The Possible Possible Automotive Applications Automotive Applications of Glass Microspheres of Glass Microspheres

4 case 4 case studies to discoverstudies to discoverthe the possible possible automotive applications automotive applications of glass microspheresof glass microspheres

Frédéric JuprelleBusiness Unit ManagerTechnical Products

SPE ANTEC® 2014 / 151

I. General introduction about glass beads

II. Case studies

1. How does BMW improve aesthetic & dimensional stability of PA - 30% glass

fibers?

2. How to improve aesthetic and scratch resistance in PP in PSA application?

3. How does LG enhance dimensional stability & surface resistance in ABS – 20%

AgendaAgenda


glass fibers?

4. What can the new E-glass grade bring to Polycarbonate resin producers?

III. Conclusion

2

SPE ANTEC® 2014 / 152


II. Case studies


fibers?



AgendaAgenda


glass fibers?


III. Conclusion

3

SPE ANTEC® 2014 / 153

Sovitec in FiguresSovitec in Figures

#1 solid glass beads producer in Europe#1 solid glass beads producer in Europe

1954 1954 –– 58 years of experience58 years of experience

5 production sites 5 production sites –– 100,000 T capacity100,000 T capacity

160 employees160 employees

4

Charleroi - BE

Buenos Aires - AG

Berlin - GE

Barcelona - ES

Metz - FR

SPE ANTEC® 2014 / 154

• Road Marking: 400 – 2,000µm

• Blasting: 50 – 500µm

• Functional filler in plastics and coatings: 1 – 50µm

� Efficient Coupling Agents for a wide resin portfolio:PA, PUR, Epoxy, PBT, PET, Polyester, Vinylester, PE, PPand now Styrenics & Polycarbonate

Sovitec portfolio and field of expertiseSovitec portfolio and field of expertise

and now Styrenics & Polycarbonate

� Processing mastery for well controlled particle sizeMicroperl®: 20 to 40µm

Omicron®: 3 to 5µm – unique GB producer to produce this particle size

5

SPE ANTEC® 2014 / 155

Sovitec’sSovitec’s Glass BeadsGlass Beads

6

Raw Material = Recycled glass

SPE ANTEC® 2014 / 156


II. Case studies


fibers?



AgendaAgenda


glass fibers?


III. Conclusion

7

SPE ANTEC® 2014 / 157

Case Study 1: PA6Case Study 1: PA6--GF GF –– Starting pointStarting point

Company: BMW

Market: Automotive

Material: PA6 + 30% glass fibers

Processing mode: Twin-screw extrusion and injection molding

Requirements:Requirements:

� Improve surface aspect and dimensional stability

� white powdered surface due to fibers

� unstable shrinkage and warpage

� Maintain good mechanical properties

8

SPE ANTEC® 2014 / 158

Case Study 1: Case Study 1: PA6PA6--GF GF –– Solution & BenefitsSolution & Benefits

Solution: substitute 1/3 of glass fibers by solid glass beads

Initial material: PA6 + 30% glass fibers

Final material: PA6 + 20% glass fiber + 10% Microperl® 050-20-215 (20µm)

Benefits:

� Surface improvement � no white powder on the surface anymore� Surface improvement � no white powder on the surface anymore

� Good Dimensional stability � warpage and shrinkage are now more stable

� Mechanical performance brought by glass fibers are retained

Additional benefits:

� Higher production output

� Cost reduction

� Improved abrasion resistance

9

SPE ANTEC® 2014 / 159

Case Study 1: Case Study 1: PA6PA6--GF GF –– Technical DataTechnical Data

� Surface improvement

PA + 20% GF + 10% GBPA + 30% GF Glass fibers are dispersedLeading to powdered surface

Beads align the fibers,leading to clean surface

� Better dimensional stability

10

GB influence on Warpage

0

20

40

60

80

100

120

140

160

PA PA + 30%

GF

PA +

30%GB/GF

PA +

30%GB

Flo

w- 47%

GB influence on Shrinkage

0

0,05

0,1

0,15

0,2

0,25

0,3

0,35

0,4

FLOW TRANSVERSAL

pe

rce

nta

ge PA6

30% GF

30% GB/GF

30% GB

- 33%- 25%

SPE ANTEC® 2014 / 160


� Keep good mechanical properties

Property Units Method PA6 30% GF 30% GB/GF

Izod Impact (unnotched)

kJ/m² ISO 180/1U n.b. 90 75

Izod Impact (notched)

kJ/m² ISO 180/1A 8 6 6

Flexural Modulus MPa ISO 178 2900 8000 7400

Flexural Strength MPa ISO 178 125 155 145

11

Tensile Modulus MPa ISO 527-2 3200 9200 8700

Elongation at break % ISO 527-2 4,5 3 4

SPE ANTEC® 2014 / 161


� Additional Benefits measured


� -14% on cycle time

� Cost reduction

-2,4% on raw material cost

50

60

70

80

90

100

110

750 800 850 900 950 1000

To

rqu

e

Production output (kg/h)

