SPE Automotive TPO Global Conference 2010 - Auto-tpo.com
SPE Automotive TPO Global Conference 2010 - Auto-tpo.com
SPE Automotive TPO Global Conference 2010 - Auto-tpo.com
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<strong>SPE</strong> <strong><strong>Auto</strong>motive</strong> <strong>TPO</strong> <strong>Global</strong> <strong>Conference</strong> <strong>2010</strong><br />
Wel<strong>com</strong>e to the 12th annual <strong>SPE</strong> <strong>Global</strong> <strong>TPO</strong> <strong>Conference</strong><br />
The Society of Plastic Engineers (Detroit Section), leading OEMs, Tier 1, and <strong>TPO</strong> suppliers have<br />
dedicated their resources to create the 12 th Annual <strong>SPE</strong> <strong><strong>Auto</strong>motive</strong> <strong>TPO</strong> <strong>Global</strong> <strong>Conference</strong>. The<br />
conference is a dynamic, interactive, and cost-effective learning experience “put together” and<br />
“contributed to” by the world’s foremost authorities on materials, processes, applications, and market<br />
trends.<br />
The pledge of the conference <strong>com</strong>mittee is simple. We strive to bring you the best, knowledgeable<br />
people who will share useful information on the latest fastest growing automotive polymers, polyolefin<br />
materials developments and trends.<br />
Last year, over 420 attendees from OEMs, Tier 1s, and resin and equipment suppliers participated in this<br />
event. Many new materials, application developments, and technologies were introduced.<br />
This year's event is expected to be even more exciting with over 47 technical papers and presentations<br />
strong on new developments and innovations. There are special new technical sessions on<br />
polypropylene <strong>com</strong>pounding, olefin-based thermoplastic elastomers and thermoplastic vulcanizates<br />
(TPEs/TPVs) and thermoforming of olefins along with the traditional sessions on materials development,<br />
surface enhancements, process enhancements, and applications.<br />
Additionally, there are four keynote speakers: Debbie Mielewski Ph. D, Technical Leader of Plastics<br />
Research, Ford Motor Company; Bob Nadin, VP of Innovation and Technology, Braskem America;<br />
Dietmar Ostermann, Director, PRTM Management Consultants; Bryan Milton VP Basic Chemical <strong>Global</strong><br />
Business Unit, ExxonMobil. Their talks will be timely, informative, enlightening and entertaining.<br />
An executive Panel Discussion, always a highlight at the <strong>Conference</strong>, will address the “New Normal…” in<br />
the automotive and plastics industries. The Panel will include representatives for Chrysler, Ford Motor<br />
Company, General Motors, IAC Group, ExxonMobil and Toyota.<br />
As mentioned above, another feature this year will be a special half day session focused on polyolefin<br />
thermoforming which is an exciting new growth market for these innovative <strong>com</strong>pounds. The objective<br />
is to help participants achieve a <strong>com</strong>petitive advantage in today's global market.<br />
We thank you for attending this conference, and we look forward to seeing you year after year. We<br />
appreciate your <strong>com</strong>ments and feedback as we are continuing to strive to meet your needs.<br />
Bill Windscheif Norm Kakarala<br />
Co-Chairman Co-Chairman<br />
Advanced Innovative Solutions, Ltd. Intiva Products<br />
President Senior Technical Fellowent Engineer
<strong>SPE</strong> <strong><strong>Auto</strong>motive</strong> <strong>TPO</strong> <strong>Global</strong> <strong>Conference</strong><br />
<strong>2010</strong> Planning/Committee Members<br />
Dr. Norm Kakarala<br />
Inteva Products L.L.C.<br />
Technical Program Chair/Keynote Speakers<br />
Dr. Gary Kogowski – Entec Polymers<br />
<strong>SPE</strong> President – Detroit Section<br />
Mike Balow<br />
Moderator – PP Compounding Session<br />
Asahi Kasei Plastics N.A.<br />
Ed Bearse<br />
Moderator – State of The Art in Olefi n Thermoforming<br />
Advanced Plastic Consulting<br />
Kelly Beauchamp<br />
House/ Proceedings Book<br />
DME<br />
Robert Eller<br />
Moderator – Applications & Process Development<br />
Session & <strong>TPO</strong>’s & TPE’s Interface Session<br />
Panel Discussion<br />
Robert Eller Associates, L.L.C.<br />
Anthony Gasbarro<br />
Moderator – Materials Development Session<br />
House/Scholarships<br />
Marubeni Specialty Chemicals<br />
Patricia Levine<br />
Registrations<br />
Detroit Section <strong>SPE</strong><br />
Rick Luxgrant<br />
Committee<br />
Chrysler L.L.C<br />
David Mitchell<br />
Committee<br />
Dow Chemical Company<br />
Dave Okonski<br />
Moderator – State of the Art in Olefi n Thermoforming<br />
General Motors Corporation<br />
Sanjay Patel<br />
Website/CD’s<br />
Flint Hills Resources<br />
Designed to be Lighter Weight<br />
Our innovative automotive portfolio of products<br />
can lighten your load.<br />
ExxonMobil Chemical is an acknowledged industry leader in the<br />
development and manufacture of advanced material solutions that<br />
significantly reduce vehicle weight without sacrificing performance.<br />
Our technicians and service representatives are experts in the automotive<br />
sector, allowing us to provide better, faster and more insightful product<br />
and technology innovations to meet our customers’ challenges.<br />
For more information on our <strong>com</strong>plete elastomer and polyolefin portfolio<br />
and support services, visit exxonmobilchemical.<strong>com</strong>/automotive today.<br />
Exxtral performance polyolefins<br />
Vistamaxx propylene-based elastomers � Santoprene TPVs<br />
Vistalon EPDM rubber � Exact plastomers<br />
©<strong>2010</strong> Exxon Mobil Corporation. The terms corporation, ExxonMobil, ExxonMobil Chemical, our and its, as used in<br />
this advertisement, sometimes refer not only to ExxonMobil Chemical Company, a division of Exxon Mobil Corporation,<br />
but collectively to all of the <strong>com</strong>panies affiliated with Exxon Mobil Corporation or to any one or more of them or their<br />
employees. Photos used in this ad may be representative of potential product applications only.
<strong>SPE</strong> <strong><strong>Auto</strong>motive</strong> <strong>TPO</strong> <strong>Global</strong> <strong>Conference</strong><br />
<strong>2010</strong> Planning/Committee Members<br />
continued<br />
Bill Windscheif<br />
Chairman/Keynote Speakers<br />
AIS Limited<br />
Thomas Pickett<br />
Sponsorship Chair<br />
Moderator – Applications & Process Development Session<br />
General Motors Corporation<br />
Ron Price<br />
Advertising/PR/Panel Discussion<br />
<strong>Global</strong> Polymer Solutions<br />
Nippani Rao<br />
Sponsors/Exhibitors<br />
Tao Associates<br />
Dr. Rose Ryntz<br />
Moderator- Surface Enhancements for High Quality Parts<br />
International <strong><strong>Auto</strong>motive</strong> Composites<br />
Mitesh Shah<br />
Moderator- Materials Development Session<br />
Scholarships<br />
LyondellBasell Industries<br />
Dr. Suresh Shah<br />
Moderator – Applications & Process Development Session<br />
Scholarships<br />
Delphi Corporation<br />
Jeff Smart<br />
Moderator – PP Compounding Session<br />
Scholarships<br />
Mitsui Plastics<br />
Patti Tibbenham<br />
Moderator – PP Compounding Session<br />
Scholarships<br />
Ford Motor Company<br />
Jeff Valentge<br />
Moderator – <strong>TPO</strong>’s & TPE’s Interface Session<br />
ExxonMobil Chemical<br />
Designed to be Green<br />
Our broad automotive portfolio of products can<br />
keep you in the black - and the green.<br />
ExxonMobil Chemical is at the leading edge of product innovations<br />
that meet the demand for lighter, more fuel efficient and more<br />
environmentally friendly vehicles.<br />
Committed to sustainability and recyclability, we hold a leadership<br />
position in the development of materials that can be recycled to<br />
reduce waste and help our customers to preserve natural resources.<br />
For more information on our <strong>com</strong>plete elastomer and polyolefin portfolio<br />
and support services, visit exxonmobilchemical.<strong>com</strong>/automotive today.<br />
Exxtral performance polyolefins<br />
Vistamaxx propylene-based elastomers � Santoprene TPVs<br />
Vistalon EPDM rubber � Exact plastomers<br />
©<strong>2010</strong> Exxon Mobil Corporation. The terms corporation, ExxonMobil, ExxonMobil Chemical, our and its, as used in<br />
this advertisement, sometimes refer not only to ExxonMobil Chemical Company, a division of Exxon Mobil Corporation,<br />
but collectively to all of the <strong>com</strong>panies affiliated with Exxon Mobil Corporation or to any one or more of them or their<br />
employees. Photos used in this ad may be representative of potential product applications only.
Exhibitor Locations<br />
Designed to be <strong>Global</strong><br />
Our well-traveled automotive portfolio of products<br />
makes an excellent <strong>com</strong>panion to any destination.<br />
ExxonMobil Chemical is dynamically expanding worldwide, allowing<br />
us to provide unique technical support and assistance to today’s<br />
automotive manufacturers.<br />
As one of a few vertically integrated manufacturers in the world, we<br />
are able to leverage our resources in Europe, Asia and the Americas<br />
to bring you a globally integrated supply chain, consistent high-quality<br />
materials and innovative <strong>com</strong>pounding solutions.<br />
For more information on our <strong>com</strong>plete elastomer and polyolefin portfolio<br />
and support services, visit exxonmobilchemical.<strong>com</strong>/automotive today.<br />
Exxtral performance polyolefins<br />
Vistamaxx propylene-based elastomers � Santoprene TPVs<br />
Vistalon EPDM rubber � Exact plastomers<br />
©<strong>2010</strong> Exxon Mobil Corporation. The terms corporation, ExxonMobil, ExxonMobil Chemical, our and its, as used in<br />
this advertisement, sometimes refer not only to ExxonMobil Chemical Company, a division of Exxon Mobil Corporation,<br />
but collectively to all of the <strong>com</strong>panies affiliated with Exxon Mobil Corporation or to any one or more of them or their<br />
employees. Photos used in this ad may be representative of potential product applications only.
7:30-8:30 am Registration/Coffee<br />
Monday October 4, <strong>2010</strong><br />
8:30 am Opening Remarks: Bill Windscheif: Advanced Innovative Solutions, Ltd.<br />
8:45-9:15 am Keynote Address: Greening the Blue Oval: Ford's Vision for a Sustainable <strong><strong>Auto</strong>motive</strong> Industry<br />
Debbie Mielewski - Technical Leader of Plastics Research, Ford Motor Company<br />
9:15 am Technical Program: Norm Kakarala: Inteva Products<br />
Materials Development Session<br />
(Moderators: Mitesh Shah: LyondellBasell Industries, and Anthony Gasbarro: Marubeni Specialty Chemicals)<br />
9:30-10:00 am Reactor <strong>TPO</strong>: Innovations in Low Temperature Ductility and <strong>TPO</strong> At-Press for Dimensional Control<br />
Frank Krabbenborg, Michael Ballot: Styron Netherlands BV<br />
10:00-10:30 am New Findings High Melt Flow <strong>TPO</strong>s Modified with Talc.<br />
Piergiovanni Ercoli Malacari: IMIFabi Spa - Italy<br />
10:30-10:45 am Break<br />
10:45-11:15 am New Elastomers for High Performance Rigid <strong>TPO</strong>s - Driving Innovation<br />
Kyle G Kummer, Kim L. Walton, Jim Hemphill, Mary Ann Jones: Dow Elastomers<br />
11:15-11:45 am Effect of Scratch Additives on Talc Reinforced PP and <strong>TPO</strong> Compounds<br />
Saied H. Kochesfahani and Paul Fink: Rio Tinto Minerals<br />
From Catalyst Design to End Performance. Developing Enchanced <strong>TPO</strong> Formulations Meeting the<br />
11:45-12:15 pm<br />
Challenges of <strong>Auto</strong>mtoive OEMS by Taking Advantage of a New Family of Ethylene/Octene Copolymers<br />
Russel Barry, Kim Walton, Jim Hemphill: Dow Europe GmbH<br />
12:15-1:00 pm Lunch<br />
1:00 - 1:30 pm Keynote Address: Braskem, a continued <strong>com</strong>mitment to the <strong>TPO</strong> marketplace<br />
Bob Nadin - VP of Innovation and Technology, Braskem<br />
1:30-2:00 pm Foam Extrusion of Thermoplastic Elastomer Vulcanizates<br />
Muguen Chee: Honan Petrochemical Corp.<br />
2:00-2:30 pm Effect of Sample Preparation and Test Methods on the Coefficient of Linear Thermal Expansion of<br />
Thermoplastic Polyolefin Blends<br />
Mitesh Shah, Todd Glogovsky: Lyondellbasell and Karalyn Mueller: Ford Motor Company<br />
2:30-3:00 pm Decreasing VOC Emissions at the Source with New Additive Technologies for Olefin Composites<br />
Louis W. Martin, Margareth Koppes: Add<strong>com</strong>p Holland BV<br />
3:00-3:15 pm Break<br />
Compounding Session #1<br />
(Moderators: Mike Balow, Asahi Kasei Plastics N.A. Inc., Jeff Smart, Mitsui Plastics, Inc. and Patti Tibbenham:<br />
Ford Motor Co)<br />
Understanding the Structure of Wheat Straw & other Natural Fibers for <strong><strong>Auto</strong>motive</strong> Thermoplastic<br />
3:15-3:45 pm Composites<br />
Leonardo Simon, Ellen Lee, and Paul Hardy: Ford Motor Company<br />
3:45-4:15 pm Advanced Polypropylene Glassfibre Compound - a Cost Efficient Way to Replace PA Under the Hood<br />
Thomas Wagner: Borealis GmbH<br />
4:15-4:45 pm Innovations in Thermoplastic Polyolefin Compounds for Thick-Sheet Thermoforming Applications<br />
S. Shah:Lyondellbasell Industires<br />
4:45-5:15 pm New Micro Fiber Developments Achieve Improved <strong>TPO</strong> Performance<br />
Donald Beuke: Mitsui Plastics Inc.<br />
5:15 pm ExxonMobil Reception (Open for All <strong>Conference</strong> Participants )
7:00-8:00 am Registration/Coffee<br />
Tuesday October 5, <strong>2010</strong><br />
8:00-8:30 am Keynote Address:<br />
Bankruptcy and Consolidation in the <strong>Global</strong> <strong><strong>Auto</strong>motive</strong> Supply Industry<br />
Dietmar Ostermann: PRTM Management Consultants<br />
Concurrent<br />
Session A<br />
<strong>TPO</strong>/TPE Interface<br />
(Moderators: Bob Eller: Robert Eller Assoc., LLC & Jeff Valentage: ExxonMobil)<br />
