Post on 17-Dec-2015
Douglas J. SoberKaneka Texas Corp2 Northpoint Drive
Suite 200Houston, TX 77060
713-503-1558dsober@kanekatexas.com
Kaneka Core-Shell Toughening Kaneka Core-Shell Toughening Systems for Thermosetting ResinsSystems for Thermosetting Resins
What is Core-Shell Rubber (CSR) ?What is Core-Shell Rubber (CSR) ?
2-Layer CSR
Co-Polymer II designedto be compatible withthermosetting resin.This is the shell.
Co-Polymer I designedfor impact resistance.This is the core.
What is Core-Shell Rubber (CSR) ?What is Core-Shell Rubber (CSR) ?
2-Layer CSR100nm
How does CSR toughen resins?How does CSR toughen resins?
• Core polymer cavitates on impact dissipating energy .
• Small, evenly dispersed particles act as a crack terminator.
Applications of CSR?Applications of CSR?
• Thermosplastic resins systems.
• Thermosetting resins systems for:- Adhesives.- Composites.- Potting Compounds & Encapsulants- Coatings- Copper-Clad Laminates
Core Shell Rubber Advantages:Core Shell Rubber Advantages:
• Outstanding Toughness Improvement:- Fracture Toughness- T-Peel Strength- Lap-Shear Strength
• No Depression of Tg.
• Wide Cure Window.
• Consistent Morphology.
• Low Ionic and Surfactant Content.
• Extremely Stable.
What is Kane Ace MX:What is Kane Ace MX:
Kane Ace MX are concentrates comprised typically of 25% by weight of CSR dispersed in various thermosetting resins. The liquids are easily poured after heating and the individual CSR domains remain uniformly dispersed during storage and formulating.
Appearance
Basic Properties of MX system
Rubber particles are homogeneously dispersed in epoxy resin.
Available as Concentrate containing 25 wt% of CSR.
Rubber particles are homogeneously dispersed in epoxy resin.
Available as Concentrate containing 25 wt% of CSR.
Conventional CSR(10wt%) in epoxy
New CSR(25wt%) in epoxy
Viscosity vs. CSR Content
0
5,000
10,000
15,000
20,000
25,000
30,000
0 5 10 15 20 25
Particle Content (wt%)
Vis
cosi
ty (
cPs)
Appearance - Cured system“Transparent”
TEM observation - Cured system
Comparison of the Kane Ace MX and Conventional CSR
1m
Kane Ace MX Products:Kane Ace MX Products:
MX 120 Standard Liquid Bis A Epoxy ResinMX 120LV Low Viscosity Liquid Bis A Epoxy ResinMX 130 Standard Liquid Bis F Epoxy ResinMX 210 Epoxidized Phenol Novolac ResinMX 224 Epoxidized Cresol Novolac ResinMX 411 Multifunctional Epoxy Resin (TGMDA)MX 451 Multifunctional Epoxy Resin (TGPAP)MX 550 Cyclo-Aliphatic Epoxy Resin*MX 715 Polypropylene Glycol
MX XYZ Proprietary Resins as supplied by customer
* May contain less than 25% CSR
T-Peel Strength Kane Ace MX
T-Peel Strength of DGEBA Epoxy/MX 120 System
0
5
10
15
20
25
30
35
T-peel Strength / pli
CSR 0% CSR 5% CSR 10%
Lap-Shear Strength OF Kane Ace MX
Adhesive layer
0
1000
2000
3000
4000
5000
6000
Lap- shearStrength / psi
Control CSR5% CSR10%
1/ 32"1/ 16"
Lap-shear Strength of DGEBA Epoxy/MX 120
Toughening Effect of Epoxy/ Kane Ace MX SystemToughening Effect of Epoxy/ Kane Ace MX System
Three-Point Bending
force
specimen: 6cm x 1.2cm x 0.5cm
pre-crack: 0.6cm depth by blade-tapping
head speed: 1mm/min.
stress
strain
strength
energy
ASTM 5095
Fracture Toughness of DGEBA Epoxy/MX 120
0
0.5
1
1.5
2
2.5
3
K1c/ MPam1/ 2
CSR 0% CSR 10%
DDSpiperidine
Fracture Toughness of DGEBA Epoxy/MX 120
0
500
1000
1500
2000
2500
G1c/ J m2
CSR 0% CSR 10%
DDSpiperidine
T-peel Strength of MX 120 vs. CTBN in DGEBA Epoxy
Control 5% 10%
CTBNCSR Master-batch0
5101520253035
T-peelStrength/ pli
Comparison of CSR and CTBNComparison of CSR and CTBN
Lap-shear Strength of MX 120 vs. CTBN in DGEBA Epoxy
Con
trol
5%
10%
CTBNCSR Master-batch0
100020003000400050006000
Lap-shearStrength/ psi
Comparison of CSR and CTBNComparison of CSR and CTBNFracture Toughness and Glass Transition Temperature
of MX 120 vs. CTBN in DGEBA Epoxy
0
100
200
300
400
500
600
control CSR Master-batch CTBN
J/m
Ｇ１ｃ
／2
0
50
100
150
200
250
TgC
／
Tg
Kaneka Corporation
• Today Kaneka is a world leader in the creation of innovative technologies in areas such as polymers, construction materials, and pharmaceuticals.
• Kaneka is a global organization with production facilities on four continents and approximately 7000 employees.
• Revenue for our latest fiscal year (ended March ‘04) is estimated worldwide at approximately $4.3 billion.
Kaneka Global Manufacturing
• Kaneka currently manufactures “Modifiers” at four sites around the world. These include:
Kaneka Japan Asia Takasago, Japan
Kaneka Texas USA Pasadena, Texas
Kaneka Belgium Europe Oevel, Belgium
Kaneka Malaysia Asia Kuantan, Malaysia
• These four sites provide Kaneka with an annual capacity of modifiers of approximately 350 million pounds.
Kaneka Texas Corporation
• A wholly owned subsidiary opened in 1983, Kaneka Texas (KTC) is responsible for marketing several Kaneka product lines throughout the Americas.
• Business operating at KTC include:• 1.) Polymer Modifiers (Kane Ace)• 2.) CPVC Resins (Kanevinyl)• 3.) Foamed Olefins Resins (Eperan, Eperan PP)• 4.) Modified Silicone for Sealants (MS Polymer)• 5.) Polyimide Film (Apical)• 6.) Nutrients (CoQ10)