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New epoxy systems enabling styrene-free high-performance SMC manufacturing Dr. Ian Swentek Application Development Engineer JEC World 2017 1 Current Trends in the Automotive Industry
New epoxy systems enabling
styrene-free high-performance
SMC manufacturing Dr. Ian Swentek
Application Development Engineer
JEC World 2017 1
Current Trends in the Automotive Industry
…at a glance
$3.4 billion*
4300 people*
~60 production sites*
*FY ‘16
Hexion is a Specialty Chemicals Company with a
leading position in the development and production of
systems, products and services for
Weight reduction and Coatings in the
Energy, Transportation and Construction markets
Technology Platforms
Epoxy
Phenolics
VersaticTM Acids
Formaldehyde
Automotive
Structural and Exterior Composites
Under The Hood parts
Suspension components
Brake pads
E-Coat to Clear Coat Coatings
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Hexion has global leadership positions across
a broad range of technologies and industries
Oilfield Proppant ResinsGlobal
Phenolic Specialty ResinsGlobal
Versatic™ Acids &Derivatives
Global
Forest Product Resins Global
Epoxy ResinsGlobal
Specialty Epoxy
BaseEpoxy
Leading Market Positions Customer Base
LEADING MARKET POSITIONS IN MORE THAN 80% OF ITS REVENUE BASE
Interior Parts
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Hexion continues investing in innovation and
collaboration with Automotive customers
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London, ON, CanadaDuisburg, Germany
R&D facility, GermanySt. Avold, France Hakusan, Japan
Composites technology innovations offer
the industry light-weighting at high build rates
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• Very high volume production
• Industry capacity largely available
• Low scrap rate and potential use of recycled fibers
• Additional design degrees of freedom over continuous fiber technologies
• Flexibility towards resin chemistries and formulations
Sheet Molding Compound (SMC) process is
a cost efficient technology
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• Picture courtesy: Fraunhofer Project Centre for Composites Research
New epoxy systems suitable for production
of high performance SMC
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EPIKOTE™ Resin TRAC 06605
EPIKURE™ Curing Agent TRAC 06608
HELOXY™ Additive TRAC 06805
EPIKOTE™ Resin TRAC 06605
EPIKOTE™ Resin TRAC 06606
EPIKURE™ Curing Agent TRAC 06608
HELOXY™ Additive TRAC 06805
Low viscosity, good fiber impregnation Higher Tg, good demolding
Recommended mix ratio 100:23:2-4 70:30:23:2-4
Recommended cure cycle 3 min @ 150 °C
5 min @ 140 °C
3 min @ 150 °C
5 min @ 140 °C
Mix viscosity
at 23 °C
DIN
53015
~7 000 ~50 000
DMA Tg
tanδ peak
ASTM
E1640
121 131
Epoxy systems allow for styrene-free
processing and low VOC automotive parts
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Standard
vinylester
SMC
Low VOC
vinylester
SMC
EPIKOTETM Resin TRAC 06605
EPIKURETM Curing Agent TRAC 06608
HELOXY™ Additive TRAC 06805
Total VOC (μg/g)
VDA 278
>10000 664** 9*
* All organic emissions are below international short term exposure limits (STEL) and
8-hour total weight averages (TWA)
** SPE ACCE 2016 Low VOC/Low Odor SMC for Interior Applications
The low mixing viscosity enables good fiber
wetting and high fiber loading
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Mechanical properties have been measured
systematically
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ExampleEP 06605 /
EK 06608 /
HA 06805
Fiber volume fraction [%] 50
DMA tanδ peak Tg [ºC] 120
TensileModulus [GPa] 33
Strength [MPa] 190
FlexuralModulus [GPa] 38
Strength [MPa] 475
Notes:
- 25mm fiber length, 15K carbon fibre
- 50% mold charge coverage
- Aligned & orthogonal properties averaged
- Molding conditions available upon request
- Hybrid/tailored systems with continuous fiber inlays
(prepreg) are recommended for structural applications
SM
C c
ha
rge
alig
nm
en
t
Hexion epoxy SMC parts exhibit superior
mechanical performance
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Competitive VE SMC
Competitive hybrid SMC
Competitive EP SMC
Hexion CFRP
Hexion GFRP
SMC is a cost efficient process due to