Production outputPA 6.6 + 30% GF

PA 6.6 + 20% GF + 10% GB

PA 6.6 + 10% GF + 20% GB

PA 6.6 + 30% GB

Compound RM cost

PA6 + 30%GF 2680 €/T� -2,4% on raw material cost

� Improved abrasion resistance

� +1,5% on weight retained

12

98,5

98

99,5

99,9

97

97,5

98

98,5

99

99,5

100

100,5

PA6 30% GF 30% GB/GF 30% GB

Weight retained after testing (%)

+1,5%

PA6 + 30%GF 2680 €/T

PA6+20%GF+10%GB 2615 €/T

SPE ANTEC® 2014 / 162


II. Case studies


fibers?



AgendaAgenda


glass fibers?


III. Conclusion

13

SPE ANTEC® 2014 / 163

Case Study Case Study 2: PP 2: PP –– Starting pointStarting point

Company: PSA

Market: Door handles, dashboard, …

Material: PP + 30% Talcum


Requirements

� Improve dimensional stability

� Improve abrasion and scratch resistance

� Improve aesthetic

14

SPE ANTEC® 2014 / 164

Case Study Case Study 2: PP 2: PP –– Solution & BenefitsSolution & Benefits

Solution: Sovitec developed a new family of coupling agent giving both the link with glass and polyolefin resin.

� Now it is possible to achieve similar results shown on PA in reinforced PP

Initial material: PP + 30% Talcum

Final material: PP + 15% Talcum and 15% Microperl® 050-20-223 (20µm)

Benefits:

� Better dimensional stability � lower and isotropic shrinkage

� Better abrasion and scratch resistance � more durable surface aspect

� Better surface aspect

15

Previous PP grade New PP grade

SPE ANTEC® 2014 / 165

Case Study Case Study 2: PP 2: PP –– Technical DataTechnical Data

� Better Dimensional Stability : Shrinkage properties

0,5

1

1,5

2

%

PP

30%

TALCUM

30% GB

223

� Better abrasion resistance

16

Taber Test CS10 – 1kg

PP + 30% Talcum(weight lost)

PC + 15% Talcum + 15% GB(weight lost)

1000 cycles 48 mg 24 mg


10000 cycles Destroyed 160 mg

0

0,5

FLOW TRANSVERSAL

15%

Talcum &

15% GB223

SPE ANTEC® 2014 / 166

Case Study Case Study 2: PP 2: PP –– Technical DataTechnical Data

� Higher scratch resistance

20

40

60

80

100

PP

30% Talcum

30% GB 223

15% Talcum &

15% GB223

� Aesthetic

17

0

20

ISO1518 (2 kg)

100 = no visible scratch 80 = low scratch 60 = medium scratch 40 = depth scratch 20 = very depth scratch

PP + 30% Talcum PP + 15% Talcum + 15% GB

SPE ANTEC® 2014 / 167


II. Case studies


fibers?



AgendaAgenda


glass fibers?


III. Conclusion

18

SPE ANTEC® 2014 / 168

Case Study 3: ABSCase Study 3: ABS--GF GF –– Starting pointStarting point

Company: LG

Market: Electronic device housing

Material: ABS + 20% GF


Requirements



� Improve surface aspect

� Maintain mechanical properties

19

SPE ANTEC® 2014 / 169

Case Study 3: Case Study 3: ABSABS--GF GF –– Solution & BenefitsSolution & Benefits

Solution: add 10% of glass microspheres

Initial material: ABS + 20% GF

Final material: ABS + 20% GF + 10% Microperl® 050-20-215 (20µm)

Benefits:

� Better dimensional stability � lower and isotropic shrinkage� Better dimensional stability � lower and isotropic shrinkage


� Surface aspect � glass fibers/glass beads dispersion improved

� Similar mechanical performance

Additional benefits:


