Date post: | 23-Dec-2015 |
Category: |
Documents |
Upload: | gerald-ross |
View: | 223 times |
Download: | 2 times |
Agenda
• Victrex Overview• Technical information on VICTREX® • Market and Application Review• AptivTMFilms• VicoteTMCoatings• Discussions
Who is Victrex Plc?
• Manufacturer of VICTREX® PEEK™ and PEEK-HT® Polymers• Public, London Stock Exchange (VCT)• £ 142.0 million 2008 Revenue• 500+ Employees, 90+ Global Employees• Three Manufacturing Sites (all UK based)
• Victrex’s strengths:
• Focus and dedication to the development and innovation of VICTREX® PEEK™ polymers.
• Proactive strategy to engage with customers and end users to develop new applications for high performance polymers, supported by extensive application technology - “win-win” mentality.
• Global footprint, relationship-driven culture.
• Passion, Innovation, Performance - for and with our customers.
Driving Market Growth with Around the World…..
Passionately exploring new products, applications, and business opportunities – creating the future!
VICTREX® is a registered trademark of Victrex Manufacturing Limited. PEEK™ and PEEK-HT™ are trademarks of Victrex plc.
A Global ResourceVTC
AITC
Victrex Sales by Industry
Automotive
Aerospace
Transportation33%
Electronics & Semiconductor
24%
Medical6%
Industrial28%
Other8%
T Series
Per
form
ance MAX- Series
VICTREX®PEEK™polymer
$40/lbs $120/lbs
VICTREXPEEK-HT®
• Down hole connectors • Back up rings and seals• Chip trays and carriers
non-ESD
•Wear at elevated temp•Oil and Gas seals
Value to Performance for Victrex Products
Polymer Hierarchy Continuous Use Temperature UL 746B
Amorphous Crystalline
Tem
pera
ture
Perf
orm
ance
Nylon
PPS (Polyphenylene sulfide)
PEI (Polyetherimide)
200°F
400°F
600°F
PPA (polyphthalamide)
PES (polyether sulfone)
PAI (Polyamide imide)
Victrex PEEK™ polymer
PI (Polyimide)
PBI(polybenzimidazole)
Victrex PEEK™ Tseries
VICTREX® PEEK Properties
VICTREX PLC MAKES NO WARRANTIES, EXPRESS OR IMPLIED, INCLUDING, WITHOUT LIMITATION, A WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE OR OF INTELLECTUAL PROPERTY NON-
INFRINGEMENT, INCLUDING, BUT NOT LIMITED TO PATENT NON-INFRINGEMENT, WHICH ARE EXPRESSLY DISCLAIMED, WHETHER EXPRESS OR IMPLIED, IN FACT OR BY LAW. FURTHER,
VICTREX PLC MAKES NO WARRANTY TO YOUR CUSTOMERS OR AGENTS, AND HAS NOT AUTHORIZED ANYONE TO MAKE ANY REPRESENTATION OR WARRANTY OTHER THAN AS
PROVIDED ABOVE. VICTREX PLC SHALL IN NO EVENT BE LIABLE FOR ANY GENERAL, INDIRECT, SPECIAL, CONSEQUENTIAL, PUNITIVE, INCIDENTAL OR SIMILAR DAMAGES, INCLUDING WITHOUT
LIMITATION, DAMAGES FOR HARM TO BUSINESS, LOST PROFITS OR LOST SAVINGS, EVEN IF VICTREX HAS BEEN ADVISED OF THE POSSIBILITY OF SUCH DAMAGES, REGARDLESS OF THE
FORM OF ACTION.
Mechanical properties of VICTREX grades
property unit 450G 450GL30 450CA30
tensile strength MPa 100 156 224
elongation at break % 100 2.7 2
flexural strength MPa 131 250 355
flexural modulus GPa 3.9 10 20.2
Izod impact (notched) J/m 83 100 90
hardness (Rockwell) R 126 124 132
thermal expansion 10-5/°C 4.7 2.2 1.5
density g/cm³ 1.32 1.49 1.44
HDT 1.8MPa °C 152 315 315
VICTREX® PEEK CTE versus other Polymers
VICTREX® PEEK expands with temperature significantly less than other engineering thermoplastics and can be used over a wider temperature range.