net shape moulding without preforming step
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SMC Cutting & moulding• Low scrap rate
• Hybrid reinforcement
• Functionalization
Pressing• Short in mould cycle times
• Controlled flow
• Netshape
Part de-moulding• Low shrinkage
• High strength/modulus
• Reproducibility
Component mixing
SMC compounding• Good fibre wetting
• Potential use recycled fibre
• Fast maturation
• Low Viscosity
• Low VOC and styrene free
The viscosity behavior facilitates sheet
forming, maturation and part molding
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Hexion epoxy SMC is easily processed on
existing SMC infrastructure
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Hexion epoxy SMC is easily processed on
existing SMC infrastructure
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CFRP seat frame structure demonstrates good
surface quality with completely filled ribs and bosses
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• Hexion low viscosity epoxy for SMC with
Mitsubishi 15k carbon fiber
• 45% fiber volume fraction
• Size: 55cm x 48cm x 10cm
• Weight: 766g
• 58% weight savings over comparable
steel design
• Cure time: 3 minutes @ 150 °C
• The Back seat inner
component was selected as
a demonstrator due to its
representative geometry.
• The molding study was
solely done to assess mold
ability and compare
productivity, waste and cost.
• Predicted optimized cycle
time 170 sec (10s load, 150s
cure cycle, 10s unload)
Epoxy CFRP with SMC technology for
semi-structural and structural applications
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Back inner & outer
Hexion epoxy CFRP with SMC technology
is cost effective
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• Resulting cost /kg weight saved: 8.6 $/kg versus steel
TOOL SPECIFICATIONS
Number of Cavities 2
Number of Actions in Tool 8
Molding Cy. Time 170sec
Tool Cost/Set $350(000/set)
Press Tonnage 800 tons
PRODUCTION COST FACTORS
Annual Production Volume 100(000)/yr
Product Lifetime 5yrs
Process Rejection Rate 3.0%
Direct Wages (w/ benefits) $35.00 /hr
Working Days/Yr 240
Working Hours/Day 15
Capital Recovery Rate 10.0%
Capital Recovery Period 8yrs
Working Capital Period 4months
Price of Electricity $0.125 /KWh
Fixed Overhead 25.0%
Maintenance Cost 3.0%
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Epoxy CFRP with SMC technology for a broad range of (semi-) structural applications
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December 2, 2013
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Seat structures
EV battery enclosures
Hood Inners
Rear & front floors
Spare wheel tubs
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JEC World 2017
Key takeaways
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Epoxy systems:Eliminate styrene monomer exposure and are low in VOC
Epoxy SMC technology:Low viscosity epoxy for superior performance in (semi)-structural applications
Barrier-to-entry:
Epoxy SMC can be deployed on current equipment with minimal risk
DISCLAIMER
The information provided herein was believed by Hexion Inc. and its affiliated companies ("Hexion") to be accurate at the time of preparation or prepared from sources believed to be
reliable, but it is the responsibility of the user to investigate and understand other pertinent sources of information, to comply with all laws and procedures applicable to the safe
handling and use of the product and to determine the suitability of the product for its intended use. All products supplied by Hexion are subject to Hexion's terms and conditions of
sale. HEXION MAKES NO WARRANTY, EXPRESS OR IMPLIED, CONCERNING THE PRODUCT OR THE MERCHANTABILITY OR FITNESS THEREOF FOR ANY PURPOSE
OR CONCERNING THE ACCURACY OF ANY INFORMATION PROVIDED BY HEXION, except that the product shall conform to Hexion's specifications. Nothing contained herein
constitutes an offer for the sale of any product.
© 2015 Hexion Inc. All rights reserved.
® and ™ denote trademarks owned or licensed by Hexion Inc.
Thank you!
JEC World 2017 21
Innovation Built on Collaboration
Your Partner in Composite Resin solutions
Meet us at Booth G54 in Hall 6
Ian Swentek – Application Development Engineer
