Kaneka Core-Shell Toughening Systems for Thermosetting Resins

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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 d
sober_at_kanekatexas.com
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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
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What is Core-Shell Rubber (CSR) ?
2-Layer CSR
100nm
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How does CSR toughen resins?

• Core polymer cavitates on impact
  dissipating energy .
• Small, evenly dispersed particles act as a
  crack terminator.

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Applications of CSR?

• Thermosplastic resins systems.
• Thermosetting resins systems for
• - Adhesives.
• - Composites.
• - Potting Compounds Encapsulants
• - Coatings
• - Copper-Clad Laminates

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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.

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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.
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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
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Comparison of the Kane Ace MX and Conventional CSR
TEM observation - Cured system
Appearance - Cured system Transparent
1mm
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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
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T-Peel Strength Kane Ace MX
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T-Peel Strength of DGEBA Epoxy/MX 120 System
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Lap-Shear Strength OF Kane Ace MX
Adhesive layer
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Lap-shear Strength of DGEBA Epoxy/MX 120
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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
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Fracture Toughness of DGEBA Epoxy/MX 120
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Fracture Toughness of DGEBA Epoxy/MX 120
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T-peel Strength of MX 120 vs. CTBN in DGEBA Epoxy
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Comparison of CSR and CTBN
Lap-shear Strength of MX 120 vs. CTBN in DGEBA
Epoxy
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Comparison of CSR and CTBN
Fracture Toughness and Glass Transition
Temperature of MX 120 vs. CTBN in DGEBA Epoxy
Tg
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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.

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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.

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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)