Relative Thermal Index (RTI)
0
50
100
150
200
250
300
PA6/6 PPA PPS PES PEI PAI PEEK
RT
I, °C
, UL7
46B
0
50
100
150
200
250
300
350
PA6/6 PPA PPS PES PEI PAI PEEK
HD
T, °
C, 1
.82
MP
aHDT – Unfilled & 30% Glass Filled
Tensile Strength vs Temperature
VICTREX® PEEK Electrical PropertiesVolume Resistivity Versus Electrification Time
VICTREX 450G
Surface Resistivities for Various EngineeringPolymers Tested at 25°C (77°F) with 50% Humidity
Lpv Comparison for Various Materials
Smoke & Toxicity
Forced Combustion Smoke Chamber Results
Key Application Requirements
Victrex® PEEK™
temperature resistance
wear resistance
excellent chemical resistancefire resistance,low smoke and toxicity
excellent hydrolysis resistance
radiation resistance
electrical properties
purity
FDAeasy processing
Most VICTREX applications require a combination of three or more
properties
VICTREX® PEEK Processing Methods
Processing
• Injection molding• Extrusion
– Sheet, Profile, Tube, Rod– Mono-, and Multi-Filament– Film– Capillary– Wire coating
• Compression molding• Coating
– Powder and Dispersion
Victrex® PEEK™ can be processed by all thermoplastic techniques:
24
Applications
Gears/Split Fingers for Copier Machines/Printers
Application: Gears for copier machine
( heating roller, skiving roller)
Product: 450G, 450CA30
KER s:
• Heat resistance ( around 220-230℃)
• Mechanical strength against high torque
• Better wear friction property
GEARSGEARS
Application: Split Finger
Product: PEEK HT
KER s:
• Able to sustain PFA coating processing
temperature (330~360 oC) for color printers
• High toughness
• Superior wear performance
SPLIT FINGERSSPLIT FINGERS
Customer: Juraron HK
OEM/End-user:Kyocera Mita HK
Application: High speed copier gear
Product: 450CA30
KERs:
• Dim stability at 220C and torque
under high speed, 50ppm or above.
• Life test 2million cycles.
• Able to sustain high wear, high
stress, high torque, as so on.
OVERVIEWOVERVIEWModel 2FB 2293
Gears For Copiers
Value Added PEEK ApplicationsChallenge: •Replace labor-intensive threaded connectors and specified torque limits•Withstand high pressures at high temperatures•Reduce creep under load
Value Added PEEK Solution:•Snap connector in place and O-rings seal the joint; no need for torque equipment•Eliminate maintenance and process controls required to ensure a good seal •PEEK meets high pressure loads under temperature and vibration without degradation of performance over time
Quick Disconnect Retainer
RFID
Aircraft Manufacturing Oil & Gas
Communications/Electronics
VICTREX PEEK Benefits reduced weight molded-in threads
metal platable custom compoundable
Requirements
replace aluminum MIL-STD-38999 creep resistance dimensional stability
Details
System: composite interconnect
Application: connector shell, nut
Material: carbon fiber reinforced
VICTREX PEEK
Value Added PEEK ApplicationsChallenge: •Replace and outperform traditional metal P-clamps and saddle clamps•Simplify installation process•Improve strength and reduce weight
Value Added PEEK Solution:•Unlike metal, clamp is completely non-corrosive and non-conductive•A “lock-open” feature keeps the clamp open and a second “lock-closed” feature keeps the clamp closed •PEEK offers strength advantages at lower weights than metals resulting in reduced fuel costs for aircraft
High Performance Clamp
Industrial
Details
System: down-holeApplication: connector housingMaterial: PEEK™ 450GL30
Requirements temperature max. 250°C high mechanical strength chemical resistance high insulation properties
PEEK™ Benefits longer lifetime corrosion resistance chemical resistance product optimisation
Diesel Exhaust Gas Sensor Connector
Details
System: Exhaust Gas SensorApplication: Electrical Connector HousingMaterial: Victrex® PEEK™ 150GL30
Requirements
Temperature >250° C
Resistance to Diesel Exhaust
Gases
Victrex® PEEK™ Benefits
Impact resistance
Heat Resistance
Chemical Resistance
