SPE Automotive TPO Global Conference 2009 - Auto-tpo.com

SPE Automotive TPO Global Conference 2009
Welcome to the Annual SPE Global TPO Conference
The Society of Plastic Engineers (Detroit Chapter), leading OEMs, Tier 1, and TPO suppliers
have pooled their resources to create the 11 th Annual SPE Automotive TPO Global Conference.
The conference is a dynamic, interactive, and cost-effective learning experience “put together”
and “contributed to” by the world’s foremost authorities on materials, processes, applications,
and market trends.
The pledge of the conference committee is simple. We strive to bring you the best,
knowledgeable people who will share useful information on the latest TPO-related
developments and trends.
Last year, over 400 attendees from OEMs, Tier 1s, and resin and equipment suppliers
participated in this event. Many new materials, application developments, and technologies
were introduced.
This year's event is expected to be as exciting with over 30 technical papers and presentations
and a special half-day session on Injection Molding & Advanced Process Control. Additionally,
there are 4 keynote speakers: Dr. David Cole, chairman of the Center for Automotive Research
(CAR) in Ann Arbor, Michigan, Neil De Koker, founding president and CEO of the Original
Equipment Suppliers Association (OESA), Nazeer Bhore, Senior Technology Advisor-Corporate
Planning at ExxonMobil Chemical, and Mr. Maurice Sessel, Vice-President, Product
Engineering at IAC.
An Executive Management panel discussion, including representatives from Ford, General
Motors, LyondellBasell, Toyota, and Dr. Cole is scheduled on Tuesday. The subject is:
Automotive Paradigm Shift Opportunities for TPO materials.
A new feature of the Conference is a special half-day session focused on a single subject. Last
year it was on thermoforming. This year, as stated above, is on advanced process control and
trouble-shooting for the injection-molding process. The objective is to help participants achieve
a competitive advantage in today's global market. The session will provide an overview of
polymerization, discussion about the compounding of propylene, polyethylene, etc. into a TPO
alloy, review decoupled molding strategies, and end with a troubleshooting discussion that
includes a lab demonstration via video link to RJG's Traverse City location.
We thank you for attending this conference, and we look forward to seeing you year after year.
We appreciate your comments and feedback as we are continuing to strive to meet your needs.
Bill Windscheif Paula D. Fasulo
Co-Chairman Co-Chairman
Advanced Innovative Solutions, Ltd. General Motors Corporation
President Staff Scientist, Retired

Bill Windscheif
Co-Chairman
Advanced Innovation Solutions, Ltd.
Sandra McClelland – Chevron Phillips Chemical
SPE President
Detroit Section
Dr. Norm Kakarala
Inteva Products L.L.C.
Technical Program Chair
Dave Okonski
Moderator – Materials Development
General Motors Corporation
Mitesh Shah
Scholarship/Moderator-Materials Development
LyondellBasell Industries
Robert Eller
Moderator – Applications Development
Robert Eller Associates, L.L.C.
Thomas Pickett
Moderator – Applications Development
General Motors Corporation
Patti Tibbenham
Moderator – Process Development
Ford Motor Company
Duane Lewis
Moderator – Surface Enhancements
ExxonMobil Chemical Corporation
Dr. Rose Ryntz
Moderator – Surface Enhancements
International Automotive Components
2009 Planning Committee Members
Paula Fasulo
Co-Chairman.
General Motors Corporation –retired
Kelly Beauchamp
Proceedings Book
DME
Lisa Wujkowski
House Coordinator
Dow Automotive
Sanjay Patel
Audio/Visual/Web Master
Flint Hills Resources
Tom Powers
Budget/Finance
Consultant
Ron Price
Panel Discussion/Communications
Global Polymer Solutions
Nippani Rao
Sponsorships
RAOAssociates
Anthony Gasbarro
Committee Member
Advanced Composites
Ed Bearse
Committee Member
Advanced Plastics Consultants
Pat Levine
Registration
SPE/Automotive Division & Detroit Section

7:30-8:30am Registration/Coffee
2009 SPE® TPO Global Conference Program
Monday October 5, 2009
8:30am Opening Remarks: Bill Windscheif - Advanced Innovative Solutions, Ltd; Paula Fasulo - General Motors (Retired)
8:45-9:15am Keynote Address: Interior Challenge
Maurice Sessel: Vice President Product Engineering, International Automotive Components
9:15am Technical Program: Norm Kakarala: Inteva Products
Materials Development Session
(Moderators: David Okonski: General Motors & Mitesh Shah: LyondellBasell Industries)
9:30-10:00am Scratch Performance of Talc-PP and Talc-TPO Compounds
Saied H. Kochesfahani, Denis Lejour, Frederic Jouffret, Wolfgang Jonischket: Rio Tinto Minerals
High Performance Reinforcement: A Pathway to Density Reduction While Maintaining Physical Properties of Polyolefin
10:00-10:30am
Composites
K. David Lake: Milliken Chemical
10:30-10:45am Break
10:45-11:15am MOS Hige Fiber for Light Weighting, Fast Cycle Time & Improved Quality TPOs
Donald Beuke: Mitsui Plastics
11:15-11:45am Improved Glass-Fiber Reinforced Polypropylene for Structural Applications
Alberto Prieto and Steve Davis: LyondellBasell Industries
11:45-12:15pm High-Performance TPEs for Stringent Automotive Applications
John Chiao and Keith Dunlap: Kraiburg TPE
12:15-1:30pm Lunch & Keynote Presentation: The Automotive Industry in Transition: A New Beginning
Neil De Koker: CEO, Original Equipment Suppliers Association
1:30-2:00pm Polypropylene Property Modification using Vistamaxx Specialty Elastomers & Exact Plastomers
Felix Zacarias: ExxonMobil Chemical
2:00-2:30pm New Higher Impact Efficiency Elastomers for High Performance Rigid TPOs
Kim Walton, Mark Berard, Theresa Hermel-Davidock, Phillip Hustad, Jim Hemphill, Didem Oner-Deliormanli, Russell Barry: The Dow
Chemical Company
2:30-3:00pm Low Density TPO Development for Automotive Exterior and Interior Applications
Todd Glogovsky: LyondellBasell Industries
3:00-3:15pm Break
3:15-3:45pm Breaking New Ground with Thermoplastic Polyolefin Body Panels
Neil Fuenmayor, Mitesh Shah, and Todd Glogovsky: LyondellBasell Industries
Effect of Edge Functionalized Layered Silicates on the Strain Hardening Property of Polymer-Clay Nanocomposite Melts in
3:45-4:15pm Extensional Flow
Tanmay Pathak and Prof. K. Jayaraman: Michigan State University
4:15-4:45pm The Flaming of Parting-Line Flash and its Effects on Paint Adhesion
Brent Nixon, Kyle Sinko, David Okonski and Elmer Santos: Ferris State University & General Motors
4:45-5:15pm Unique Flow of Polypropylene at the Weld-Line Behind an Obstacle in Injection Molding
Yutaka Kobayashi, Gensei Teramoto and Toshitaka Kanai: Kanazawa University, Japan
5:30pm ExxonMobil Reception (Open for All Conference Participants )

7:00-8:00am Registration/Coffee
2009 SPE® TPO Global Conference Program
Tuesday October 6, 2009
8:00-8:30am Keynote Address: The Outlook for Energy: A View to 2030
Dr. Nazeer Bhore: Senior Technology Advisor-Corporate Planning, ExxonMobil Corporation
Injection Molding & Advanced Process Control Seminar
(Moderators: David Okonski: General Motors & Shane Vandekerkhof: RJG, Inc.)
8:30-9:00am Polymer Basics: Morphology and Microstructures
9:00-9:30am Decoupled Molding Strategies: Separating Fill from Pack
9:30-9:45am Break
9:45-10:15am Troubleshooting the Injection Molding Process: Cause and Effect of Some Common Defects
10:15-10:45am Troubleshooting the Injection Molding Process: Defect Focus from Simple to More Advanced
10:45-11:30am Lab Demonstration via Video Linked to RJG Laboratory
11:30-12:00am Keynote Speaker: The Auto Future: A New Beginning?
Dr. David Cole: Chair, Center for Automotive Research
12:00-2:00pm
Lunch & Panel Discussion: Challenges & Opportunities in the New Automotive Industry
(Moderators: Bob Eller: Robert Eller Assoc., LLC & Ron Price: Global Polymer Solutions
Executives: Matt Carroll: General Motors Co., Dr. David Cole: Center for Autmotive Research, Stephen Dwyer: LyondellBasell Industries,
Nand Kochhar: Ford Motor Co., Jeff Makarewicz: Toyota Motor Corp.
Applications Development
(Moderators: Bob Eller: Robert Eller Assoc., LLC & Tom Pickett, General Motors Co.)
2:00-2:30pm TPO Position in the Global Automotive Market & Effects of Global Economic Situation
Bob Eller, Robert Eller Assoc., LLC
2:30-3:00pm TPO Development for the 2010 and Beyond
Sassan Tarahomi, IAC North America
3:00-3:30pm Over-Molding New Cost Effective Soft Touch TPV on PP Substrates with Improved Properties
Jeff Valentage & Hermann-Josef Holz: ExxonMobil Chemical
3:30-3:45pm Break
3:45-4:15pm Digital Color Solutions for Automotive TPO Applications
Jim Harper, Techmer PM
4:15-4:45pm Structure-Property Relationship of Novel Metallocene-Based R-TPO for Interior Parts
Motoko Ito, Shouichi Fukunaga, Kenji Matsuoka, Kouichi Honda, and Kiyoshi Yukawa: Japan Polypropylene Corporation
4:45-5:15pm Superior Appearance Material in Airbag Cover Applications
Dr. Nadeem Bokhari: Autoliv North America; Kousuke Ohtani, Tetsuya Hisayama, & Noboru Yamaguchi: Sumitomo Chemicals Co. Ltd.
5:15-5:45pm Optimization of Scratch Resistance for Molded in Color (MIC) Interior TPO Injection Molded Plastics
Renee Hotton: General Motors Co.
5:45pm SPE Detroit Section Reception (Open for All Conference Participants, Cash Bar )

