welcome to helvoet rubber & plastic technologies · 13485, ohsas18001, fda 21 cfr 820 assembly...

Welcome to Helvoet Rubber & Plastic Technologies

26-09-2018, Veldhoven

Hybrid Precision Parts: Bonding Various Materials in Critical Applications

Ing. J.W. (Hans) van der Meer

THERMOSET THERMOPLAST RUBBER & LSR ASSEMBLY

Topics

Introduction

What is a hybrid part?

Material combinations

Types of bonding

Mechanical bonding

Chemical bonding Applying bonding agents

Direct bonding & 2K

Hybrid parts in critical applications

Testing of the bonding strength

Product examples

Introduction

Personal introduction

Hans van der Meer

HLO chemistry (specialisation in environmental chemistry)

Weiterbildungsstudium Kautschuktechnologie Leibniz Universität Hanover

4 year at Cabot Leiden Technical Centre (supporting Rubber Blacks)

11 years at Helvoet Rubber & Plastic Technologies B.V.

A stable partner on your side

About us

General FiguresFounded in 1939

~ 750 employees

6 manufacturing locations

world wide customer base

Member of Hydratec industries (Listed on Euronext Amsterdam)

Production Figures

> 200 injection moulding and rubber processing machines

> 100 machines for post-processes

> 30 automated assembly lines

> 1 billion components produced per year

> 4.300 tons yearly material consumption of thermoplastics, thermosets, rubber & LSR

Helvoet locations

Global service, local care

MUNICH

Thermoset, Thermoplastic

ISO 9001, 14001

Simulations, Insert-Moulding

PUNE

Thermoset, Thermoplastic, (LSR)

ISO 14001, IATF 16949

Lapping, Assembly

LOMMEL

Thermoset, Thermoplastic

ISO 14001, IATF 16949

Finishing processes, High volumes

TILBURG

Thermoplastic

ISO 9001, 14001, 13485, OHSAS18001, FDA 21 CFR 820

Assembly lines, Cleanroom

HELLEVOETSLUIS

Thermoplastic, Rubber, LSR

ISO 9001, IATF 16949, ISO 22000, 13485, DVGW

Assembly lines, Compounding

Kaniow

Rubber

ISO 9001, IATF 16949

Assembly and inspection

US Michigan & California

Engineering & Sales

NAFTA and Mercosur markets

Spain Alicante

Engineering & Sales

Extensive material range to fulfill your needs

Material toolbox

Thermoset

Phenolic, BMC

Special treatments / coatings

similar thermal extension as metal

resistant against aggressive media

good thermal insulation

lightweight

Thermoplastic

Commodities

PP, PS, PE

High performance plastics

ABS, PC, PPS, PEEK,

PBT, COC, COP,

TPE, PA66, PBT,

PPA

LSR

Excellent light

transmittance

Superior tensile

strength, elongation,

tear strength, and

compression

Rubber

Own compounding

Customized recipes

NBR, HNBR, EPDM,

FKM, VAMAC,

Bonding with other

materials

Our customer base

http://www.wabco-auto.com/home

http://www.wabco-auto.com/home

http://www.bsh.be/

http://www.bsh.be/

http://www.google.nl/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&ved=0ahUKEwjO8POH9vbSAhVGOxoKHUfNC9EQjRwIBw&url=http://www.farmingmonthly.co.uk/directory/&bvm=bv.150729734,d.ZGg&psig=AFQjCNFFWJv6oR44ihxwre1VUsawTWcTmg&ust=1490712240146496

http://www.google.nl/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&ved=0ahUKEwjO8POH9vbSAhVGOxoKHUfNC9EQjRwIBw&url=http://www.farmingmonthly.co.uk/directory/&bvm=bv.150729734,d.ZGg&psig=AFQjCNFFWJv6oR44ihxwre1VUsawTWcTmg&ust=1490712240146496

Topics

Introduction



Types of bonding

Mechanical bonding


Direct bonding & 2K



Product examples


With a hybrid part we mean a product that consists of two different materials which are fixed together by either mechanical or chemical bonding.

In most cases it is a combination of a hard material and a softer material.

The softer material often has a sealing or damping function.

The hard and soft component can be made in one mould (2k) or in two separate moulds (k+k).