8:30-9:00 am <strong><strong>Auto</strong>motive</strong> <strong>TPO</strong>s and TPEs: Competition in a Changing <strong>Global</strong> Market<br />
Bob Eller: Robert Eller Associates<br />
9:00-9:30 am TPV for <strong><strong>Auto</strong>motive</strong> Body Seal Applications.<br />
Nobuhiro Natsuyama, Tatsuo Sassa, and Hirofumi Jyohoji: Sumitomo Chemical Co.,Ltd.<br />
9:30-10:00 am <strong><strong>Auto</strong>motive</strong> Weatherseals Trends with Thermoplastic Vulcanizates<br />
Mike Bednarik: ExxonMobil Chemical Europe Inc.<br />
10:00-10:15 am Break<br />
High Performance Reinforcement for Lightweighting Polyolefin <strong><strong>Auto</strong>motive</strong> Parts while Maintaining High<br />
10:15-10:45 am Surface Quality<br />
Wouter Reyntjens: Milliken Chemical<br />
10:45-11:15 am Talc Application in SEBS Compounds<br />
Gilles Meli, Frederic Jouffret, Saied H. Kochesfahani: Rio Tinto Minerals<br />
11:15-11:45 am Use of Naturally Occurring Fibers to Replace Oil Derived Materials in Weatherseal Applications<br />
Jean-Marc Veille, Marie-Laure Tachon, Thierry Gaudryn, Christophe Baley: Cooper Standard <strong><strong>Auto</strong>motive</strong><br />
Concurrent<br />
Session B<br />
Thermoforming<br />
(Moderators: Ed Bearse: Advanced Plastic Consultants LLC, David Okonski: General Motors Corp.)<br />
8:30-9:00 am New Thermoforming Grades of <strong>TPO</strong>s and Caps<br />
Eric Short: Mytex Polymers<br />
9:00-9:30 am Quality Controls of <strong>TPO</strong> Sheets<br />
Roger Jean: Premier Material Concepts<br />
9:30-10:00 am New Caps for <strong>TPO</strong> Sheet for Exterior and Interior<br />
Tom Barr: Akzo-Nobel<br />
10:00-10:15 am Break<br />
10:15- 12:00 pm Case Studies on Industrial Applications:<br />
Heavy Truck Bumpers in <strong>TPO</strong><br />
Matthew Korteum: Brentwood Industries<br />
Chrome Film on <strong>TPO</strong> Parts for Camaro, Mustang, & Challenger<br />
Daryl Green: Retro USA<br />
Thermoformed Parts for Imports<br />
Kevin Gibson: Star Design LLC<br />
<strong>TPO</strong> Fender Flares for SUVs<br />
Bushwacker
12:00-12:45 pm Lunch<br />
12:45- 2:00 pm<br />
Concurrent<br />
Session A<br />
Panel Discussion: The "New Normal" Challenges and Opportunities<br />
(Moderators: Bob Eller: Robert Eller Assoc., LLC & Ron Price: <strong>Global</strong> Polymer Solutions<br />
Executives: Simon Holmes - ExxonMobil Chemical, Kathy Minnich - Ford, Dale Gerard - General Motors, Larry Sak -<br />
Chrysler, Rose Ryntz - IAC Group<br />
Surface Enhancements #1<br />
(Moderator: Dr. Rose Ryntz: International <strong><strong>Auto</strong>motive</strong> Components)<br />
2:00-2:30 pm Surface Enhancements: The Role of Specifications on Product Performance<br />
Dr. Rose Ryntz: International <strong><strong>Auto</strong>motive</strong> Components<br />
2:30-3:00 pm<br />
A Comparative Study of Scratch Visibility Assessment Between Erichsen Delta L and ASTM/ISO Methods<br />
R.L. Browning, P. Liu, H. Jiang, M. Hossain, J. Li†, A. Gasbarro† and H.-J. Sue: Texas A&M University<br />
3:00-3:30 pm Relationship between Subjective and Objective Surface Characteristics of <strong><strong>Auto</strong>motive</strong> Interior Materials<br />
Prof. V. Bhise and Prof. P.K. Mallick, University of Michigan-Dearborn<br />
3:30-4:15 pm Extended Break for Reviewing Exhibits<br />
4:15-4:45 pm The Influence of Colorant on Mold in Color <strong>TPO</strong> Appearance<br />
Dr. Sassan Tarahomi: International <strong><strong>Auto</strong>motive</strong> Components<br />
4:45-5:15 pm Influence Stabilizers Can Have on Pigments<br />
Steven L. Goldstein: BASF Corporation<br />
5:15 pm SABIC Reception (Open for All <strong>Conference</strong> Participants )<br />
Concurrent<br />
Session B<br />
Compounding Session #2<br />
(Moderators: Mike Balow, Asahi Kasei Plastics N.A. Inc., Jeff Smart, Mitsui Plastics, Inc. and Patti Tibbenham:<br />
Ford Motor Co)<br />
2:00-2:30 pm Applying DMA Technique to Develop Novel PP Compounds<br />
Dr. Deen Chundury, Hala Elias, John Klein, Ramesh Iyer, Mike Balow: Asahi Kasei Plastics N.A. Inc.<br />
2:30-3:00 pm Additives to Optimize Properties, Dimensions, and Conversion Cost in <strong><strong>Auto</strong>motive</strong> PP-Based Resins<br />
Adam Watson, Johnny Netzloff: Milliken Chemical<br />
3:00-3:30 pm Tailored Wollastonite Products for Reinforced Polyolefin Applications<br />
Gary Phillips: NYCO Minerals, Inc.<br />
3:30-4:15pm Extended Break for Reviewing Exhibits<br />
4:15-4:45 pm Milled Fiberglass as a Potential Reinforcement in <strong>TPO</strong> Materials<br />
Andrew Hopkins, Harry Karian, and Jonathan O'Leary: Rhetech Inc. & Hammermill Glass Inc.<br />
4:45-5:15 pm Recycling of <strong><strong>Auto</strong>motive</strong> Paint Over-Spray into Useful Polypropylene Compounds<br />
Chris Surbrook: Midland Compounding & Consulting Inc.<br />
5:15 pm SABIC Reception (Open for All <strong>Conference</strong> Participants )
7:00-8:00 am Registration/Coffee<br />
Wednesday October 6, <strong>2010</strong><br />
8:00-8:30 am Keynote Address: Feed Stock Drivers and Their Impact on <strong><strong>Auto</strong>motive</strong> Plastics<br />
Bryan Milton, VP Basic Chemical <strong>Global</strong> Business Unit, ExxonMobil Corporation<br />
Concurrent<br />
Session A<br />
Applications and Process Development Session<br />
(Moderators: Bob Eller: Robert Eller Assoc., LLC, Tom Pickett: General Motors Corp. and Dr. Suresh Shah: Delphi<br />
Corp.)<br />
8:30-9:00 am Latest European Trends for <strong><strong>Auto</strong>motive</strong> Interior Materials<br />
Juergen Buehring: Benecke-Kaliko<br />
9:30-9:30 am Thermal Stability Comparison of Slush TPE and PVC Foils in Instrument Panel Cross-Sections<br />
Patricia L. Pendergast: Inteva Products, LLC<br />
9:30-10:00 am The Advantages of Using MuCell Microcellular Foaming with Long Glass Polypropylene<br />
Scott Powers: Trexel, Inc.<br />
10:00-10:15 am Break<br />
10:15-10:45 am Commercialization of Injection Moldable Composites Utilizing Wheat Straw Fiber<br />
Paul A. Hardy,: A. Schulman, E. C. Lee: Ford Motor, L. Simaon: U. of Waterloo<br />
10:45-11:15 am Vibration Welding of Thermoplastic Olefins (<strong>TPO</strong>s)<br />
C. Yang, Bill Heatherwick: Lyondellbasell, Branson<br />
Evaluation of Different Durometer Materials for Stone Impingement Resistance in <strong><strong>Auto</strong>motive</strong> Exterior<br />
11:15-11:45 pm Applications<br />
Tom Pickett, Brad Tice, Kristina Baldwin: General Motors<br />
Concurrent<br />
Session B<br />
Surface Enhancements #2<br />
(Moderator: Dr. Rose Ryntz: International <strong><strong>Auto</strong>motive</strong> Components)<br />
8:30-9:00 am Stick-slip Phenomena and Its Influence On Polymer Scratch<br />
Han Jiang, Yonghua LI, Bo Yang, Yan YANG, Zhongfu LUO, Chao DING, Guangqiang CHEN, and H.-J. Sue:<br />
Sothwest Jiaotong University, Kingfa Science & Technology Co and Texas A&M University<br />
9:00-9:30 am Study of Scratch Performance of Polypropylene Based <strong><strong>Auto</strong>motive</strong> Material<br />
Yonghua LI, Bo Yang, Yan YANG, Zhongfu LUO, Chao DING, Guangqiang CHEN, and Han Jiang: Kingfa Science<br />
& Technology Co<br />
Improving the Scratch Resistance and Molding Characteristics of <strong>TPO</strong>s, TPVs, and Glossy <strong><strong>Auto</strong>motive</strong><br />
9:30-10:00 am Parts<br />
Kathrin Lehmann and Charles Milburn: Evonik Goldschmidt Corporation<br />
10:00-10:15 am Break<br />
10:15-10:45 am The Evolution of Surface Texture During the Application and Curing of <strong><strong>Auto</strong>motive</strong> Coating Systems<br />
Cindy A. Peters, Kevin R.J.Ellwood, and Mark E. Nichols: Ford Research and Advanced Engineering<br />
Critical Role of Particle/Polymer Interphase in Long-Term Performance of a ZnO/Polyurethane Hybrid<br />
10:45-11:15 am Coating<br />
Xiahong Gu, Guodong Chen, Minhua Zhao, Stephanie S. Watson, Tinh Nguyen, Joannie W. Chin, and Jonathan<br />
W. Martin: National Institute of Standards and Technology<br />
Update on Developments for Scratch and Mar Additives; Effect of the Additive Formulation on the Scratch<br />
11:15-11:45 am Performance and Other Secondary Attributes<br />
Nikolas Kaprinidis, Hung Pham, Johanne Wilson: BASF Corporation
Sponsor/Exhibitors
Thank you sponsors for your support.
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that are lower cost alternatives<br />
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Enabling…<br />
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• Paintability<br />
Interior – Soft <strong>TPO</strong><br />
Enabling…<br />
• Broad Processing Window<br />
• Surface Quality Retention<br />
• Aesthetics and Haptics<br />
Delivering a Broad Elastomer<br />
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Advanced polyolefins for a demanding industry<br />
<strong>Global</strong> innovation from concept to launch<br />
Adflex, Dexflex, Hifax, Hosta<strong>com</strong>, Indure, Lupolen, Pro-fax, Sequel and Softell are trademarks owned or used by<br />
LyondellBasell group <strong>com</strong>panies. Adflex, Dexflex, Dexpro, Hifax, Hosta<strong>com</strong>, Indure, Lupolen, Pro-fax and Sequel<br />
are registered in the U.S. Patent and Trademark Office.<br />
LyondellBasell is the world’s largest<br />
producer of polypropylene and a premier<br />
global supplier of advanced polyolefins<br />
used in automotive exteriors, instrument<br />
panels and interior trim.<br />
With a dedicated and highly responsive<br />
global <strong><strong>Auto</strong>motive</strong> Business Unit, the<br />
<strong>com</strong>pany offers a unique portfolio of<br />
products and technologies used by<br />
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Pro-fax, Sequel and Softell.<br />
For more information, visit:<br />
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• Scratch and Mar Resistance<br />
• Color Control<br />
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CONFERENCE
Material Development
Reactor <strong>TPO</strong>: Innovations in Low Temperature Ductility and <strong>TPO</strong> At-Press<br />
for Dimensional Control<br />
Frank Krabbenborg and Michael Ballot<br />
Styron Netherlands BV<br />
Abstract<br />
Material specifications for exterior <strong>TPO</strong> applications require materials which are highly ductile at<br />
temperatures as low as -40˚C. A <strong>com</strong>pounded <strong>TPO</strong> must use a particular PP, and 30-35%<br />
additional elastomer to obtain such a ductile performance. The <strong>com</strong>position <strong>com</strong>plexity and an<br />
additional heat history has to be added via <strong>com</strong>pounding to meet the specifications. A new reactor<br />
<strong>TPO</strong> INSPIRE DTF8200 has been developed which is fully ductile at -40˚C. This performance<br />
is the result of a product design based on specific elastomer design and MWD distribution while<br />
still being produced in the reactor. The resulting flexural modulus is greater than 950 MPa and<br />
coefficients of linear thermal expansion (CLTE) = 90-100µm/m·˚C. This reactor <strong>TPO</strong> will meet<br />
the functional requirements for many bumper fascia designs. In cases where higher modulus<br />
and/or lower CLTE is required, a novel 70% talc filled master-batch has been developed to allow<br />
easy dispersion within an injection molding press to control part fit and finish. The system name<br />
is INSPIRE At-Press TF8200.71 and examples of large part fascia developments mixing reactor<br />
<strong>TPO</strong> and 70% talc MB will be shown.
<strong>SPE</strong> <strong>TPO</strong> Sterling Heights <strong>2010</strong><br />
Title: New findings high melt flow <strong>TPO</strong>s modified with talc.<br />
By<br />
Piergiovanni Ercoli Malacari (product and application development) - IMIFabi Spa - Italy<br />
Abstract<br />
Several actual polyolefin based materials are formulated to exhibit high fluidity<br />
to fill larger and thinner mold cavities for stringent automotive requirements.<br />
Talc is generally used in such products as active an modifier, for instance, to<br />
enhance stiffness, to lower molding shrinkage and to minimize CLTE. Very fine,<br />
to ultrafine talc grades are normally formulated to achieve superior reinforcing<br />
results, preserving the resistance to impact, typically requested for many<br />
automotive formulations.<br />
To get the best results in polymer modification, it is fundamental to achieve<br />
the maximum talc dispersion in the polymeric matrix. The usage of high fluidity<br />
resins could lead to some possible talc dispersion problems with subsequent<br />
lack in mechanical and aesthetical properties.<br />
IMIFabi Talc <strong>com</strong>pany has recently developed a new portfolio of products<br />
specifically designed to maximize talc dispersability, granting higher<br />
mechanical performances in the final <strong>com</strong>pound even in high melt flow <strong>TPO</strong>s.<br />
IMIFabi will present their latest results in modifying high fluidity <strong>TPO</strong>s with this<br />
innovative family of products.
Speaker’s Bio.<br />
Name: Piergiovanni Ercoli Malacari<br />
Title: Product and application development<br />
Company: IMIFabi Spa - Italy<br />
Experience:<br />
He has been working since 1990 in thermoplastic<br />
materials field.<br />
He has had several job experiences in both<br />
production and development areas.<br />
He worked for several years in both <strong>com</strong>pounding<br />
area (R&D and technical assistance) and plastic<br />
manufacturing (rigid sheets extrusion, medical<br />
tubing, plastic recycling)<br />
Now, in IMI-FABI, he is in charge for the<br />
development of products as well as application of<br />
IMI-FABI talcs in thermoplastic field.<br />
Educational Background: He took a degree in<br />
chemical engineering at “Politecnico di Milano” -<br />
Italy. His technical knowledge is mainly related to<br />
thermoplastics materials and their modifications as<br />
well as applications.
