distributed by: Request Quote or Samples · MATERIA AT A GLANCE 5 • A manufacturer of high...

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distributed by: Request Quote or Samples

Transcript of distributed by: Request Quote or Samples · MATERIA AT A GLANCE 5 • A manufacturer of high...

Page 1: distributed by: Request Quote or Samples · MATERIA AT A GLANCE 5 • A manufacturer of high performance thermoset resins with unique performance properties • Founded in 1998 •

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2

TABLE OF CONTENTS

1. Materia overview and capabilities

2. Proxima® resins

3. Examples of market segment positioning

• Oil & gas

• Chemical processing

• Electronics

• Alternative energy

• Defense

4. Proxima® resin processing

5. The Materia difference

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3

THE PROXIMA® RESIN DIFFERENCE

1

10

100

1000

0 50 100 150 200 250

Glass Transition Temp (°C)

No

tch

ed

Izo

dIm

pact

(J/m

)

Polyurethanes

High Temp Epoxies

Proxima® Thermoset Resins

Proxima® resins combine high temperature stability with high impact toughness.

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PROXIMA® PROCESSING VALUE PROPOSITION HIGHLIGHTS

4

• Processable by a wide variety of methods

• Tunable process window from seconds to

hours

• Lower viscosity enables efficient infusion and

high filler levels

• Very low capital investment required

RTM/RIM

VARTM

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MATERIA AT A GLANCE

5

• A manufacturer of high performance

thermoset resins with unique

performance properties

• Founded in 1998

• Nobel-prize winning chemistry

• 90 US and 270 foreign patents

• World-class technical services and

support

• Only resin system that utilizes

Grubbs Catalyst® technology

We enable our global customer base

to be more competitive in the market

with…

• High Temperature Subsea

Insulation and Buoyancy Products

• Tough, Downhole Tools for High

Pressure and High Temperature

• High Speed and High Frequency

Electronics

• Advanced Composites

THERMOSET

RESINS

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CAPABILITIES AND LOCATIONS

Manufacturing – Huntsville, TX

Technical Center of Excellence – Pasadena, CA

• Resin system expertise

• Product development

• Application development &

testing

• Prototyping

• Resin production

• ISO 9001 certified

• Tolling services

• Located 65 miles north of Houston

• Analytical

• Process optimization

• Molding consultation and

sample production

• Molded part CNC machining

• Resin molding

• Reaction injection molding

• Molded part CNC machining

• Molded part painting

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MARKETS SERVED

Subsea Insulation

Chlorinated

Fluid HandlingDownhole Tools

Electronic

Materials

Subsea Buoyancy

Lightweight

Pressure Vessels

Auto Composites

Proxima® HPR

“super-tough”

Proxima® STR

“filler-compatible”

Proxima® HTI

“high-temp stability”

Proxima® ACR

“advanced composites”

YouTube

Proxima® resins offer superior performance in diverse applications. Materia customers include

world class global industry leaders throughout the oil and gas value chain, and other industries.

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PROXIMA® RESINS

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NORBORNENE

MONOMERS

PROXIMA®

THERMOSET NORBORNENE POLYMER

9

PROXIMA® RESINS

• Two-part thermoset resin system

• Based on dicyclopentadiene (DCPD) and a family

of co-monomers

• Ring Opening Metathesis Polymerization enabled by

Materia’s proprietary Grubbs Catalyst® technology

• Leveraging a portfolio of 15+ monomers and 20+

metathesis catalysts

UNREINFORCED

POLYMERSSYNTACTIC

FOAMS

CONTINUOUS

FIBER

COMPOSITES

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PROXIMA® RESIN FAMILY*

0

100

200

300

400

500

0 20 40 60 80 100 120 140 160 180 200

Ten

sile

Mo

du

lus

(ksi

)

Glass Transition Temp (°C)

Proxima® HTI resins for

high temp insulation

Proxima® ACR resins for

GF and CF composites

Proxima® HPR

high-performance resins

Proxima® STR resins

for syntactic foams

*Product line definitions:

Proxima® ACR = advanced composite resins product line

Proxima® HTI = high temperature insulation resins product line

Proxima® STR = syntactic thermoset resins product line

Proxima® HPR = high performance resins product line

Proxima® resins combine high temperature stability with superior resistance to damage.

