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LUCOBIT products based on ethylene butyl acrylate and its possibilites in wire and cable and compounding applications Dr. Sandro Kohn 25.04.2011. Table of contents. LUCOBIT AG – company profile LUCOBIT products for wire and cable applications and some selected examples

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  1. LUCOBIT products based on ethylene butyl acrylate and its possibilites in wire and cable and compounding applications Dr. Sandro Kohn 25.04.2011

  2. Table of contents • LUCOBIT AG – company profile • LUCOBIT products for wire and cable applications and some selected examples • Motivation of LUCOBIT AG to develop HFFR grades based on etyhlene butyl acrylate • Positioning and opportunities of LUCOBIT HFFR grades compared to established HFFR grades • Further opportunities in compounding • Summary and conclusions

  3. LUCOBIT AG – company profile

  4. LUCOBIT AG- head quarter and world wide oriented distribution network

  5. LUCOBIT AG- product divisions • 1.3 • Film 1.2 Compounding 1. Flexible polymers 1.4 Extrusion coating 1.5 Foams 1.1 Wire &Cable 2. Waterproofing 3. Asphalt modification

  6. Wire and cable compounder vs. wire and cable manufacturer- recommended LUCOBIT grades

  7. Wire and cable compounds with the main benefits and typical dosage of Lucofin 1400HN, Lucofin 1400MN and Lucofin 1492 Extractfromwireandcablenewsletter / inplastics Nr. 1/2010

  8. Typical design of a medium/high voltage power cable showing typical applications (marked green) for Lucofin grades 1: Copper conductor 2: Conductor shield: internal semi conductive compound based on Lucofin 14000MN 3: Insulation XLDPE–XLLDPE compound requiring high cleaniness Lucofin 1400HN / Lucofin 1400MN- water treeing test being a major challenge 4: Conductor shield: external semi conductive compound based on Lucofin 14000MN 5: Conducting bond 6: Layer of copper 7 : HFFR sheathing made of Lucofin HFFR grades or other HFFR grades based on Lucofin 14000HN / Lucofin 1400MN / Lucofin 1492

  9. Typical design of a low voltage power cable showing typical applications (marked green) for Lucofin grades 1: Copper conductor 2: HFFR / non HFFR insulation based on Lucofin HFFR grades or Lucofin 14000HN / Lucofin 1400MN / Lucofin 1492 3: HFFR / non HFFR bedding based on Lucofin 14000HN / Lucofin 1400MN / Lucofin 1492 4: Binder tape 5: HFFR / non HFFR sheathing based on Lucofin HFFR grades or Lucofin 14000HN / Lucofin 1400MN / Lucofin 1492

  10. Typical design of a telecommunication cable showing typical applications (marked green) for Lucofin grades 1: Copper conductor 2: HFFR / non HFFR insulation based on Lucofin HFFR grades or Lucofin 14000HN / Lucofin 1400MN / Lucofin 1492 3: Metallic shield 4: HFFR / non HFFR sheathing based on Lucofin HFFR grades or Lucofin 14000HN / Lucofin 1400MN / Lucofin 1492

  11. Case study - Lucofin 1400 MN as a major ingredient in a semiconductive compound • Customer: global wire and cable compounder • Status: commercial business with Lucofin 1400 MN • Request: Deliver black loaded semiconduvtive compound resulting in an extruded layer with superior smoothness • Crucial for success: Compared to competition EBA Lucofin 1400MN delivers excellent cleaniness and outstanding quality management system, including continuous online measurement of film grade

  12. Case study - Lucofin 1400MN as a major ingredient in a HFFR compound • Customer: global wire and cable manufacturer and compounder • Status: commercial business with Lucofin 1400 MN • Request: Deliver excellent dispersion and bonding of EBA to a mineral flame retardant in a highly filled HFFR compound • Crucial for success: Compared to competition autoclave EBA with comparable BA-content Lucofin 1400MN delivers better dispersion and bonding resulting in superiour mechanical properties

  13. Characteristics of HFFR compounds • Halogen Free Flame Retardants • Low smoke generation • Non-corrosive gases • Used if required security of people and protection of values • Very good dielectric properties • Recyclability

  14. Applications for HFFR cables

  15. Applications for HFFR cables continued

  16. Polymers consumed by the cable industry in western europe 2000-2009

  17. Chemical composition and property analysis of established HFFR systems- new approach by LUCOBIT AG

  18. m m m m n n n n Molecular structures of some ethylene acrylic esters and ethylene vinyl acetate EBA (ethylene butyl acrylate) EMA (ethylene methyl acrylate) EVA (ethylene vinyl acetate EEA (ethylene ethyl acrylate)