7:00am Registration/Coffee (Concurrent Sessions)
2009 SPE® TPO Global Conference Program
Wednesday October 7, 2009
Process Development: Aluminum Tooling for Injection Molding Seminar
(Moderator: Patti Tibbenham - Ford Motor Co.)
8:00-8:15am Plenary Presentation: Aluminum Tooling for Injection Molding of TPO Materials
Patti Tibbenham, Ford Motor Company
8:15-9:00am Mold Design Improvements, Surface Coatings, Heat Transfer and Part Price Opportunities
Robert Beard, P.E., President of Robert A. Beard & Associates Inc.
9:00-9:30am Properties of Aluminum Materials for Injection Molds
Dave Wirth, Clinton Aluminum
9:30-10:00am Designing Production Aluminum Molds
Greg Eidenberger, Paragon Die & Engineering
10:00-10:15am Break
10:15-10:45am Case Studies of Production Aluminum Tooling
Dave Dickerson: DRS Industries
10:45-11:15am Manifold Considerations (Thermal 2-3d Analysis)
Rich Oles: Plastic Services Group Inc. (PSG)
11:15-11:45am Lessons Learned in Graining and Repair of Aluminum Tooling for Injection Molding
Ron Smierciak: Alcoa
Surface Enhancements
(Moderators: Duane Lewis: ExxonMobil Chemical & Dr. Rose Ryntz: International Automotive Components)
8:00-8:30am Plenary Presentation: Interior Automotive Plastic Aesthetic and Performance Trends
Dr. Rose Ryntz: International Automotive Components
8:30-9:00am Mar Resistance Testing and Evaluation of the Thermoplastic Olefins
Robert Browning, George Wei, & Hung-Jue Sue: Texas A&M University; Kevin Reid: Phillips Sumika
9:00-9:30am Mechanical Modeling of Scratch Induced Periodic Damage
Han Jiang, John Whitcomb & Hung-Jue Sue: Texas A&M University
Update on Developments for Scratch and Mar Additives: Effect of the Additive Formulation on the Scratch Performance and
9:30-10:00am Other Secondary Attributes
Nikolas Kaprinidis, Per Magnus Kristiansen, Martin Brunner and Johanne Wilson: Ciba Corporation, a part of the BASF Group
10:00-10:15am Break
10:15-10:45am Atmospheric Pressure Plasma: Surface Treatment for Painting without Wet Chemistry
Shaun Glogauer: Plasma Treat North America
10:45-11:15am Latest Developments in Coatings Technology that Provides Striking Appearance and Durability over TPO
Arjun Dhake: Dhake Industries
11:15-11:45am Study of Scratch Resistance of Polypropylene Blend for Automobile
Shan Jin, Yonghua Li, Bo Yang, Zhongfu Luo: Kingfa SCI 7 TECH., CO., LTD.
11:45-12:15pm New and Innovative Testing Technologies for Effect Finishes
Greg Shrider and Richard Scott: BYK - Gardner USA
12:15-12:45pm Conventional and Low VOC Bonding Solutions for TPOs
Walt Polifka: Adchem Corporation

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ADCAM
GLOBAL PLASTICS
RECOVERY, INC.
CONFERENCE

Americhem, Inc.
155 E. Steels Corners Dr.
Cuyahoga Falls, Ohio 44224
Web Site: www.americhem.com
Phone: (330) 926-4000
Fax: (330) 926-2100
E-Mail: bconway@americhem.com
Contact Name: Brett Conway
Job Title: Sales Manager
Phone: (419) 349-2109
E-mail: bconway@americhem.com
t h e a d h e s i v e t a p e e n g i n e e r s
1852 Old Country Road
Riverhead, New York 11901
www.adchem.com
Phone: 631-727-6000
Fax: 631-727-6010
E-Mail: info@adchem.com
Contact: Walt Polifka
Job Title: Business Development Manager
Phone: 631-727-6000 X323
E-mail: wpolifka@adchem.com
Products & Services:
• Color and Additive Masterbatches
• 100:1 Color Masterbatch
• Scratch & Mar Technology
• Special Effects
• Exterior Paint Replacement Technology
Adchem Corporation manufactures a
complete line of adhesive tape systems,
including double-coated papers, films,
tissues, foams and fabrics; transfer tapes;
single-side-coated products; and other
custom-coated specialty products. Their
100% solids adhesives, solvent acrylics and
solvent rubber adhesives are used in many
different industries, including transportation,
electronic, medical and others.

1062 Fourth Ave
Sidney, OH 45365
Web Site: www.advcmp.com
Phone: (937) 575-9800
Fax: (937) 492-0306
Contact Name: Brian Williams
Job Title: Marketing Manager
Phone: (937) 575-9800
E-mail: brian.williams@advcmp.com
321 Brentwood Drive
Reading, PA 19611
WWW.Brentwoodindustries.com
Phone: 610-376-1900
Fax: 610-736-1209
Contact: David Fry
Sales Manager
610-236-1107
David.fry@brentw.com
Products & Services:
� Mold-In-Color TPO Technology.
� High Impact Polymers (100% ductility at -40°C)
� Seamless Airbag Instrument Panels.
� Bumper Fascia Polymers.
� Low Gloss Interior Polymers.
� High Gloss Exterior Polymers.
� Lightweight Polymers.
� Fast Cycle Time Polymers.
� Technical Services (Processing, Mold-Flow, Tool and Part
Design Recommendations).
______________________________________________________
Custom Thermoform Service
• Heavy gauge thermoforming, Precision CNC
Trimming, materials up to ½” thick
• Light gauge thermoforming, Medical Packaging,
Consumer Packaging, Complete Design Capability

BYK-Gardner USA
9104 Guilford Road
Columbia, MD 21046
Phone 800-343-7721 or 301-483-6500
Fax 800-394-8215 or 301-483-6555
General Email info.BYK.Gardner.USA@altana.com
Web www.byk.com/instruments
Contact Karen Nance
Title Inside Sales Manager
Email Karen.Nance@altana.com
BYK-Gardner, a worldwide partner of the automotive, paint and
plastic industries, offers quality control instrumentation to measure
color and appearance properties such as metallic and solid color,
gloss, orange peel, DOI and haze. We also provide a full line of
physical testing instruments- applicators and drawdown cards; film
thickness gages; impact, flexibility and hardness testers;
viscometers and more.
Great people. Great products.
Great company.
Combining existing BASF capabilities with the people, products
and technology acquired with Ciba gives BASF a more powerful
portfolio to help automotive OEMs make their products better.
Great people, great products. The Chemical Company.
Visit us at the 2009 SPE Automotive TPO Conference.
www.basf.us
Light stabilizers
Scratch resistance
additives
Antioxidants
Colorants and
effect pigments
UV absorbers
Antistatic agents
Flame retardants

29111 Stephenson Hwy
Madison Heights, MI 48071
www.DME.net
Contact: Kelly Beauchamp
DME Sales Representative
248-705-4188
kelly_beauchamp@dme.net
Dow Elastomers
4520 E. Ashman St.
9008 Building
Midland, MI 48642
www.dowelastomers.com
Phone: 800-441-4369
E-Mail: CUSTINFOGRP1@dow.com
Contact: Customer Information Group
An Essential Mold Technology Resource
• Hot Runner Systems
• Hot Runner Service Center
• Mold bases & Plate Items
• Mud Quick-Change Systems
• Mold & Die Components
• Moldflow Analysis
• Heating & Cooling Components
• Control Systems
• Molding Equipment & supplies
• Moldmaking Supplies
• Applications Engineering
• Technical Service
Products & Services:
Dow is delivering solutions to the interior and exterior hard TPO
industry by enabling:
• Impact strength / toughness / resiliency
• Excellent processability
• Gloss Control
• Paintability
We will introduce the next generation to the ENGAGE TM family –
which will deliver superior performance while meeting your
material and handling needs.

1250 Harmon Road
Auburn Hills, MI 48326
phone: 248-391-6300
www.dowautomotive.com
Contact: Kelly Pippine
Marketing Manager
248-393-3068
email: kpippine@dow.com
LyondellBasell Industries Phone: 517-336-2400
2727 Alliance Drive Fax: 517-336-2415
Lansing, MI 48910
http://polymers.lyondellbasell.com
Dow Automotive Systems is a leading provider of
polyurethanes, elastomers, films, fluids, adhesives,
emissions solutions and acoustic-management
materials to the global transportation industry. By
working collaboratively with passenger vehicle,
commercial transportation and aftermarket
customers, Dow Automotive Systems is developing
industry-leading solutions to address a wide range of
critical market needs – increasing energy efficiency,
improving safety and health, reducing exhaust
emissions and enhancing vehicle quality and appeal.
For additional information about Dow Automotive,
visit www.dowautomotive.com
Lyondellbasell delivers sustainable value to the automotive industry by offering innovative resins that address customers' most
challenging application requirements.
Be it bumpers, grilles, instrument panels, interior trim, under-the-hood applications or structural parts and body panels – the versatility and
economics of LyondellBasell’s polypropylene creates customer opportunities for cost-effective and innovative design concepts that can enhance
both passenger safety, comfort and quality. Our lower density resins can help improve fuel economy and reduce raw material costs.
LyondellBasell’s worldwide network of strategically located supply facilities target uniformity of specifications – wherever in the world
materials are sourced.

Sumitomo Chemical America, Inc Headquarter: 212-572-8200 David Risetter
28175 Haggerty Road Fax: 248-994-7673 General Manager, Petrochemicals Division
Novi, MI 49127 269-921-3354
www.sumichem.com drisetter@sumichem.comwww.espolex.com
Reaching New heights in Global Supply
Sumitomo Chemical’s Petrochemicals & Plastics Division engages in the development, manufacture and sale of a wide range of petrochemical
products, including plastics such as polyethylene and polypropylene; synthetic rubber; and organic chemicals such as propylene oxide and
styrene monomer.
In order to meet the needs of a diverse customer base, our focus is on the development, manufacture and sale of high-performance resins like
Thermoplastic Elastomer and Polymer Alloys as well as concentrating on application development utilizing advanced manufacturing and
application technologies in foamed, extruded and molding applications.
The Sumitomo Chemical Group global network includes production and sales operations in North America, South America, Japan, Europe,
Korea, China, South Asia and Middle East.
ExxonMobil Chemical Company
13501 Katy Freeway
Houston, Texas, U.S.A. 77079
www.exxonmobilchemical.com
About ExxonMobil Chemical
ExxonMobil Chemical is one of the world’s premier petrochemical companies with manufacturing, technology and
marketing operations around the world. The company delivers a broad portfolio of products and solutions efficiently and
responsibly, with a commitment to create outstanding customer and shareholder value. ExxonMobil Chemical endorses the
principles of sustainable development, including the need to balance economic growth, social development and
environmental considerations.

1330 Lake Robbins Dr., Ste.400
The Woodlands, TX 77380
Sanjay Patel
734-451-2072
sanjay.patel@fhr.com
Polypropylene Products
• High impact and low temperature ductility
• High quality zero gap interior trim products
• Stiffness and Impact balanced materials
TPO Products
• Cold temperature impact ready
• Energy management designed for HIC and SABIC
• Exterior and underhood capable
Totally "Green" Recovery of Painted Plastic TPO Scrap
Automotive Reactor Grades Products for Demanding
Applications
GPRI offers patented new "green" technology for removing paint from your plastic scrap without material degradation.
Like sprues and risers, recovered plastic is restored to the original pre-painted "as molded" condition and is ready to be
remolded into the "Class A Surface" part as originally intended. All coating colors, including white, are completely
removed from scrap material with zero material loss and without residual paint adhesion problems. 26 different plastics
and coatings have been successfully processed to date, including "soft touch". Consignment processing service is
available as well as in-plant/in-line systems for high volume producers. The 100% EPA approved, closed loop process
will end your scrap issues and reduce costs. For more information contact: Ron Janik, V.P. of Sales
Ph: 248 522-6929 - Cell: 248 924-4421 - E-mail: r.janik@globlalplasticsrecovery.com

IMI Fabi LLC
Second and Marshall
Benwood, WV 26031
WWW.IMIFabi.com
Phone: 304-233-0050
Fax: 304-232-0793
info@imifabi.com
2625 N. berkeley Lake Road, Suite 100
Duluth, GA 30096
Web Site: www.Kraiburg-TPE.com
Phone: 678-584-5020
Fax: 678-584-0500
E-Mail: Info-USA@Kraiburg-TPE.com
Contact Name Keith W. Dunlap
Job Title: Director, Sales and Marketing
Phone: 678-584-5193
E-mail: Keith.Dunlap@Kraiburg-TPE.com
Talc Powders for Plastics
Compacted and powder HTP, HM, BT, CH, NB, GT
• IMIFAbI Talc Company, a leading talc manufacturer;
with mining, milling facilities supplying performing talc
grades around the world.
• Headquartered in Milan, Italy, IMIFAbI talc has been
growing over the years to reach an international dimension,
having operations in Europe, the USA, and in Asia, all
equipped with same milling and micronizing processes,
allowing IMIFABI talc to have a unique service: supply
consistent products world wide at local lead time
conditions.
• IMI Fabi Talc Company has invested in various talc
deposits around the word, thus offering diversified talc
grades with million of tons in proven reserves. IMI Fabi is
the right partner for all of your current and future projects.
KRAIbURG TPE Corporation
2625 N. berkeley Lake Road, Suite 100
Duluth, GA 30096 USA
Phone: (678) 584-5020 • Fax: (678) 584-0500
Website: www.kraiburg-tpe.com
Custom engineered TPE and more…
KRAIBURG TPE manufactures thermoplastic elastomers based on
HSBC (hydrogenated styrene block copolymers) and markets them all
around the world. In addition to custom solutions, the company offers,
under the THERMOLAST® and HIPEX® brand names, a broad
spectrum of standardized compounds to cover a wide range of
applications. The company produces at sites in Germany, the US and
Malaysia. KRAIBURG TPE also maintains sales offices in the USA, UK,
France, Italy, Spain, China and India.

