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Introduction to SkyPURA
2015.
distribuito in Italia da:
FERRO-PLAST SRL VIA GRANDI, 25 20090 VIMODRONE, MI Tel. +39 02 27409415 Fax +39 02 27409420 www.ferroplast.com [email protected]
1
Agenda
[Session #1] Introduction to SkyPURA (PCT)
[Session #2] Fiber applications
[Session #3] Film applications
1
3
SkyPURA PCT is a high performance engineering plastic with excellent thermal stability, toughness and fast crystallization half time.
SkyPURA PCT has outstanding thermal resistance property that can tolerate high temperature of SMT reflow process.
SkyPURA - Introduction
PPS
PETG
PET Ecozen
Price
, Perf
orm
ance
PCT
224
245
260
289
PET Nylon66 PCT LCP
260
270
PPS PPA
SMT, Reflow temp. zone
HDT for engineering plastics
Therm
al Sta
bility
PEEK
HDPE
LDPE
LLDPE PS
PVC
HIPS
ABS
Amorphous Semicrystalline
PA66
PA6
TPE
PBT
PP
POM PMMA
PES
PSU
PEI PA46
PC/ABS
PC/PET PS/PPE
4
SkyPURA - Introduction
SkyPURA PCT base resin is produced by reacting TPA and CHDM (1,4-cyclohexane dimethanol).
SK Chemicals is the only vertically integrated company that produces PCT using captive TPA and CHDM in Korea.
SkyPURA Main Properties
High Reflectivity and Durability
Long Term Heat Resistance
Low Moisture Absorption
Reflow and Lead-free Soldering Capable Resin
Chemical Resistance
Cleanliness : Free of Particles, Low Oligomers
Excellent metal adhesive
Obtain out-of-mold surfaces with high gloss, metal effect and specialty colors
Lightweight
TPA CHDM
PCT Compound
Fiber
TPA
CHDM
Film
Food Contact
Home Application
Automotive
Electrical Electronic
PCT Base Resin
5
SkyPURA - Product Grade
SK Chemicals commercialized PCT in 2012, with the current application of LED reflectors and engineering plastics.
SK chemicals currently provides 2 different grades of PCT base resin.
New PCT grades are now being developed for film & fiber applications, utilizing PCT’s intrinsic properties & benefits at each application.
Grade Film & Fiber
(being developed) SkyPURA 0302 SkyPURA 0502 Remark
Intrinsic Viscosity (dl/g) ≥ 0.80 0.65 0.75
Mn(kg/mol) 32.5 25±2 32.5 GPC, reference PS with X-PS column
Polydispersity (Mw/Mn) 2.5 2.2 2.5
Melting point (Tm(℃)) ≤ 280 286±3 286±3
DSC scan rate 10℃/min
Crystallization temperature under cooling (Tmc(℃))
≤ 215 235±5 235±5
Glass transition temperature Tg(℃)
≤ 89 89 89
Color-L* 88±4 88±4 90±4
After crystallization @ 150℃, 1hour
Color-a* 0±3 0±3 0±0.3
Color-b* b* < 6 b* < 6 b* < 6
6
SkyPURA - Advantage for LED reflector
SkyPURA PCT offers comprehensive initial reflectance and reflectance stability required in light-emitting diode(LED) packages found in display backlight and general lighting
SkyPURA PCT is applied for middle watt (0.5~1.5W) as main material and extended toward high watt market by customers
[Wattage/PKG]
Ceramics
SMC
EMC
PCT
PA9T
PA10T
PA6T
1.5
0.5
4,000 MT
10,000 MT
7,000 MT
2,000 MT
2,000 MT
Consumption [’14]
(compound)
Total 25,000 MT
High Reflectivity and Durability
Long Term Heat Resistance
Low Moisture Absorption
for LED Reflector
for Connectors
Reflow and Lead-free Soldering Capable Resin
Long Term Heat Resistance
Good Electrical Properties
Low Moisture Absorption
SkyPURA - Applications and Characteristics
7
SkyPURA PCT is suitable for LED reflectors because of its high stability towards heat, moisture and light
SkyPURA PCT has Good electrical properties also make it possible for PCT to be used for connectors
SkyPURA - Applications and Characteristics
8
Good thermal, Color, Hydrolytic Stability
Good Electrical Properties
Low Moisture Absorption
for Film
Good laundry durability at high temperature
Excellent chemical resistance/ hydrolytic stability
Shape/performance stability and durability
SkyPURA PCT is expected to expand its application to film and fiber fields mainly due to the good thermal and hydrolytic stabilities.
