Title: Kaneka Core-Shell Toughening Systems for Thermosetting Resins
1Kaneka 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
2What 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
3What is Core-Shell Rubber (CSR) ?
2-Layer CSR
100nm
4How does CSR toughen resins?
- Core polymer cavitates on impact
dissipating energy . - Small, evenly dispersed particles act as a
crack terminator.
5Applications of CSR?
- Thermosplastic resins systems.
- Thermosetting resins systems for
- - Adhesives.
- - Composites.
- - Potting Compounds Encapsulants
- - Coatings
- - Copper-Clad Laminates
6Core 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.
7What 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.
8Basic 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
9Comparison of the Kane Ace MX and Conventional CSR
TEM observation - Cured system
Appearance - Cured system Transparent
1mm
10Kane 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
11T-Peel Strength Kane Ace MX
12T-Peel Strength of DGEBA Epoxy/MX 120 System
13Lap-Shear Strength OF Kane Ace MX
Adhesive layer
14Lap-shear Strength of DGEBA Epoxy/MX 120
15Toughening 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
16Fracture Toughness of DGEBA Epoxy/MX 120
17Fracture Toughness of DGEBA Epoxy/MX 120
18T-peel Strength of MX 120 vs. CTBN in DGEBA Epoxy
19Comparison of CSR and CTBN
Lap-shear Strength of MX 120 vs. CTBN in DGEBA
Epoxy
20Comparison of CSR and CTBN
Fracture Toughness and Glass Transition
Temperature of MX 120 vs. CTBN in DGEBA Epoxy
Tg
21Kaneka 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.
22Kaneka 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.
23Kaneka 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)