Milacron LLC
29111 Stephenson Highway
Madison Heights, MI 48071
Contact: Steve Wood
Automotive Accounts Manager
Office/cell: 513-702-2197
E-mail: steve_wood@milacron.com
1403 Port Road
Jeffersonville, IN 47130
www.mytexpolymers.com
Phone: 812-280-2900
Fax: 812-280-2904
E-Mail: customer_service@mytexpolymers.com
Contact: Eric Short
Job Title: Sales Manager
Phone: 248-705-2830
E-mail: eric_short@mytexpolymers.com
Injection Molding Machines
All-Electric, Hydraulic, Multi-Component
6 ton to 6600 ton
Process Support Equipment
Auxiliary equipment, robots and automation systems
Products & Services:
Contract Services
Retrofit controls – 2 nd /3 rd Injection Units
� Major North American Supplier of Interior and
Exterior Advanced Polypropylene Materials.
� Wholly owned by the Mitsubishi Chemical Company.
� 235,000 Square Foot Facility Centrally Located in
Southern Indiana.
� Additional Detroit Based Sales and Technical
Support.
� Global Resource Expertise from Strategically Located
Global Affiliates.
� Ability to Formulate New Advanced
Products/Precision Formulas for Consistent Quality
Products.
� Commercial & Developmental Compounding Lines.
� A2LA Certified Test Laboratory.
� 24 Hour Customer Service and Technical Support.
� Material Approvals from both U.S. & J.T. OEM’s.
� ISO TS 16949:2002 / ISO 17025

4855 Thirty Seventh St. SE
Grand Rapids, MI 49512-4068
Contact Name: Stu Allen
Job Title: Sales and Distribution Manager
Phone: 616-581-7287
E-mail: stu.allen@noblepolymers.com
803 Mountain View Dr.
P.O. Box 368
Willsboro, NY 12996
www.nycominerals.com
Phone: 518-963-4262
Fax: 518-963-4187
E-Mail: info@nycominerals.com
Contact Name: Gary Phillips
Job Title: VP of Marketing and Application
Development
Phone: 313-388-7241
E-mail: gary.phillips@nycominerals.com
Products & Services:
Noble Polymers is a custom compounder that provides innovative
solutions to engineering problems.
• Supply Array of Commercial Resins
– Ecobarrier® - soft, highly filled TPO’s with recycle
content for sound deadening
– Regis® - rigid, high strength, low shrink TPO’s for
exterior trim
– Forte® - PP based nanocomposites for automotive interior
trim, leisure & recreation, HVAC
– Flextuff® - extrusion grade TPE
• Contract Manufacturing – toll
• Compound Custom Development
– Resins tailored to given application
– Development & testing for individual projects (A2LA
Certified Polymer Laboratory)
• TS 16949 and ISO 14001 certified
NYCO Wollastonite - Proven Reinforcements for
Balancing Costs and Performance
• Improved mechanicals
• Lowers CLTE (no gap)
• Excellent melt strength
• High stiffness with good ductility
• Lower density – thin wall composites
• Improved mar/scratch and gouge resistance
• Odorless, non-dusting

RTM.Plactics.TPO.Ad 7/18/08 9:58 AM Page 1
www.riotintominerals.com
Minerals that make a difference
Solutions that make a difference
4000 Embassy Parkway
Suite 208
Akron, OH 44333
Web Site: http://www.robertellerassoc.com
Contact: Robert Eller
President
Phone: 330-670-9566
Fax: 330-670-9844
Rio Tinto Minerals is the acknowledged
world leader in developing industrial
minerals, and developing solutions
for customers
• Scratch and Mar Resistance
• Color Control
• Odor Control
• Higher Stiffness
• Higher Impact
• Cost Effective Flame Retardancy
Cimpact CB7
Luzenac R7
Steaplast 9502
JetFil 7C
Cimpact 710R
Cimpact 710HS
HAR-Talcs
Jetfine Talcs
Strategies to support autoplastic management
decision making for:
• Market participation
• Product positioning
• Technology diversification
• Acquisitions/mergers
• Asia market presence
Firebrake ZB
Firebrake 415
Firebrake 500

ShINIL ChEMICAL INDUSTRY
Sihwa Industrial Complex 5Ba-104Ho,
675-4, Sunggokdong, Danwon,
Ansansi, Kyunggido, KOREA
Postal Code : 425-836
http://www.shinil-chemical.net
PJ YOON
R&D Director
pj.yoon@shinil-chemial.net
Phone: +82-31-499-2430
Fax: +82-31-499-1080
E-Mail: shinilchemical@shinil-chemical.net
World Headquarters & Technical Center
1401 Crooks Road
Troy, MI 48346
Insight. Inside. Inteva.
www.intevaproducts.com
Phone: 248.655.8886
E-mail: info@intevaproducts.com
Contact Name: Norm Kakarala
Job Title: Senior Technical Fellow
Phone: 249-655-8483
E-Mail: nkakarala@intevaproducts.com
Products & Services:
SHINCON – Conductive Polymer
SHINSTRA – Engineering Plastic
CNT MASTER BATCH
SHINSTAT – ESD Control Polymer
POLYGLUE – Adhesive Resin
SHINNANO – Nano Polymer
SHINFLAM – Flame Retardant
SPYLON - Thermoplastic Resin
Products & Services:
Inteva has deep roots of more than 90 years as a leading supplier of
Interiors and Closures for leading OEMS around the globe. From
past to present, our innovative excellence helped these systems and
components evolve from simply meeting functional needs to fitting
precise buyer lifestyles.
• Interior Systems that meet precise needs for driving
comfort, convenience, look and feel
• Cockpits that raise the bar with complete integration,
assembly, and sequencing services.
• Latch & Closure Systems that embody complexity for
functional simplicity
• Door Modules & Window Lift Systems that reduce costs
and increase reliability

1 Quality Circle
Clinton, TN 37716
Web Site: www.techmerpm.com
Phone: 865-457-6700
Fax: 865-457-3012
E-Mail: jmurphy@techmerpm.com
Contact: Jack Murphy
Job Title: Director of Sales .
Phone: 865-457-6700
Techmer PM offers a complete line of
colorant and additive masterbatch
designed for automotive applications.
SWT PC-25 Direct to TPO Water Based Coating
The SWT Group Headquarter: 519-967-0020 Stephen Regular
1591 Kildare Rd. Fax: 519-967-1220 Coatings Sales and Technology Manager
Windsor, Ontario, N8W 2W2 519-967-0020, ext 236
www.swtgroup.com sregular@swtgroup.com
SWT PC-25 Direct to TPO Water based Coating
SWT has developed a water based coating that adheres directly to TPO and polypropylene substrates with no pretreatment. In adhesion testing,
SWT PC-25 had a result of 5B when applied directly to TPO and PP while achieving excellent hardness, flexibility, and solvent and humidity
resistance.
The benefits of this coating could provide cost savings and VOC reduction not only to companies already painting TPO and polypropylene but
also to companies that would prefer to use these substrates over easier to coat alternatives such as ABS and polyurethanes

CONFERENCE

Material Development

Improving Scratch Performance of Talc-PP and Talc-TPO Compounds
Saied H. Kochesfahani* – Rio Tinto Minerals, Denver, CO
Denis Lejour and Frederic Jouffret, Rio Tinto Minerals, Toulouse, France
The scratch performance of talc-PP and talc-TPO compounds has been of great interest
especially in automotive interior and exterior applications where appearance plays an
important role in the customer approval of car quality. While polypropylene or TPO
based automotive parts offer many cost/performance advantages over other materials,
the scratch and mar performance of these products typically does not fulfill all customer
expectations.
Talc offers a great affinity with polypropylene and is, therefore, the reinforcing additive of
choice in many PP and TPO compounds, where it significantly improves the rigidity and
dimensional stability of the products. However, the mineral-filled TPO compounds still
lack a desirable scratch and mar performance. Significant effort has been focused on
understanding the scratch and mar behavior of plastics and specifically PP based
material in recent years, in which Rio Tinto Minerals has played a pioneering role in
understanding the effect of talc on scratch performance and identifying solutions to
improve the scratch performance of talc-reinforced plastics.
The objective of this study is to conduct systematic scratch performance analyses
utilizing a very large database of talc-PP and talc-TPO samples at Rio Tinto Minerals to
understand the effect of talc parameters (particle size, crystalline structure, mineralogy,
etc.) and scratch additives on the scratch performance of talc-PP and talc-TPO
compounds, and to identify the best performing talc-based formulations for improved
scratch resistance. The newly developed scratch test method at Texas A&M University
and the associated ASTM and ISO standard methods were used in this study to
consistently compare and evaluate the scratch performance of different samples. This
paper presents the results of these analyses and introduces Rio Tinto Minerals current
best solution for improving scratch performance in talc-PP and talc-TPO compounds.
*Speaker: Dr. Saied Kochesfahani is Development Manager for polymer applications at Rio Tinto
Minerals. He holds a Ph.D. in Chemical Engineering from the University of Toronto, and has authored or
co-authored about 40 publications. He has been a member of Tappi for over 13 years and joined SPE in
2006. Phone: 303-713-5231, Email: saied.kochesfahani@riotinto.com.

Abstract
High Performance Reinforcement:
A Pathway to Density Reduction
While Maintaining Physical Properties of Polyolefin Composites
K. David Lake
Milliken Chemical, 920 Milliken Road
Spartanburg, SC 29304
Light-weighting initiatives in the automotive industry continue to be a driving force for the
development of new lower density / higher performance composites. With new CAFE
standards on the horizon along with the continued development of vehicles using
alternative energy sources, the demand for lighter weight and structurally sound
automotive parts may now be at an all time high.
To address this market need, Milliken Chemical is now commercializing a new mineralbased
reinforcing additive for polyolefin composites. This additive, known as HPR (high
performance reinforcement) will serve to complement and surpass Milliken's current
offering of Hyperform® nucleating agents in enabling excellent physical properties with
reduced density as compared to other conventionally filled polyolefins. For instance,
compared to talc-filled polypropylene, HPR will typically provide comparable or superior
performance with only about one-third of conventional talc concentrations. Therefore,
part weight reductions up to 15 - 20% may be readily achieved. Supporting illustrations
in this presentation will include comparative data in flexural modulus, shrinkage, tensile
strength, impact strength, and heat deflection temperature.
While imparting exceptional flexural modulus properties to polyolefins that rival those
obtained with chopped glass, HPR may also be considered for high stiffness applications
where a superior surface finish is desired. In this regard, examples relating to scratch
resistance, gloss, and surface appearance will also be provided. These combined
attributes may even provide an environment for light-weighting to be considered via thinwalling
of parts that are now made with conventional unfilled polyolefins.