HI-STAT LEXINGTON,
A Stoneridge Company
FPC connectors
Details
Application: FPC ConnectorMaterial: Victrex® PEEK™ 90GL30
Requirements• High-temp for lead-free solders
• Superior weld strength to LCP• Impact strength• Stiffness• Processability
PEEK™ Benefits• Thermal resistance• Superior weld strength and impact to LCP• High modulus• Able to fill the tool with 0.1-mm thickness
Mobile Phone Co-axial Connectors
Victrex® PEEK™ Benefits
• Longer product life
• Lower part cost (smaller part
size)
• Product optimisation
Requirements
• Mechanical strength
• Creep resistance
• Temperature resistance up to
260°C
• Frequency up to 6 GHz
• Partweight 0,01 gr
Details
System: Mobile Phone PlugApplication: Coaxial plugMaterial: Victrex® PEEK™ 150GL30
Mobile Phone Hinge
Details
System: Mobile PhoneApplication: HingeMaterial: PEEK™ 150CA30
Requirements Superior wear & fatique performance Stiffness Mechanical strength
PEEK™ Benefits High wear & fatique performance High stiffness for carbon filled grades
Mobile Phone Hinge
Materials Tested• POM 500P, 500CL (w/ PTFE)
• Metal (MIM, metal powder inj.)
• PEEK 450G
Test Result (1-stop hinge) torque
against cycles loss%
Metal powder inj. same 100K 40%
Mg injection same 100K 20%
POM 500P 100P 100K 20-30%
450G 450G 100K 15%
Mobile Phone Hinge – Torque Loss Comparison
Requirement
< 20~30% loss in torque, 100K cycles.
Teletronics
Details
System: Coffee machineApplication: Filter plateMaterial: PEEK™ 450G
Requirements
Hydrolysis resistance Dimensional stability Food contact approval
PEEK™ Benefits longer lifetime cost reduction FDA and EEC approval
Teletronics
Details
System: domestic ovenApplication: guideMaterial: PEEK™ 450FC30
Requirements
high mechanical strength low wear thermal performance dimensional stability
PEEK™ Benefits
longer lifetime optimises system function no lubrication necessary cost reduction
Available Victrex films & formats
• Film types– Unfilled PEEK film in amorphous or crystalline– Mineral filled films for property enhancement
• Modulus, wear, dimensional stability– Black film
• Film thickness / width capabilities– Thickness range of 0.0002 – to 0.03 inches (5 – 750 µm) (1/4 to 30 mil)– Standard widths of 650 and 1500 mm (25 to 60 inches)
• Others– Matte / Gloss is standard surface finish– Slitting available to 45 mm roll width– Plasma surface treatment available
Composite film structures
(carbon or glass)
Thermoforming – (6 to 750 µm)
APTIV film Conversion Examples
Laser machining and laser printing
Laminating – metal substrate
Metallization -(5 um to 35 um copper)
Adhesive film-backed tapes
Die cutting / stamping
Heat sealing
APTIV film Properties
Tensile Modulus @ 23°C (73°F)
Dielectric Constant at 23°C (73°F)
Dielectric Strength - 50 µm film, 23°C (73°F)
Moisture Uptake @ 50% RH, 23°C (73°F)
Water Vapor Permeation @ 23°C 100% RH
Hydrolysis Resistance – 5 days @ 150°C (302°F), 100% RH. (Measured change in key mechanical properties)
Taber Abrasion Wear Resistance
Puncture Resistance
Tear Strength
Oxygen Transmission at 23°C, 0% RH
Radiation Resistance
APTIV film - Case StudyAlternator armature wedge & slot liner
Key requirements:• High temperature capable – 280 C max temp. • Electrically insulating at >200 amps• Excellent mechanicals to survive challenging assembly
process • 420 µm thickness
APTIV film benefits:• Single layer of APTIV film replaced 3 layer system
of NOMEX™/PET/NOMEX• Single layer of APTIV film provided manufacturing
yield benefits.• Low friction of APTIV film aids assembly process
APTIV film - Case Study
Thrust Washer for CD/DVD Spindle Motor
Key requirements:• Wear resistance at over 5,000 rpm• Electrical insulation • Various film thicknesses 100 – 450 µm • Tight thickness tolerance
APTIV film benefits:• Combination of wear life and tight thickness tolerance provide customer with best performing wear surface. APTIV film reduces chance of read/write errors in CD/DVD drives.
