の処理実施
Confidential
単位 Unit：MPa
2014/4/3
Ability evaluation of combination composites
using TP
【Reliability data／Flexural fatigue test】
Sample：TP of combination composite
（Resin t=3mm/Al t=1mm）
Condition：Frequency 30Hz
Mode：one side amplitude（See the right figure）
Stress
PM-9640
Amplitude
Metal
【Image of fracture】
300
Stress ( MPa)
250
Resin
only
PM-9640
Combination composite
【SEM image】
200
MCs
150
100
Aluminum
50
No crack
0
1,E+00 1,E+01 1,E+02 1,E+03 1,E+04 1,E+05 1,E+06 1,E+07
Cycle
Confidential
2014/4/3
Confidential
He leak test
In order to confirm the tightness between metal and resin, We entrusted He
leak test to the other company.
Compound：Phenolic molding compound
Metal：Aluminum (A5052)
Rarefaction：3 or 15 μm
Depth of rarefaction
He leak amount (Pa・m3／sec)
3μm
0.9×10-11
15μm
0.9×10-11
Considering that the general target of tightness is <10-7, our
composites meet the general needs. There seems no difference
derived from depth of rarefaction.
Confidential
2014/4/3
ＴＰ/Mechanism of Resin-Metal adhesion
（Observation of cross-section）
Confirmation of the adhesion state with SEM
Compound：Thermoset molding compound
（Phenol）
Metal：Aluminum
Sample：TP for flexural test
Molding：Compression molding（180℃x3min）
【Flexural fracture】
Resin layer
×500
Aluminum layer
Cross-section
for observation
【Resin only：Brittle fracture】
【Combination composite：
effect of reinforcement】
×2500
The part of rarefaction is filled with compound.
This is why the adhesion is high.
Confidential
2014/4/3
Confidential
Integrally molded method of resin and metal
Integrally molding with the sheet metal by transfer molding
pot
Upper die
Resin part
Metal part
cull
sprue
Lower die
Resin Flow
Resin flow push sheet metal against die and fix it there.
Confidential
2014/4/3
Application
Resin model
Engine bracket
Inverter case
Confidential
battery case
Reactor
2014/4/3
FOR FURTHER INFORMATION, PLEASE CONTACT
YOUR LOCAL OFFICE OR VISIT YOUR GLOBAL WEB SITE:
EUROPE
ASIA PACIFIC
AMERICAS
Vyncolit NV
Sumitomo Bakelite Co., Ltd.
Wiedauwkaai 6
B9000 GENT
Belgium
Tel. +32 9 2950-100
Fax +32 9 2950-200
Tennoz Parkside Building
5-8 Higashi-Shinagawa 2-chome,
Shinagawa-ku
Tokyo 140-0002
Japan
Tel: +81-3-5462-4111
Sumitomo Bakelite North
America, Inc.
46820 Magellan Drive, Suite C
Novi, MI 48377
USA
Tel: +1 (248) 313-7000
GLOBAL MATERIALS ENGINEERING
CONSULTING, SALES, SUPPORT
SBHPP group is market leader in Engineering
Thermosetting Compounds. With companies
based in Japan, Belgium and USA, SBHPP
specializes in short & long fiber (carbon,
glass, aramide) reinforced polymers such as
phenolic, polyimide & epoxy with
outstanding thermo-mechanical properties.
The company provides a huge choice of
technical assistance to customers, ranging
from initial design to prototyping from its
Japanese, European & American Technical
Market Development Centers. Its broad
product line is essential to the development
of high-tech structural applications based on
molding polymers with a special emphasis
on automotive components.
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