Copyright © 2014 Owens Corning. All Rights Reserved. Images © istockphoto.com
TYPE30® DIRECT ROVING: DELIVERING VIABLE POLYURETHANE PULTRUSION: A TECHNOLOGY STATUS OWENS CORNING BRYAN MINGES, PRODUCT MANAGER EPTA CONFERENCE MARCH 6, 2014
Copyright © 2014 Owens Corning. All Rights Reserved. Images © istockphoto.com, Paulo Manuel Furtado Pires / shutterstock.com
SUPPORTING PULTRUSION WORLDWIDE
A world leading producer of fiberglass Innovator in glass fiber solutions for 75 years 200+ researchers in 6 R&D centers Worldwide manufacturing of Type 30® direct roving
Yuhang, CN L’Ardoise, Fr
Rio Claro, B
Amarillo, TX
Mexico City, MX
Gous, RU
Taloja IN
Doudian, CN
WHY CHOOSE OWENS CORNING?
Inventor of Type 30® Single End Roving
with a long history of introducing innovative, robust products that meet stringent performance and quality requirements throughout the value chain.
Broad range of glass fiber products
offers customers more specialized combinations of polymer/resin matrix and reinforcement options. Globally available products manufactured in
multiple facilities providing unrivaled supply redundancy. Local technical support combined with global
account coordination provides customers with outstanding response times and vital market intelligence.
Copyright © 2014 Owens Corning. All Rights Reserved. Images © istockphoto.com
POLYURETHANE IN THE PULTRUSION MARKET
PERSPECTIVE ON THE PULTRUSION MARKET
Polyurethane’s Place in Pultrusion • Owens Corning has provided key global
innovations critical to market growth
• There is significant opportunity for application
development in traditional resin systems, but
also in the adoption of polyurethane
• We expect global growth in polyurethane of
15% CAGR in the near term
• Critical to this growth is the support of existing
pultruders and new entrants into the market
KEY TRENDS AND DRIVERS IN POLYURETHANE USE
• Reliable and fast processing
• Cost effective performance
• Reduced material cost
• Product customization/design
flexibility
• Improved impact strength
• Thinner wall thickness
• Higher specific strength and transverse
properties
• Lower water absorption
• Better abrasion resistance
• Improved fastening strength
• Reduced emissions/VOCs (less styrene)
* Data from OC internal analysis
Window profiles
• Light weight
• High strength
• Abrasion resistance
• Corrosion resistance
• Transverse properties
to reduce thickness
• Reduced reliance on
mat reinforcements
Wind blade components
• Reduced production time
• Excellent pull out strength
• Fatigue resistance
• Material savings
NEW AND EMERGING POLYURETHANE APPLICATIONS
Structural profiles
• Flexural strength
• Compressive strength
• Interlaminate shear
• In-plane shear
Retaining walls
• High abrasion resistance
• Impact strength
• Thinner walls due to higher mechanicals
• Enhanced aesthetics
NEW AND EMERGING POLYURETHANE APPLICATIONS
Copyright © 2014 Owens Corning. All Rights Reserved. Images © istockphoto.com
REINFORCEMENT SOLUTIONS IN POLYURETHANE PULTRUSION
• Improved mechanical performance in tensile, impact and transverse strength
• Fast impregnation
• Excellent strand opening
• Minimal color variation/consistent pigmentation
• Complete run-out
• Decreased resin use/higher FVF
• High and low tex availability
• Great visual appearance
• Multi-resin compatibility (PU, UPE, VE, EP)
• Corrosion resistance
• Process consistency in climate fluctuations
• Excellent electrical properties
• Reliable supply/global manufacturing
• Consistent quality
CHALLENGE TO GLASS FIBER REINFORCEMENTS
IMPACT OF RESIN/REINFORCEMENT BOND
Flexural strength (ksi) of reinforced composites
1,3001,500
+15%
PU good bonding PU bad bonding
* Based on internal OC testing at 80% FWF
Good bonding
Poor bonding
REINFORCEMENT PERFORMANCE
60
80
100
120
140
160
180
200
220 Flexural strength in UPE and PU – initial results and at 72 hour boil
PU
PU 72 hr
UPE
UPE 72 hr
Owens Corning PulStrand™
3000
Competitor reference #1
Competitor reference #2
* Based on internal OC testing at 79% FWF
Stress-Rupture of Composite Rods in AIR
10
100
1 10 100 1000 10000 100000 1000000Time to Failure (hours)
Lo
ad
(%
ult
ima
te)
45%
50 years
Advantex glass
Traditional E-glass
Stress-Rupture of Composite Rods in Normal Acids (HCl - H2SO4)
1
10
100
1 10 100 1000 10000 100000 1000000Time to Failure (hours)
Lo
ad (
% u
ltim
ate
)
50 years
Advantex Glass
Traditional E-Glass
12.1%
0.9%
r2 = 0.97 - Advr2 = 0.96 Trad E
.
73 hrs
* Data from OC internal analysis
GLASS FORMULATION IMPACT ON CORROSION RESISTANCE
DELIVERING A COMPREHENSIVE RANGE OF REINFORCEMENT SOLUTIONS FOR PULTRUSION
Single-End Rovings Unifilo®/ Continuous Filament Mats Non-wovens
Complexes, Fabrics, Stitched and Needled
Mats Bulky Rovings
Single-End rovings are generally used in all pultruded products,
usually as principal reinforcement
Provide axial strength and stiffness High reinforcement content Available in a range of tex values Specifically sized to different resin systems for optimal performance
Unifilo® mats are also widely used in pultrusion process for better
transverse mechanical properties
High mat tensile strength, also at elevated temperatures when wet with resin Low density Easy processing: both faces well bound and easy to splice Good compatibility with UP, VE, Epoxy and acrylic resins Available in a full range of weights and widths
Veils are designed to create a high quality surface layer on the
pultruded part
Small bundle size to give uniform and veil-like appearance Easy wet out in most pultrusion resins
Fabrics, complexes and mats – with sufficient tensile strength for
processing through a die, and which can be impregnated with
resin under operating conditions – may all be used
Being filamentized to a greater or lesser extent, producing loops or
filaments misaligned from the axial direction
Provides some reinforcement in the transverse direction to improve shear properties Produces a scouring action to clean the die and prevent lost edges in tight radii Easy to wet out