SPE Automotive TPO Global Conference 2009
Speaker’s Biography
Name:
David Lake
Title:
Development Associate
Company:
Milliken Chemical
Experience (Brief Summary):
David has been employed by Milliken and Co. since 1983 and for
the last 18 years has worked in Milliken Chemical’s Polymer
Additives business. There he has worked in various roles
including research, technical service, field support, project
management, and applications development. He has developed
extensive expertise in formulating, clarifying, and nucleating
polypropylene and has also gained wide experience in
numerous extrusion and molding processes where
polypropylene articles are fabricated. David has played an
integral role for his company in the development and
commercialization of key successful clarifiers and nucleators in
the Millad® and Hyperform® product lines. He is currently
involved with Milliken Chemical’s efforts to expand into
reinforcing additives for polypropylene. David is the lead or coauthor
of 7 issued US patents.
Education:
B.S. Chemistry, Presbyterian College – 1983
Industry/Trade Affiliations:
American Chemical Society and Society of Plastics Engineers

DonBeuke@aol.com - Technical Consultant 918-914-2947
GO GREEN with MOS Hige Fiber for Light Weighting, Fast Cycle Time,
and Improved Quality TPO's
Donald Beuke with Mitsui Plastics Inc.
ABSTRACT
As gasoline prices, manufacturing and materials continue to rise; automobile manufactures are
turning to parts molded with lighter weight filled TPO’s. With the advent of MOS Hige fiber
from Ube and marketed and serviced by Mitsui, molder saves money and car company achieves
improved quality parts and improved fuel efficiency. 8-10 % of a 70% masterbatch of 0.5x15
micron magnesium oxy-sulfate (MOS) whisker fibers at 70% can be combined with 0-10 % talc to
provide TPO’s with:
1) Lower cost molded parts (molder);
a. 15-35% reduction in mold cycle time
b. 10-15% weight reduction
2) Fuel savings (consumer) GO GREEN;
a. Reduced weight = fuel savings
3) Quality Improvements (car company);
a. Low shrinkage
b. reduction of scratch and mar
c. improved molded-in color (higher color saturation from resin rich surface)
d. high flow resulting in smoother, flatter surface.
e. increased sound absorption for quieter interior parts
Talc filled TPO with MOS Hige A Talc filled TPO control
PP 73-82 % PP 70%
Tafmer 10% Tafmer 10%
Talc 0-7% Talc 20%
70% MOS fiber MB 8-10%
Density 0.92-.099 Density 1.05
Flex Mod 1600-2,500MPa Flex Mod 2,400MPa
MFR 20-50 g/10min MFR 8.7g/10min
Impact -40c 6.6m/sec to -30c N.Izod Impact -30 N. Izod
Part thickness 2.7 mm Part thickness 3.0 mm
Part weight 7.65 lbs Part weight 9 lbs
Cycle time 45 seconds Cycle time 60 seconds
Fuel savings: $3.24 Fuel savings: 0
Presenter: Don Beuke is on his 35 th anniversary as a Chemist and Engineer in product & market development, sales,
and technical service of plastics and additives. He holds a variety of patents with many of the previous companies he
worked for. These companies are; PPG Coatings and Resins Division, Ciba-Geigy Plastics Additives Dept, Phillips 66
Company Plastics Division, Petrolite Polymers Division, Wed-Tech Compounding (now Ingenia) . He is currently,
employed for over 14 years as a Technical and Marketing consultant exclusively with Mitsui & Co. (USA) Inc. and
Mitsui Plastics Inc.

Improved Glass-fiber Reinforced Polypropylene for Structural Applications
Alberto Prieto, Product and Application Development Engineer
Steve Davis, Customer Project Manager
LyondellBasell Industries
Abstract:
Structural applications are one of the fastest growing segments for polypropylene due to advances
such as long glass fiber reinforcement (LGF). Front-end carriers, instrument panel carriers, and
running boards are all examples of applications where the use polypropylene has been enabled by
LGF. There are several approaches possible for making parts reinforced by LGF, including
conventional compounds or to use a direct injection molding compounder (D-LFT) to compound
at the press. More recently, attention has turned to ways to save cost versus LGF compounds.
LyondellBasell has developed a new generation of short glass fiber reinforced materials with
improved stiffness and tensile strength which have replaced LGF in several applications. These
new developments will be discussed in detail with application examples. LyondellBasell has also
contributed to the advancement of the D-LFT process through the development of high melt flow
rate resins and compounds which are successfully used in the D-LFT processes. This includes
two SPE Innovation Award-winning applications.
LyondellBasell Industries’ Hostacom EYS 755P compounded polypropylene (PP) resin is being used to
produce the front-end carrier for the Volkswagen Golf/Jetta/Bora platform. This application won the 2007
SPE Automotive Innovation Award in the Process/Assembly/Enabling Technology category. The part is
produced by AKsys de Mexico, who uses the Krauss-Maffei Injection-Molding Compounder (IMC)
process. This is the first front-end module in North America to use KraussMaffei’s twin-screw Injection
Molding Compounder (IMC) to mix and mold long glass.
Photo: Society of Plastics Engineers

SPE Automotive TPO Global Conference: Speaker Bios
KRAIBURG TPE Corporation
2625 N. Berkeley Lake Road, Suite 100
Duluth, GA 30096 USA
Phone: (678) 584-5020 • Fax: (678) 584-0500
Website: www.kraiburg-tpe.com
Custom engineered TPE and more…
KRAIBURG TPE manufactures thermoplastic elastomers based on
HSBC (hydrogenated styrene block copolymers) and markets them
all around the world. In addition to custom solutions, the company
offers, under the THERMOLAST® and HIPEX® brand names, a
broad spectrum of standardized compounds to cover a wide range
of applications. The company produces at sites in Germany, the
US and Malaysia. KRAIBURG TPE also maintains sales offices in
the USA, UK, France, Italy, Spain, China and India.
Address line: 2625 N. Berkeley Lake Road
Suite 100
City: Duluth
State/Province: GA
Postal Code: 30096
Web Site: www.Kraiburg-TPE.com
Phone: 678-584-5020
Fax: 678-584-0500
E-Mail: Info-USA@Kraiburg-TPE.com
Contact Name Keith W. Dunlap
Job Title: Director, Sales and Marketing
Phone: 678-584-5193
E-mail: Keith.Dunlap@Kraiburg-TPE.com
High-Performance TPE’s for Stringent Automotive Applications

High-Performance TPE’s for Stringent Automotive Applications
John Chiao and Keith Dunlap
Thermoplastic elastomers (TPE’s) have been widely used in the automotive industry for their cost advantages
and performance benefits such as processing versatility and lighter part weight for improved fuel economy.
However However, the the utilization of of TPE’s TPE s in automotive under under-hood hood components components has been limited limited by the the stringent
requirements of high temperature and medium resistance (oils, fuels, fluids, etc…) Recently, KRAIBURG TPE
has developed an innovative TPE based material technology tailored for these challenging environments and
applications. A series of materials have been launched with properties that were only attainable in the past by
high-performance rubber compounds processed using time-consuming vulcanization. This new generation of
TPE’s, branded as HIPEX ® , , offers similar properties p p of those found in high-performance g p rubber compounds. p
They have combined the ability to withstand temperatures up to 170oC and exhibit chemical resistance to motor
oils, fuels, greases, and coolants. In addition to adhering to polyamide (PA) and polyacetal (POM), HIPEX ®
products demonstrate optimal adhesion to polybutylene terephthalate (PBT), and thus cover most engineering
polymers utilized in the engine compartment. The materials show good process-ability under typical
thermoplastic molding conditions. HIPEX ® resins are suitable for a number of applications inside and out outside
th the engine i bbay, iincluding l di seals, l plugs, l caps, gaskets, k t ddrive i bbelts, lt ttubes, b connectors, t hhoses, cables bl and d even
noise and vibration dampening. They can be used as a replacement for acrylic elastomers (ACM) or ethyleneacrylic
elastomers (AEM) and are ideally suited for working temperature performance up to 150oC. This presentation will describe the typical make up of HIPEX ®
and compare p the pperformance of current polymers p y and
technologies used in stringent automotive applications. Finally,
it will compare those polymers in a cost vs. benefit analysis of
materials targeted for rubber replacement, higher cost
polymeric material replacement, processing ease, and need for
secondary operations.
We thank you in advance for your consideration.
Kraiburg TPE Corporation 2625 N. Berkeley Lake Road, Suite 100, Duluth, GA 30096

Keith W. Dunlap, Director of Sales and Marketing, KRAIBURG TPE
Keith has over 15 year experience in the plastics industry with executive level management experience in global
markets with companies that produced and distributed engineering thermoplastic resins, films and sheet systems,
processed plastics for automotive, medical, consumer and industrial applications and compounded elastomeric
materials for specific application requirements. He has held positions of increasing responsibility for companies that
include GE Plastics, Bayer’s Polymers Division, Porex Corporation and KRAIBURG TPE. He is a graduate of Northern
Illinois University in Engineering and has completed post graduate MBA work at the University of New Hampshire in
addition he holds a minor in Graphic Arts and has business leadership and marketing certifications from the John F.
Welch Leadership Development Center at Crotonville, NY. Keith resides in Atlanta, GA and has a son of 11 years.
John J. Chiao PHD, Senior Scientist, KRAIBURG TPE
Dr. John Chiao manages the quality and development department at KRAIBURG TPE. His daily responsibilities range
from developing new TPE formulations for consumer, industrial and automotive applications, to providing technical
services for worldwide customers. Dr. Chiao has over 11 years of industry experience in specialty chemicals, resins
and polymeric materials. Prior to joining KRAIBURG TPE, he worked as a senior scientist with Cytec Specialty
Chemicals and R&D manager with Tesa Tape. Dr. Chiao has co-authored more than 25 technical publications and
patents on TPEs, UV/EB curable resins, pressure sensitive adhesives, nanocomposites, and conducting polymers. He
holds a Ph.D. in polymer chemistry from Michigan State University, an MBA in Financial Management from Georgia
State University, and a B.S. in polymer science from Nanjing University (China). John lives in Marietta, GA with his
wife and two children.