20

SPE ANTEC® 2014 / 170

Case Study 3: ABSCase Study 3: ABS--GFGF–– Technical DataTechnical Data

� Lower and isotropic shrinkage

� Better scratch resistance

Sample ABS ABS + 20% GF ABS + 20% GF + 10% GB ABS + 20% GB

Shrinkage (parallel) 0,80 % 0,50 % 0,40 % 0,20 %

Shrinkage (perpendicular) 1,00 % 0,70 % 0,40 % 0,20 %

ABS + 20% GF + 10% GBABS + 20% GF


21

Scratch done with a Clemen, 2kg Weight, Tungsten bead

ABS ABS + 20% GF ABS + 20% GF + 10% GB ABS + 20% GB

Weight lost (%) 2,3 2,8 1,7 0,9

Abrasion done with an abrasive paper 40, 10000 cycles

SPE ANTEC® 2014 / 171

Case Study 3: Case Study 3: ABSABS--GF GF –– Technical DataTechnical Data

� Better Surface aspect

ABS+20%GF+10% GB

ABS+20%GF

Clean surface aspect due the dispersion of

glass fiber

� Mechanical performance are retained

22

Property Units Method ABS 20% GF 20% GF 10% GB

Charpy Impact (unnotched) kJ/m² ISO 180/1U n.a. 22 22

Charpy Impact (notched) kJ/m² ISO 180/1A 12 12 10

Flexural Modulus MPa ISO 178 2370 5000 5200

Flexural Strength MPa ISO 178 62 125 125

Tensile Strength MPa ISO 527-2 38 90 95

Elongation at break % ISO 527-2 15 4 8

SPE ANTEC® 2014 / 172

Case Study 3: Case Study 3: ABSABS--GF GF –– Technical DataTechnical Data

� Additional Benefits measured


60

70

80

90

100

110

120

To

rqu

e ABS + 20% GF

ABS + 20%GF + 10%GB

ABS + 20% GB

At same torque �� higher production output

23

ABS + 20% GF ABS + 20% GF + 10% GB ABS + 20% GB

Cycle Time 50 seconds 45 seconds 39 seconds

Saving 5 seconds (10%) 11 seconds (22%)

50

60

750 800 850 900 950 1000

Speed (kg/h)

ABS + 20% GB

10 to 22% shorter cycle time measured

SPE ANTEC® 2014 / 173


II. Case studies


fibers?



AgendaAgenda


glass fibers?


III. Conclusion

24

SPE ANTEC® 2014 / 174

Case Study 4: New grade for PC Case Study 4: New grade for PC –– Starting pointStarting point

Company: -

Market: Various applications – Suitcases, Cars, electronic, …

Material: PC


Requirements



� Improve processing

25

SPE ANTEC® 2014 / 175

Case Study 4: New grade for Case Study 4: New grade for PC PC –– Solution & BenefitsSolution & Benefits

Solution: Sovitec developed a new glass composition to answer OEM customer request

The chemical structure of E-glass naturally leads to higher compatibility between the

resins and the beads.

Initial material: PC

Final material: PC + 15% of Microperl® 050-20-EG (20µm)

Benefits:

� Better dimensional stability � lower and isotropic shrinkage


� Easier processing

26

SPE ANTEC® 2014 / 176

Case Study 4: New grade for Case Study 4: New grade for PC PC –– Technical DataTechnical Data

� Easier processing

� The addition of glass beads clearly improve the extrusion and injection of PC compounds : ball bearing

effect, less defects, …

To produce 500 pieces within specifications

Formulation Cycle TimeNb of injected

piecesTotal time for this

production

PC 44s 512 375 min

PC + 15% GF 48s 552 442 min


27

PC + 15% GF 48s 552 442 min

PC + 15% GB 36s 501 300 min

Taber Test CS10 – 1kg

PC (weight lost)

PC + 15% GB(weight lost)



10000 cycles Destroyed 65 mg

64% more resistant than PC for 2x cycles

SPE ANTEC® 2014 / 177

Case Study 4: New grade for Case Study 4: New grade for PC PC –– Technical DataTechnical Data

� Higher scratch resistance

PC + 15% GBPC

� Better dimensional stability

28

0

20

40

60

80

100

120

140

PC PC + 15% GF PC + 15% GB

Warpage (%)

- 55%

SPE ANTEC® 2014 / 178

Benefits of Glass Benefits of Glass Beads Beads -- ConclusionConclusion

Glass microspheres offer a wide set of technical and economic advantages, alone or blend to your current solution.

By substituting a portion of GF, or replacing silica by microspheres into several thermoplastic resins (PA / PP / PO / PBT / Styrenics / PC…), we improve the following properties :

� Dimensional Stability: warpage, shrinkage and isotropic behavior

� Surface aesthetic: uniform color and aspect

� Scratch & Abrasion resistance: shallower scratch & excellent abrasion resistance

� Processing speed: production output (extrusion, injection, film, …) & less waste

� Cost reduction: cost-savings

� …

29

SPE ANTEC® 2014 / 179

Thank you for your attentionThank you for your attention

SPE ANTEC® 2014 / 180

The Possible Possible Automotive Applications Automotive Applications of Glass Microspheres of Glass Microspheres

Documents

glass beadsii

solid glass beadsinitia

glass fibersprocessing

new eglass grade

solid glass beads producer

scratch resistance

case studies1

surface aspect