SkyPURA PCT also can be used for oven trays because of its long-term heat resistance and FDA approval
for Oven Tray
Long Term Heat Resistance
FDA Approval
for Fiber
Heat Resistance - PCT vs. PET Stability of fibers under hot, moist conditions (27 lbs. live steam)
PCT PET
Specific gravity 1.23 1.38
Melt point ºC/ºF 290/555 250/480
Tenacity (grams/denier) 2.5-3.0 4.5
Elongation (% at break) 35 60
Work recovery
from 2% extension 90 80
from 5% extension 55 40
from 10% extension 35 20
Compression Recovery (%)
from 34.5 mPA (5000psi) 44 31
Shrinkage (%)
190 ºC (air) <1 <6
100 ºC (water) <0.5 <1
Safe ironing temperature (ºC) 205 145
(This slide was referred from ; http://www.fitfibers.com/PCT_fibers.htm)
PCT’s feature as compared to PET
less dense so it offers greater bulk.
provides softness inherent to the molecular composition.
offers better release properties than PET which means that reusables wash and clean up easier.
has better hydrolytic stability than PET so it better withstands the rigors of repeated washings and sterilization
has a higher melt point than PET.
has better chemical resistance to auto fluids and printed circuit board cleaning chemicals than PET.
10
- PCT Fiber application : Heat Resistance
Bedding, Clothing, Pad, Carpet, Laundry net. Etc
(High end apparel, Hotel, Hospital)
- Good laundry durability at high temperature
- Good chemical resistance/ hydrolytic stability
- Shape/performance stability and durability
- Softer hand feel (vs. PET)
- Allergy Free
Car seat, Tarpaulin & Outdoor product
- Long term stability and durability
- Shape/performance stability
- Good chemical resistance/anti-contamination
Fabric, Knit
- The Application Candidates for PCT Fiber
11
Industrial bag filter / Normal filter
- Shape/performance stability and durability
- Steam/detergent cleaning, chemical resistance
- Light, Soft toughness
- Good decontamination, dust elimination
Automobile/Building insulation, Padding
- Weight loss (10% less, vs. PET)
- Shape/performance stability and durability
- High heat resistance/Chemical resistance
- Soft Crimp / Heat reservance
Non-woven Fabric
12
- The Application Candidates for PCT Fiber
※ PCT has better stability against oxidative degradation than PPS.
Difficulties Causes Solutions
Hazy film during Casting
too high rate of crystallization
Control crystallization rate of material by Copolymerization Molecular Weight (Intrinsic viscosity > 0.80)
Haze or rupture during orientation step
Different Elongational Properties
Copolymerization Adjust the Orientation Process Condition, optimized for PCT
Most biaxially oriented film process and equipments are optimized for PET.
The Differences in the properties of PCT from that of PET
can cause difficulties in the process to manufacture PCT film,
most cases of which are related to highly crystalline properties of PCT.
Copolymerization of PCT can be an effective solution to relieve the problem.
Orientation study is now being done
to understand different elongation behavior of PCT, as compared to PET.
14
- Film Application : Technical issues in the PCT film process
Observation of PCT film surface, heat treated for 2 hour at 150℃, with microscope (×500)
shows much less formation of oligomer for PCT or PCT copolymer film than the case of PET film.
PCT has much less oligomer contents, compared with PET, which gives better processability at extrusion molding step, due to much less contamination of die and rolls.
15
- Film Application : Low Oligomer Content
PET PCT copolymer
0 0.5 1 1.5
PET
Modified
PCT
PCT
1.21
0.08
0.12
Oligomer %
Hydrolytic stability test for PCT film and sheet : PCT has better hydrolytic stability than PET
As shown observation results of PCT sheet surface and PET, for 5000 hour under 85℃, 85% humidity PCT surface is clean(no crack), but crack was observed at PET surface.
Hydrolytic Stability for PCT film
(Retention of elongation under 120℃, 100% humidity)
Hydrolytic Stability for PCT sheet (with microscope, X5)
(Observation of sheet surface under 85℃, 85% humidity, 5000hr)
PCT
PET
16
- Film Application : Excellent Hydrolytic Stability I
This slide shows moisture absorption stability of films made by SK .
Interestingly, PCT films show better hydrolytic stability than even hydrolytically stabilized PET films.
Hydrolytic Stability for PCT film
(Moisture absorption under 85℃, 85% humidity, 3000hr)
17
- Film Application : Low Water Absorption
0.0
0.2
0.4
0.6
0.8
1.0
1.2
1.4
PCT PET
0.36
1.26
%
Moisture Absorption (85℃, 85%, 5000hr)
720 hr 1200 hr 1800 hr 3000 hr 5000 hr
686 Sampyeong-dong, Bundang-gu, Seongnam-si, Gyeonggi-do 463-400 Korea
Jae Hwang Cho, Manager / Phone: +82-2-2008-2455 / E-mail: [email protected] Fax: +82-2-2008-2319
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