Abstract:
Polypropylene Property Modification using Vistamaxx Specialty
Elastomers and Exact Plastomers
Felix Zacarias
ExxonMobil Chemical Company
388 South Main Street
Akron, OH 44311
330-849-5159
This paper presents the basic principles of modifying the properties of polypropylene (PP) using
Vistamaxx specialty elastomers (propylene specialty elastomers) and Exact plastomers in applications
requiring impact modification and flexibility. Although both can be used to gain these properties, the precise
physical properties obtained can be significantly different due to their level of compatibility with PP. A
study of different blends of each polymer with PP resin was examined and a side by side comparison of the
key properties reported. By using this comparison, the compound or dry blend can be optimized by using the
correct polymer selection to meet specific application needs. The results from this work will provide
recommendations on material selections for compounding applications when using propylene specialty
elastomers and plastomers.
Applications Technology Development Engineer
email: felix.zacarias@exxonmobil.com
phone: 330-849-5159

New Higher Impact Efficiency Elastomers for High Performance Rigid TPOs
Kim L. Walton 1 , Mark Berard 1 , Theresa Hermel-Davidock 1 , Phillip Hustad 1 ,
Jim Hemphill 1 , Didem Oner-Deliormanli 1 , Russell Barry 2
Dow Elastomers
The Dow Chemical Company
1 Freeport, TX 77541
2 Horgen, Switzerland
Specifications for rigid TPO’s continue to evolve. In a recent Voice of the Customer
survey along the TPO compound value chain, the interviewees indicated that new rigid
TPO specifications will call for an increase in flexural modulus with no change in lowtemperature
impact resistance. Thus, TPO suppliers face increasing challenges to find
the right combination of polypropylene, impact , and reinforcing agent to meet ever more
demanding performance requirements.
A new family of high efficiency impact modifiers has been developed to meet these
increasing demands. The new impact modifier exhibits 15 – 20% higher impact
efficiency than best-in-class, commercial ethylene/1-octene copolymers (EO). It exhibits
equivalent low-temperature, high-speed dart impact efficiency as styrene/ethylene-1butene/styrene
block copolymers with 15% higher modulus in TPO at equivalent levels.
Characterization and performance of this new class of impact modifiers will be discussed.
IDI@ -30C, % ductile
60
50
40
30
20
10
0
New Impact Modifier
1700 1800 1900 2000 2100 2200
Chord Modulus, MPa
0.5 dg/min, 0.863 g/cc EO
6.7 m/s dart speed
Figure 1 Comparison of new impact modifier with commercial EO elastomer used in
rigid, reactor-TPO compound

Kim L. Walton Biography
Kim Walton received his Bachelor of Science degree in Polymer Science from the
University of Southern Mississippi and his Master of Science degree in Macromolecular
Science from Case Western Reserve University. From 1983 – 1996, Mr. Walton worked
for The Dow Chemical Company in a variety of applications including chlorinated
polyethylene for single ply roofing and vinyl siding impact modification, biaxially
oriented polyethylene film and ethylene/1-octene copolymer based cross-linked foams.
He joined DuPont Dow Elastomers L.L.C in 1996 where his development focus was on
Engage® for flexible automotive interior applications, blow molding, and
thermoforming. He rejoined Dow in July, 2005 and is leading the technical development
for polyolefin elastomers and plastomers. He is a senior member of the Society of
Plastics Engineers. He is an author or co-author of ten patents and twenty two outside
publications.
Contact Information
Kim L. Walton
Dow Elastomers
The Dow Chemical Company
2301 Brazosport Blvd., B-1470
Freeport, TX 77541
Phone: 979-238-3466
Fax: 979-238-0235
email: klwalton@dow.com

Abstract:
Low Density TPO Development for Automotive Exterior and Interior Applications
Todd Glogovsky
LyondellBasell Industries
An increase in public awareness regarding environmental issues backed by State and Federal
Agencies has influenced consumers purchasing behavior and North America Businesses.
Federal and State sponsored limits on carbon emissions through initiatives such as “Cap and
Trade” are impacting the North American Automotive Industry. These initiatives have spawned
new technology developments to meet new environmental requirements. Weight reduction
targets will provide benefits of piece part cost, transportation cost, and environmental saving
which can be applied to the business’s best interest. LyondellBasell Industries has utilized new
catalyst and compounding technologies to develop novel polymers and polymer blends with
equal or better mechanical performance and dimensional control while providing significant
weight reductions. These technologies are being applied to the design of plastic resins for TPO
exterior and interior components. This presentation will summarize these activities.

Breaking New Ground with Thermoplastic Polyolefin Body Panels
Neil Fuenmayor, Customer Project Manager
Todd Glogovsky, Technical and Marketing Manager
LyondellBasell Industries
Abstract:
Thermoplastic Polyolefins (TPOs) are commonly used for automotive exterior
applications like bumper fascia for their light weight and excellent cost/performance
balance versus other engineering thermoplastics. Improvements in TPO stiffness/impact
balance and reduced coefficient of linear thermal expansion (CLTE) have enabled TPO to
be considered for vertical body panel applications such as fenders, tailgates, and roof
spoilers. This paper will examine the state of the art of TPO materials suitable for body
panel applications and give specific application examples, such as the Ford Kuga
illustrated below.
LyondellBasell Industries’ Hifax TRC 280X compounded polypropylene (PP) resin is
being used to produce the tailgate outer panel and the roof spoiler for the Kuga, Ford’s
new European crossover model. It is the first time Ford in Europe has used an advanced
polyolefin in a body panel application.
Photo: Ford Motor Company

Strain Hardening of Polypropylene-Clay Nanocomposite Melts in Uniaxial
Extensional Flow
Tanmay Pathak* and K. Jayaraman
Dept. of Chemical Engineering and Materials Science, Michigan State University
Strain hardening of polymer melts in elongational flow is important for a
variety of polymer processing operations such as thermoforming, foaming and blow
molding. It is well known that linear polypropylene does not strain harden in melt
extensional flow. The effect of dispersing two different organoclays at different levels
in linear polypropylene on the transient uniaxial extensional viscosity has been
investigated in this work. The matrix polymer was a linear polypropylene grafted with
maleic anhydride (PP-g-MA); two different grades of organoclay with different ionic
surfactants were used as filler. The neat PP-g-MA matrix did not show any strain
hardening at different extensional strain rates. The nanocomposite melt with (I.44P)
organoclay exhibited significant level of strain hardening at several extensional strain
rates whereas the nanocomposite melt with (I.30P) organoclay showed much lesser
strain hardening at those extensional rates, as can be seen in Figure 1. The I.44P clay
has a quaternary ammonium ion surfactant with two C-18 tails as compared to I.30P
clay which has a primary ammonium ion surfactant with single alkyl tail. The extent
of strain hardening for the nanocomposites was also investigated based on several
other factors such as the amount of maleic anhydride in matrix and its molecular
weight, the clay loading, and also the effect of melt temperature.
η E + (Pas)
1.0E+07
1.0E+06
1.0E+05
1.0E+04
150°C
1.0E+03
Neat PP-g-MA
1.0E+02
1.0E+01
0.1 s-1
0.5 s-1
1.0 s-1
2.0 s-1
0.01 0.1 1 10 100
t (sec)
X 100
X 10
5 wt% I.30P clay
5wt% I.44P clay
Fig 1: Uniaxial melt extensional viscosity: Neat PP-g-MA shows no strain hardening;
Nanocomposite with 5wt% I.30P clay shows lesser strain hardening, and the one with
5wt% I.44P clay shows significant strain hardening.
*Speaker: Tanmay Pathak is a graduate student at Michigan State University. He
holds a B.E degree in Chemical Engineering and is currently pursuing a doctoral
degree in Chemical Engineering at Michigan State University under the guidance of
Dr K. Jayaraman.

Unique flow of polypropylene at the weld line behind an obstacle in injection molding
Yutaka Kobayashi, 1,3 Gensei Teramoto, 1 Toshitaka Kanai 2,3
1 Prime Polymer Company, Limited, Sodegaura-City, Chiba 299-0265, Japan
2 Idemitsu Kosan Company, Limited, Ichihara-City, Chiba 299-0193, Japan
3 Graduate School of Natural Science & Technology, Kanazawa University, Kanazawa-City,
Ishikawa 920-1192, Japan
Abstract
This paper deals with weld line of metallic mold-in-color polypropylene behind an obstacle in
an injection molded plaque. Broad uneven gloss section was observed visually along weld line
after disappearing V-notch weld. Generally, disk-shaped metallic pigments were oriented
parallel to the wall by laminar flow. The pigments at the weld behind an obstacle were ordered
vertically at the core zone in the plaque. When the pigments were eliminated from PP, black line
was observed at the same position of the metallic weld. From the measurement of crystal
structure, black line was caused by rapid cooling of molten resin. Although an irregular flow
pattern was not simulated by a flow analysis, it was suggested that elongational flow occurred
along weld line after fading away V-notch weld. The unique flow made order the pigments
obliquely at the advancing flow-front and disturb the subsequent flow of hot resin which
transferred heat to the crystallizing place.
Short biography
Yutaka Kobayashi is a senior research associate in Prime Polymer Co. Ltd,.(a joint
company of Mitsui Chemical and Idemitsu Kosan (Japan)). He entered Idemitsu in 1985.
He has been developing Polypropylene (PP) compounds in Prime Polymer since 2005
and studying in a doctoral program of Kanazawa University (Japan) since 2009. He
specializes in morphology of PP induced by injection molding.

SPE AutomotiveTPO Global Conference 2009
Speaker’s Biography
Name: Yutaka Kobayashi
Title: Senior research associate
Company: Prime Polymer Co. Ltd,.
(a joint company of Mitsui Chemical and Idemitsu Kosan (Japan))
* Present: Senior researcher & senior manager
Advanced Composites, Inc.
1062 S Fourth avenue, Sidney, OH 45365
Experience (Brief Summary):
2009 July: Advanced Composites, Inc.
2005 April: Prime Polymer Co., Ltd.
1985 April: Idemitsu Kosan Co., Ltd.
I has been developing Polypropylene (PP) compounds for 24 years. I
specialize in morphology of PP induced by injection molding.
Education:
2009- A student in a doctoral program of Kanazawa University
(Japan)
1985; Graduate Gumma University (Japan), MS
1982; Graduate Gumma University (Japan), BA
Industry/Trade Affiliations:

Special Session

About the Instructor
Shane Vandekerkhof
Shane Vandekerkhof joined the RJG Team in 2003 as a member of the Customer Support team, where he quickly
gained knowledge and understanding of RJG’s systems and hardware. He quickly became qualified to conduct on-site
training for RJG customers that included hands-on training on RJG’s software and equipment.
After two years Shane took on the role of Business Development for Europe where he was responsible for creating new
accounts, supporting existing accounts, and working with sales representatives. He traveled extensively during this
period to lay the groundwork for RJG to expand into this region. He established contacts and researched the area for
further expansion.
Shane is currently one of RJG’s Trainer/Consultants. His background, knowledge and abilities made the transition into
this role an easy one. His responsiblities include teaching RJG Systematic courses as well as Master Molder
Certification courses. Shane’s quick grasp of molding essentials have made him a valuable member of the RJG Team.
Before coming to RJG Shane attended Michigan State University, Davenport University, and Northwestern Michigan
College where he studied Computer Information systems.
What some of Shane’s students had to say about their training:
“Course had excellent content which is applicable in a real world setting – not just textbook – instructor was
enthusiastic and presented great real world examples.” Jerry Driscoll – Panduit
“A clear, systematic approach to a very interactive process. RJG’s use of training & techniques coupled with
technology make them a world class partner.” Stephen Balsam – L&L Products
“Great job of breaking the process down to easy to understand pieces.” Chris Benbow –Flextronics
RJG, Inc. ~ 3111 Park Drive ~ Traverse City, MI 49686 USA ~ Phone: 231-946-3111 ~ Fax: 231-947-6403 ~ Web: www.rjginc.com