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PROXIMA® RESINS – NOT TRADITIONAL POLY-DCPD

More Robust

Grubbs Catalysts

Fewer process

controls

Fewer defects

Low odor

products

Filler compatible

Broader

Monomer

Toolbox

High elongation

monomers

Low-DCPD and

DCPD-free

systems

Films / coatings

with Low

dielectric Loss

Tunable, reactive

functional groups

Application

Engineering

Formulations

designed to meet

application needs

Resin/catalyst

selection for cure

profile target

Composite

fabrication-

friendly

Processing

RIM

Mold Casting

RTM/VARTM

Materia has expanded the potential of DCPD thermosets due to a larger family of monomers from

which to select, and due to exclusive use of a more robust catalyst.

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ADVANTAGES OF PROXIMA® RESINS OVER COMPETITIVE pDCPD RESINS

Proxima®

Resin

Advantages

Reproducible processing, compatible with additives, glass/carbon fiber composite formulations

Pot-life control from seconds to days

Controlled curing – no problems with thick parts and exotherms

Translucent properties for subsurface inspection significantly improves quality assurance and part reliability

Promixa’s translucency allows

for subsurface inspection

Competitive pDCPD resins can have molding defects

that are very difficult to identify in thick parts

3

Proxima® resins enable customer differentiation due to it high temperature stability with

superior resistance to damage.

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MARKET SEGMENT POSITIONING

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MARKET SEGMENTOIL & GAS

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OFFSHORE OIL & GAS

Materia Focus Area: Thermal insulation products

Materia products: Proxima® HTI polymers

Competition: Silicone, neoprene rubber

Value proposition: Exceptional hot wet stability, easy processing for onshore

and offshore operations, and excellent adhesion to other polymers

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CASE STUDY: HIGH TEMP SUBSEA INSULATION

Source: Miesner & Leffler, Oil and Gas Pipelines in Nontechnical Language

In record time Materia built the capacity to provide on-time delivery of Proxima® resin solutions for

40 miles of pipeline while delivering the highest quality product meeting all performance specifications.

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PROXIMA® HTI 1400 WATER UPTAKE KINETIC STUDY

17

• Short duration study – Average of 3 cube sizes (1” , 1.5”, 1.75”). Cube size did not drastically alter uptake values.

• Long duration study – ASTM D638 Type I tensile specimens.

RESULTS

• Very low equilibrium water content <1%

• Equilibrium is reached quickly

-1.0

0.0

1.0

2.0

3.0

4.0

5.0

0 15 30 45 60 75 90 105 120 135 150 165 180

% W

EIG

HT

CH

AN

GE

TIME (DAYS)

SHORT DURATION UPTAKE VARIABLE TEMPERATURE

LONG DURATION UPTAKE 204 °C (400 °F)

0.0

1.0

2.0

3.0

4.0

5.0

4 38 66 93 149 204

% W

EIG

HT

CH

AN

GE

TEMPERATURE (°C)

1 DAY UPTAKE

3 DAY UPTAKE

7 DAY UPTAKE

Extensive testing performed to successfully validate a 30 year service life.

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OFFSHORE OIL & GAS

Focus Area: Subsea buoyancy

Materia products: Proxima® STR 3190

Competition: Epoxy

Value proposition: Lighter weight and faster processing

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CASE STUDY: SUBSEA BUOYANCY WITH STR RESINS

High Performance

Syntactic Foams for

Subsea Buoyancy

Defect-free large

castings

Lower density than

other products

Higher strength

(+10%) than epoxy

▪ Single pour casting of large units

(>60 gallons)

▪ 23-30% lower density than epoxy and

polyurethane resins

▪ A portfolio of thermoset resin products

available based on customer requirements.