Topics

Introduction



Types of bonding

Mechanical bonding

Chemical bonding

Applying bonding agents

Direct bonding & 2K



Product examples


Hard / soft combinations:• Metal / Plastic

⁻ Stainless steel with PC

⁻ Stainless steel and PA

⁻ ..

• Metal / Rubber⁻ i.e. magnetic stainless steel with NBR

⁻ Brass and HNBR

⁻ Aluminium with FKM

⁻ Stainless steel with LSR (VMQ)

⁻ ..

• Plastic / Rubber⁻ PPA with AEM rubber

⁻ PPS with FKM

⁻ PA with LSR (VMQ)

⁻ ..

• Plastic / TPE⁻ PP with SEBS

⁻ ..

Topics

Introduction



Types of bonding

Mechanical bonding


Direct bonding & 2K



Product examples

Types of bonding

Bonding type

Mechanical Chemical

Bonding agents(use of adhesives)

Direct bonding(without bonding agents)

Topics

Introduction



Types of bonding

Mechanical bonding


Direct bonding & 2K



Product examples

Mechanical bonding

Soft component

Hard component

+ All material combinations possible - Limited design freedom

- Limited functional integration

- Tensions in the soft material

- Less fatigue resistant

- No adhesive bond between soft and hard component!!

Sealing area

Topics

Introduction



Types of bonding

Mechanical bonding


Direct bonding & 2K



Product examples

Chemical bonding

Soft component

Hard component

+ Maximum design freedom

+ Maximum functional intergration

+ Material saving

+ Less tension concentrations

+ Better fatigue resistance

+ Sealability

+ Adhesive bond between soft and hard component

- Not possible for all substrate combinations

Sealing area

Chemical bonding

Important principles to obtain a chemical bond:

• Wetting- A high surface area gives a better wettability (polar bonding agents)

• Diffusion- Inter diffusion of different polymeric chains

- Entanglements of chains in the boundary surface

• Reaction⁻ Physical reactions: i.e. hydrogen bonds

⁻ Chemical reactions: i.e. functional groups, crosslinking

Chemical bonding

Wetting / surface energy:

Hard component

Good wetting

Bad wetting

Chemical bonding

Diffusion:

Inter diffusion of different polymeric

chains

Entanglements of chains (mechanical adhesions)

Chemical bonding

Reaction:

Combination of physical “reaction” ie. Hydrogen

bonds (Y-X) and Chemical reaction via functional groups and crosslinking

resulting in ionic bonds (X)

xxx

xx

x

xxx

Y

Y

Y

Chemical bonding – use of bonding agents

Rubber

TopcoatPrimer

Substrate

Adsorption / mechanical anchoring

Chemical bonding / mechanical inter diffusion

Schematic example using a bonding system:

Bonding system


What is a bonding agent:

- Dispersion/suspension of various materials:- Polymers

CSM, CR, Chlorinated NR, phenol- / Epoxy resins

- Fillers, Pigments Carbon black, Silica's, Metal oxides, metal

- Cross linkers Isocyanates, Silanes, rubber accelerators

- Solvents Ketones, Aromatic hydrocarbons, Alcohols, water

Topics

Introduction



Types of bonding

Mechanical bonding


Direct bonding & 2K



Product examples


Process steps:

Met

al

Pla

stic

Cleaning

Degreasing (washing)

Drying Activation

Cleaning

Plasma treatment

Blasting

Various blasting materials

Apply bonding agent

Primer (optional)

Topcoat / one-coat

Apply bonding agent

Primer (optional)

Topcoat / one-coat

Vu

lcan

isat

ion

+ Proven technology- The use of bonding agents require a lot of sensitive process steps

Dry

ing

Dry

ing

Dry

ing

Dry

ing

Sto

rage


Methods for applying the bonding agents:

• Dipping• 10 to 50% dilution with solvent

• Brushing• Use undiluted• For large parts

• Spraying• 50-200% dilution with solvent

• Best system for applying a precise layer thickness.