New Elastomers for High Performance Rigid <strong>TPO</strong>s - Driving Innovation<br />
Kyle G. Kummer 1 , Kim L. Walton 1 , Jim Hemphill 1 , Mary Ann Jones 2<br />
Dow Elastomers<br />
The Dow Chemical Company<br />
1 Freeport, TX 77541<br />
2 Midland, MI<br />
ABSTRACT<br />
A new family of high performance impact modifiers has been developed to meet the increasing<br />
demands in <strong>TPO</strong> performance. The new impact modifiers have shown higher impact efficiency<br />
and recent testing has shown minimal impact on scratch and dimensional stability. Furthermore,<br />
these new products can be designed for bulk handling ability while maintaining high impact<br />
performance. The performance of this new class of impact modifiers will be discussed.
Effect of Scratch Additives on Talc Reinforced PP and <strong>TPO</strong> Compounds<br />
Saied H. Kochesfahani and Paul Fink – Rio Tinto Minerals, Denver, CO<br />
Frederic Jouffret, Rio Tinto Minerals, Toulouse, France<br />
The scratch performance of talc-PP and talc-<strong>TPO</strong> <strong>com</strong>pounds has been of great interest especially<br />
in automotive applications where appearance plays an important role in the customer approval of<br />
car quality. While polypropylene or <strong>TPO</strong> based automotive parts offer many cost/performance<br />
advantages, the scratch performance of these materials typically does not fulfill all customer<br />
expectations.<br />
Rio Tinto Minerals has been actively studying the scratch performance of talc-reinforced PP and<br />
<strong>TPO</strong> <strong>com</strong>pounds and presented a summary of these studies in 2009 <strong><strong>Auto</strong>motive</strong> <strong>TPO</strong> <strong>Conference</strong><br />
outlining its current best solutions as:<br />
1) Utilizing submicron Jetfine ® talc products to maximize scratch performance in the<br />
absence of scratch additives and to minimize potential effects of scratch additives on<br />
mechanical properties of <strong>com</strong>pounds when scratch additives are used.<br />
2) Utilizing Luzenac ® R7, a treated talc product with proprietary surface coating, by itself<br />
for applications where moderate improvement in scratch performance is required and in<br />
<strong>com</strong>bination with other scratch additives where the maximum scratch performance is<br />
required.<br />
This paper presents new results from the continuation of these studies with the objective<br />
of <strong>com</strong>paring the performance of different scratch additives and offering solutions to<br />
maximize the scratch performance of PP and <strong>TPO</strong> <strong>com</strong>pounds. A high impact <strong>TPO</strong> and a<br />
medium impact PP copolymer will be used in these studies at 20% talc loading and the<br />
optimum loading re<strong>com</strong>mended for each scratch additive.<br />
As an introductory experiment in this study and to <strong>com</strong>bine the effect of Jetfine ® talc<br />
products with the proprietary additive used in Luzenac ® R7, the scratch performance of<br />
submicron Jetfine ® 3CC has been evaluated using Texas A&M scratch test method at<br />
20% talc loading in a high impact <strong>TPO</strong> formulation with and without the proprietary<br />
additive used in Luzenac ® R7 and Erucamide.<br />
The results show that using Luzenac ® R7 additive improves the scratch performance<br />
moderately (from 7 to 12 N) without affecting the mechanical properties of <strong>com</strong>pound,<br />
and the addition of 0.3% Erucamide to the formulation further improves the scratch<br />
performance (to 16 N) while the <strong>com</strong>pound remained ductile at -20°C with a flexural<br />
modulus as high as 2100 MPa.<br />
The paper will report on the results of further studies with other scratch additives.
Scratch Load at Onset of Visibility, N<br />
25<br />
20<br />
15<br />
10<br />
5<br />
0<br />
Flexural Modulus<br />
Scratch Load at Onset of Visibility<br />
Jetfine 3CC Jetfine 3CC Jetfine 3CC<br />
+ R7 Additive + R7 Additive + Erucamide<br />
Figure 1. Scratch and flexural modulus of Jetfine ® 3CC in a high-impact (ductile at -<br />
20°C) <strong>TPO</strong> formulation (60% homopolymer PP, 20% ethylene-octene<br />
elastomer, 20% talc) with or without surface treatment with Luzenac ® R7<br />
additive and 0.3% Erucamide<br />
2500<br />
2000<br />
1500<br />
1000<br />
500<br />
0<br />
Flexural Modulus, MPa
From Catalyst Design to End Performance: Developing<br />
Enhanced <strong>TPO</strong> Formulations Meeting the Challenges of<br />
<strong><strong>Auto</strong>motive</strong> OEMS by Taking Advantage of a New Family of<br />
Ethylene/Octene Copolymers<br />
R.Barry, K.Walton, J.Hemphill<br />
Dow Elastomers<br />
Abstract<br />
Ethylene-Octene elastomers have be<strong>com</strong>e the dominant material for<br />
impact modifying polypropylene to produce <strong>TPO</strong> for automotive<br />
applications. The automotive industry continually strives to<br />
reduce weight, improve fuel efficiency, and differentiate through<br />
design and aesthetics. They constantly demand ever greater<br />
performance from <strong>TPO</strong>s. The ability of the elastomer to improve<br />
the properties of PP is dependant on the <strong>com</strong>patibility to the PP<br />
matrix. Recent advances in catalyst technology have permitted<br />
the capability to produce elastomers with molecular architecture<br />
tailored for specific applications. Recent Voice of the Customer<br />
results across the automotive value chain have reinforced the<br />
need for lighter weight, stiffer <strong>TPO</strong>-based parts while meeting<br />
increasingly demanding toughness requirements. This <strong>com</strong>bination<br />
of new molecular architecture capability and market need has<br />
resulted in the development of elastomers with better low<br />
temperature impact efficiencies, improved CLT, and easier<br />
handling characteristics, while improving <strong>TPO</strong> demoulding<br />
performance. This paper presents modeling work done at The Dow<br />
Chemical Company examining how to design <strong>TPO</strong> formulations to take<br />
advantage of these new elastomers, and gives examples of how<br />
<strong>com</strong>pounds could be designed in future to offer lower weight,<br />
greater design freedom, and better aesthetics.
Abstract Title : Foam Extrusion of Themoplastic Elastomer Vulcanizates<br />
<strong>TPO</strong> conference Abstract : Material Developments<br />
Abstract<br />
Thermoplastic Elastomer Vulcanizates prepared by dynamic vulcaninzing process, is a<br />
material which has both the properties of a thermosetting rubber and thermoplastics. TPEV is<br />
rapidly replacing vulcanized rubber and flexible PVC in various industrial regions for its cost<br />
effectiveness and eco-friendliness. Recently these requirements for replacing rubbers have<br />
expanded to foaming area.<br />
TPEV is a difficult material to foam due to its unique morphology and low melt strength.<br />
In this presentation, high melt strength TPEV/layered silicate nano<strong>com</strong>posites were prepared<br />
by usage of nano-clay acting as a nucleus for bubble formation and high melt strength<br />
polypropylene to provide high melt strength during foaming process. Compared to general<br />
TPEV, high melt strength TPEV/layered silicate nano<strong>com</strong>posites shows improved melt<br />
strength behavior, cell density and cell distribution when extrusion foamed.<br />
Compared to conventional TPEV, Foam-TPEV has controllable density and improved<br />
<strong>com</strong>pression set properties. These unique properties of Foam-TPEV can be applied in various<br />
automotive parts. (weather-strips, overslam bumpers, etc…)<br />
Keywords: Thermoplastic Elastomer Vulccanizate, Nano<strong>com</strong>posite, HMSPP, Foam.<br />
1
Effect of Sample Preparation and Test Methods on the Coefficient of<br />
Linear Thermal Expansion of Thermoplastic Polyolefin Blends<br />
Mitesh Shah, Todd Glogovsky<br />
Lyondellbasell<br />
Lansing, MI<br />
Karalyn Mueller<br />
Ford Motor Company<br />
Dearborn, MI<br />
ABSTRACT<br />
As OEM part designers look for improved fit and finish on exterior fascia and trim parts,<br />
the dimensional stability has be<strong>com</strong>e an increasingly important performance<br />
characteristic of <strong>TPO</strong>. One of the key material attributes reflecting dimensional stability<br />
is the coefficient of linear thermal expansion (CLTE). This paper reviews various test<br />
methods of measuring CLTE and focuses on the effect of sample preparation and<br />
variations in test methods on CLTE performance. The CLTE data generated using<br />
various test methods on plaques is <strong>com</strong>pared with the real world data on exterior trim<br />
parts. Finally, re<strong>com</strong>mendations for choosing the test method that best represents the real<br />
world are provided.
Decreasing VOC Emissions at the Source with New<br />
Additive Technologies for Olefin Composites<br />
Louis W. Martin<br />
Add<strong>com</strong>p North America Inc.<br />
Margareth Koppes<br />
Add<strong>com</strong>p Holland BV<br />
Abstract<br />
Fiber-reinforced olefin <strong>com</strong>posites are widely used in a growing number of other industries<br />
for their cost- and weight-reduction opportunities and good balance of physical and<br />
mechanical properties. However, new pressures and regulations in the transportation and<br />
<strong>com</strong>mercial and residential construction industries intended to improve “interior” air quality in<br />
Europe, Asia, and North America are spurring new research in additive technologies to reduce<br />
emission of volatile organic <strong>com</strong>pounds (VOCs), odors, and fogging for polymeric materials.<br />
Unfortunately, there are many pathways for the release of VOC emissions in molded olefin<br />
<strong>com</strong>pounds, including residues left over from base resin polymerization, as well as from<br />
<strong>com</strong>ponents used in the additive package itself. Much work [1-5] has already been done to<br />
help reduce VOCs, odors, and fogging in olefin <strong>com</strong>pounds by addressing coupling-agent<br />
purity, which, ironically, has also been shown to help improve mechanical properties of the<br />
resultant <strong>com</strong>pounds. Advanced coupling-agent technology – which sets new industry<br />
standards for purity, performance, and low additive levels – is now <strong>com</strong>mercially available and<br />
has reduced VOCs several orders of magnitude in olefin <strong>com</strong>pounds.<br />
Since the pressures to improve air quality and reduce VOCs are increasing, past successes<br />
in one area will not allow a <strong>com</strong>pany to maintain market leadership by standing still. More<br />
work is clearly needed. The next logical step has been to try to reduce additional VOCs in<br />
other <strong>com</strong>ponents of the masterbatch (primarily the stabilization package) by increasing the<br />
purity of <strong>com</strong>ponents at the source. Some success has been achieved in this area, which will<br />
be reported in this paper, and a new low-VOC masterbatch has been developed.<br />
However, there are still cases where VOCs cannot be eliminated at the source in <strong>com</strong>ponents<br />
of the masterbatch – either because of the technical challenges involved or because the<br />
<strong>com</strong>ponent is supplied by another <strong>com</strong>pany. In such cases, a third strategy is needed. One<br />
such approach has been to study the use of adsorbents and stripping agents during extrusion<br />
<strong>com</strong>pounding of the masterbatch to capture and flashoff (in the case of stripping agents) or<br />
permanently bind up (in the case of adsorbents) VOCs and fogging or odor causing emissions<br />
This paper will report on the results of this latest research and discuss availability of new<br />
products that continue to evolve to meet evolving emissions standards.
Polypropylene Compounding
Understating the Structure of Wheat Straw and other Natural Fibers for<br />
Applications in <strong><strong>Auto</strong>motive</strong> Thermoplastics Composites<br />
Leonardo C. Simon, Ellen C. Lee and Paul A. Hardy<br />
Abstract<br />
Agricultural fibers are lightweight and renewable materials that can contribute to sustainable<br />
transportation. The major <strong>com</strong>ponents in the formulation of thermoplastic <strong>com</strong>posites can be<br />
classified as resins, fillers, fibers or additives. Therefore, agricultural by-products can be used as<br />
feedstock for manufacturing fillers or fibers for polyolefin <strong>com</strong>posites. Wheat straw is of great<br />
interest because it is available annually in large quantities on a global scale and it does not<br />
<strong>com</strong>pete with the food⁄feed supply chain. This presentation will discuss the structure of the wheat<br />
straw in terms of morphology (particle shape, size and aspect ratio), chemical <strong>com</strong>position<br />
(cellulose, hemicellulose, lignin and ashes), density and its thermal degradation (temperatures<br />
and activation energy). This discussion will then be extended to four other materials: soy, flax,<br />
hemp and sisal. These natural fibers were used in the formulation polypropylene and their<br />
properties were measured. The properties of these thermoplastic <strong>com</strong>posites will be discussed in<br />
terms of the properties of the natural fibers.<br />
lsimon@uwaterloo.ca Department of Chemical Engineering, University of Waterloo, 200<br />
University Av. West, Waterloo, ON, Canada N2L 3G1; elee9@ford.<strong>com</strong> Materials Science<br />
Department, Ford Research Laboratory, Ford, 2101 Village Road, Dearborn, MI 48124;<br />
paul_hardy@us.aschulman.<strong>com</strong> A. Schulman Inc., Product Technology Center, 1183 Home<br />
Av., Akron, OH, 44310-2508
Short Bio (September <strong>2010</strong>)<br />
Leonardo C. Simon<br />
Associate Professor, Department of Chemical Engineering<br />
University of Waterloo<br />
200 University Avenue West<br />
Waterloo, ON, N2L 3G1<br />
Leonardo C. Simon is Associate Professor in the Department of Chemical Engineering at<br />
the University of Waterloo, in Canada. He obtained his BEng (1995) and MEng (1998) in<br />
Chemical Engineering and his PhD (2001) in Materials Science, all from the Federal<br />
University of Rio Grande do Sul located in Porto Alegre, Brazil. He joined Department of<br />
Chemical Engineering at the University of Waterloo in 2002 as Assistant Professor and<br />
received tenure in 2007.<br />
His research areas include the synthesis, characterization and properties of polymer<br />
materials, polymer nano<strong>com</strong>posites and bioproducts, and modeling polymerization<br />
mechanisms. He teaches at undergraduate (Materials Science and Engineering) and<br />
graduate (Polymer Science) levels.<br />
Awards:<br />
-Early Research Award in 2005<br />
-Young Canadian Innovator Award in 2006<br />
-Best Paper Award at the <strong>SPE</strong> <strong><strong>Auto</strong>motive</strong> Composites <strong>Conference</strong> in 2007<br />
-Canada’s Top 40 Under 40 in 2009<br />
For additional information visit http://lsimon.uwaterloo.ca.<br />
For contact please use lsimon@uwaterloo.ca
The cost-effective PA replacement: Borealis presents energy- and<br />
production-efficient alternative<br />
Thomas Wagner<br />
OEM Manager<br />
Borealis<br />
GmbH St. Peter Straße 25<br />
4021 Linz Austria<br />
Abstract<br />
Pioneering steps by Borealis in the field of polypropylene glass fibre (PP-GF) <strong>com</strong>pound technology<br />
are opening up new ground for its use in under-the-hood and semi-structural parts.<br />
The traditional domain of PA and PA <strong>com</strong>pounds, and steel / steel-hybrid <strong>com</strong>positions, leading<br />
OEMs such as VW and BMW are already experiencing the production efficiency, weight-reduction<br />
and environmentally-friendly benefits of PP-GF <strong>com</strong>pounds for these applications.<br />
Thomas Wagner, OEM Manager Borealis’ Mobility Business Unit, highlights the significant<br />
contribution advanced easy-processing PP <strong>com</strong>pounds are making to improving system costs and<br />
energy efficiency for OEMs and Tier Ones without <strong>com</strong>promising parts’ performance.<br />
Borealis presents cost-effective environmentally-friendly PP solution to automotive industry
Curriculum Vitae<br />
Education<br />
2007 Commercial Excellent Program, IMD<br />
2004 Master in Key Account Manager MDI,<br />
Sep. 1999 – July 2001 Academy for Marketing and Management<br />
Sep. 1984 - June 1989 Higher technical School for Chemistry<br />
Working Experience<br />
01/10 – open BOREALIS<br />
OEM-Manager<br />
03/07 – 12/2009 BOREALIS<br />
Application Marketing Manager, <strong><strong>Auto</strong>motive</strong> Interior<br />
03/05 – 03/07 PLEON Publico Public Relations & Lobbying,<br />
Senior Consultant & Office Manager<br />
07/00 – 03/05 Borealis<br />
Market Development Engineer<br />
11/96 – 07/00 Zizala GmbH Lichtsysteme, (<strong><strong>Auto</strong>motive</strong> Tier1)<br />
deputy of quality assurance manager<br />
09/96 – 12/96 Ankerbrot AG, Vienna<br />
Quality Assurance Manager<br />
06/91 – 08/96 General Biscuits Austria, (Danone-Groupe)<br />
Export Manager to non EU countries<br />
deputy of production manager<br />
07/89 – 06/91 Ybbstaler Obstverwertung<br />
R&D Lab, Method development for HPLC and GC
Innovations in Thermoplastic Polyolefin Compounds for Thick-Sheet<br />
Thermoforming Applications<br />
S. Shah<br />
Lyondellbasell<br />
Mansfield, TX<br />
ABSTRACT<br />
Thermoplastic polyolefin (<strong>TPO</strong>) <strong>com</strong>pounds continue to gain acceptance as a viable<br />
material for thick-sheet thermoforming applications in the transportation industry. The<br />
primary advantages of <strong>TPO</strong>s in <strong>com</strong>parison to the incumbent styrenics (ABS, HIPS) and<br />
fiber reinforced plastics (FRP) used in these applications are its superior balance of<br />
stiffness-impact properties, excellent weatherability and enhanced chemical resistance.<br />
This paper highlights the attributes of a new <strong>TPO</strong> material designed for thick-sheet<br />
thermoforming. The new <strong>TPO</strong> material exhibits improved melt strength and a broader<br />
thermoforming processing window relative to existing <strong>TPO</strong> materials, while maintaining<br />
or exceeding the balance of physical and durability properties.