PROXIMA SYNTACTIC FOAM

Proxima® syntactic foams give the processing ease of polyurethanes & better-than-epoxy performance.

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DOWNHOLE OIL & GAS

Focus Area: Downhole tools, consumables, drillable components

Materia products: Proxima® HPR polymers

Competition: various

Value proposition: Tough/durable, abrasion resistant, light weight, and fast drill-out

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CASE STUDY: CASING CENTRALIZERS

Longer wells and faster

completions;

Greater value in longer

horizontal wells

Lower Friction

Lighter Weight

Higher Ductility

drag

weig

ht

Proxima® Thermoset vs. Metals▪ A casing centralizer maintains pipe in the

center of a wellbore to ensure well

completion and integrity

▪ In horizontal wells, drag must be reduced to

facilitate completion and enable longer

horizontal well drilling

▪ Use HPR 2100, HPR 2112 or HPR 2124

Proxima® centralizers provide reduced coefficient of friction and can withstand well

conditions of >300 °F.

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22

PROXIMA® RESINS FOR FILLED SYSTEMS

PROPERTYMETHOD

(ASTM)UNIT

HPR 2029

pure polymer

HPR 2029

ceramic-filled

Density D792 g/mL 1.04 1.55

Moisture Absorption D570 wt.% < 0.2 < 0.2

Compressive Strength D695 psi 13,600 27,000

Compressive Modulus D695 psi 319,000 550,000

Tensile Strength D638 psi 11,000 10,200

Tensile Modulus D638 psi 372,000 820,000

Elongation at Break D638 % 12 4%

Glass Transition Temp DMA °C 176 250

Proxima® HPR 2029 is an example of a low viscosity, filler-compatible formulation designed for

maximizing thermal and mechanical properties; enabling metal replacement and light-weighting.

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INTRODUCING PROXIMA® ACR 4350

You no longer have to sacrifice viscosity, toughness or light weight in order to get a high Tg composite.

POLYMER PROPERTYMETHOD

(ASTM)UNIT

TYPICAL

VALUE

Density D792 g/mL 1.05

Tg DSC °C 189

Compressive Strength D695 MPa 100

Compressive Modulus D695 MPa 2,360

Tensile Strength D638 MPa 72

Tensile Modulus D638 MPa 2,700

Elongation @ Break D638 % 11

Flexural Strength D790 MPa 108

Flexural Modulus D790 MPa 2,760

Fracture Toughness, KIC D5045 MPa·m1/2 2.0

When compared to 350 °F cure epoxies:

• Higher KIC and elongation equates to

improved toughness and damage

tolerance

• Lower density = lighter weight

• Lower water absorption and stable

thermal performance under hot/wet

aging

• Comparable Tg values in excess of 180 °C

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MARKET SEGMENTCHEMICAL PROCESSING

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CHEMICAL PROCESSING

Focus Area: Pipe and tank for corrosive fluid handling

Materia products: Proxima® HPR polymers

Competition: Vinyl ester / fiberglass

Value proposition: Longer service life, lighter weight

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CASE STUDY: CORROSIVE FLUID HANDLING

• Customer needed a material with corrosion resistance to handle a process that converts sea water to Cl2, NaOH and H2 at 90 °C

• Proxima® HPR polymer provides 6+ years service lifetimes in the caustic environment of chlor-alkali electrolysis.

• The cell tops are made in a single cast using ~800 lbs of resin and part thicknesses of 1 – 5”.