SPE Automotive TPO Global Conference 2009
RJG Special Session – 4 hrs, including video lab demonstration
Session Title: Injection Molding & Advanced Process Control
Session Moderator: David Okonski – General Motors
Session Presenter: Shane Vandekerkhof – RJG, Inc
Description: Special session on advanced process control and trouble-shooting for the
injection-molding process to help participants achieve a competitive
advantage in the global market.
Session Content (via PowerPoint media/presentation):
• Polymer Basics
o Overview of Polymerization – focus on polypropylene (PP) and
polyethylene (PE) and the compounding of PP and PE into a TPO alloy
o Commonly used fillers/reinforcements and their effects on the material
properties – such as strength and impact – of TPO
o Effect of polymer chain variation on morphology:
� Molecular weight / molecular weight distribution
� Polymer viscosity and its impact on the injection-molding process
• Decoupled Molding Strategies – define “Decoupled Molding”
o Define the basic benefits of a Decoupled I Process
o Define the basic benefits of a Decoupled II Process
o Define the basic benefits of a Decoupled III Process
o Define and discuss the underlying principles of “Scientific Injection
Molding for (Advanced) Process Control”
• Troubleshooting the Injection-Molding Process
o Discuss cause/effect of some common defects:
� Relate material variation (lot-to-lot and mat’l-to-mat’l) to defects
� Relate machine variation to defects
� Relate tool variation to defects
o Defect focus (proceeding from simple to the more advanced):
� A general discussion of Shorts, Flash, & Sink
� Surface defects – such as gloss, tiger striping and gate blush – for
an as-molded, non-grained & grained, class A interior part
� Minimize dimensional variations due to warp for a body-side
cladding
� Minimize the effect of residual stress on the impact properties of a
fascia
Lab demonstration via internet video link to RJG Laboratory in Traverse City, Michigan
• Demo of current eDART (process monitoring) system
• Live troubleshooting lab
o Produce defects and interact with attendees on possible causes
o Verify root causes using eDART system

Application Development

Robert Eller Associates LLC
CONSULTANTS TO THE PLASTICS AND RUBBER INDUSTRIES
TECHNICAL / ECONOMIC / MARKET ANALYSIS & MANAGEMENT DECISIONS
4000 Embassy Parkway · Suite 208 · Akron, OH 44333-8328 USA
Phone 330-670-9566 / Fax 330-670-9844
E-mail: bobeller@robertellerassoc.com / Home Page: http://www.robertellerassoc.com/
Effects of the Global Economic Situation on Automotive TPOs
Robert Eller
Abstract: The global recession has severely impacted automotive markets and demand for automotive
TPOs. The recent uptick in the market is promising, but the automotive plastics paradigm and the
associated supply chain have shifted. This new paradigm is creating opportunities for increased
demand for automotive TPOs driven by fuel economy requirement shifts, increased emphasis on
weight reduction, increased modular construction and the demand for global vehicle platforms. The
new paradigm offers TPO opportunities in:
- Advanced battery applications
- New applications associated with polyolefin-based composites (both mineral filled and advanced
long fiber reinforced)
- Exterior panels
- A new generation of absorption components
- Multi-shot molded components
- An expanded range of soft touch applications
This paper explores the macroeconomic shifts associated with the global recession and the impacts on
automotive demand, the supply chain, and opportunities for TPOs in the new automotive plastics
paradigm.
r/mydox/SPE TPO 2009/Abstract REA SPE TPO 2009.doc

SPE Automotive TPO Global Conference
Oct 5 – 7, 2009
TPO Development for the 2010 and Beyond
Sassan Tarahomi
IAC North America
ABSTRACT 1
2008 was a wake-up call to all of us in the automotive industry, especially the material engineers and
purchasing managers who were shocked by crude oil price rising to $145 per barrel. We all knew chemicals
derived directly from crude oil such as Ethylene, Propylene, Butylenes, Butadiene and so many others would
follow oil price and eventually their prices sky rocketed to new highs. In the summer and fall of 2008
Polypropylene price was hovering around $1.00 /lb which in turn forced TPO prices to go up as well.
Do we need more refineries to process more oil to lower resin cost?
Well, in early 1980’s, there were about 300 refineries in the U.S with a combined capacity of 18 million barrels
of oil per day. Now, with great improvement in our efficiency we have only 149 refineries producing same amount
of oil per day as 30 years ago.
Why don’t we build more refineries?
New refineries require tremendous financial commitments which take anywhere from 20 to 30 years to
amortize. With record oil prices in the last year or so, it would make perfect sense to invest in building new
refineries. Then why, there hasn't been a new refinery built in the US since 1976. Answer is oil is depleting at a
very fast rate, there would not be any oil to refine 20 years from now, and therefore building new refineries would
not make sense, because there won't be enough oil left to refine by the time new refineries could pay for
themselves. Answer is not more refineries.
The objective of this paper is to closely examine key factors effecting TPO price in the next several decades
and to provide a guideline for developing new TPO resins for Automotive and other industries.
1 Author: Sassan Tarahomi, Material Eng. Manager, IAC N.A., Dearborn, Michigan

Over-Molding New Cost Effective Soft Touch TPV on Polypropylene
Substrates with Improved Surface Durability, Soft / Dry Feel, and High
Temperature Resistance.
Jeffrey Valentage and Hermann-Josef Holz ExxonMobil Chemical Company
Global Automotive Marketing, Polymers
Abstract:
The perceived quality of the vehicle interior is dominated by the “look” and “feel” of the
interior surfaces. A broad range of materials with different levels of perceived quality is
currently used. The products range from injection molded neat PP on the low end up to
assembled multi-layer structures with thermoformed skins or leather for luxury vehicles.
2-Component injection molding (2-K) allows the construction of an all polyolefinic
system consisting of a stiff PP substrate for carrying load and a grained thin top-layer
skin to give improved comfort.
A new Santoprene TM TPV product has been developed for 2K molding a soft touch skin
over polypropylene based substrates. The new TPV product offers several performance
advantages, which include:
- High flow for ease of molding a thin skin layer
- Product stability over a broad temperature range
• Maintains dry soft feel
• Minimal gloss change
- High Durability: scratch, mar and abrasion resistance
- Low emissions
- Provides system cost savings while improving the interior appeal: Eliminates the
needed for secondary steps such as soft touch paint or a separate skin/foam laminate
The presentation will focus on the aforementioned performance attributes of the new
product and review the advantages / disadvantages of the various overmolding techniques.
Speaker: Jeffrey Valentage has been involved in the plastics automotive industry for
over 20 years. He began his career as a Process/Project Engineer and Manufacturing
Manager at a major plastics molder, joined the ExxonMobil Chemical-Automotive
Business Unit, Farmington Hills, MI in 1997, and served as an Applications Engineer and
OEM Account Manager. Jeffrey is currently focusing on global automotive marketing
for polymers at the ExxonMobil Chemical Headquarters in Houston, TX. Jeffrey holds a
BS degree in Business Administration from the University of Phoenix.
jeff.valentage@exxonmobil.com

Digital Color Solutions for Automotive TPO Applications
Jim Harper, Techmer PM, Clinton, TN
Nearly every vehicle system is envisioned and evaluated using virtual, computer-aided imaging tools.
Automotive parts subject to critical color evaluation, however, have been excluded from the computer
revolution. The nuances of color, its subjective nature, metamerism, textural effects and the like, have
caused development to proceed through a tedious sample-making and visual approval process, only to
converge on a set of compromised colors. Digital tools and color development processes now exist to
accelerate the master approval process. The objective of the paper is to describe and illustrate the
advantages of digital color development as a precursor to physical sample making.
TPO color, molded in various grains, represents one subset of the overall interior color. Since the color
development plaque issued by an OEM is typically an injection-molded part, TPO color matching is
usually straightforward. Obtaining parts approval may be somewhat more complicated since the final
part might be adjusted for lightness/darkness due to grain, lighting, and viewing angles used to
subjectively evaluate the part.
Other components, textiles for example,
are dissimilar to the master plaque in
many ways. As thin-section parts,
frequently colorants used in the master
plaque cannot be used in textiles due to
lightfastness considerations. The textile
texture is dramatically different from the
master plaque and every submission is an
interpretation or a guess as to what the
appearance group is trying to achieve. At
the end of the process all of the interior
parts are mutually compared and must
have the same hue in three illuminants.
Obtaining the final, critical match for
every commodity that meets the
approver’s subjective standard is difficult.
Digital development, using real-world colorants as the basis for mathematical color modeling, is able to
harmonize color at the front of the process. Color is applied digitally to the various interior textures and
provides the communication interface to evaluate color formulations before samples are made.
Afterwards, a preliminary set of physical samples based on a digital approval can verify color, harmony,
and weathering performance--all at the beginning of the mastering process.

STRUCTURE-PROPERTY RELATIONSHIP STUDY OF NOVEL
METALLOCENE-BASED R-TPO FOR INTERIOR PARTS
By Shouichi Fukunaga 1 , Kenji Matsuoka 1 , Kouichi Honda 1 , Kiyoshi Yukawa 2 , and
Motoko Ito 3
1
Japan Polypropylene Corporation, Product Technical Center 1
2
Japan Polypropylene Corporation, Polymerization Technical Center
Toho-cho 1, Yokkaichi, Mie 510-0848, Japan
3
Japan Polypropylene Corporation, Marketing & Overseas Business Group, Sales &
Marketing Division
4-14-1,Shiba, Minato-ku, Tokyo 108-0014, Japan
Abstract
TPOs have become increasingly popular for manufacturing automotive exterior and
interior parts mainly because of their many apparent advantages, including light weight,
recyclability, productivity, low cost, etc. For interior parts applications, TPOs are
expected to replace PVC and PU foam materials if further improvements in TPO
properties, such as softness, gloss, grain retention, stickiness, abrasion, and scratch
resistance, can be made. To address the above challenges, JPP has recently developed an
advanced metallocene catalyst technology for our original gas-phase HORIZONE
process to produce a series of novel R-TPOs that possess unique property attributes
unmatched by conventional Z-Nat R-TPOs. In this presentation, we will highlight the
attractive physical and mechanical properties of a series of soft R-TPOs and show their
p otentials for automotive interior parts applications.
Stickiness
(Anti-Bleed out
Good
Property)
Low Temperature
Resistance -40
(Tg:°C)
Flexural Modulus (MPa)
0
-20
Bad
Worse
0
80
100
120
140
200
400
600
800
80
Heat resistance
(Tm:°C)
40
80
Charpy Impact
Strength(23 °C)
(kJ/m2 Charpy Impact
Strength(23 °C)
(kJ/m ) 2 )
60
40
20
Transparency
(Haze:%(2mm sheet))
WELNEX ® WELNEX ®
Conv. R-TPO(RCP Base)
Conv. R-TPO(Homo Base)
Fig. 1. Schematic Showing Physical Property Differences of the Novel Metallocene R-TPO
WELNEX TM Against Conventional R-TPOs.