SUNIT SHAH<br />
Sunit Shah is currently a Technology Manager with Equistar Chemicals LP, a<br />
Lyondellbasell <strong>com</strong>pany. With Lyondellbasell and predecessor <strong>com</strong>panies since 1992, he<br />
has held various positions in technology development and business management,<br />
responsible for the development and <strong>com</strong>mercialization of engineered polyolefin<br />
<strong>com</strong>pounds and thermoplastic elastomers for automotive and consumer/industrial<br />
applications. Sunit Shah received a Masters degree in Plastics Engineering and Polymer<br />
Science from the University of Massachusetts.<br />
Sunit Shah<br />
Technology Manager<br />
Equistar Chemicals, LP<br />
100 S. Mitchell Road,<br />
Mansfield, TX 76063<br />
Office: 817-792-1406<br />
Mobile: 817-291-1961<br />
sunit.shah@lyondellbasell.<strong>com</strong>
D.Beuke@mitsui.<strong>com</strong> – Senior Mgr of Technical and Sales<br />
“New Micro Fiber Developments Achieve Improved <strong>TPO</strong> Performance”<br />
Donald Beuke - Mitsui Plastics Inc.<br />
ABSTRACT for the <strong>2010</strong> <strong><strong>Auto</strong>motive</strong> <strong>SPE</strong> <strong>TPO</strong> <strong>Conference</strong><br />
With automotive 2016 CAFÉ standards of 35.5MPG looming on the horizon, <strong>com</strong>pounders, molders and<br />
car <strong>com</strong>panies are turning to lighter weight filled <strong>TPO</strong>’s. With the advent of a Patent Pending nucleated<br />
surface treated micro fiber from Ube, higher flexural modulus and improved impact <strong>TPO</strong>’s are achieved.<br />
This presentation will explore the <strong>TPO</strong> physical property improvements of NST (nucleated surface treated)<br />
MOS (magnesium oxysulfate) Hige (wisker type micro fibers). We will <strong>com</strong>pare and contrast NST-MOS<br />
Hige to current methods of adding the nucleating agent direct to the <strong>TPO</strong> <strong>com</strong>pounds.<br />
RESULTS*<br />
Nucleating agent Nucleator<br />
added via**<br />
Sodium 2,2-methylene<br />
bis(4,6-di-tertbutylphenyl<br />
)phosphate<br />
p-tert-butyl benzoic<br />
acid<br />
a.Nucleated<br />
Surface<br />
Treatment<br />
b.Added to<br />
extruder<br />
(control)<br />
a.Nucleated<br />
Surface<br />
Treatment<br />
b.Added to<br />
extruder<br />
(Control)<br />
Benzoic Acid a.Nucleated<br />
Surface<br />
Treatment<br />
b.Added to<br />
extruder<br />
(control)<br />
HDTdegC CLTE x<br />
10-4 th<br />
120<br />
(4%<br />
increase)<br />
0.74<br />
(12%<br />
reduction)<br />
Flex Mod.<br />
MPa<br />
2320 (30%<br />
increase)<br />
Izod<br />
impact<br />
kJ/m2<br />
5.8<br />
(7%<br />
increase)<br />
Density<br />
g/c3<br />
9/22/<strong>2010</strong> 1<br />
0.960<br />
115 0.84 1790 5.4 0.961<br />
118 0.71 2110 5.9 0.960<br />
112 0.86 1940 5.2 0.959<br />
116 0.75 2100 5.8 0.961<br />
112 0.85 1940 5.4 0.960<br />
• **MOS <strong>TPO</strong> Compound formula:<br />
o 89.5 impact PP (8% ethylene, 30MFR)<br />
o MOS Hige fiber + Nucleating agent addition method:<br />
� a) 10% MOS Hige Micro Fiber with 1% nucleating agent surface treatment (NST)<br />
� b) or 10% MOS Hige Micro fiber<br />
� + 0.1% nucleating agent added<br />
o 0.3% Calcium Stearate lubricant<br />
o 0.1% Evernox 10<br />
o 0.1% Everphos 168<br />
100%
• * US Patent Application US200/0292047 A1 November 26, 2009<br />
o Assigned to: Ube Material Industries Ltd.<br />
o Inventors: Shinichi Yamamoto, Takashi Kishimoto<br />
D.Beuke@mitsui.<strong>com</strong> – Senior Mgr of Technical and Sales<br />
RESULTS:<br />
When a variety of acid and acid ester nucleating agents are used to surface treat the magnesium oxysulfate<br />
micro fiber (NST-MOS Hige), significant increases in stiffness, heat distortion, -30c Izod impact and a<br />
reduction of the coefficient of linear thermal expansion are achieved <strong>com</strong>pared to normal addition of the<br />
same nucleating agents to the <strong>TPO</strong> <strong>com</strong>pound.<br />
CONCLUSIONS:<br />
With the advent of NST-MOS Hige <strong>com</strong>bined with special grades of Talc, <strong>TPO</strong>’s of 30-50MFR, 2,300-<br />
3,000MPa flexural modulus and -30c Notched Izod Impact’s and -30 Multi Axial Impact is now<br />
achievable.<br />
NST-MOS Hige allows lower density and thinner gauge automotive parts, resulting in 15-20% weight<br />
reduction and lower part costs. NST-MOS empowers the Molders and OEM’s to achieve both car and<br />
truck weight reduction necessary to meet 2016 CAFÉ requirements of 35.5MPG with the added benefit of<br />
overall cost savings.<br />
BIOGRAPHY:<br />
Presenter: Don Beuke is on his 37 th year as a Chemist and Engineer in product & market development, sales, and<br />
technical service of plastics and additives. He holds a variety of patents with many of the previous <strong>com</strong>panies he<br />
worked for. These <strong>com</strong>panies are; PPG Coatings and Resins Division, Ciba-Geigy Plastics Additives Dept, Phillips 66<br />
Company Plastics Division, Petrolite Polymers Division, Wed-Tech Compounding (now Ingenia) . He has been a<br />
Consultant for Mitsui totaling 16 years. Don is currently employed by Mitsui Plastics Inc. as a Senior Manager of<br />
Technical, Sales and Business Development.<br />
9/22/<strong>2010</strong> 2
Applying DMA Technique to Develop Novel PP<br />
Compounds<br />
Deen Chundury, John Klein<br />
Asahi Kasei Plastics North America<br />
900 E. Van Riper Road<br />
Fowlerville, MI 48836<br />
Abstract<br />
Dynamic Mechanical Analyzer (DMA) has been utilized to study the<br />
viscoelastic behaviors of plastic <strong>com</strong>pounds. Elevated temperature<br />
creep resistance property is one of the key performance<br />
characteristics for load-bearing applications.<br />
In this paper, we examine a novel accelerated technique to<br />
generate long term creep behavior using DMA property through<br />
effective use of the time-temperature superposition master curves.<br />
We also present application of this technique to develop and<br />
<strong>com</strong>mercialize the next generation glass fiber reinforced<br />
polypropylene <strong>com</strong>pounds as potential alternatives to expensive<br />
engineering plastics.<br />
*For consideration to be presented at 12 th Annual <strong>SPE</strong> <strong><strong>Auto</strong>motive</strong> <strong>TPO</strong> <strong>Global</strong> <strong>Conference</strong>,<br />
October 3-6, <strong>2010</strong>, Sterling Heights, Michigan, USA
Dr. Deen Chundury is currently Technical Director of Polypropylene Research and<br />
Development at Asahi Kasei Plastics NA. Previously, he worked as a Group Director of<br />
Technology, Specialty Plastics Business Unit, Ferro Corporation.<br />
Deen areas of expertise have been in plastics <strong>com</strong>pounding, reactive extrusion, polymer<br />
alloys and blends, nano-<strong>com</strong>pounds, polymer synthesis. He is co-inventor of 29 U.S.<br />
Patents and co-authored 47 journal and conference publication including a book chapter.
Productivity and Performance...<br />
Additives to Optimize Properties, Dimensions, and Conversion Cost in <strong><strong>Auto</strong>motive</strong> PP-Based Resins<br />
Adam Watson<br />
Milliken Chemical<br />
Warpage, dimensional specifications, mechanical property balance, and cycle time are all critically<br />
important measurements in the production of polyolefin-based automotive parts. With their beneficial<br />
effects on these properties and measurements, novel nucleating agents can be used to improve performance<br />
and overall cost. In this presentation, Milliken demonstrates how to fine tune properties and performance<br />
with various formulations and the productivity enhancements that result.
Adam Watson<br />
<strong>Global</strong> Product Line Manager, Plastic Additives Business,<br />
Milliken Chemical<br />
Adam Watson is a global product line manager for Milliken Chemical’s Plastics Additives<br />
business. He is responsible for the strategic direction, business development, marketing<br />
and global <strong>com</strong>munication of Milliken’s nucleation and reinforcement technologies.<br />
He began his career with Milliken in 2003 in a business development role, and served most<br />
recently as a national account manager for North America. Prior to joining Milliken, Watson<br />
worked in various technical, sales and market development roles with BASF.<br />
Watson’s career areas of focus have included engineering, manufacturing and supply chain<br />
management, application and market development, and national account management.<br />
Adam graduated from the University of Virginia, in Charlottesville, VA, with a bachelor’s of<br />
science degree in Mechanical Engineering. He holds an MBA from Clemson University in<br />
Clemson, SC.<br />
# # #<br />
Page 1 of 1
Tailored Wollastonite Products for Reinforced Polyolefin<br />
Applications<br />
Gary Phillips<br />
Vice President Marketing & Application Development<br />
After pioneering the production and use of fine diameter, high aspect ratio wollastonite, NYCO<br />
perfected grades in manufacturing various lengths to diameter products to meet the demanding<br />
performance requirements of automotive polypropylene & engineering alloy <strong>com</strong>posites. The<br />
3 primary grades in NYGLOS® 8, NYGLOS 4W and NYGLOS 2000 has been found to<br />
provide the necessary balance of physical properties required by selected end use applications.<br />
Each of the NYGLOS® grades provide a different range of stiffness and impact values based<br />
on the <strong>com</strong>posite requirements in flexural modulus, impact, scratch resistance, specific gravity<br />
as well as <strong>com</strong>pounding/unit cost. The NYGLOS family based on the high fiber modulus of the<br />
base substrate can be tailored in length to diameter providing flexibility in the fiber properties.<br />
Each L/D provides it own unique values in stiffness, low CLTE, dimensional stability, flexural<br />
strength & scratch resistance. The first noted application was the use of a high aspect ratio fiber<br />
in NYAD G chemically modified for the replacement of milled glass in General Motor<br />
Advanced Passenger Van front vertical body panels (RRIM). The success of this <strong>SPE</strong><br />
<strong>com</strong>posites award <strong>com</strong>posite promoted the replacement of Potassium Titanates in RRIM<br />
applications at Toyota. As market conditions changed from Thermosets to Thermoplastics<br />
promoted the use of NYCO’s fine diameter products in Polypropylene at Ford, GM, Chrysler,<br />
BMW and Volkswagen primarily for interior hard trim applications. Today’s <strong>com</strong>posite<br />
requirements are considerably more stringent in regards to the balance of physical properties,<br />
specific gravity, wall thickness and cost. The demand for high reinforcing minerals to meet<br />
these demands continues to promote the investigation and <strong>com</strong>mercialization of NYCO’s<br />
family of reinforcements for polyolefin applications with focus on automotive high-end<br />
<strong>com</strong>posites.<br />
To address the growth and development of Polypropylene Vertical body panels, NYCO has<br />
recently developed and <strong>com</strong>mercialized a non directional high reinforcing product in NYGLOS<br />
2000. Do to its engineered particle size control has been found to provide <strong>com</strong>parable<br />
shrinkage differential in both directions to platy-type materials and can be employed in existing<br />
applications (tooling), while providing an excellent overall balance of stiffness, impact, low<br />
CLTE, scratch resistance, surface appearance & Paintability.
NYGLOS 2000, NYGLOS 4W & NYGLOS 8 are chemically modified with a proprietary<br />
blend of reactive and non reactive silane coupling agents that contain at least two different<br />
reactive groups within their molecules. Providing improved dispersion and wet out during<br />
<strong>com</strong>pounding as well as to improve mechanical strength and other properties of the polymer<br />
<strong>com</strong>posite. NYCO’s portfolio of surface modification consist of > 30 types of chemistry<br />
tailored by polymer and its related requirements, all batch processed to guarantee consistency,<br />
certification and its reactivity when coupled to the base substrate.<br />
NYCO has also unveiled a new conductive wollastonite trade named Elektra-Stat targeting<br />
the replacement of conductive carbon black without loss of stiffness and Charpy impacts. As<br />
well as a candidate as a partial replacement of conductive carbon fiber to reduce raw material<br />
cost.<br />
Comparative data, processing and feeding will be discussed in this presentation.
