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 info@ferroplast.com

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Agenda

[Session #1] Introduction to SkyPURA (PCT)

[Session #2] Fiber applications

[Session #3] Film applications

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2

PCT(Polycyclohexylenedimethylene Terephthalate)

Session I.

Introduction to SkyPURA (PCT)

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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

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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

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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

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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

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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

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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

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PCT (Polycyclohexylenedimethylene Terephthalate)

Session II.

Fiber Applications

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.

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- 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

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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

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- The Application Candidates for PCT Fiber

※ PCT has better stability against oxidative degradation than PPS.

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PCT(Polycyclohexylenedimethylene Terephthalate)

Session III.

Film Applications

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.

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- 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.

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- 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

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- 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)

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- 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: j.h.cho@sk.com Fax: +82-2-2008-2319

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