wim van de velde

Wim Van de Velde, Director of Marketing, Plastic Additives

May 2014, Wards Interior Automotive

conference, Dearborn,MI

Light Weight Automotive TPOs with

Improved Aesthetics, an additive

approach

1

©2013 Milliken & Company

Confidential

Agenda

• Milliken & Company

• Hyperform®HPR-803i:

What is it?

How does it perform?

Commercial interior case studies

2

©2012 Milliken, Private & Confidential

Milliken & Company

3


Confidential

Milliken & Company

H

H Headquarter

Technical center

• Founded in 1865. Headquartered in

Spartanburg, SC, USA

• 7,000+ associates

• Global presence- 45 facilities around

the world

Technical Innovation

• Community of

innovators

• More than 5.000

patents


Confidential

Milliken & Company

Floor CoveringBeautifying offices, hotels, airports,

homes, and commercial

environments around the world

Performance MaterialsCustom-engineered textiles for a variety of

industrial markets including automotive

(hoses, airbags, interlinings, tires)

Apparel & Specialty FabricsFabrics for industrial applications

such as healthcare, hospitality,

table linens, office interiors, labels,

and much more

Performance SolutionsAssisting organizations to become safer and

more competitive in the marketplace


Confidential

Milliken Chemical: innovation

Silicone chemistry

Performance plastic

additives

Polymeric bound

chemistry

Silicone

Performance plastic additives

R & D projects

Colorants for Clear PPColorants for PU

Colorants for detergents

Hyperform HPN

Nucleating agentMillad NX 8000 Clarifying agent

Hyperform HPR

Reinforcing agent

Stiffness/impact balance

Scratch resistance

Crystallization speed

Crystallization orientation

Barrier

Opticals


Hyperform®HPR-803i: what is it?

7


Confidential 8

HPR-803i Technology• Reinforcing Agent for Automotive PP Compounds

HPR offers a drop-in solution for OEM’s to light weight vehicle PP; low-cost,

low-hanging fruit solution. Brings additional scratch resistance and

colorability value.

Hyperform® HPR-803i is a synthetic

mineral-based reinforcing additive

• Fiber length = 20 microns

• Fiber diameter = 0.5 micron

• Mohs hardness = 2.5

(Talc = 1.0 ; glass fiber = 6 to 7)

• Density = 2.3

(Talc = 2.7; glass fiber = 2.6)

Testing performed in 35MFR interior grade Medium impact

copolymer.


Hyperform®HPR-803i: how does it

perform?

9


Confidential

Easy-to-implement reinforcing technology

10

Hyperform HPR-803i reinforced PP

HPR-803i in the Market

5 to 15 % Weight

reduction

Scratch improvement

Runs on conventional IM equipment

Easier to process

compounds

Recycled PP performance

booster

Meeting increasing lightweight demands in automotive


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Different filler types for PP with class A surface finish

11

Reinforcing efficiency

Modulu

s

Filler loading

Molders and compounders can realize high-performance, reduced density materials and parts

with HPR-803i in filled PP and TPO applications

Ratio Exposed

Surface / Volumex 2x 3,5

Hyperform

HPR 803i

Calcium-

carbonate

Fine talcs

Coarse talcs

TalcCaCO3


Confidential

Using HPR-803i hybrids for interior and exterior parts

12

Weight and density reduction

Talc filled

Part density > 1.0 Kg/dm3

HPR-803i hybrid

Part density

between 0.95 and 0.99 Kg/dm3


Confidential

Lower compound viscosity enables easier processing

290

300

310

320

330

340

350

360

20% Talc 13% HPR-803i/talc

9% HPR-803i/talc 7% HPR-803i

Filling length

(m

m)

Flow length

Flow length

13

Ease of processing

Higher weld line

strengthFaster cycle time

Lower extrusion

temperature

Easier filling of

the mold

Spiral flow sample( = injection point)


