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Kaneka Core-Shell Toughening Systems for Thermosetting Resins

Kaneka Core-Shell Toughening Systems for Thermosetting Resins. Douglas J. Sober Kaneka Texas Corp 2 Northpoint Drive Suite 200 Houston, TX 77060 713-503-1558 dsober@kanekatexas.com. What is Core-Shell Rubber (CSR) ?. Co-Polymer I designed for impact resistance. This is the core.

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Kaneka Core-Shell Toughening Systems for Thermosetting Resins

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  1. Kaneka Core-Shell Toughening Systems for Thermosetting Resins Douglas J. Sober Kaneka Texas Corp 2 Northpoint Drive Suite 200 Houston, TX 77060 713-503-1558 dsober@kanekatexas.com

  2. What is Core-Shell Rubber (CSR) ? Co-Polymer I designedfor impact resistance.This is the core. Co-Polymer II designedto be compatible withthermosetting resin. This is the shell. 2-Layer CSR

  3. What is Core-Shell Rubber (CSR) ? 2-Layer CSR 100nm

  4. How does CSR toughen resins? • Core polymer cavitates on impact dissipating energy . • Small, evenly dispersed particles act as a crack terminator.

  5. Applications of CSR? • Thermosplastic resins systems. • Thermosetting resins systems for: • - Adhesives. • - Composites. • - Potting Compounds & Encapsulants • - Coatings • - Copper-Clad Laminates

  6. Core Shell Rubber Advantages: • Outstanding Toughness Improvement: • - Fracture Toughness • - T-Peel Strength • - Lap-Shear Strength • No Depression of Tg. • Wide Cure Window. • Consistent Morphology. • Low Ionic and Surfactant Content. • Extremely Stable.

  7. What is Kane Ace MX: Kane Ace MX are concentrates comprised typically of 25% by weight of CSR dispersed in various thermosetting resins. The liquids are easily poured after heating and the individual CSR domains remain uniformly dispersed during storage and formulating.

  8. Basic Properties of MX system Rubber particles are homogeneously dispersed in epoxy resin. Available as Concentrate containing 25 wt% of CSR. Appearance Viscosity vs. CSR Content Conventional CSR (10wt%) in epoxy New CSR (25wt%) in epoxy

  9. Comparison of the Kane Ace MX and Conventional CSR TEM observation - Cured system Appearance - Cured system “Transparent” 1mm

  10. Kane Ace MX Products: MX 120 Standard Liquid Bis A Epoxy Resin MX 120LV Low Viscosity Liquid Bis A Epoxy Resin MX 130 Standard Liquid Bis F Epoxy Resin MX 210 Epoxidized Phenol Novolac Resin MX 224 Epoxidized Cresol Novolac Resin MX 411 Multifunctional Epoxy Resin (TGMDA) MX 451 Multifunctional Epoxy Resin (TGPAP) MX 550 Cyclo-Aliphatic Epoxy Resin* MX 715 Polypropylene Glycol MX XYZ Proprietary Resins as supplied by customer * May contain less than 25% CSR

  11. T-Peel Strength Kane Ace MX

  12. T-Peel Strength of DGEBA Epoxy/MX 120 System

  13. Lap-Shear Strength OF Kane Ace MX Adhesive layer

  14. Lap-shear Strength of DGEBA Epoxy/MX 120

  15. Toughening Effect of Epoxy/ Kane Ace MX System Three-Point Bending strength force stress energy strain specimen: 6cm x 1.2cm x 0.5cm pre-crack: 0.6cm depth by blade-tapping head speed: 1mm/min. ASTM 5095

  16. Fracture Toughness of DGEBA Epoxy/MX 120

  17. Fracture Toughness of DGEBA Epoxy/MX 120

  18. T-peel Strength of MX 120 vs. CTBN in DGEBA Epoxy

  19. Comparison of CSR and CTBN Lap-shear Strength of MX 120 vs. CTBN in DGEBA Epoxy

  20. Comparison of CSR and CTBN Fracture Toughness and Glass Transition Temperature of MX 120 vs. CTBN in DGEBA Epoxy Tg

  21. Kaneka Corporation • Today Kaneka is a world leader in the creation of innovative technologies in areas such as polymers, construction materials, and pharmaceuticals. • Kaneka is a global organization with production facilities on four continents and approximately 7000 employees. • Revenue for our latest fiscal year (ended March ‘04) is estimated worldwide at approximately $4.3 billion.

  22. Kaneka Global Manufacturing • Kaneka currently manufactures “Modifiers” at four sites around the world. These include: Kaneka Japan Asia Takasago, Japan Kaneka Texas USA Pasadena, Texas Kaneka Belgium Europe Oevel, Belgium Kaneka Malaysia Asia Kuantan, Malaysia • These four sites provide Kaneka with an annual capacity of modifiers of approximately 350 million pounds.

  23. Kaneka Texas Corporation • A wholly owned subsidiary opened in 1983, Kaneka Texas (KTC) is responsible for marketing several Kaneka product lines throughout the Americas. • Business operating at KTC include: • 1.) Polymer Modifiers (Kane Ace) • 2.) CPVC Resins (Kanevinyl) • 3.) Foamed Olefins Resins (Eperan, Eperan PP) • 4.) Modified Silicone for Sealants (MS Polymer) • 5.) Polyimide Film (Apical) • 6.) Nutrients (CoQ10)

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