Superior Appearance Material in Airbag Cover Applications
Dr. Nadeem Bokhari
Autoliv North America
Kousuke Ohtani
Tetsuya Hisayama
Noboru Yamaguchi
Sumitomo Chemical Co., Ltd.
Abstract:
Airbag covers in automotive applications require a specific rigidity in applications such as in
driver and passenger airbag systems. One key criteria used in evaluating materials has
been their impact strength at low temperature deployments without breaking or tearing
beyond the tear seam design. In addition to this performance criteria, the molded part must
provide good cosmetics since it is clearly visible to the occupants inside the vehicle. To
balance such diversified requirements, olefinic elastomer-based TPO and styrenic
elastomer-based TPS have been used in these applications.
Currently, the incumbent technologies have been challenged in trying to satisfy both
performance and cosmetics when producing a non-painted cover. The challenge is trying
to maintain part performance and low gloss through the tear seam where most cosmetic
defects occur. Areas of high or uneven gloss require manufacturers to cover these defects
with paint in order to pass the visual quality requirements of their customers.
Under such circumstances, the authors have developed a new material technology that
delivers the cosmetic requirements on non-painted airbag covers while maintaining the most
demanding performance requirements in cold temperature deployments.
Dr. Nadeem Bokhari
Autoliv North America, American Technical Center
TEL: 248-276-7853, FAX: 248-475-9835
E-mail: nadeem.bokhari@autoliv.com
Sumitomo Chemical Co., Ltd. Petrochemicals Research Laboratory
TEL: +81-436-61-5352, FAX: +81-436-61-5344
E-mail: ohtanik2@sc.sumitomo-chem.co.jp

Optimization of Scratch Resistance for Molded in
Color (MIC) Interior TPO Injection Molded Plastics
Abstract
Renee Hotton
General Motors Corporation
As customer dissatisfaction with interior trim pieces is tracked by the JDPowers question
on surface durability there is a need to increase the surface durability of the molded in
color parts. In particular, door lowers are parts that are susceptible to scratching those
results in a poor surface appearance.
An assessment of the various parameters that can affect surface durability was conducted
using talc filled TPO materials to determine the optimum set. The following P – diagram
shows the control factors, noise factors, and the outputs used for the evaluation.
Control Factors:
Grain
Gloss
Material
Color
Interior Trim Plaque
Noise Factors:
Molding Condition
Aging
Piece to Piece (Test to Test)
Outputs:
Erickson Score
(STB)
The presentation will include a detailed description of the Design for Six Sigma
methodology used, the factors that were evaluated and the test results that were obtained.
The interpretation of the test results relative to the optimization direction will also be
discussed.
Speaker: Renee Hotton is a Materials Engineer in the Material and Corrosion
Engineering Department at General Motors Corporation. Her current responsibility is in
Interior Plastics for a variety of programs. Renee has a Bachelor of Science Degree in
Chemical Engineering from Michigan State University. Email: renee.a.hotton@gm.com.

Process/Surface

Mar Resistance Testing and Evaluation of Thermoplastic
Olefins
Robert L. Browning 1* , Peng Liu 1 , Hung-Jue Sue 1 and Kevin Reid 2
1 Polymer Technology Center, Department of Mechanical Engineering
Texas A&M University, College Station, TX 77843, USA
2 Phillips-Sumika, Bartlesville Technical Center, Bartlesville, OK 74004
Abstract
Throughout the history of the field of tribology, little has been done to assign explicit
definitions to the terms associated with the various types of surface damage from sliding
contacts. A deep investigation reveals that each of these terms can be described by a
unique testing and evaluation scenario.
Our past work in the field of tribology, with close association with various sectors of the
polymer industry, has sought to disambiguate these terms and has been met with a fair
amount of success. This study
aims at investigating “mar”
behavior on polymer surfaces via
development of an effective
testing and analysis methodology
derived from the current
ASTM/ISO scratch test method
and has been applied to model
TPO systems with and without
slip additive that possess high and
low gloss surfaces.
Percentage Change
-100
Abrasion Characterization of High Gloss TPO
150
100
50
0
-50
Gloss
Roughness (Ra)
-150
0 1 2 3 4 5 6
It will be shown how gloss,
Applied Normal Load (N)
surface roughness and digital
image contrast are inter-related regarding mar testing and evaluation of TPOs. The
implications of this new test methodology compared to the current industrial practices
will also be discussed.
* Speaker: Robert Browning (B_Squared02@yahoo.com) is currently working on completing his doctoral
degree in Material Science & Engineering. His research is concerned with polymer structure-property
relationships with an emphasis on tribological behavior.

Process Development Session:
Aluminum Tooling for Injection Molding Seminar Agenda
Plenary Presentation: Aluminum Tooling for Injection Molding of TPO Materials
Patti Tibbenham, Ford Motor Company
Mold Design Improvements, Surface Coatings, Heat Transfer and Part Price Opportunities
Robert Beard, P.E., President of Robert A. Beard & Associates Inc.
Properties of Aluminum Materials for Injection Molds
Dave Wirth, Clinton Aluminum
Designing Production Aluminum Molds
Greg Eidenberger, Paragon Die & Engineering
Case Studies of Production Aluminum Tooling
Dave Dickerson: DRS Industries
Manifold Considerations (Thermal 2-3d Analysis)
Rich Oles: Plastic Services Group Inc. (PSG)
Lessons Learned in Graining and Repair of Aluminum Tooling for Injection Molding
Ron Smierciak: Alcoa
The automotive industry is constantly driving toward cost opportunities, faster time to
market and improved quality. In addition, the industry is moving toward more niche vehicles
with lower production volumes. These drivers make aluminum tooling a current and important
topic of interest in the automotive plastics industry.
All aspects of aluminum tooling will be included from the perspective of the OEM, tier 1
suppliers, mold manufacturers, to the material suppliers. This discussion will include an open
forum on current and past successes and failures utilizing this technology for production molds.
Aluminum material grades and applications will be reviewed. Mold manufacturing design
details and cost savings opportunities for production aluminum molds will be highlighted. Case
studies of current production tools for automotive applications will be discussed. Additionally,
specific hot runner considerations for aluminum will be covered with 2d and 3d thermal
simulations of the cooling characteristics comparing conventional steel and aluminum materials.
Finally, lessons learned in the graining and repair of aluminum tooling for injection molds will
be included.
Aluminum tooling is not appropriate for every automotive plastic component, and this is
more apparent once individuals understand the realities of aluminum tooling. All of the speakers
have cooperated to make this seminar an educational opportunity; informing the conference
participants so everyone can make their own individual decisions relative to production
aluminum tooling.
Speakers:
Patricia Tibbenham is a technical expert in Plastics Research at Ford Motor Company. She
holds a BS in Mechanical Engineering from GMI and a MS in Engineering Management from
Wayne State University. Patricia has spent over 20 years working on plastic components in the
automotive industry and she holds several U.S. Patents. Email: ptibbenh@ford.com

Robert Beard is a licensed Professional Engineer with over 40 years experience in the plastics
industry. He is a Honored Fellow member of SPE. For the past 6 years, he has concentrated on
getting existing and new molds to be better heat exchangers and reducing cycle times by 20% to
40%. www.Plastic-Solvers.com
David Wirth is the North American Aluminum Mold Specialist and Midwest Sales Manager for
Clinton Aluminum and Stainless Steel. He plays an active role in marketing Clinton Aluminum
and is currently working with a mill to develop and bring to market a new alloy for the injection
mold market. David also worked at ThyssenKrupp Specialty Steel Tool Steel Division, covering
Wisconsin, Iowa and Minnesota for Die Cast and Injection Mold Markets.
Greg Eidenberger is the Sales Manager for Paragon D&E located in Grand Rapids, Michigan.
Greg has been with Paragon for over 28 years, as a Detail Draftsman, Tool Designer, Program
Manager, Technical Sales, Business Unit Manager and now the Sales Manager for the last 5
years. Greg has been instrumental in working with many of Paragon's customers who are using
Aluminum Alloy's for Medium and Low Volume Production Tooling.
Dave Dickerson is the Plant Manger for DRS Industries in Holland, Ohio. Dave has been with
the company since 1989 starting as a plastic injection mold maker apprentice, with a focus solely
on aluminum plastic injection molds. Dave served his apprenticeship with DRS, becoming a
journey mold maker and worked through the years as a working Shop Foreman. The Plant
Manager position was offered to Dave in 1999, where as his duties are to oversee the day to day
operations of an aluminum mold builder/plastic injection molder. In 1999 DRS started to
produce and run aluminum low volume tooling for plastic injection molded parts, and has
become the authority on the construction and running of production aluminum tools.
Richard Oles started out setting up and operating multi-spindle screw machines, turned Mold
Maker, Engineering manager, IT manager, General Manager, President and CEO over the past
23 years. Each position built off the experience of the prior, and then he entered into the Hot
Runner manifold world in 1999 with a Swiss based firm. This role set the stage for his current
position as CEO of North America operations for the German based Hot Runner manufacturer,
PSG Plastic Service Group, Inc.
Ron Smierciak, Market Development Manager, Alcoa Forgings and Extrusions – Ron has been
engaged with the development of Alcoa’s mold alloy, QC-10, since 2005. He is responsible for
the product development of Alcoa QC-10. Ron actively promotes the benefits of aluminum
tooling to molders and original equipment manufacturers in North America, Europe, and Asia.
Prior to his involvement with Alcoa and QC-10, Ron developed products for thin film coatings
serving the semiconductor and flat panel display industries.

Mechanical Modeling of Scratch Induced Periodic Damage
Han Jiang 1* , John D. Whitcomb 2 and Hung-Jue Sue 1
Polymer Technology Center, Department of Mechanical Engineering 1
Department of Aerospace Engineering 2
Texas A&M University, College Station, TX 77843, USA
Abstract
Regardless of the polymer type, periodic occurrence of scratch-induced damage features
is commonly observed. The above phenomenon is believed to be the result of a “stickslip”
process involving the scratch tip.
The stick-slip process is caused by the presence of a horizontal degree of freedom of the
tip and the oscillation between the static and kinetic frictional behaviors. In addition, the
tip geometry and material
pile-up ahead of the 300 Distance Between Periodic Scratch Damage
scratch tip will further
complicate the scratch tip
movement during scratch.
250
200
1 2
2 [( μμ s − μμ
k ) F n + κκ
δδ
e F n ]
D =
k h
Periodic Distance
To understand this 150
Blunter tip
complex phenomenon, a
simplified analytical
100
Scratch
indentation
model on the stick-slip
phenomenon is proposed
to account for the
observed periodic scratchinduced
damage features
50
0
0 5 10 15
Scratch Normal Load
20
Without
indentation
25 30
on polymer surfaces. Through the above modeling effort, fundamental understanding of
the scratch behavior under various scratch conditions is gained. Implication of the above
study for fundamental understanding of the mechanical nature of the ASTM/ISO scratch
test is also discussed.
* Speaker: Han Jiang (jianghantamu@gmail.com) is conducting his post-doctoral research at Texas A&M
University. His research focuses include structure-property relationship of polymers and composites,
damage & failure analysis, tribology, finite element modeling, constitutive relationship, etc.