  19. Major features imparted by ethylene acrylic esters and ethylene vinyl acetate in comparison with standard LDPE/LLDPE

  20. LUCOFIN1400MN, EBA LUCOFIN1400HN, EBA HDPE LDPE MDPE LLDPE VLDPE ULDPE 45 62 E-modulus of ethylene butyl acrylate and other polyethylene types EMA, EEA EVA POE/POP EPDM/EPM 10 100 1000 E-modulus [MPa]

  21. C H C O O H 3 Thermal decomposition of EVA and EBA at different temperatures yielding corrosive and non-corrosive by-products, respectively T > 210 °C R R + R R corrosive acetic acid O C C H 3 O R T > 280 °C + R H C C H C H C H R 2 2 3 R C non-corrosive olefin O H O C O O C4 H 9

  22. Thermogravimetric analysis of EBA vs. EVA EBA (17 % BA) EVA (19 % VA)

  23. Maximum processing temperature of some polar polyethylenes and some mineral flame retardants

  24. Vicat temperature and melting point of EBA and EVA of comparable comonomer content

  25. Glass transition temperature of polyethylene and some polar ethylene copolymers

  26. Dynamical Mechanical analysis of EBA vs. EVA

  27. TGA of HFFR compounds based on EBA/MDH and EVA/ATH EBA/MDH based HFFR compound EVA/MDH based HFFR compound

  28. MFI of HFFR compounds based on EBA/ATH and EVA/ATH at various weightsas a function of melt temperature

  29. MFI of HFFR compounds based on EBA/MDH at various weightsas a function of melt temperature

  30. Output of HFFR compounds based on EBA/ATH and EBA/MDH as a function of melt temperature

  31. Elongation at break of HFFR compounds based on EBA/MDH and EVA/ATH as a function of storage temperature Storage time: 4 days

  32. Dynamical Mechanical analysis of HFFR compounds based on EVA/MDH and EBA/MDH

  33. Water absorption of various HFFR grades

  34. Elongation at break of some HFFR compounds before/after water storage and relative change Storage time: 4 days, temperature: 80 °C

  35. Volume resistivity of some HFFR grades and percentage volume resistivity before/after storage in water

  36. Limited oxygen index (LOI) of some HFFR grades

  37. Chemical composition and property analysis of established HFFR systems- new approach by LUCOBIT AG continued

  38. Property landscape of Lucofin HFFR grades and other HFFR grades

  39. Target markets and opportunities for Lucofin HFFR grades • Cables in cold areas • Regions with harsh winters • Refrigerated rooms • Outdoor • Snowy/icy conditions • Cables in hot areas • Regions with long summers • Outdoor • Areas at elevated temperatures • Long life time required • Cables of high prodcution output • Lucofin 7440 HFFR based on EBA/MDH • Fast line speed products • Cables in wet areas • Ships and marine • Outdoor • Channels • Off-shore

  40. Targeted LUCOBIT HFFR grades • Step 3. Step 2. Step

  41. Compliance of LUCOBIT HFFR grades with norms and technical standards

  42. 6. Summary of most promising opportunities PRIORITY RANKING OF OPPORTUNITIES • Colour masterbatches • Additive + filler masterbatches • (Impact) modification inside polyolefin based compounds (also for W&C) • Enginnering plastics impact modification • PVC compounds

  43. Case study: Colour MB for Plastics processing company • Customer : Plastics processing company • Product: Colour MB • What they do: Carriersystem for colour MB = 50% LDPE ,MFR=20 + 50 % Lucofin 1400MN • Why they add EBA : polarity , > filler load, better dispersion

  44. Case study : MB /blown films for Plastics processing company • Customer : Plastics processing company • Product: MB for blown films • What they do: GMS MB for blown MB carrier:100 % :1400MN • Why they add EBA : polarity, semi chemical bonding of GMS to EBA (Not good with LDPE)

  45. Case study: bitumen mats for Automotive supplier • Customer : Automotive supplier • Product: self compounded bitumen mats for sound/vibration damping • What they do: Bitumen + ECB (1235) + high amount of Ba(SO)4 +CaCO3 • Why they add ECB : bitumen compatibility, polymer modification with elastomeric polymers (EBA) to increase impact and bending properties of mats

  46. Summary and conclusions LUCOBIT AG offering reactor grades, grafted grades and HFFR grades mainly based on EBA for various wire and cable applications Lucofin HFFR grades provide advantages for cables in wet, cold and hot conditions compared to established HFFR grades Lucofin 7410 HFFR (EBA/ATH) with standard, Lucofin 7440 HFFR (EBA/MDH) with fast line speed Further opportunities in various other compounding applications

  47. Thank you for your attention!

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