Confidential

Reducing the filler content and a harder surface result in better scratch

14

Scratch resistance

2.27

3.62

1.17

1.53

0

1

2

3

4

5

6

7

Fine grain (VW K31) Coarse grain (VW K3A)

Delt

a L

valu

e

10N Erichsen scratch

15% Talc 6% HPR-803i

Talc HPR-803i Talc HPR-803i


Confidential

Applications for HPR-803i containing PP compounds

15

Hyperform®HPR-803i


Commercial interior case studies

16


Lightweighting & foaming

17


Confidential

Lightweight foamed parts

Case Study – foamed parts

Engine cover - typical

foamed application

Challenge – evaluate the performance of

Hyperform® HPR-803i in chemical and mechanical

(gas inject) foaming applications

Mechanical foaming material – 20% 2µ talc filled

Chemical foaming material – 20% 1µ talc filled

Reduce part weight

Evaluate stiffness

Evaluate impact

Targ

ets


Confidential

Lightweight Foam Technology

19


Mechanical Foam

N2 or CO2 added to polymer

Creates small, uniform voids

Gas displaces polymer

Equipment changes necessary

Foaming agent added to polymer

Creates small, uniform voids

Gas displaces polymer

May leave residual chemicals

Special equipment

incorporates the gas

into polymer

Chemical foaming

agent added to polymer

Chemical Foam


Confidential

Mechanical foaming

20


12%

3%

0%

2%

4%

6%

8%

10%

12%

14%

Talc HPR-803iSti

ffness

loss

wit

h f

oam

ing

45.4

41.3

52.9

47.249.9

44.948.5

43.9

0

10

20

30

40

50

60

Un-foamed Foamed

Part

weig

ht

(g)

No f

ille

r

20% t

alc

fille

d

10% t

alc

+ 3

% H

PR

10% H

PR-8

03i

No f

ille

r

20% t

alc

fille

d

10% t

alc

+ 3

% H

PR

10% H

PR-8

03i

11% 7%

Materials: 35 mfr impact coploymer, 2µ talc

Gas foaming allowed for 11% weight

reduction over control, and HPR-803i allows

another 7% weight reduction over talc

HPR-803i

maintains higher

stiffness than talc


Confidential

Chemical foaming

21

Case Study

13%

4%

0%

2%

4%

6%

8%

10%

12%

14%

Talc HPR-803iSti

ffness

loss

wit

h f

oam

ing

215

185

245

215230

205

225

195

0

50

100

150

200

250

300

Un-foamed Foamed

Part

weig

ht

(g)

No f

ille

r

20% t

alc

fille

d

10% t

alc

+ 3

% H

PR

10% H

PR-8

03i

No f

ille

r

20% t

alc

fille

d

10% t

alc

+ 3

% H

PR

10% H

PR-8

03i

12% 9%

Materials: 18 mfr medium impact coploymer, 2µ talc

Chemical foaming allows for 12% weight

reduction over control, and HPR-803i allows

another 9% weight reduction over talc

HPR-803i maintains

higher stiffness

than talc


Confidential

Foaming and Impact Strenght

22

Case Study

32%

25%

0%

5%

10%

15%

20%

25%

30%

35%

Talc HPR-803i

Impact

loss

wit

h f

oam

ing

Materials: 18 mfr medium ICP, 1µ talc

84%

52%

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

Talc HPR-803i

Impact

loss

wit

h f

oam

ing

Multi-Axial Impact, 23°C, 2.2 m/s Notched Charpy impact , 23°C

Materials: 35 mfr impact coploymer, 2µ talc

Mechanical Foam Chemical Foam

Foaming is known to negatively affect impact

strength. However in some interior

applications this is not of major concern.