Update on Developments for Scratch and Mar Additives;
Effect of the additive formulation on the scratch performance
and other secondary attributes
Nikolas Kaprinidis*. Per Magnus Kristiansen, Martin Brunner and Johanne Wilson
Ciba Corporation, a part of the BASF group, 540 White Plains Road, Tarrytown, NY 10591
Abstract
As the automotive industry becomes increasingly competitive, scratch and mar performance is
progressively more important to automotive OEM’s. Such performance directly affects consumer
perception, which is being tracked by agencies such as J.D. Powers. This has led to closer
scrutiny by OEM’s on the various test methods and a reconsideration of the acceptable standards
is taking place. The previous benchmark of scratch resistance at 10N loading, usually determined
by the popular 5 finger test method is no longer acceptable by many automotive OEM’s as they
strive for increased product performance.
Improving scratch performance for TPOs can be accomplished by additive technologies, of which
there are by now several ones available on the market. Although little differentiation is seen at
scratch levels of 10 N, the differences become more apparent at loadings of 15 N and higher.
Besides scratch resistance, secondary attributes are becoming even more important and will be
considered by automotive OEM’s since they also contribute to the overall consumer perception of
the vehicle. The efficacy and performance of anti-scratch additives may vary based upon the
composition and type of resin, as well as other additives present in the formulation which – in
combination – may lead to undesired effects. The second part of the paper will discuss such “side
effects” caused by other additives.
Figure 1: Comparison of scratch performance in 20% talc filled TPO for three commercial
scratch additives using Erichsen Cross-cut test method
ΔL (scratch visibility)
8
6
4
2
0
blank blank
5 N 10 N 15 N
0.5% 0.5% Slip Slip
3% 3% SR2 SR2
3% 3% SR SR 11

* Dr. Nikolas Kaprinidis (Speaker) is responsible for application and product development
department at Ciba – a part of the BASF group. He holds a Ph. D in Physical Organic Chemistry
from New York University and spent two post-doctoral stays at UC Berkeley and Columbia
University. He has published extensively and holds patents in various application areas of
plastics. Dr. Kaprinidis is a member of ACS and has been with the company 11 years. Tel: 914-
785-2739; e-mail: nikolas.kaprinidis@ciba.com

ABSRACT FOR SPE AUTOMOTIVE TPO 2009 Conference
Presentation Title: Atmospheric Pressure Plasma: Surface Treatment for Bonding and
Painting Applications Without Wet Chemistry
Speaker Name: Shaun Glogauer
Speaker Job Title: Sales And Marketing Manager – Plasmatreat North America
The presentation for this conference will consist of a brief introduction to plasma and
plasma technology, outlining how the process works in laymen’s terms. Plasma is
basically excited air molecules that work to clean and activate a surface for bonding and
coating applications. This process can often lead to the elimination of aggressive
primers, adhesion promoters, and solvent wiping applications. In other words, there are
some truly revolutionary applications possible with this technology from both an
environmental and quality standpoint. The ultimate goal is to reduce or eliminate wet
chemistry in the process. Following this introduction, there will be a description of
practical applications within the automotive industry as well as a few very short videos to
illustrate the technology. The presentation will conclude with a brief summary and a
question and answer period.

Latest Developments in Coatings Technology that Provides Striking
Appearance and Durability over TPO
Arjun Dhake
Dhake Industries
Abstract
Thermoplastic polyolefin (TPO) substrates continue to be used more and more in various
automotive interior applications. At the same time, automotive designers are demanding
more sophisticated and futuristic finishes on the interior of cars while still meeting all of
the durability requirements.
With the latest developments from Dhake Industries, auto designers can combine the
wanted aesthetic appeal with lower cost materials like TPO to give the ultimate in lowcost
yet luxurious interiors.
With the use of proprietary coating formulations, Dhake Industries can apply numerous
types of metallic colors to any TPO substrate. This includes the much sought after
chrome-look coatings in the automotive industry. Auto designers trend towards bright
chrome or satin chrome plating on many interior components. Now coatings that
simulate bright chrome and satin chrome plating can be used on lower cost TPO
substrates to achieve a similar look at a much lower cost. The material cost is decreased
by using TPO instead of typical ABS or PC/ABS for plating. Also, the cost of painting is
much less than the cost of plating.
Dhake Industries has been a leader in chrome-look and metallic coating formulations, and
has developed various products to decorate TPO materials with these kinds of colors.
With and without the use of adhesion promoters, this paper will examine the various
methods of coating TPO to give the look and durability that the auto industry desires.
Speaker Information:
Arjun Dhake has received his B.S.E. in Chemical Engineering from The University of
Michigan and his M.B.A. from The Ross School of Business at The University of
Michigan. Arjun is currently Vice President of Business Development at Dhake
Industries, a global paint and coating manufacturer for the automotive industry.
Email: adhake@dhakeindustries.com Phone: 734-420-0101

Study of Scratch Resistance of Polypropylene Compound for
Automobile
LI Yonghua, YANG Bo, LUO Zhongfu, JIN Shan
(KingFa Sci.& Tech.Co., Ltd., Guangzhou, 510520,China)
ABSTRACT: Scratch resistance is critical for plastic auto parts to maintain their new
appearance. In this study, the effect of scratch-resistant additive content on the
scratch resistance of talc-filled ethylene-α-olefin copolymer/polypropylene blends for
auto interior parts was investigated by scratch morphology, scratch width, and change
of lightness. The effect of grained surface type on the scratch resistance was also
examined. The results indicated that the addition of 1.5% scratch-resistant additive
significantly improved scratch resistance. Scratch resistance was dependent on the
depth, angle, and concentration of grains. Scratch resistance decreased with
increasing depth, angle, and concentration of grains.
The scratch test followed the Volkswagen interior scratch test standard PV3952. 40×
40mm pattern(Fig 1). 10N was applied at a speed of 1000 mm/min.
Fig 1 Scratch test surface pattern
Speaker: Shan Jin, Graduate Student, Michigan State University, Office Phone:
517-355-2220 email: jinshan@msu.edu
Authors: LI Yonghua, YANG Bo, LUO Zhongfu, Kingfa Science & Tech Co.
Contact Information: LI Yonghua, liyonghua@kingfa.com.cn, or liyhp@163.com

New and Innovative Testing Technologies for Effect Finishes
Greg Shrider and Richard Scott : BYK - Gardner USA
The look of effect finishes is continuously changing to create distinct visual appearances.
Therefore, the range of effect pigments – different aluminum grades to special pearlescent
pigments – used in automotive and industrial applications is increasing. Designers are
seeking for colors which can change their look depending on the lighting conditions to
pronounce the styling of a product. These types of effect finishes can appear grayish under
cloudy sky, but start to live with colorful sparkling effects in the sunshine.
On the other hand color harmony with add-on parts, uniform application without causing
undesirable effects such as “cloudiness or mottling” and easy as well as cost efficient repair
(liquid metal) is becoming more and more of a challenge.
New and innovative testing technologies were developed to quantify special effects such as
sparkle, graininess and mottling with image analysis. The factors influencing the total color
impression will be discussed and explained using several practical application examples.
1

Abstract
Conventional and Low VOC Bonding Solutions for TPO
Materials
Walt Polifka
Adchem Corporation
TPO materials, with their low surface energy characteristics, present unique bonding challenges for
manufacturers of pressure sensitive adhesives. Add into the equation a second substrate, such as, a foam,
vinyl, other low energy surface finish or material and the bonding challenge increases. Adhesive tape
construction and the adhesive used play a role in a successfully engineered bonding solution. TPO’s
engineered for specific applications will require the bonding system also satisfy the requirements of the
application. Emerging interest in Low VOC adhesive systems further complicates bonding choices.
Automotive interior and other industrial specifications will be impacted by Low VOC adhesive technology.
Adchem will explore available adhesive chemistries, the challenges and solutions they provide for the TPO
user.
Surface Energy by Substrate
(Dynes/cm)
Stainless Steel 400+
Glass 60+
Polycarbonate 52
Epoxy 48
ABS 46
Anodized Aluminum 34
HDPE 34
Fluoropolymer 32
LDPE 32
Rigid PVC 32
Urethane 32
Polyester 30
PP 30
TPO 30
Walt Polifka has been part of the Business Development team of Adchem Corporation for over ten years.
He is responsible for new business development for pressure sensitive tape products in several industrial
markets. His prior experience includes 15 years in fluid handling equipment and 14 years experience with
polyester resin and urethane foam chemistries. Walt holds a B.S. degree in Chemical Engineering from
Lehigh University. He and his wife Nan currently live in the Pocono Mountains region of Pennsylvania.

Executive Panel

Executive Management Panelists
Matt Carroll is engineering group manager-Materials for Body Exterior, Electrical and
Batteries at General Motors Co. Carroll was previously body vehicle systems engineer
for the 2006MY Buick® Lucerne. Before joining the automaker, Carroll worked for both a
TPO supplier and a paint supplier. He holds a Master’s Degree in Chemical Engineering
from Wayne State University and was a member of the SPE Detroit Section Board from
2005-2007. Carroll also has nine publications and one patent to his credit.
Dr. David Cole, chairman of the Center for Automotive Research (CAR), is an
internationally renowned speaker, writer, and expert on the automotive industry and
will also be a keynote speaker at this year’s SPE Automotive TPO Global Conference.
Cole was formerly director of the Office for the Study of Automotive Transportation
(OSAT) at the University of Michigan’s Transportation Research Institute. Through CAR,
Cole organizes an annual Automotive Management Briefing. This year’s event, held
August 4-7, was entitled “Today’s Turmoil: A Foundation for Success.” He has worked
extensively on internal-combustion engines, vehicle design, and overall automotive
industry trends. His recent research has focused on strategic issues related to
restructuring of the North American industry and trends in globalization, technology,
market factors, and human-resource requirements. Cole holds B.S. degrees in
Mechanical Engineering and Mathematics, an M.S.M.E. and a Ph.D. – all from the
University of Michigan.
Stephen Dwyer is senior vice-president at LyondellBasell Polyolefins where he is
responsible for its automotive business in the Americas. He has worked in the olefins
industry for over 28 years at both Exxon Chemicals and LyondellBasell Polyolefins
serving in various leadership roles in both North America and Europe. Dwyer has also
published and presented numerous papers on the olefins industry and technological
developments.
Nand Kochhar is chief engineer-Global Materials Engineering & Standards, and
executive technical leader-Global CAE at Ford Motor Co. Previous assignments at Ford
have included chief engineer-Core Vehicle Engineering, chief engineer-Vehicle
Attributes & CAE, vehicle engineering manager-F Series® Super Duty truck, and chassis
design & release manager-Mondeo® in Europe. Kochhar has also held several
supervisory and technical specialist positions within North American Product
Development at the automaker.
Jeff Makarewicz has been vice-president-Materials Engineering Division at the Toyota
Technical Center (TTC), the North American research arm for Toyota Motor Engineering
& Manufacturing, North America, Inc. (TEMA) since 2008, where he has responsibility
for materials R&D, including materials research, design, development and evaluation.
Makarewicz joined TTC in 1990 as an engineer in the Materials Engineering Department,
Paint & Finishing Group and spent two years at Toyota Motor Corp. in Nagoya, Japan

working on anti-corrosion materials evaluation, design, and development. Prior to
joining Toyota, Makarewicz worked for BASF in the Paint and Colorants Division. He
holds numerous patents and earned a B.S. degree in Chemistry from the University of
Michigan.
Executive Management Moderators
Bob Eller is president, Robert Eller Associates LLC (REA), a firm specializing in
management consulting for the global plastics and rubber industries where he and his
team carry out numerous technology, strategy, and manufacturing analyses, pricing
forecasts, product positioning analyses, and crisis-management analyses in automotive
plastics for clients around the world. Prior to forming his own firm in 1991, Eller worked
in various positions at ExxonMobil, A. D. Little, Phillip Townsend Associates, Charles
River Associates, and Multibase. Eller holds an undergraduate degree in Chemical
Engineering from Massachusetts Institute of Technology and M.S. degrees in Polymer
Science and Chemical Engineering from Brooklyn Polytechnic.
Ron Price has spent over 35 years in polymer global business management, marketing,
and sales involving both engineering and olefin polymers, primarily in the durable goods
and automotive sectors. In fact, he launched over 20 new polymers and alloys to the
automotive industry. He has worked at companies such as DuPont, Borg Warner
Chemicals, ExxonMobil, and Huntsman and continues to be active as a marketing and
business consultant for new business, strategic marketing, and sales development. He
has published over 25 articles and has made hundreds of presentations at regional,
national, and international events. Price is also a recipient of three awards from the
Detroit Section of SPE: Outstanding Achievement (2000), Lifetime Achievement (2005)
and Outstanding Member (2006). He also was inducted as an Honored Service Member
(2007) by SPE International.

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