POLYCARBONATE ET ALLIAGE POLYCARBONATE COPOLYESTER POUR LES SEGMENTS MÉDICALE, OPHTALMIQUE & ÉLECTRIQUE

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2 Lexan* LET S TALK ABOUT POLYCARBONATE POLYCARBONATE ET ALLIAGE POLYCARBONATE COPOLYESTER POUR LES SEGMENTS MÉDICALE, OPHTALMIQUE & ÉLECTRIQUE CFP, Les Plastiques Transparents, Lyon March 29 th 2012 Riyas Moujavid Technical Support Engineer France

3 CONTENT SABIC today Polycarbonate properties Healthcare & Cosmetic: Lexan* & Xylex* & Stat-Loy* Eyewear & ophthalmic segment: Lexan* HFD Electrical: Lexan* CFR No. 2

4 SABIC TODAY

5 SABIC COMPANY INFO We are one of the world s leading manufacturers of chemicals, fertilizers, plastics, and metals. 1976, our beginning 36 years of growth 2nd largest global diversified chemical company* 95th largest public company in the world* 88 B$ total assets 50 B$ annual revenue 33,000 employees 40 countries 6 Strategic Business Units 1 Corporate Research & Innovation Center 14 Technology Centers 3 Application Centers 150 new products each year 8,000 global patents No. 4

6 SABIC COMPANY INFO 1. Global positioning 2. Increase demand in transparent materials No. 5

7 PLASTICS FAMILIES & POLYCARBONATE SEGMENTS 1. In France : B/C, Electrical,Consumer, Medical 2. Glass replacement : EXATEC* solution in automotive 1. Broad portfolio : from polyoleifins ETP 2. PC & PC blends: PC, PC/ASA, PC/ABS, PC/PBT, PC/PEst No. 6

8 POLYCARBONATE PROPERTIES

9 POLYCARBONATE PROPERTIES Bisphenol A Polycarbonate Amorphous Tg = 145 C Density = 1.20 g/ccm O CH 3 O CH 3 O C +++ High Transparency % 2.5 mm >90 % +++ Impact resistance Izod impact notched, 23C 65 kj/m2 Izod impact unnotched, 23C no break +++ Temperature resistance Heat Distortion Temp. 0.45MPa 138 C Vicat softening point B/ C +++ Flame Retardancy UL94 or HB to V0 GWFI IEC C +++ Dimensional stability Mould Shrinkage % +++ Processability Melt temperatures C +++ Flow MVR 300C/1.2Kg 3-65 ccm/10min +++ Unique colors transparent, opal whites, IR No. 8

10 100 TYPICAL POLYCARBONATE TRANSMISSION CURVES % Transmission Wave length in nm Natural Orange Red Green Grey Violet Light transmission in function of thickness Transmission (%) Thickness (mm) Polycarbonate no dyes Polycarbonate with dyes No. 9

11 10 POLYCARBONATE ADDITIVES Pigment & Dyes Transparent, Translucent and Opaque colors Special effect colors, sparkle, flake, marble, metal. Fiber glass for modulus (10.000MPa) & strength (150MPa) with reduced impact Sulfonate salts to improve flammability resistance, Mold release for easy de-molding Anti-oxidants for better melt stability and heat aging UV-absorbers for longer weathering PTFE for wear resistance (opaque) Impact modifiers for low temperature ductility Blends with other polymers for flow and chemical resistance No. 10

12 HEALTHCARE & COSMETIC

13 APPLICATION REQUIREMENTS Common General Considerations Optical Clarity; Colorability Impact Resistance Ductility for rigorous use Cold & high temp performance Dimensional Stability High Flow & Release complex designs, miniaturization Specialization added strength, lubricity, Flame Resistance Healthcare / Packaging Considerations Sterilization Diversity gamma, autoclave, EtO Biocompatibility ++ ISO or USP Class VI Food Contact Compliance US FDA, EU FC Chemical Resistance disinfectants, cleaners, lipids, IV solutions Antimicrobial No. 12

