SABIC Innovative Plastics

1. SABIC Innovative Plastics™ Global Application Technology Secondary Operations Dirk Noordegraaf Customer Seminar Ljubljana Slovenia 14.05.2008

2. 2

3. Global Application Technology

4. 4 Locations

5. 5 Application Development Expertise Facts about SABIC Innovative Plastics: 10,300 employees world-wide $6.6 Billion in Revenues in 2006 60 locations world-wide $150 million 2006 investments in technology Facts about SABIC Innovative Plastics: 10,300 employees world-wide $6.6 Billion in Revenues in 2006 60 locations world-wide $150 million 2006 investments in technology

6. 6 Customer Innovation Process

7. 7 GApT Capabilities Overview

9. 9 Application development Analysis Functional demands separable y/n,<5x, sealing Test requirements dynamic, static, durability Design Material properties amorphous crystalline Assembly aspects space, 3D, aesthetics, size, load (direction) Choice Material strength, temperature, environment Assembly technique material pairing, economics, cycle time Test Before assembly tolerances End product performance, reject rate

10. 10 Possibilities to join parts

11. Assembly Decision Tree

12. 12 Welding techniques

13. 13 Welding techniques

14. Weldprocess comparison

15. 15 Hot Plate Welding

16. Hot plate welding Parameters Temperature (200-360°C) Heating time (10-20 s) intrusion pressure Separation time Weld intrusion Cooling time pressure

17. Hot plate welding Characteristics Components held against a heated tool, then pressed together Plate temp. for amorphous Tg+140°C, semi-crystalline Tm+70°C Radiation hot plate distance several tenths (semi-crystalline) No size limitations / 3D joints possible Welds can be air and water tight Long cycle times (> 20 s) • Tips Use dry materials to avoid porosity of weld (not for Cycolac) Use travel stops to avoid excessive flash, and improve strength To avoid sticking use PTFE based coatings up to 260-290°C

18. 18 Hot plate Welding Plate Temperature

19. 19 Hot Plate Welding non-contact

20. Design for hot plate welding

21. 21

22. 22 Vibration welding Parameters Frequency (100-240 Hz) Amplitude (0.35-2.0 mm) Weld time (2-8 s) pressure (0.5-5 MPa) Cooling time pressure

23. 23 Vibration welding Characteristics Heat generation by rubbing the interfacial surfaces under pressure Short cycle times (5-15 s) Weld line in one plane, same as vibratory motion Tips Weld line must be (fixed) very rigid to avoid loss of weld activity Use butt joint, energy director may be added to initiate rapid heat build-up and melting Do not over-pressurize semi-crystalline materials (low melt visc.)

24. 24 Design for vibration welding

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31. 31 Courtesy of Branson

32. 32 Ultrasonic Welding

33. 33 Ultrasonic Welding Process Parameters Frequency (20-40 kHz) Amplitude (10-40 µm amorph.) (25-60 µm crystal.) Energy Pressure 1-3 bar Weld time (0.2-2.0 s) Cooling time (0.2-0.5 s) Hold Pressure 1-3 bar Trigger ~ 0.5 bar Intrusion 0.1-0.8 mm

34. 34 Ultrasonic welding machine

35. 35 Ultrasonic welding Characteristics Longitudinal vibrations are boosted and directed to weld area, where interface melts Very short cycle times (<2 s) Part sizes max. 200 mm (amorph.) or 70 mm (semi-cryst.) Tips Use energy director (for amorphous) or shear joint (preferred for semi crystalline) With dissimilar materials, activate highest melting/viscosity material with sonotrode Use dry material (preferably no release grades)

36. 36 Heat generation principle

37. 37 Design for ultrasonic welding

38. 38 Design Variations

39. 39  Compatibility table for Ultrasonic welding

40. 40 Laser Welding

41. 41 Laser Welding Principle

42. 42 Key Elements for Laser Welding

44. 44 Transmission of natural resins in NIR

45. 45 Gap Bridging Surface layer is heated indirectly Gap = air = excellent heat barrier Polymer expands by appr. 10 % during heating ? closes thermal gap Maximum gap depends on polymers, doping concentration and on seam width Rule of thumb for maximum gap: < 100 µm (contour) < 300 µm (quasi simultaneous)

46. Weld design for transmission welding

47. 47 Welding Methods

49. 49 Summary

50. Screw Assembly ofThermoplastic Components

51. 51 Factors that influence performance Design Screw Boss Mould Material Strength/Stiffness Ductility/Notch sensitivity Elongation at break Relaxation Process Moulding Screw installation

52. 52 Screw types

53. 53 Thread geometries

54. 54 Thread-cutting screws Tensile stress in screw Compression between screw head and top of boss Low tension between plastic and thread flank Stress distribution comparable with bolt & nut For materials with low elongation at break

55. 55 Thread-forming screws Permanent deformation of plastic boss Radial and axial stresses in boss No compression under screw head necessary For all thermoplastics except highly filled (³40%)

56. 56 Thread-forming screws design Flank angle 30° for low radial stresses Thread pitch max. 8° for vibration resistance Core diameter small to enable material flow Tolerances only + tool to reduce thread stripping

57. 57 Boss design for moulded parts

58. Painting of Plastics

59. 59 Key Factors in Paint Adhesion Clean Surface Must be free of all surface contamination (dirt, oils, release) Power Wash – Multi -Stage Acid type is most common and preferred Solvent Wipe – Sometimes used but chance of operator error is high Wetting Intimate contact (wetting) is a key requirement for obtaining adhesion Power Wash should improve potential for wetting Surface energy of the substrate must be equal or greater than the surface energy of the coating