Applications & Impressions: Hellevoetsluis, bonding technology

Important parameters

Surface energy of cleaned and activated parts

Correct surface roughness (metal parts) after blasting

Applying primer in correct layer thickness (micron level)

Applying topcoat in correct layer thickness (micron level)

Correct drying times for bonding agents

Correct packaging of coated parts to prevent contamination of bonding layer

Bonding rubber/metal and rubber/plastic hybrid parts

Applications & Impressions: Hellevoetsluis, bonding technology

Automated cleaning

Automated blasting

Automated spraying with bonding agents

Drum coating machine

Clean environment according latest industry requirements

Bonding rubber/metal and rubber/plastic hybrid parts

Topics

Introduction



Types of bonding

Mechanical bonding


Direct bonding K+K & 2K



Product examples

Bonding 2 materials together without the use of bonding agents.

K+K: first the hard component is moulded (i.e. plastic).

The soft component is over moulded onto the hard component.

The process takes place in two different moulds.

2K: first the hard component is moulded (plastic).

The soft component is over moulded in a second step, but in the same mould.

Applications & Impressions: Hellevoetsluis, bonding technologySelf bonding Rubber possibilities

Self bonding Rubber possibilities

Process steps:

Pla

stic

K

+K

Pla

stic

2

K

Optional plasma treatment

Molding of plastic part + moulding Soft component

(Rubber/TPE) in one mould

+ Proven technology+ Few process steps- Higher costs of 2K moulds with complex temperature demands (especially for rubber)- More limited material combinations

Moulding of soft component (Rubber/TPE in

separate mould

Packaging

Examples:

Self-adhesive LSR (VMQ) to metal, PBT, PA and other materials.

FKM to PA612, PA4-6

AEM (Vamac) to PPA

HNBR to PA 6-3-T

SEBS to PP



AEM – Vamac – rubber (two sides)Plastic (PPA)No bonding agentsStrong bonds

Topics

Introduction



Types of bonding

Mechanical bonding


Direct bonding & 2K



Product examples

Selection of materials:

• In order to select the correct hard and soft materials it is important to understand the proposed function of the product:

• Temperature range (low and high)

• Mechanical forces on the product

• Contact media

• Food contact

• If this information is know, we can investigate if there is a good combination possible as all used materials should be suitable for the environment.

Applications & Impressions: Hellevoetsluis, bonding technologyHybrid parts in critical applications

Bond strength:

• A good bond strength makes failing on the interface of the soft and hard component impossible.

• The failure takes place in the weakest part, normally the soft component.

• A good bond strength is stronger than the strength of the soft component.

Applications & Impressions: Hellevoetsluis, bonding technologyHybrid parts in critical applications

Topics

Introduction



Types of bonding

Mechanical bonding


Direct bonding & 2K



Product examples

Testing of the bond strength:

• As it is difficult to test the bond quality of parts in a consistent way, it is important to evaluate the capability of the bonding during the development of the part.

• Standardized tests can help to obtain objective data on the strength of the bond.

Applications & Impressions: Hellevoetsluis, bonding technology Testing


Based on ISO 5600


Conical shaped substrate parts (various metals or plastics)

Soft elastic component

Yes/No bonding agent(s)



Good bonding is a 100% rubber break

Failure modes:1. Separation between substrate surface and soft

component (i.e. rubber).

When using bonding agents:1. Separation between substrate surface and primer2. Separation between primer and topcoat.3. Separation between bonding agent (topcoat) and

soft component (i.e. rubber).

Testing of the bond strength (example Brass, one-coat system and HNBR):


Failure between bondingsystemand substrate

Failure between bondingsystem

and rubber

Partial failure between bonding system and rubber and partial rubber

break

100% thick rubber break

Break force 350 Newton






Bonding strength and type of failure can be determined after:

1. Moulding2. Ageing in air3. Ageing in various application liquids (oil, fuels, AdBlue, water etc..)4. Ageing in plasticizers5. Ageing in hot distilled water6. Ageing in salt water7. Ageing in acid environments

Topics

Introduction



Types of bonding

Mechanical bonding


Direct bonding & 2K



Product examples

Bonded parts impression

Manufacturing your competitive advantage

Hans van der Meer

Rubber Technologist & Materials engineer

Helvoet Rubber & Plastic Technologies

Tel.: +31 (0) 181331324

Email: [email protected]

www.helvoet.com

RELIABILITYMULTIPLE TECHNOLOGIES MANUFACTURINGCO-DEVELOPMENT

Where can we support you?

Thank you for your attention!

welcome to helvoet rubber & plastic technologies · 13485, ohsas18001, fda 21 cfr 820 assembly...

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