14 LEXAN* FDA & HEALTH CARE PORTFOLIO Key Applications : FDA UL94 V2 Portfolio Very High Flow; MVR=26 Medium flow; MVR=12 HF1140 ( R ) 244 R Airless covers for cosmetic Food/drink packaging Cosmetic packaging HP 121 C limited + EtO HEALTHCARE HPS HPS7 HPX HPH 121 C limited + EtO + γ/e-beam 121 C limited + EtO + γ/e-beam + lipid resistance 121 C medium + EtO + improved processing 134 C medium + EtO + γ/e-beam Key Applications Renal care dialyzers Blood reservoirs Inhalers Syringes Luer locks HPH C extended + EtO + γ/e-beam New development No. 13

15 STAT-LOY* RESINS STATIC CHARGE MANAGEMENT APPLICATION Inhalation Devices CHALLENGE More efficient Aerosol and Powder Dispensing Permanent Antistatic Static (no adhesion of drug on enclosure) Product Purity, Formulation Fix Design Flexibility, Colorability or Transparency SOLUTION A3000LTH Stat-Loy* (ultra pure transparent) resin Clear (86% lighttransmittance, 10% haze) Low VOC outgassing, low leachable Ions Based on ABS resins Formulation Lock, Preassessed for Biocompatibility acc. ISO BENEFIT Reliable multiple and accurate Dosing Eliminate Costs for expensive additional coating needed for antistatic performance Maintains Antistatic behaviour also after dishwasher cleaning No. 14

16 PC/POLYESTER RESIN: XYLEX* WHAT IS Xylex*? Blend of polycarbonate and polyester Polyester Blend Technology Chemical resistance improved Excellent Transparency: clear ABS < Xylex* Good Chemical resistance: PC < PC/Polyester < PA12 Low processing temperature grade Chemical resistance data No. 15

17 LEXAN* COPOLYMERS LEXAN* HFD

18 POLYCARBONATE MOLECULAR WEIGHT EFFECTS Izod Notched Impact (J/m) PC Impact vs. Molecular weight Molecular Weight Higher MW PC resins show slightly better mechanical properties Impact modifiers can also improve impact properties but material is not transparent anymore No. 17

19 DIFFERENTIATION BY COPOLYMERS Copolymers Performance Standard PC Backbone not additive Requires unique technology/investment Specialized monomers, technology, manufacturing Higher/unique performance in advanced applications Advanced Technology Expanded properties New and existing markets Additives Blends Standard technology Established properties Mature markets Innovation O O O Monomers Lexan* Copolymer Resins O O a O Compounds New O b Mixtures not chemically bound Requires typical compounding assets Product/color development for broad polymer base Standard/incremental performance in applications No. 18

20 LEXAN* HFD RESINS DUCTILITY ADVANTAGES When? When you like the MFI of standard PC resin, but need better impact When you like the impact of standard PC but need better flow 65 MFI Lexan HFD resin Ductile 23 o C 65 MFI Standard PC Brittle 23 o C Notched Izod Ductile/Brittle Temp vs MFR D/B transition temp (C) Standard PC HFD - PC HF1110 HFD1810 EXRL0672 / HFD EXRL0681 / HFD1711 HFD HFD1212 EXRL0682 / HFD1212 FLOW 101 EXRL0683 / HFD vs. HFD1413 HFD1413 standard PC EXRL0684 / IMPACT HFD1014 HFD MFR (g/10min, 300C/1.2kg) Why? For a given melt flow, Lexan HFD resin has o C better Ductile/Brittle (D/B) transition temperature compared to standard PC resins No. 19

21 LEXAN* HFD RESINS SUPERIOR FLOW Spiral flow (cm) mm 2.29mm 3.05mm 260 o C 290 o C 315 o C 0 PC HFD PC HFD PC HFD Lexan HFD resin has up to 40% more flow compared to similar PC resin Std PC Std PC Lexan* HFD Std PC Lexan* HFD Lexan* HFD 1.52mm 2.29mm 3.05mm No. 20

22 LEXAN* HFD RESINS OPTICAL PROPERTIES What? Std PC clarity Lower molded in stress Lower birefringence Standard PC HFD of same MW Where? Thin wall displays Functional optics 2 1 No. 21