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MARKET SEGMENTELECTRONICS

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ELECTRONICS

Focus Area: Printed circuit boards, IC packaging, Electronic adhesives

Materia products: Proxima® polymer resins

Competition: Polyphenylene ether, cyanate esters, AND polyimide

Value proposition: Superior dielectric properties and competitive pricing

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ELECTRICAL PROPERTIES

MATERIA

PROPERTY STANDARD UNIT VALUE

Dielectric constant (@10 GHz) ASTM D2520-13 - 2.45

Loss tangent (@10 GHz) ASTM D2520-13 - 0.0012

Dielectric Strength ASTM D149 V/mil 1800

Surface Resistivity ASTM D257 Ohms > 9.7 x 1015

Volume Resistivity ASTM D257 Ohm-cm > 2.3 x 1016

ADVANCED PCBs

IC SUBSTRATE DIELECTRICS

Proxima® Ultra-Low Loss Resin (Developmental Products)

Proxima® resins are in development for telecom, military, automotive, and oil & gas applications.

Current focus is B-stage resins for prepreg applications

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MARKET SEGMENT ALERNATIVE ENERGY

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ALTERNATIVE ENERGY

Focus Area: Matrix thermoset resin for glass and carbon fiber wind blades

Materia products: Pre-commercial (targeting product launch in 2020)

Competition: Epoxy

Value proposition: Lighter weight, superior fracture toughness, longer

design life, and faster processing

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32

TOUGH COMPOSITES USING A TOUGH POLYMER

Damage zone of Proxima® laminate is 48%

smaller than that of the epoxy laminate

PROPERTYMETHOD

(ASTM)UNIT ACR 4100

INFUSION

EPOXY

Damage after impact3 D7136-07 mm2 403 779

1 Data treatment per Reeder and Crews (NASA) for fracture

toughness at crack initiation2 Laminates prepared by VARTM of 1200 gsm unidirectional glass

fabric and cured at 120 °C for 2h 3 Tested by Delsen Testing Laboratories

Epoxy ACR 4100

Proxima® ACR 4100 outperforms standard

epoxies by 5x in crack propagation tests

PROPERTYMETHOD

(ASTM)UNIT ACR 4100

INFUSION

EPOXY

Fracture Toughness, KIC1 D5045 MPa∙m1/2 2.6 0.5

Interlaminar Fracture

Toughness, GIC2 D55281,2 J/m2 1,700 330

Proxima® resins are tougher than epoxy resins, one of the primary reasons customers select Proxima.

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33

ACR 4100 – PROPERTY RETENTION & WATER ABSORPTION

MATERIA

Tg Stability

(°C)

Day

0

Day

55

Day

82

Epoxylaminate

103 83 86

Proximalaminate

129 133 132

Proxima laminates absorb less water

and retain properties better than

market leading epoxy laminates

Salt Water Absorption Test: ~160 Days at 60 °C

0.00%

0.20%

0.40%

0.60%

0.80%

0 1000 2000 3000 4000

Weig

ht

chan

ge

Time (h)

Proxima laminate

Epoxy laminate

Nutt et al, Polymer Degradation and Stability, 124, (2016), 35-42.

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CASE STUDY: LESS CARBON FIBER IN PRESSURE VESSELS

$2MM in funding from the

Department of Energy to lower the

cost of hydrogen storage vessels

REDUCTION IN VOIDS / DEFECTS

New tank manufacturing process of

vacuum pressure infusion of dry wound

forms

HIGH TOUGHNESS RESIN

Better fatigue properties and off-axis

properties for improved performance

after cycling

NEW WINDING PATTERNS

New patterns supported by the dry-

winding that may not be achievable with

wet-winding

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LOWER VOID CONTENT CONFIRMED

SEM images for void detection

COPV with low void content (<0.5 vol.%) is achievable through infusion

Wet-wound epoxy tank with voids (3 to 9%

across 7 different regions).Infused tank with no detectable voids across 7

regions.

35

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36

PROXIMA® COMPOSITES FOR WEIGHT REDUCTION

Proxima® resins enable metal replacement and light-weighting in many industries.