September <strong>2010</strong><br />
Subject: Background Summary for Gary Phillips<br />
Gary is Vice President of Marketing and Application Development for NYCO<br />
Minerals and has been employed with NYCO since 1982. His primary responsibility<br />
is for the development of Wollastonite and chemically modified products globally<br />
for reinforced plastic applications.
Milled Fiberglass as a Potential Reinforcement in <strong>TPO</strong> Materials<br />
Andrew Hopkins, Harry Karian<br />
Rhetech Inc.<br />
Jonathan O'Leary<br />
Hammermill Glass Inc.<br />
Abstract<br />
The study was performed to examine the utility of milled fiberglass as a reinforcement in typical<br />
<strong>TPO</strong> material systems. Several sources of milled glass were obtained, varying in both geometry<br />
and surface chemistry. Physical and thermal properties of the materials are reported.
Andrew R. Hopkins, Ph.D.<br />
Executive Vice President<br />
Andrew “Andy” Hopkins is executive vice president for RheTech Inc., a<br />
privately held, reinforced thermoplastics <strong>com</strong>pounder serving the<br />
transportation, consumer and construction markets. He is responsible<br />
for all <strong>com</strong>mercial, marketing, technical, and new product development<br />
activities.<br />
His career has focused on the development and successful implementation of market<br />
led business strategies that have a high technology <strong>com</strong>ponent. Prior to joining<br />
RheTech in 2007, he spent 11 years at Owens Corning, a $6 billion Fortune 500<br />
<strong>com</strong>pany. He held executive management positions within Owens Corning’s Composite<br />
Solutions Business, including director, North America Marketing and Sales; and,<br />
general manager, Owens Corning <strong><strong>Auto</strong>motive</strong>. In addition, he was general manager,<br />
StaMax BV, a highly successful European automotive polymers joint venture between<br />
Owens Corning and SABIC.<br />
Hopkins also worked at Capgemini Consulting and the Warner Lambert Company in senior<br />
management roles related to healthcare.<br />
Hopkins earned a doctorate in Organic Chemistry from the University of Kent, UK, and a<br />
bachelor of science in Chemistry from the University of London. He is an elected Fellow<br />
of the Royal Society of Chemistry and a member of the Society of Plastics Engineers<br />
(<strong>SPE</strong>).<br />
RheTech, Inc.<br />
1500 E. North Territorial Road<br />
Whitmore Lake, MI 48189<br />
734-769-0585
Recycling of <strong><strong>Auto</strong>motive</strong> Paint Over-spray<br />
into Useful Polypropylene Compounds<br />
Chris Surbrook<br />
New Business Development<br />
Midland Compounding & Consulting, Inc.<br />
Christopher Chrzanowski<br />
Preferred Filter Recycling, LLC<br />
Abstract<br />
In September 2008, General Motors heralded in the move towards environmentally<br />
conscience manufacturing into U.S. <strong><strong>Auto</strong>motive</strong> manufacturing, with its <strong>com</strong>mitment to<br />
“to make half of its major global manufacturing operations landfill-free by the end of<br />
<strong>2010</strong>”. As part of that effort, GM is working to divert from landfill the almost 8 million<br />
pounds a year of sludge collected from paint booth filtration systems. The current<br />
filtering methods utilize a water bath process that captures the paint overspray, as well<br />
as other airborne particles, and drains them into a collection basin. The first difficulty to<br />
over<strong>com</strong>e in recycling this material is to evacuate the remaining 20-25% water weight<br />
from the sludge. The second difficulty is separating out contamination of things like metal<br />
shavings and organic growth that were collected, or occurred during storage. Even the<br />
most diligent of cleaning processes, would not yield material that could be used-back as<br />
paint, because color segregation is not possible. These issues are inherent in<br />
automotive paint shops around the world and the industry is looking for ways to repurpose<br />
this material. This paper describes how through, an innovative recycling<br />
process, automotive paint sludge can be converted and reprocessed into meaningful<br />
polypropylene <strong>com</strong>pounds. These <strong>com</strong>pounded materials offer physical properties<br />
suitable for applications within the automotive supply chain and can be processed in the<br />
same manner as conventional recycled polypropylene materials for injection molded<br />
products. Some of the applications approved for these materials include being blended<br />
with prime for pallets, clutch trays, spindle trays, and part totes for in-plant and plant to<br />
plant transport.<br />
e-mail: csurbrook@midland<strong>com</strong>pounding.<strong>com</strong>
Christopher M. Surbrook<br />
New Business Development, Midland Compounding & Consulting, Inc.<br />
Chris started in the plastics industry selling additives and other materials as the North American Business<br />
Manager for Mica-Tek division of Microfine Minerals Limited, a global manufacturer of industrial<br />
minerals and colorants. Here he gained experience in manufacturing operations, market development, and<br />
sales and distribution management. He went on to purchase some of the technologies away from<br />
Microfine, and co-found All Plastics, Inc. where his primary responsibilities were research and managing<br />
developmental projects, ultimately be<strong>com</strong>ing President from 2003-2005. Most of the products he<br />
developed for All Plastics pertained to mineral based effect pigments. His expertise in the field of optical<br />
effect pigments and color <strong>com</strong>pounding, lead him to be<strong>com</strong>e Chief Scientific Officer for Bordener<br />
Engineered Surfaces in Midland, Michigan, where he established a relationship with Midland<br />
Compounding & Consulting while developing and <strong>com</strong>mercializing a mineral filled polypropylene<br />
laminate sheet.
<strong>TPO</strong>s/TPEs Interface
Robert Eller Associates LLC<br />
CONSULTANTS TO THE PLASTICS AND RUBBER INDUSTRIES<br />
TECHNICAL / ECONOMIC / MARKET ANALYSIS SUPPORTING MANAGEMENT DECISIONS<br />
___________________________________________________________________________<br />
696 Treecrest Drive · Akron, OH 44333-2726 USA<br />
Phone 330-670-9566 / Fax 330-670-9844<br />
AUTOMOTIVE <strong>TPO</strong>s AND TPEs:<br />
COMPETITION IN A CHANGING GLOBAL MARKET<br />
Prepared for:<br />
12th ANNUAL <strong>SPE</strong> AUTOMOTIVE <strong>TPO</strong> GLOBAL CONFERENCE<br />
Detroit, MI<br />
October 5, <strong>2010</strong><br />
Presented by: ROBERT ELLER<br />
ABSTRACT<br />
The global recession has severely impacted automotive markets and associated demand<br />
for automotive <strong>TPO</strong>s, other TPEs, and PP <strong>com</strong>pounds. Recent growth in global and N.<br />
American auto sales is promising and has experienced a strong first half <strong>2010</strong>, but the<br />
second half <strong>2010</strong> growth is likely to slow. As the global (auto market) footprint and<br />
driving forces for material substitution shift, new opportunities are being created for<br />
<strong>TPO</strong>s and TPEs.<br />
Robert Eller Associates, LLC
Robert Eller Associates LLC<br />
CONSULTANTS TO THE PLASTICS AND RUBBER INDUSTRIES<br />
TECHNICAL / ECONOMIC / MARKET ANALYSIS & MANAGEMENT DECISIONS<br />
4000 Embassy Parkway · Suite 208 · Akron, OH 44333-8328 USA<br />
Phone 330-670-9566 / Fax 330-670-9844<br />
E-mail: bobeller@robertellerassoc.<strong>com</strong> / Home Page: http://www.robertellerassoc.<strong>com</strong>/<br />
ROBERT ELLER is President of Robert Eller Associates LLC (REA), a firm specializing in<br />
consulting to management of the plastics and rubber industries. His <strong>com</strong>pany has offices in<br />
Akron, Ohio and China.<br />
<strong><strong>Auto</strong>motive</strong> plastics AND <strong>TPO</strong>s are a consulting specialty of REA. Bob and his associates have<br />
carried out numerous technology, strategy, and manufacturing analyses, pricing forecasts,<br />
product positioning analyses, and (recently) crisis management analyses in the autoplastics<br />
industry in North America, Europe, Japan and China. In addition to single client analyses and<br />
acquisition support studies, REA has <strong>com</strong>pleted several multiclient analyses, including:<br />
- Specialty Thermoplastic Elastomers . . . Markets, Economics, Technology, Intermaterials<br />
Competition in Europe/U.S./Japan and China<br />
- <strong><strong>Auto</strong>motive</strong> Interior Soft Trim: Skins, Foams, Coated Fabrics, Textiles, and Acoustic Barriers<br />
- Opportunities for Advanced Technology Nonwovens for <strong><strong>Auto</strong>motive</strong> Surface and Construction<br />
Applications in N. America and Europe<br />
His <strong>com</strong>pany is currently actively working in the analysis of:<br />
-The changing role of <strong>TPO</strong>s and other TPEs in the autoplastics sector<br />
-The evolving role of thermoplastic <strong>com</strong>posites materials and fabrication technologies in the<br />
auto<br />
sector<br />
-The role of plastics in electric drive vehicles and advanced battery technology<br />
Bob is a graduate of M.I.T. (Chemical Engineering) and has an M.S. in Polymer Science and<br />
Chemical Engineering from Brooklyn Polytechnic. Employment experience includes<br />
ExxonMobil, A. D. Little (1966-1981), Phillip Townsend Associates, Charles River Associates<br />
(Vice President), Multibase (a French/U.S. <strong>com</strong>pounding <strong>com</strong>pany-General Manager) and<br />
Robert Eller Associates LLC (President, 1991 – Present).<br />
He has been the moderator of the interiors/new applications sessions of this <strong>SPE</strong><strong>TPO</strong> conference for<br />
the past 11 years.<br />
b/mydox/bio/spe<strong>tpo</strong>09 bio
TPV for automotive body seal applications.<br />
Nobuhiro Natsuyama<br />
Tatsuo Sassa<br />
Hirofumi Jyohoji<br />
Sumitomo Chemical Co., Ltd.<br />
Body Seal is configured by several parts. The extrusion glass run channel parts are<br />
joined together by injection corner parts. Injection corner material is required to have<br />
multi functions as it is difficult to be multi layered parts. Required functions are<br />
adhesion strength with extrusion parts, flow ability to achieve superior appearance,<br />
together with good elastomeric propertied such as <strong>com</strong>pression set. For the application,<br />
Sumitomo Chemical had developed “ESPOLEXTM” by TPV technologies which achieved<br />
higher balanced properties by focusing molecular structures and their morphology.<br />
Scope of this paper is to introduce “ESPOLEX TM” technologies how the materials had<br />
developed.
<strong>SPE</strong> <strong><strong>Auto</strong>motive</strong> <strong>TPO</strong> <strong>Global</strong> <strong>Conference</strong> <strong>2010</strong><br />
Speaker’s Bio.<br />
Name: Nobuhiro Natsuyama<br />
Title: TPV for automotive body seal applications<br />
Company: Sumitomo Chemical Co., Ltd.<br />
Experience: (Brief Summary)<br />
1989 -1996 ; Sumitomo Chemical Co., Ltd. EPDM research laboratory<br />
1996- ;Sumitomo Chemical Co., Ltd. TPE research laboratory<br />
Educational Background:<br />
1984 - 1989 ; Kitakyuushu national college of technology<br />
Industry/Trade Affiliations:
AUTOMOTIVE WEATHERSEALS TRENDS<br />
WITH THERMOPLASTIC VULCANIZATES<br />
Eric Jourdain<br />
Specialty Polymers Technology & Marketing Associate<br />
ExxonMobil Chemical Company<br />
<strong>TPO</strong> <strong>Conference</strong> – Detroit, MI – October <strong>2010</strong><br />
ABSTRACT<br />
Ethylene propylene diene rubbers (EPDM) are largely used in automotive sealing system<br />
due to their excellent cost and performance balance over the lifetime of the car. Today,<br />
thermoplastic elastomers penetrate the weatherseal applications due to their ability to<br />
offer weight reduction, processing simplification, recyclability, and even longer term<br />
sealing performance <strong>com</strong>pared to traditional thermoset EPDM rubbers.<br />
Even more, thermoplastic vulcanizate (TPV) <strong>com</strong>binations allow for metal reinforcement<br />
elimination and the design of innovative automotive sealing <strong>com</strong>ponents, with multiple<br />
integrated functionalities that are difficult and costly to achieve with thermoset rubber.<br />
In this paper, we will show how we can leverage the versatility of TPVs to develop<br />
innovative grades and processing for integrating different properties to replace EPDM,<br />
structural metal and surface modifiers. These novel <strong>com</strong>ponents allow significant<br />
<strong>com</strong>ponent weight reduction and process simplification.<br />
We will provide examples of innovative developments, such as corner moldings, glass<br />
run channels, attachment system, surface modification and tie layers, and their impact on<br />
system weight, performance and aspect. Finally, we will give a market perspective of the<br />
development of TPVs in automotive sealing systems.
<strong>SPE</strong> <strong><strong>Auto</strong>motive</strong><strong>TPO</strong> <strong>Global</strong> <strong>Conference</strong> <strong>2010</strong><br />
Speaker’s Biography<br />
<strong>SPE</strong>AKER: ERIC JOURDAIN,<br />
ExxonMobil Chemical<br />
Marketing and Technology Engineering<br />
• French citizen<br />
• Graduated Chemical Engineer - Bordeaux - France,<br />
• Engineering degree from the French Rubber Institute - Paris.<br />
• Master in Business Administration ( IAE) - Paris<br />
• Joined ExxonMobil Chemical in 81 as a sales representative in France.<br />
• In 84 - Technology Center in Belgium for EPDM Vistalon Technical Development<br />
in Europe.<br />
• In 93 assignment in USA at the Baytown Polymer Center – Texas.<br />
• In 97, moved to the European Technology Center with a global responsibility for<br />
polymer and application developments in automotive weatherseal applications.<br />
• Joined in 04 Santoprene Specialty Products as Technology Associate, leading<br />
Product Development for automotive weatherseal.<br />
• Currently Technology and Marketing manager for automotive weatherseal market<br />
segment in Specialty Elastomer Business of ExxonMobil Chemical<br />
ExxonMobil Chemical<br />
Specialty Elastomers Business<br />
Hermeslaan 2<br />
1831 Machelen – Belgium<br />
+32 2 722 3747<br />
Eric.jourdain@exxonmobil.<strong>com</strong>
Eric ________________________________<br />
Jourdain _____________________________<br />
ExxonMobil Chemical<br />
Specialty Elastomers Business ___________<br />
Hermeslaan 2<br />
1831 Machelen - Belgium<br />
+32 2 722 3747<br />
eric.jourdain@exxonmobil.<strong>com</strong><br />
• Ingénieur Physique Chimie - Bordeaux<br />
• Ingenieur Ifoca en 1978<br />
• IAE - Paris<br />
• A rejoint ExxonMobil Chemical in 81 en France.<br />
• En 84 ingénieur d’application caoutchouc - European Technology Center en<br />
Belgique<br />
• En 93, ingénieur développement aux USA - ExxonMobil Polymer Center<br />
• En 97, responsable des développements des Elastomères et leurs application dans<br />
l’automobile European Technology Center - Belgique<br />
• En 2004, responsable du développement des TPV Santoprene pour application<br />
dans les joints d’étanchéité automobile<br />
• Depuis 2008, Technology and Marketing Application Manager pour le marché des<br />
Elastomères <strong>Auto</strong>mobile dans la Business Unit « Specialty Elastomer » d’<br />
ExxonMobil Chemical
High Performance Reinforcement for Lightweighting Polyolefin<br />
<strong><strong>Auto</strong>motive</strong> Parts while Maintaining High Surface Quality<br />
Milliken Chemical Company<br />
Light-weighting initiatives in the automotive industry continue to be a driving force for the development of<br />
new lower density / higher performance <strong>com</strong>posites. With new CAFE standards on the horizon along with<br />
the continued development of vehicles using alternative energy sources, the demand for lighter weight<br />
and structurally sound automotive parts may now be at an all time high. Novel reinforcing agents can be<br />
used to address these needs.