APTIV film – Case Study
Speaker tweeter dome using mineral filled APTIV film
Key requirements:• Exacting acoustic characteristics• Thermo-formable• High temperature performance• Excellent fatigue properties
APTIV film benefits:• Cabasse required a film which met a challenging set of requirements. It had to have extremely high modulus with light weight for excellent sound characteristics while being formable in standard processing equipment.
Mobile Phone – Speaker Diaphragm
Details
System: Mobile PhoneApplication: Speaker DiaphragmMaterial: PEEK™ Film
Requirements Temp. range at 204~260oC for both manufacturing process and full power operation. Chemical resistance Extreme dynamic fatiques over the lifetime Low moisture absorption
PEEK™ Benefits High heat performance Superior resistance to chemicals Great fatique performance Low mositure absorption vs. PI Processability vs. PI
APTIV film – Case StudySurface Mount Condenser Microphone
Key Requirements:• 25 micron film with tight thickness tolerance• High temp. capable – Must survive lead-free soldering operations• Excellent dielectric properties• Chemical resistance to surface mount assembly products. • Ease of manufacturing - 4 million units / month
APTIV film benefits:• APTIV film provided a solution to the challenges of high temperature surface mount soldering operations while allowing the customer to meet competitive market pricing for their finished surface mount microphones.
APTIV film – Case Study
Tennvac® Film Antenna
Key Requirements:• Excellent electrical properties across range of temperature and humidity levels.• Strong chemical resistance• High mechanical properties including higher tear strength versus polyimide film.• High temperature performance, up to 260 C• Excellent bond strength with vapor deposited metals.
APTIV film benefits:• APTIV film provides Tennvac with a film which can be thermally bonded directly to a metal substrate without an adhesive. This improves bond strength, performance and reliability of the device.
The Next Generation of Coatings for Durability and Long Life
Coatings applications
• Electrostatic (powder) Coating: – Powders are sprayed directly onto a heated substrate. Powders melt to
form the coating typically 100 – 1000 microns dft (4-40 mil dft).– Typical applications – Pans, rice cookers, dampers, bushings, cylinder
head gaskets, bearings, parts for corrosion resistance– Vicote 700 series products
• Dispersion Coating – The formulated aqueous based coating is sprayed onto the substrate
which is subsequently heated to form a thin film on the substrate (25-100 dft).
– Typical applications – cookware, irons, engine piston rings, bearings, large parts in chemical plants for corrosion resistance, coating glass and Kevlar™ fabrics.
– Vicote 700 (powder) or 800 (dispersions) series
• Thermal Spray– Powder is passed through flame to melt and melt the polymer which
adheres and solidifies on the cool surface. (Under development)– Potential Applications – Objects that can’t be heated in an oven.
Mobile Phone – Coating on Phone Sliding Rails
Details
System: Mobile PhoneApplication: Coting on phone sliding railsMaterial: VICOTE 810
Requirements Low noise generation Low coefficient of friction Wear resistance Surface hardness > 4H No particles generated after 100,000 cycles of sliding testing
PEEK™ Benefits Low coefficient of friction Superior wear performance Surface hardness
• Kyocera is using a-Si photoconductive drum in order to achieve
longer file (resulted from higher wear resistance).
• Oxide forms on the surface of the a-Si drum, which results in
cleaning roller subjected to high torque while scrubbing the oxide
films from the a-Si photoconductive drum.
• The gears fabricated from Victrex PEEK materials had high
mechanical strength and is able to with stand the torques without
deformation.
OVERVIEWOVERVIEW
Cleaning Roller Gear
Cleaning Roller Gear
Thank you!