23 Security Visor... A Case Study - Actual Weight = 106 (+/-) 2g - Trial using HFD1830 (without molding changes) = 98g - Actual Wall Tickness = 1.65 a 1.7mm (not uniform wall) - Wall Tickness after molding(tool changes) = 1.0mm - Weight Reduction = -35% weight reduction Impact x Flow Process Benefits : - Scrap reduction(increase Yield and Productivity) - Avoid re-works/avoid Secundary Operations (e.g. Flash removal) - No need Big Injection Machine (High Flow = Low Pressure to fill the mold) Better Performance : - Impact Properties - Increased Ductility - Increased Optical Quality - Excellent Transparency - UV Resistance No. 22

24 NFR LEXAN* RESINS EYEWEAR High flow; MFI=17.5 OQ2220 Lexan* Polycarbonate Resins Optical Eyewear Safety-UV Block Ophthalmic-380 nm Sun Ware-400 nm Standard flow; MFI=7.5 Very High flow; MFI=25 Medium flow; MFI=10.5 Standard Flow; MFI=7.5 Very High flow; MFI=25 Medium flow; MFI=12.5 Standard Flow; MFI=8.5 Standard Flow; MVR=6 OQ2720 OQ3120 OQ3420 OQ3820 OQ4120R OQ4320 ( R ) OQ4620R OQ4820 MVR: (ml/10 min) ISO 300C/1.2Kg MFI: (gr /10 min) ASTM 300C/1.2Kg Key Attributes : Key Applications : Glass-like transparency & gloss OQ3 grades are melt filtered for highest cleanliness High refractive index High Impact UV cut & wide variety of color OQ2: Safety-ware OQ3: Eyewear/Lens (ophthalmic) OQ4: Sun-wear, visors (400 nm UV cut off) No. 23

25 A FAMILY OF ADVANCED COPOLYMERS POLYCARBONATE RESINS LEXAN* CFR NEW PRODUCTS

26 POLYCARBONATE FLAMMABILITY RESISTANCE Limiting Oxygen Index for different polymers Limiting Oxygen Index - ASTM D2863 / ISO 4589 No. 25

27 LEXAN* CFR COPOLYMER A REAL INTEREST OF THE ELECTRICAL SEGMENT Technology highly branched reactive endcapped technology All color capability Benefits Improved flame resistance thinner wall V0 performance over standard clear FR PC resins New flame resistance capability 5VA performance over clear FR PC resins Compliance with ECO protocols Standard PC type optical properties Improved melt flow and process capability over existing clear FR PC resins Potential Applications Notebook Cover LED Lighting Lens Tube Bulb Television Bezel Decoration Part Innovative eco-fr solution, teflon, bromine, chlorine, phosphorus free No. 26

28 LEXAN* CFR COPOLYMER WEEE TCO 99 (International) DIN/VDE RoHS The Nordic Swan (Scandinavia, Finland) 2 7 No. 27

29 LEXAN* CFR COPOLYMERS: SPIRAL FLOW Spiral 1,5mm, T mould = 80 C CFR - Very High flow CFR Standard viscosity High flow V0 transparent Lexan* Spiral Flow at Recommended Processing Temperatures 2 8 No. 28

30 Lexan* CFR Resin PC, MVR 21 EXRL0702 Thermal Color Stability Weeks: 0 3 YI PC, MVR 21 EXRL0702 YI Test condition: 120 C Similar Color Shift Compared to Standard Polycarbonate 2 9 No. 29

31 Clear Optical Quality & Purity High Light Transmission, Low Haze High Gloss & Refractive Index Colorable Tough Impact & Abuse Resistant Excellent Mechanical & Electrical Properties Cold and High Temperature Performance Flame Retardant Stable Dimensional Stability Predictable Long Term Properties Reasonable Weatherability & Thermal Stability Processing Options Injection, Foam & Blow Molding Sheet, Film & Profile Extrusion Recycling 3 0 No. 30

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33 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 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 No. 32

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