<strong>SPE</strong> <strong><strong>Auto</strong>motive</strong><strong>TPO</strong> <strong>Global</strong> <strong>Conference</strong> <strong>2010</strong><br />
Speaker’s Bio<br />
NAME: Dr. Wouter Reyntjens<br />
COMPANY: Milliken Chemical Europe<br />
Dr. Wouter Reyntjens was born in Belgium in 1975 and lives with his family near<br />
Brugge in Belgium.<br />
He obtained his PhD in polymer chemistry from Ghent University, Belgium.<br />
He started his career as a process chemist at Solutia, Inc. in Belgium. He joined the<br />
plastic additives group of Milliken Chemical Europe in 2003 as applications lab<br />
manager.<br />
Presently, he is new business development manager at Milliken Chemical Europe.<br />
Dr. Wouter Reyntjens has published several scientific reports and authored one<br />
international patent.
Talc Application in SEBS Compounds<br />
Saied H. Kochesfahani – Rio Tinto Minerals, Denver, CO<br />
Gilles Meli and Frederic Jouffret, Rio Tinto Minerals, Toulouse, France<br />
Thermoplastic elastomers (TPEs) offer attractive advantages since their mechanical<br />
properties could be tailored to specific applications and they could benefit from the lower<br />
cost of thermoplastic processing. Conventional elastomers, however, could be at a better<br />
cost position partly because they may benefit from heavy filler loading. Utilization of<br />
suitable additives in TPEs could enhance the cost-performance and market position of<br />
these materials in many applications including automotives.<br />
Talc is <strong>com</strong>monly used to reinforce and improve dimensional stability of plastics<br />
including <strong>TPO</strong>s. It is also used to reinforce rubber and improve its processing abilities<br />
and mechanical properties. This paper utilizes an experimental study conducted on the<br />
functions of talc in SEBS <strong>com</strong>pounds to analyze the benefits of talc in modifying<br />
mechanical properties and improving processing of these <strong>com</strong>pounds.<br />
The results show that talc, especially ultrafine microcrystalline Mistron ® talc products,<br />
could be utilized as a cost effective performance additive in SEBS <strong>com</strong>pounds and TPEs<br />
in general to increase reinforcement (Figure 1), hardness, and cut/tear resistance. Talc is<br />
also shown to have a unique effect in reducing anisotropy of SEBS <strong>com</strong>pounds that<br />
cannot be easily achieved by other means (Figure 2). The utilization of talc could also<br />
reduce the material costs and especially the processing costs of TPE <strong>com</strong>pounds due to<br />
improved flow properties (Figure 3).<br />
Modulus, MPa<br />
6.0<br />
5.5<br />
5.0<br />
4.5<br />
4.0<br />
3.5<br />
3.0<br />
100% Modulus<br />
300% Modulus<br />
Without Filler Calcium<br />
Carbonate<br />
Talc N°1 Talc N°2 Talc N°3 Talc N°4<br />
(40-µm topcut) (20-µm topcut) (10-µm topcut) (10-µm topcut)<br />
Figure 1. Effect of talc particle size and morphology on SEBS <strong>com</strong>pound modulus at<br />
100% and 300% elongation in <strong>com</strong>parison with the unfilled and calcium<br />
carbonate filled <strong>com</strong>pounds.
Isotropy<br />
1.5<br />
1.4<br />
1.3<br />
1.2<br />
1.1<br />
1.0<br />
0.9<br />
0.8<br />
0.7<br />
0.6<br />
0.5<br />
100% Modulus, MPa<br />
300% Modulus, MPa<br />
Tear Strength, kN/m<br />
Tensile Strenght, MPa<br />
Elongation at Break,<br />
%<br />
Calcium Carbonate Talc N°4 Talc N°4-PP MB<br />
Figure 2. Effect of talc and talc-PP MB on increasing SEBS <strong>com</strong>pound isotropy.<br />
Injection Molded Spiral Length, mm<br />
330<br />
280<br />
230<br />
180<br />
130<br />
80<br />
Calcium Carbonate<br />
Talc N°4<br />
Talc N°4-PP MB<br />
34%<br />
36%<br />
26%<br />
500 bars 750 bars 1000 bars<br />
Figure 3. Effect of talc on improving SEBS <strong>com</strong>pound flow properties and the<br />
enhanced effect when talc-PP MB was used (26% to 36% improvement in<br />
melt flow).
Name: Saied H. Kochesfahani<br />
Company: Rio Tinto Minerals<br />
<strong>SPE</strong> <strong><strong>Auto</strong>motive</strong><strong>TPO</strong> <strong>Global</strong> <strong>Conference</strong> <strong>2010</strong><br />
Speaker’s Bio<br />
Dr. Saied Kochesfahani is “Development Manager” for polymer applications at Rio Tinto Minerals. He is<br />
responsible for talc applications in Americas and flame retardant Firebrake ZB applications globally.<br />
Saied has a Ph.D. from University of Toronto, has been an active member of <strong>SPE</strong> since 2006, and is a<br />
frequent presenter at <strong>SPE</strong> conferences.<br />
Prior to Joining <strong>SPE</strong>, he was an active member of TAPPI with over 14 years of affiliation with pulp and<br />
paper industry. Saied has authored or co-authored over 40 publications in polymers and pulp and paper<br />
applications and led the development of a new technology in chemical recovery from R&D to<br />
<strong>com</strong>mercialization.
Use of naturally occurring fibers to replace oil<br />
derived materials in Weatherseal applications<br />
Jean-Marc Veille<br />
Cooper Standard <strong><strong>Auto</strong>motive</strong><br />
European R&D<br />
April, <strong>2010</strong><br />
Green material: Natural Fibers loaded seal<br />
2<br />
9/22/<strong>2010</strong><br />
1
Green material: Natural Fibers loaded seal<br />
Green material: Natural Fibers loaded seal<br />
3<br />
4<br />
9/22/<strong>2010</strong><br />
2
FULL TITLE OF PAPER<br />
SESSION NUMBERS<br />
FULL NAME OF <strong>SPE</strong>AKER<br />
COMPANY / UNIVERSITY<br />
BRIEF BIOGRAPHY<br />
CURRENT POSITION<br />
<strong>SPE</strong> AUTOMOTIVE TPE GLOBAL<br />
October 4-6 th <strong>2010</strong><br />
BIOGRAPHICAL INFORMATION<br />
To be <strong>com</strong>pleted in CAPITAL LETTERS<br />
Thermoplastic filled with Natural Fibers , Wheatersealing<br />
application<br />
JEAN-MARC VEILLE<br />
Cooper-Standard <strong><strong>Auto</strong>motive</strong><br />
French , he followed his Mechanical Engineer Studies at SUP MECA<br />
the National Mechanical Engineer School of Paris . He started his<br />
career at the Research Center of Citroen , in Rennes , then joined<br />
the <strong>com</strong>pany Standard Products. After working in Brazil and the<br />
United States he came back as Director R&D in charge of Materials<br />
& Advanced Studies. At Cooper Standard he has lead the<br />
introduction of TPE to replace rubber , for European OEM like PSA.<br />
R&D DIRECTOR<br />
1
Application Development
Abstract<br />
<strong>SPE</strong> <strong>TPO</strong> <strong>Conference</strong> <strong>2010</strong><br />
Latest European Trends for <strong><strong>Auto</strong>motive</strong> Interior Materials<br />
The lecture highlights new <strong>TPO</strong> concepts for improved material properties, for<br />
performance/cost-ratio optimization, and for “green” and electrical cars.<br />
With the new 5series of BMW there is the first time since more than 10 years that<br />
BMW use a thermoformed <strong>TPO</strong> decorative sheet for the upper instrument panel.<br />
The main reasons for BMW to use the so called TEPEO2 ® surface material from<br />
Benecke-Kaliko AG were the outstanding surface appearance which can be<br />
realized with that surface concept <strong>com</strong>bined with the possibility to get a one<br />
piece bi-tone cockpit to reasonable costs. Some material related aspects will be<br />
discussed.<br />
More and more cars will be equipped with bright colors also in the upper areas of<br />
interior parts in the future. Up to now, usage of bright colored <strong>TPO</strong> films in these<br />
upper areas is limited due to a yellowing effect of PUR back foamed <strong>TPO</strong> films<br />
during accelerated ageing. We present a new concept granting a significant<br />
reduction of this yellowing effect so that bright colors can be applied also in the<br />
upper areas of distinctive parts without the need of specification changes.<br />
In Europe there is a strong trend for using high resolution grains. Because of its<br />
regular or textile like character these surfaces are very sensitive towards scratch<br />
and mar. Especially for <strong>TPO</strong> based decorative surface materials it´s a big<br />
challenge to over<strong>com</strong>e these probem.<br />
Based on new <strong>com</strong>pounds Benecke-Kaliko is able to make these grains<br />
applicable also for <strong>TPO</strong> surface materials for the automotive interior. These new<br />
<strong>com</strong>pounds are also useable for the TEPEO2 ® concept of Benecke-Kaliko to get<br />
decorative surfaces with a very homogenous undistorted surface appearance.<br />
With increasing market demands for “green” and electrical cars the weight of<br />
automotive interior parts attracts more and more attention. Within its “Designed<br />
Green” strategy, Benecke-Kaliko AG offers a solution how weight of automotive<br />
interiors can be reduced significantly by smart selection and <strong>com</strong>bination of light<br />
weight decorative surface materials.<br />
Dr. Juergen Buehring<br />
Benecke-Kaliko AG<br />
Beneckeallee 40, 30419 Hannover<br />
Germany<br />
49 511 6302 7205<br />
juergen.buehring@benecke-kaliko.de
<strong>SPE</strong> <strong><strong>Auto</strong>motive</strong><strong>TPO</strong> <strong>Global</strong> <strong>Conference</strong> <strong>2010</strong><br />
Speaker’s Biography<br />
Name: Dr. Juergen Buehring<br />
Company: Benecke-Kaliko AG<br />
Experience (Brief Summary):<br />
Working with <strong>TPO</strong> materials for the car interior since more than<br />
15 years<br />
Education: Doctor thesis in 1996 with a study about the<br />
crosslinking behaviour of different rubbers<br />
Industry/Trade Affiliations: since 1995 at Benecke-Kaliko AG,<br />
Different functions in R&D (material development for foils,<br />
Product development, Development of Slush skins,<br />
Development of polyolefinic foams) and Production (Foils and<br />
polyolefinic foams),<br />
Since 2006 responsible for global R&D activities of Benecke-<br />
Kaliko AG
THERMAL STABILITY COMPARISON OF SLUSH TPE AND PVC FOILS IN<br />
INSTRUMENT PANEL CROSS-SECTIONS<br />
Patricia L. Pendergast<br />
Manager, Materials Engineering<br />
Inteva Products, LLC<br />
Composite structures, consisting of a flexible foil, polyurethane foam, and a<br />
structural plastic substrate, were subjected to dry heat aging exposure (120 o C, 2<br />
weeks). The test samples included areas that were fabricated to simulate the<br />
passenger side hidden airbag door. After <strong>com</strong>pletion of exposure, the samples<br />
were examined and <strong>com</strong>pared to untested parts. Judgment criteria included<br />
shrinkage, distortion, and integrity of the airbag score line. In addition, foils were<br />
subjected to dry heat aging and then subjected to various mechanical tests.<br />
Foils tested included several <strong>com</strong>mercial grades of PVC as well as one emerging<br />
<strong>com</strong>mercial grade of TPE. Test results clearly demonstrated performance<br />
superiority (as well as <strong>com</strong>pliance to customer requirements) of the TPE foils.
The Advantages of Using MuCell Microcellular Foaming with<br />
Long Glass Polypropylene<br />
Abstract:<br />
Scott Powers<br />
MuCell brings a new option for warpage reduction, weight reduction and improved<br />
flowability when injection molding long glass polypropylene. MuCell can reduce the<br />
unwanted side effects that are sometimes inherent when using a long glass reinforced<br />
polymer.<br />
Scott Powers<br />
Technical Development Manager<br />
Trexel, Inc.<br />
45 Sixth Road<br />
Woburn, MA 01801<br />
Phone (616) 635-7707<br />
s. powers@trexel.<strong>com</strong>
SCOTT POWERS<br />
Technical Development Manager for Trexel Inc.<br />
Resident of Michigan<br />
Plastics Engineer for 23 years.<br />
Undergraduate degrees in Plastic Engineering and Production Management from<br />
Ferris State University.<br />
Masters degree in Technology Management from Illinois Institute of Technology<br />
Member of the Society of <strong><strong>Auto</strong>motive</strong> Engineers<br />
Senior Member of Society of Plastics Engineers<br />
Scott has done part design, process development and material formulation for<br />
many industries including Department of Defense, Formula One Racing and<br />
NASA.<br />
2003 recipient of the Modern Plastics Design of the Year award.<br />
Previous work included 10 years with BASF (2 years in Germany) 4 years with<br />
Victrex high performance polymers and 4 years as an industry consultant.
Commercialization of Injection Moldable Composites Utilizing Wheat Straw Fiber<br />
Hardy, P.A., A.Schulman, Akron, OH 44310<br />
Lee, E.C., Ford Motor Company, Dearborn, MI 48124<br />
Simon, L.C., University of Waterloo, Waterloo, ON, N2L3G1<br />
In order to advance the <strong>com</strong>mercialization of natural fiber reinforced plastics for automotive use,<br />
a partnership was formed between academia, natural fiber processor, material supplier, and<br />
OEM. This partnership improved the <strong>com</strong>munication along the supply chain that resulted in<br />
optimized material properties to meet OEM specifications and application part performance.<br />
Fiber processing technologies and resin formulations were developed and tested with existing<br />
OEM material specifications in mind. Several products have been developed that meet current<br />
material specifications, offer significant weight savings over conventional mineral and glass<br />
reinforced <strong>com</strong>posites, and are <strong>com</strong>petitively priced. Furthermore, these products are more<br />
sustainable due to the significant renewable content being sourced from agricultural BioMass<br />
which results in a reduction of carbon dioxide emissions. In this presentation, we will explore<br />
the effects of natural fiber type, loading levels, property <strong>com</strong>parisons between bio-based<br />
materials and existing petroleum-based non-renewable filled materials, and natural fiber supply<br />
chain control. A case study will show how partnerships such as this one can expedite a<br />
successful application.