Confidential

Outcome

23

Case Study - foaming

Hyperform® HPR-803i allowed for additional weight

reduction with reduced filler content and lower

density

More tests needed to understand the effect of HPR-

803i particle size on the formation of foam structure

using either technologies

Targ

ets

Part weight reduced ~8%

Stiffness & impact requirement met


Decreasing Weight, Increasing Recycled

PP, and Improving Scratch Resistance

24

Luxus/Nissan Case Study


Confidential 25

The Strength of Partnership

• Development of PP compounds containing new reinforcing agent

• Validation of the PP compounds and trims

• Reinforcing fiber supplier


Confidential 26

PP Weight Reduction and Recycled Content

258 278

226232

16157

0

100

200

300

400

500

600

700

Talc Talc/HPR Hybrid

We

igh

t (g

)

Molded Part component split (g)

Filler

Virgin PP & Additives

Recycled PP 40

49

35

41

25

10

0

10

20

30

40

50

60

70

80

90

100

Talc Talc/HPR Hybrid

(%)

Material recipe component split (% in weight)

12% lighter part combined with increased recycled PP content

645 g 568 g

-77g 12% weight reduction

9 % increased recycled PP


Confidential 27

Luxus TDS – Door panel application

12% weight reduction


Confidential 28

Scratch Resistance

Improved scratch resistance AND higher recycled PP

HPR/Talc

Talc

5.80

1.4

0.0

1.0

2.0

3.0

4.0

5.0

6.0

7.0

25% Talc Talc-HPR

Delt

a L

valu

e

10N Erichsen scratch


Confidential 29

Dimensional Properties

New compound on existing moulds :

Dimensions within specifications


Weight Reduction & Scratch Resistance

Improvement

30

Grupo Antolin Door Panel Case Study


Confidential

Doorpanel Grupo Antolin

Case study HPR-803i

429

403

390

395

400

405

410

415

420

425

430

435

16 % Talc 9 % mineral filler (HPR/Talchybrid)

Weig

ht

(g)

Weight reduction

0.5

0.8

0.4 0.4

0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

Fine grain (K31) Coarse grain (K3A)

Delt

a L

Scratch resistance16 % Talc 9 % mineral filler (HPR/Talc hybrid)

Polypropylene compound with Hyperform HPR-803i

enables 6% weight reduction and scratch improvement


Confidential

Doorpanel Grupo Antolin

Case study HPR-803i

Polypropylene compound with Hyperform HPR-803i

enables 6% weight reduction and CO2 emission reduction

Wei

ght

Red

uct

ion • 52 g saved per car

for 2 rear doors

• 7,8 tons/y lessmaterial (1)

C0

2 e

mis

sio

n r

edu

ctio

n • 462 g CO2/car saved

• 111 tons CO2/y saved(2)

(1) For production of 150.000 cars/year

(2) Average single car mileage of 30.000 km per car


Lighter weight, improved scratch,

reduced color, improved flow, and

improved weld strength compound

33

Inno-Comp Case Study


Confidential

Stiffness = meets OEM specs

Impact = meets OEM specs

Density = <1.0 g/cc

OEMs get lightweight parts

Improved scratch performance

Reduced color loading

Improved flow properties

Improved weld-line strength

Compound reformulation

34

Case study on HPR-803i

Stiffness = meets OEM specs

Impact = meets OEM specs

Density = >1.0 g/cc

281

262

230

250

270

290

20% Talc 13% mineral filler(HPR/Talc Hybrid)

Weig

ht

(g)

0

20

40

60

80

100

20% talc 13% mineral filler(HPR/Talc Hybrid)C

om

posi

tion b

y w

eig

ht,

%

PP Total filler


Confidential 35

Inno-Comp TDS – Application in B-pillar

7% weight reduction


Confidential

Using HPR-803i hybrids for interior and exterior parts

36

Weight and density reduction

Talc filled

Part density > 1.0 Kg/dm3

HPR-803i hybrid

Part density

between 0.95 and 0.99 Kg/dm3

Thank you! Questions?

3

7

Wim Van de Velde

Marketing Director, Plastic Additives

Milliken & Company

920 Milliken Road M-209

Spartanburg,SC 29303

T +1 864 503 6047 / C +1 864 680 7064

[email protected]

wim van de velde

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