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PROXIMA® - HALF THE CARBON FOOTPRINT OF EPOXY

37

Cradle-to-gate analysis by Sustainability A to Z

0

1

2

3

4

5

6

7

8

9

Proxima

Epoxy

kg C

O2

eq

uiv

ale

nts

The production of Proxima generates ~ 50%

less carbon than epoxy

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MARKET SEGMENT DEFENSE

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39

DEFENSE

Focus Area: Metal replacement for light-weighting, ballistic protection

Materia products: Proxima® HPR and ACR polymers

Competition: Steel, Aluminum, various others

Value proposition: Tough, light weight, and filler-compatible

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NEAT RESINS SHOW SUPERIOR PROPERTIES TO EPOXIES1

MATERIA

1 Knorr, D. B. et al, “Overcoming structural versus energy dissipation trade-off in highly crosslinked polymer networks: ultrahigh strain response in

polydicyclopentadiene”, Composites Science and Technology, 114, 2015, 17-25.2 KE50 = ½•m(V50)

2, conducted with a 0.22 caliber gas gun.

pDCPD Neat

Resin Panel

DGEBA/D230

(Epoxy 1)

DGEBA/PACM

(Epoxy 2)

High speed camera images of the impact

event at the V50 values

RESIN TgKE50

(22 °C)2 KIC

pDCPD 142 °C 3.31 2.13

Epoxy 1 96 °C 1.42 0.76

Epoxy 2 164 °C 1.00 0.69

Proxima® resins are tougher than epoxy resins which is one of the key advantages for ballistics

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41

PROXIMA® COMPOSITE BALLISTIC TESTING

MATERIA

V50 Ballistic Limit Test Shot Spacing

Size (in.)24 x 24 x

0.45

Total / V50

Shots11/11 4” Triangle

No

Penetration

Weight

(lbs)10.61 V50 (fps) 1,597 1.5” Apart

No

Penetration

Areal

Density

(psf)

4.72High Partial

(fps)1,595

1.25” from

unprotected edge

No

Penetration

Thickness 0.45

Low

Complete

(fps)

1,5974” Triangle (attack

side -26 °F)

No

Penetration

Threat44 Mag

240 LSWC

Range of

Results112

4” Triangle

(Conditioned 120 °F)

No

Penetration

1 Composite was tested by U.S. Test Labs under the MIL-STD-662F V50 Test

E-Glass Woven Roving

Composite

Proxima® resins are infusion friendly and the inherent toughness translates to composite parts

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PROXIMA® RESIN PROCESSING

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43

PROXIMA® RESIN PROCESSING METHODS

Materia provides engineering support for a variety of Proxima® resin processing methods.

• Mold casting

• RIM / RTM

• VARTM

• Centrifugal casting

Vacuum-assisted resin transfer molding

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44

PROCESSING – REACTIVITY CONTROL

0

20

40

60

80

100

120

140

0 1 2 3 4 5 6 7 8

VIS

CO

SIT

Y (

CP

)

TIME (HOURS)

WORK TIME AT 30 °C

Proxima® resins enable significant formulation flexibility with controlled curing, from seconds to hours;

enabling customers to enhance their product portfolios.

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45

PROCESSING – VIDEO DEMONSTRATIONS

Proxima® resins enable significant formulation flexibility with controlled curing, from seconds to hours;

enabling customers to enhance their product portfolios.

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46

THE MATERIA DIFFERENCE

• Materia goes beyond delivery of just a superior polymer but ensures excellence through formulation and applications engineering support

• Materia is nimble and can enhance your speed to market through immediate access to functional leaders

• Proxima resins can enhance your product portfolio and differentiate your offering in the marketplace

• We offer a total cost of ownership advantage: using Proxima®

thermoset resins can lower your capital expenditures and enable higher throughput

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THANK YOU

www.materia-inc.com© 2017 Materia, Inc.

60 N San Gabriel Blvd.

Pasadena, CA 91107

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