Name: Paul Hardy<br />
Company: A. Schulman, Inc.<br />
<strong>SPE</strong> <strong><strong>Auto</strong>motive</strong><strong>TPO</strong> <strong>Global</strong> <strong>Conference</strong> <strong>2010</strong><br />
Speaker’s Bio<br />
Paul Hardy is currently the Business Manager at A. Schulman, Inc. for their Polyfort, Polytrope and<br />
AgriPlas product lines. Paul has worked at A. Schulman for over 10 years in various product management<br />
and product development positions. Throughout Paul's career he has worked in many niche specialty<br />
product/market areas directed at light weighting. While at his previous employer Omnova Solutions, Inc.,<br />
Paul received a patent for the development of a latex additive which enabled the production lightweight<br />
gypsum wallboard.
Vibration Welding of Thermoplastic Olefins (<strong>TPO</strong>s)<br />
C. Yang, Lyondellbasell, Lansing, MI<br />
Bill Heatherwick, Branson Corporation Sterling Heights, MI<br />
ABSTRACT<br />
Vibration welding is being widely used to join automotive parts molded from<br />
thermoplastic olefins (<strong>TPO</strong>s) and other plastics. To establish optimized welding<br />
parameters, it is important to understand how <strong>TPO</strong> recipes and welding parameters affect<br />
welding strength. In this study, a DOE experiment demonstrated how welding<br />
parameters affect weld strengths of a known pair of <strong>TPO</strong> materials, which have<br />
significant difference in physical properties. A number of <strong>TPO</strong> materials were then<br />
welded with selected welding parameters to probe effects of the <strong>TPO</strong> recipe on welding<br />
strengths. The recipe factors considered in this work include filler and scratch mar<br />
additives. The results herein reported should help select vibration welding parameters<br />
used to join parts molded from <strong>TPO</strong>s.
Abstract<br />
EFFECT OF FLEXURAL MODULUS & DUROMETER FOR STONE<br />
IMPINGEMENT RESISTANCE IN PLASTIC AUTOMOTIVE EXTERIOR<br />
APPLICATIONS<br />
Tom Pickett, General Motors<br />
Brad Tice, General Motors<br />
Kristina Baldwin, General Motors<br />
The exterior of the automobile is subjected to stone impingement during the life of the vehicle.<br />
Lower exterior trim applications such as the rocker moldings, body side moldings, assist steps,<br />
air deflectors, mud guards, wheel openings, stone protectors, grilles and fascias are subjected to<br />
stone impingement. OEM styling is requiring lower exterior trim applications to have designs<br />
with angles that subject the exterior trim parts to a high amount of stone impingement. The<br />
exterior trim parts must be durable and not crack. Also the part must look aesthetically pleasing<br />
even after a high amount of stone impingement.<br />
There are many variables that can influence the stone impingement performance of plastic<br />
exterior trim parts. The design, type of plastic material, flexural modulus (stiffness), durometer<br />
(hardness), grain, color, gloss, paint, and decorative film are some critical variables that<br />
influence the performance of the part to stone impingement. This paper focuses on the variables<br />
of type of material, flexural modulus and durometer and how they each affect the stone<br />
impingement resistance. Three families of plastic materials that are <strong>com</strong>monly used mold in<br />
color automotive exterior trim applications were evaluated for stone impingement resistance:<br />
thermoplastic polyolefin (<strong>TPO</strong>), thermoplastic vulcanizates (TPV) and thermoplastic elastomer<br />
styrenic block copolymer (TES). In addition, <strong>TPO</strong>, TPV and TES materials with different<br />
flexural modulus and durometers were evaluated to see the affect of flexural modulus and<br />
durometer on stone impingement resistance.<br />
Contact: Tom Pickett, General Motors Materials Engineering, phone 248-431-9724, E-mail:<br />
tomjpickett@yahoo.<strong>com</strong><br />
Tom has 24 years experience at General Motors as a Plastics Development Engineer,<br />
Manufacture Engineer, Plastics Process Engineer, Finance and Plastics Materials Engineer. Tom<br />
is very active in <strong>SPE</strong>. He is the <strong>2010</strong> <strong>SPE</strong> <strong><strong>Auto</strong>motive</strong> Division Councilor, 2011 ANTEC Chair<br />
of <strong><strong>Auto</strong>motive</strong> Session, <strong>2010</strong> <strong><strong>Auto</strong>motive</strong> <strong>TPO</strong> <strong>Global</strong> <strong>Conference</strong> Planning Committee<br />
Sponsorship Chair & Moderator, <strong>2010</strong> <strong>SPE</strong> <strong><strong>Auto</strong>motive</strong> Innovations Awards Planning<br />
Committee, <strong>SPE</strong> Detroit Section Board of Director Member and <strong>SPE</strong> <strong><strong>Auto</strong>motive</strong> Division<br />
Board Member. Tom is Past President of <strong>SPE</strong> Detroit Section, and Past Chair of <strong>SPE</strong><br />
<strong><strong>Auto</strong>motive</strong> Division.
Biography of Tom Pickett<br />
Tom Pickett is a Materials Engineer at General Motors. Tom has worked at GM for 24<br />
years in various functions. Tom has worked as a Plastics Development Engineer, a<br />
Manufacturing Engineer, a Plastics Process Engineer, and a Plastics Materials Engineer.<br />
He holds 3 patents and 2 trade secrets.<br />
Tom is an active member of the Society of Plastics Engineers. He has been a member of<br />
<strong>SPE</strong> for 26 years. He has held numerous positions on the <strong>SPE</strong> Detroit Section Board of<br />
Directors and the <strong>SPE</strong> <strong><strong>Auto</strong>motive</strong> Board of Directors. Tom is Past President of the <strong>SPE</strong><br />
Detroit Section and Past Chair of the <strong>SPE</strong> <strong><strong>Auto</strong>motive</strong> Division. Tom is a member of the<br />
<strong>SPE</strong> <strong><strong>Auto</strong>motive</strong> <strong>TPO</strong> <strong>Global</strong> <strong>Conference</strong> Planning Committee, Co-Moderator of the<br />
Application Session and Chair of the <strong>TPO</strong> <strong>Conference</strong> Sponsorship Committee.<br />
Tom has a BA in chemistry from the College of the Holy Cross, a Masters of Science in<br />
Plastics Engineering from the University of Massachusetts at Lowell and a Masters of<br />
Business Administration from the University of Detroit-Mercy.
NAME: Bill Heatherwick<br />
<strong>SPE</strong> <strong><strong>Auto</strong>motive</strong><strong>TPO</strong> <strong>Global</strong> <strong>Conference</strong> <strong>2010</strong><br />
Speaker’s Bio<br />
Bill Heatherwick is the Director of <strong>Global</strong> Product Management for Branson Ultrasonics Corporation; a<br />
subsidiary of Emerson Electirc.<br />
His career in plastics began in 1991 after graduating from Illinois State University earning his Bachelor of<br />
Science degree from the Industrial Technologies Plastics Program. His professional career has allowed<br />
him to work in various industry segments, most notably the <strong><strong>Auto</strong>motive</strong>, Packaging, and Textiles.<br />
He is the author of papers related to plastic assembly, and has consulted on many plastic joining studies<br />
related to plastic joining technologies.<br />
Professional Affiliations include Society of Plastics Engineers (<strong>SPE</strong>), Society of <strong><strong>Auto</strong>motive</strong> Engineers<br />
(SAE), and Packaging Machinery Manufacturers Institute (PMMI)
Process/Surface
A Comparative Study of Scratch Visibility Assessment Between<br />
Erichsen Delta L and ASTM/ISO Methods<br />
R.L. Browning, P. Liu, H. Jiang, M. Hossain, J. Li † , A. Gasbarro † and H.-J. Sue<br />
Polymer Technology Center<br />
Department of Mechanical Engineering<br />
Texas A&M University<br />
College Station, TX 77843-3123<br />
† Advanced Composites, Inc.<br />
Ann Arbor, MI 48108<br />
For automotive applications, <strong>TPO</strong> surface aesthetics is often a key factor of concern. Visible<br />
scratch damage can significantly <strong>com</strong>promise quality perception and customer satisfaction. Over<br />
the years, many testing and analysis methodologies have been developed to evaluate the<br />
resistance of polymers to scratch visibility. Among them, The Erichsen and ASTM/ISO test<br />
methods are considered quantitative and have both been recognized by the automotive industry.<br />
The Erichsen test method uses multiple equally spaced scratches at constant load to produce a<br />
cross-hatched pattern. The difference between the luminosity of light scattered by the resulting<br />
pattern and the luminosity of the virgin background is taken as the Delta-L value and is<br />
<strong>com</strong>monly used as a metric for ranking. The ASTM D7207/ISO 19252 method employs a<br />
single-pass, progressive load scratch. Scratch visibility is assessed using a digital image analysis<br />
software package that automatically determines the onset of visibility when the contrast between<br />
the scratch damage relative to the virgin background reaches 3%. This study serves not only to<br />
<strong>com</strong>pare and contrast the Erichsen and ASTM/ISO methods, but it also aims at showing that the<br />
ASTM/ISO method is both an effective quality assessment tool and a product development tool<br />
with scientific merit.
"Relationship between Subjective and Objective Characteristics of<br />
<strong><strong>Auto</strong>motive</strong> Interior Materials"<br />
Prof. V. Bhise and Prof. P.K. Mallick, University of<br />
Michigan-Dearborn, Dearborn, MI 48128<br />
Abstract: In this presentation, we will present the methodology we<br />
have been developing in determining the subjective or perceptual and<br />
objective or physical characteristics of automotive interior<br />
materials. We will also provide a number of examples of how this<br />
methodology is being applied to evaluate a number of interior<br />
materials.<br />
Contact Info: P. K. Mallick [pkm@umich.edu]
Abstract<br />
Stick-slip Phenomena and Its Influence On Polymer Scratch<br />
Han Jiang 1<br />
Southwest Jiaotong University, Chengdu, 610031, China<br />
Yonghua LI, Bo Yang, Yan YANG, Zhongfu LUO, Chao DING, Guangqiang CHEN<br />
Kingfa Science & Technology CO.,LTD., Guangzhou 510520, China<br />
H.-J. Sue<br />
Texas A&M University, College Station, TX,77843<br />
The stick-slip phenomenon is <strong>com</strong>monly observed during polymer scratch process. The<br />
occurrence of stick-slip and its characters are controlled by many factors according to previous<br />
analytical study. It is believed the stick-slip will change the surface roughness which eventually<br />
induces the scratch visibility. Both ASTM and Erichsen test methods are employed to study the<br />
loading effect of stick-slip phenomenon during polymer scratch. The influence of stick-slip<br />
phenomenon on scratch performance is studied. Possible solutions to minimize the occurrence of<br />
stick-slip phenomena thus improve the scratch resistance of polymeric material are also<br />
discussed.<br />
Keywords: stick-slip; polymer scratch; automotive interior parts<br />
1. Speaker: Han Jiang (jianghan@swjtu.edu.cn) is working for Southwest Jiaotong University as a faculty<br />
memeber. His research focuses on polymers tribology, numerical simluation of material damage etc.
Han Jiang’s Bio.<br />
Han Jiang received his Ph.D. degree of Mechanical Engineering from Texas A&M University at<br />
2009. Now he is working as a faculty member at Southwest Jiaotong University, Sichuan ,China.<br />
He has years of research experience at the polymer mechanical properties, damage and failure<br />
analysis and numerical simulation. His research involves the experimental and numerical study of<br />
surface scratch phenomena of polymeric materials, time and temperature effect on durability of<br />
engineering materials, wear of high performance plastic bio-materials.
Study of Scratch Performance of Polypropylene Based <strong><strong>Auto</strong>motive</strong><br />
Abstract<br />
Material<br />
Yonghua LI, Bo Yang, Yan YANG, Zhongfu LUO, Chao DING, Guangqiang CHEN<br />
(Kingfa Science & Technology CO.,LTD., Guangzhou 510520, China)<br />
Han Jiang 1<br />
(Southwest Jiaotong University, Chengdu, 610031, China)<br />
Scratch behaviors of polypropylene based <strong>com</strong>posites for automotive applications were studied.<br />
Erichsen scratch test method was utilized. Delta L value was adopted as the index to evaluate the<br />
scratch resistance. It was found that the scratch resistance was well correlated with the scratch<br />
width. The narrower the scratch, the smaller delta L value was observed. SEM analysis also<br />
showed that stick-slip phenomena was responsible for material removal and severe surface<br />
damage. It was one of the main causes to induces scratch visibility, i.e., decrease scratch<br />
resistance of polypropylene <strong>com</strong>posites. To improve the scratch performance, the occurrence of<br />
stick-slip phenomena has to be minimized or eliminated during the scratch.<br />
Keywords: Scratch; stick-slip; polypropylene; automotive interior parts<br />
1. Speaker: Han Jiang (jianghan@swjtu.edu.cn) is working for Southwest Jiaotong University as a faculty<br />
memeber. His research focuses on polymers tribology, numerical simluation of material damage etc.
Yonghua Li received his M.S. in materials science from South China University of Technology.<br />
He is a senior engineer in Kingfa. Li has 9 years experience in <strong>TPO</strong>. He is an author of 7 Chinese<br />
Patents and 14 publications.
Improving the scratch resistance and molding characteristics of <strong>TPO</strong>’s, TPEV’s, and<br />
glossy automotive parts.<br />
By Kathrin Lehmann<br />
Evonik<br />
Industrial Specialties Business Line<br />
Polypropylene and thermoplastic polyolefins are used in a variety of automotive<br />
applications. The improvement of the antiscratch properties of a final product like the<br />
dashboard, the interior door panel, or the middle console of a car has be<strong>com</strong>e more and<br />
more important during the last few years. SEBS or other softer <strong>TPO</strong> based materials are<br />
used for automotive parts like air bag covers or cup holders. Those parts often not only<br />
require antiscratch properties, but also good melt flow or enhanced demolding properties<br />
as well.<br />
Evonik’s Industrial Specialties business line has developed TEGOMER®<br />
Antiscratch 100 specifically to improve the permanent scratch resistance of PP/<strong>TPO</strong>/talc<br />
<strong>com</strong>pounds for use in the automotive industry. Permanency is important since today’s<br />
customers expect an undamaged and visually appealing surface even after several years<br />
of intensive use and/or exposure to the elements. In addition, the product TEGOMER H-<br />
Si 6440 P has found a home in a new application using softer <strong>TPO</strong> based materials,<br />
which will be illustrated at our table top with real automotive parts. In addition to<br />
improving the scratch resistance of SEBS, it allows for improved demolding. This results<br />
in a reduced number of rejected parts at the molding location and thus a reduction in<br />
overall costs. The third product in the organomodified siloxane technology family of<br />
products is TEGOMER M-Si 2650, which is also used in a number of automotive<br />
applications. It is designed to ensure an unscratched surface of glossy black parts with<br />
piano lacquer appearance that are made from PC/ABS or PMMA/ABS, i.e. for<br />
electronics in the middle console. Additionally, it provides significantly improved melt<br />
flow of TPE-V and other grades, which results in less material usage and ultimately in an<br />
overall cost reduction.