60. 60 Theories in Paint Adhesion Mechanical Interlocking Coating interlocks around profile (irregularities, pores) of the substrate Sanding or chemical etching the substrate surface can enhance this mechanism Interdiffusion Assumes that paint molecules have the ability to diffuse and entangle with the substrate Solvents, resin type and level of cure all play a role Absorption Theory Materials held together by electrostatic forces

61. Molding No high shear (Tool design, Injection Speed) Tool Temperature (Crystallinity) Holding Pressure (Surface Quality) Back Pressure (Shear, Mixing) Cleaning Small series Solvent wipe Large Series Power-wash Remove Additives from the Surface Paint Formulation Less restriction towards Solvents Water based Paints: limited systems available Paint Process Good wet-ability required

62. Molding Melt T + Residence time Degradation Melt T + Injection Speed Degradation Melt T + Holding Pressure Bulk Stress Melt T + Tool T Surface Stress Cleaning Small series Mild solvents to be used alcohols (IPA). Large Series Power wash Remove Additives from the Surface Paint Formulation Mild Solvents to be used (Minimize aromates) Good paint-ability with waterborne paints Paint Process Thickness Flash off

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67. 67 Evaluation

68. 68 Adhesion Testing

69. 69 Wave scan Measurements

70. 70 Surface quality Ondulo inspection

71. 71 Surface & Material Analysis

72. High Speed Impact Tests

73. Metallisation of Plastics 

74. 74 Metallization of Plastics: Why

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77. 77 Metallisation Technologies

78. 78 Metallization Technologies and Materials 

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80. 80 Vacuum Metallization

81. 81 Vacuum Metallization

82. 82

83. 83 Basic process of Vacuum Metallization

84. 84 Metallic High Vacuum Deposition

85. 85 Applications

86. 86 Properties of applied layers

87. 87 Vacuum metallization on Plastics CTQ’s

88. 88

89. 89 Applications

90. 90 Categories of Plating on Plastics Electroless-Copper/Nickel Double-Sided Plating Selective Plating Electroplating Copper/Nickel Copper/Nickel/Other Metals Sn, Au, Cr, Black Cr, Satin Ni Special Processes; Molded Interconnect Devices

91. Surface Treatment Clean - - - Surfactants Etch (functionalize) - - - CrO3/H2SO4 Neutralize - - - NH2OH/H2SO4 Catalyze - - - PdCl2/SnCl2 Accelerate - - - HBF4 Electroless Copper or Nickel Plate Electroplate Copper Strike - Improve Conductivity & Enhance Metal Adhesion Bright Acid Copper - Leveling & Ductility Semi-Bright Nickel - Adhesion, Corrosion Protection Bright Nickel - Luster, Sheen & Corrosion Protection Microporous Nickel - Sacrificial layer to provide very small sites for corrosion to prevent large corrosion

92. ABS Resin Plating Structure

93. 93 Process Illustration- Double-Sided Plating

94. 94 Plateable Plastics ABS ABS/Polycarbonate Blends Mineral filled PA 6 Noryl* GTX Glass Mineral filled Ultem* Polycarbonate Polyesters Polyphenylene Ether Aryl and Aromatic Nylons PolyarlyAmides Polybutylene Terephlatate Polysulfones Other Engineering Plastics

95. 95 Plateable Plastics Cycolac* S705, MG37EP(N) Cycoloy* MC1300, CP8320, CP8930 Not recommended Noryl* PN275, PN235 Ultem* 2300, 2312, 3452 Valox* EH7020HF Only some specially mineral filled products GTX VP7115

96. 96 Non Plateable Plastics

97. Thank you!Questions?

98. 98 Disclaimer THE MATERIALS, PRODUCTS AND SERVICES OF SABIC INNOVATIVE PLASTICS HOLDING BV, ITS SUBSIDIARIES AND AFFILIATES (“SELLER”), ARE SOLD SUBJECT TO SELLER’S STANDARD CONDITIONS OF SALE, WHICH CAN BE FOUND AT http://www.sabic-ip.com AND ARE AVAILABLE UPON REQUEST. ALTHOUGH ANY INFORMATION OR RECOMMENDATION CONTAINED HEREIN IS GIVEN IN GOOD FAITH, SELLER MAKES NO WARRANTY OR GUARANTEE, EXPRESS OR IMPLIED, (i) THAT THE RESULTS DESCRIBED HEREIN WILL BE OBTAINED UNDER END-USE CONDITIONS, OR (ii) AS TO THE EFFECTIVENESS OR SAFETY OF ANY DESIGN INCORPORATING SELLER’S PRODUCTS, SERVICES OR RECOMMENDATIONS. EXCEPT AS PROVIDED IN SELLER’S STANDARD CONDITIONS OF SALE, SELLER SHALL NOT BE RESPONSIBLE FOR ANY LOSS RESULTING FROM ANY USE OF ITS PRODUCTS OR SERVICES DESCRIBED HEREIN. Each user is responsible for making its own determination as to the suitability of Seller’s products, services or recommendations for the user’s particular use through appropriate end-use testing and analysis. Nothing in any document or oral statement shall be deemed to alter or waive any provision of Seller’s Standard Conditions of Sale or this Disclaimer, unless it is specifically agreed to in a writing signed by Seller. No statement by Seller concerning a possible use of any product, service or design is intended, or should be construed, to grant any license under any patent or other intellectual property right of Seller or as a recommendation for the use of such product, service or design in a manner that infringes any patent or other intellectual property right. SABIC Innovative Plastics is a trademark of Sabic Holding Europe BV * Trademark of SABIC Innovative Plastics IP BV