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

JEC World 2017 2

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

JEC World 2017 3

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

>

JEC World 2017

Key takeaways

JEC World 2017 20

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

ian.swentek@hexion.com