Abstract:<br />
The Evolution of Surface Texture During the Application and<br />
Curing of <strong><strong>Auto</strong>motive</strong> Coating Systems<br />
Cindy A. Peters, Kevin R. J. Ellwood, and Mark E. Nichols<br />
Ford Research and Advanced Engineering<br />
Dearborn, MI 48121<br />
<strong><strong>Auto</strong>motive</strong> paint appearance is a <strong>com</strong>plex interaction of the color, gloss, and<br />
surface texture of the coating. Undulations in the surface of the coating give rise to the<br />
texture, often referred to as "orange peel". There are a number of potential sources of<br />
surface texture in automotive coatings including telegraphing of texture from underlying<br />
layers, shrinkage of the coating during cure, differential cure rates of co-curing layers<br />
(basecoat and clearcoat, for example), and patterns introduced during the application<br />
(spray) process. Minimizing the texture, or orange peel, in coatings results in smoother<br />
finishes and improved overall appearance.<br />
Instrumentation now exists to study and quantify the formation of texture in<br />
automotive paint systems. The Byk-Wavescan quantifies texture based on the<br />
wavelength of the surface roughness. Also now available are non-contacting, optical<br />
profilometers that image and quantify the surface texture of the coating. A heated stage<br />
can be coupled with the optical profilometer to measure and image the coating texture<br />
during solvent flashing, curing, and cooling. Once the sources of texture are defined,<br />
these tools can be used to learn how to minimize the texture. This requires optimizing<br />
substrates, coating properties, and processing conditions.<br />
Understanding coating rheology is of key importance in learning how to control<br />
the texture of the paint. The work of Bhattacharya and coworkers has been extended to<br />
allow for the measurement of the rheological properties of coatings during flash and<br />
elevated temperature cure. Special fixtures have been used to measure the viscosity of<br />
coatings with an open surface to permit solvent evaporation instead of the traditional,<br />
closed-surface, parallel plate measurements. Coating rheology contributes to the ability<br />
of the paint film to level out before cure which, in turn, affects the final texture.<br />
Measurements and imaging of the leveling process can be used to calculate viscosity<br />
profiles and simulate the leveling of surface defects (spray patterns, etc.).<br />
This work presents the effects of substrate, cure rate, coating rheology, and<br />
application on the formation of texture (orange peel) during the curing of automotive<br />
coatings. Direct imaging of texture development was ac<strong>com</strong>plished using a noncontacting<br />
profilometer and a programmable hot stage, which enabled quantification of<br />
texture size and scale during solvent flashing, curing, and subsequent cooling of the<br />
coating system. Additional experiments examining the process of paint leveling during<br />
flash and cure are also presented. Texture, appearance, and leveling results were<br />
correlated with separate viscoelastic measurements made during the curing process.
Critical Role of Particle/Polymer Interphase in Long-term Performance<br />
of a ZnO/Polyurethane Hybrid Coating<br />
Xiaohong Gu*, Guodong Chen, Minhua Zhao, Stephanie S. Watson,<br />
Tinh Nguyen, Joannie W. Chin, and Jonathan W. Martin<br />
Materials and Construction Research Division<br />
National Institute of Standards and Technology, Gaithersburg, MD 20899<br />
ABSTRACT<br />
Nanoparticle-filled polymeric coatings have attracted great interest in recent<br />
years because the incorporation of nanofillers can significantly enhance the mechanical,<br />
electrical, optical, thermal and antimicrobial properties of coatings. Due to the small filler<br />
size, the volume fraction of the interfacial area in nano-filled systems is drastically<br />
increased, and the interphase be<strong>com</strong>es important in the performance of the nano-filled<br />
system. However, techniques used for characterizing nanoparticle/polymer interphase are<br />
limited, and thus, the mechanism by how interfacial properties affect the long-term<br />
performance of nanofilled polymeric coatings is not well-understood. In this study, the<br />
role of the nanoparticle/polymer interphase in the long-term UV weathering performance<br />
of a nano-ZnO filled polyurethane (PU) coating system was investigated. The effects of<br />
the parameters that can influence the particle/polymer interfacial properties, such as size,<br />
loading, surface modification of the nanoparticles, on photodegradation of ZnO/PU films<br />
were evaluated. The interfacial regions before and after UV exposures were characterized<br />
by atomic force microscopy (AFM)-based techniques. By <strong>com</strong>bining tapping mode AFM<br />
and novel electric force microscopy (EFM), the embedded particle/polymer interphases<br />
were successfully detected from the surface of the ZnO/PU films. The interfacial<br />
properties strongly affected chemical, thermo-mechanical and morphological properties<br />
of the UV-exposed ZnO/PU films. Furthermore, it was observed that the ZnO/polymer<br />
interphases played a critical role in accelerating the photodegradation of PU coatings. A<br />
hypothesis was proposed that the photodegradation was initiated in the vicinity of the<br />
particle/polymer interphases and then propagated to the polymer matrix during UV<br />
exposure for the ZnO/PU coating.
Update on Developments for Scratch and Mar Additives;<br />
Effect of the additive formulation on the scratch performance<br />
and other secondary attributes<br />
Abstract<br />
Nikolas Kaprinidis, Hung Pham and Johanne Wilson<br />
BASF Corporation, 100 Campus Drive Florham Park, NJ 07932<br />
As the automotive industry be<strong>com</strong>es increasingly <strong>com</strong>petitive, scratch and mar performance is<br />
progressively more important to automotive OEM’s. Such performance directly affects consumer<br />
perception, which is being tracked by agencies such as J.D. Powers. This has led to closer<br />
scrutiny by OEM’s on the various test methods and a reconsideration of the acceptable standards<br />
is taking place. The previous benchmark of scratch resistance at 10N loading, usually determined<br />
by the popular 5 finger test method is no longer acceptable by many automotive OEM’s as they<br />
strive for increased product performance.<br />
Improving scratch performance for <strong>TPO</strong>s can be ac<strong>com</strong>plished by additive technologies, of which<br />
there are by now several ones available on the market. Although little differentiation is seen at<br />
scratch levels of 10 N, the differences be<strong>com</strong>e more apparent at loadings of 15 N and higher.<br />
Besides scratch resistance, secondary attributes are be<strong>com</strong>ing even more important and will be<br />
considered by automotive OEM’s since they also contribute to the overall consumer perception of<br />
the vehicle. The efficacy and performance of anti-scratch additives may vary based upon the<br />
<strong>com</strong>position and type of resin, as well as other additives present in the formulation which – in<br />
<strong>com</strong>bination – may lead to undesired effects. The second part of the paper will discuss such “side<br />
effects” caused by other additives.<br />
Figure 1: Comparison of scratch performance in 20% talc filled <strong>TPO</strong> for three <strong>com</strong>mercial<br />
scratch additives using Erichsen Cross-cut test method<br />
ΔL (scratch visibility)<br />
8<br />
6<br />
4<br />
2<br />
0<br />
blank blank<br />
5 N 10 N 15 N<br />
0.5% 0.5% Slip Slip<br />
3% 3% SR2 SR2<br />
3% 3% SR SR 11
* Dr. Nikolas Kaprinidis (Speaker) is responsible for application and product development<br />
department at Ciba – a part of the BASF group. He holds a Ph. D in Physical Organic Chemistry<br />
from New York University and spent two post-doctoral stays at UC Berkeley and Columbia<br />
University. He has published extensively and holds patents in various application areas of<br />
plastics. Dr. Kaprinidis is a member of ACS and has been with the <strong>com</strong>pany 11 years. Tel: 914-<br />
785-2739; e-mail: nikolas.kaprinidis@ciba.<strong>com</strong>
Executive Panel
<strong>TPO</strong> Executive Panel<br />
Dr. Dale A. Gerard: Senior manager for GM NA Materials / Corrosion / Fluids<br />
Engineering & Laboratories, General Motors Corporation.<br />
After being the <strong>Global</strong> Leader for GM Powertrain Materials Engineering for<br />
several years Dr. Gerard was recently appointed the head of General Motors North<br />
America Materials / Corrosion / Fluids Engineering and Laboratories for Powertrain and<br />
Vehicle Operations. Dr. Gerard is also GM’s <strong>Global</strong> Leader in these areas.<br />
The integration of the Vehicle and Powertrain Materials, Corrosion and Fluids<br />
Engineering and the nine associated laboratories were done to optimize engineering and<br />
laboratory support in the development of product & process technologies in the areas of<br />
materials (metals, plastics, elastomers, and textiles), corrosion resistance, and fluids.<br />
Kathy Minnich: Manager for North American Materials Engineering, Ford Motor<br />
Company in Dearborn, MI.<br />
In this capacity she is accountable for a broad scope of engineering and analytical<br />
services. Responsibilities include management of the subject matter experts for corrosion<br />
protection, fastener and materials engineering, operation of the full service Ford Central<br />
Laboratory analytical resource and oversight of the global materials management<br />
enterprise with work streams designed to ensure regulatory <strong>com</strong>pliance and material<br />
sustainability.<br />
During her 32 year career at Ford, Kathy held positions in Component Design and<br />
Release Engineering, Chassis and Body Materials Engineering, Fastener Engineering and<br />
Corrosion Protection Engineering. She has more than 20 years of personal, hands-on,<br />
experience in material selection, processing, durability assessment and failure analysis for<br />
automotive <strong>com</strong>ponents.<br />
Her formal training includes a B.S. in Chemical Engineering from the University<br />
of Detroit, an M.S. in Chemical Engineering from the University of Michigan and an MS<br />
in Industrial Engineering from Wayne State University. Kathy is an active member of<br />
ASM and served on the Executive Board in 2008-09. She supports SAE, previously<br />
serving on the Hydraulic Brake Committee and several sub<strong>com</strong>mittees over a 10 year<br />
period. Kathy is also active in DIR-AG (Directors of Industrial Research and Analytical<br />
Group), supporting several industry benchmarking <strong>com</strong>mittees.<br />
Larry Sak: Head of Materials, Fasteners & Material Standards, Chrysler Group<br />
LLC.<br />
Mr. Sak was appointed Head of Materials, Fasteners & Material Standards at<br />
Chrysler Group LLC in June of 2009. In this position he oversees a diverse team<br />
of Specialists, Engineers and Technicians responsible for all Metallic and<br />
Organic Material Engineering, Corrosion Resistance, Advanced Lightweight<br />
Material Development, Material Analysis/Characterization, and Fastener<br />
Engineering.
He joined Chrysler in 1983 as a test engineer, holds a BS in Mechanical<br />
Engineering from Michigan State University, a MBA from the University of Detroit<br />
Mercy, and is a 20+ year member of the SAE.<br />
Mike Bernas: General Manager of the Materials Engineering Division, Toyota<br />
Technical Center (TTC). TTC, Toyota’s North American R&D center, a division of<br />
Toyota Motor Engineering & Manufacturing, North America, Inc. (TEMA).<br />
Mr. Bernas has responsibility for materials R&D, including materials evaluation,<br />
design and development.<br />
Mr. Bernas joined TTC in 1992 as an Engineer in the Materials<br />
Engineering Department, Resins Group. In 2009 he was promoted to General<br />
Manager of the Materials Engineering Department where he is responsible for<br />
the evaluation, development and design of paints, resins and parts.<br />
Dr. Rose Ryntz: Director of Material Engineering, International <strong><strong>Auto</strong>motive</strong><br />
Components, IAC Group North America.<br />
Dr. Ryntz obtained a Ph.D. degree in polymer/organic chemistry from the<br />
University of Detroit in 1983 and a MBA from Michigan State University in 2002.<br />
She was employed at various <strong>com</strong>panies (Dow Chemical, DuPont, Ford Motor,<br />
Akzo Nobel, and Visteon) prior to her current role as Director of Material<br />
Engineering at International <strong><strong>Auto</strong>motive</strong> Components, IAC Group North America.<br />
She has been a prolific lecturer both domestically and internationally,<br />
being an invited lecturer at many symposia. Dr. Ryntz has published extensively,<br />
with over 90 publications, 25 patents, and four books.<br />
Dr. Ryntz has been the recipient of many prestigious awards, including<br />
International Biographical Center Who's Who in the World, Best Paper and Best<br />
Speaker awards through the Federation of Societies for Coatings Technology<br />
(FSCT) and Society of Plastic Engineers (<strong>SPE</strong>), the FSCT Women in Coatings<br />
Management Achievement Award , George B. Heckel Award and Matiello Award,<br />
the American Chemical Society (ACS) Roy Tess Award, the Women <strong><strong>Auto</strong>motive</strong><br />
Association International Professional Achievement Award, the Outstanding<br />
Leadership Award sponsored by the Engineering Society of Detroit (ESD), the<br />
Elias Singer Best Paper Award sponsored by the University of Southern<br />
Mississippi, the Gold Award sponsored by the ESD, a Roon Award sponsored by<br />
the FSCT, and the Henry Ford Technology award presented by the Ford Motor<br />
Company for outstanding technical contributions to the Company.<br />
She has served as President of the FSCT from 2005 – 2007 and was<br />
elected as a Fellow to the Society of Plastics Engineers in 2006. She currently<br />
serves on the board of directors of the Detroit Section of the <strong>SPE</strong>.
Simon Holmes: Specialty Elastomers <strong>Global</strong> Marketing Manager,<br />
ExxonMobil Chemical Company,<br />
Mr. Holmes received his degree in polymer technology from the University of<br />
Manchester in the UK. He joined ExxonMobil in 1987 as a sales development engineer<br />
for the automotive sector.<br />
He then moved onto to the EPDM technical group at the European laboratory in<br />
Brussels. In this role Simon assisted converters to maximize material performance and<br />
improve processing of extruded weatherseals and coolant hoses. Following a succession<br />
of sales and marketing roles he was appointed Polyolefins European Technical Manager.<br />
In 2001 Simon became the sales manager for PE and PP in Asia Pacific. He lived<br />
in both Hong Kong and Singapore before moving to Houston in 2007 for his current<br />
assignment as <strong>Global</strong> Marketing Manager for the Specialty Elastomers business unit. As<br />
marketing manager his current responsibilities include Santoprene TM TPV, Vistalon TM<br />
EPDM, and Vistamaxx TM propylene based elastomers and Exact TM plastomers.<br />
Executive Panel Moderators<br />
Bob Eller is president, Robert Eller Associates LLC (REA), a firm specializing in<br />
management consulting for the global plastics and rubber industries where he and his<br />
team carry out numerous technology, strategy, and manufacturing analyses, pricing<br />
forecasts, product positioning analyses, and crisis-management analyses in automotive<br />
plastics for clients around the world. Prior to forming his own firm in 1991, Eller worked<br />
in various positions at ExxonMobil, A. D. Little, Phillip Townsend Associates, Charles<br />
River Associates, and Multibase. Eller is a graduate of Massachusetts Institute of<br />
Technology in Chemical Engineering and also holds M.S. degrees in Polymer Science and<br />
Chemical Engineering from Brooklyn Polytechnic.<br />
Ron Price has spent over 30 years in global business management, marketing, and sales<br />
involving both engineering and olefin polymer, primarily in the durable goods and<br />
automotive sectors. In fact, he launched over 20 new polymers and alloys to the<br />
automotive industry. He has worked at <strong>com</strong>panies such as DuPont, Borg Warner<br />
Chemicals, ExxonMobil, and Huntsman and continues to be active as a marketing and<br />
business consultant for new business, strategic marketing, and sales development. He has<br />
published over 25 articles and has made hundreds of presentations at regional, national,<br />
and international events. Price is also a recipient of <strong>SPE</strong>’s Outstanding Achievement<br />
(2000), Lifetime Achievement (2005), and Outstanding Member (2007) awards.
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