energy-efficient solutions with silicone...

CREATING TOMORROW'S SOLUTIONS

Engineering Silicones, May, 15th, 2012

Peter Gustafsson, Udo Wachtler

ENERGY-EFFICIENT SOLUTIONS WITH SILICONE ELASTOMERS

Company Profile Corporate Communications, March 2012 , Slide 1

Wacker Chemie AG

WACKER Group (2011)

ALMOST A CENTURY OF SUCCESS

• Founded in 1914 by Dr. Alexander Wacker • Headquartered in Munich

• Sales: €4.91 billion • EBITDA: €1.1 billion • R&D: €173 million • Investments: €981 million • Employees: 17,168

Company Profile Corporate Communications, March 2012 , Slide 2

*€992 million

*€1,594 million*€928 million

*€1,448 million

*€145 million

Group sales in 2011: €4,910 million

A WELL-BALANCED PORTFOLIO

* Including internal sales

Total divisional sales in 2011 (incl. internal sales): € 5,107 million**

** Balance of other / consolidation €-197 million

SILTRONIC

WACKER SILICONES

WACKER POLYMERS

WACKER POLYSILICON

WACKER BIOSOLUTIONS

Energy-Efficient Solutions with Silicone Elastomers Engineering Silicones, May, 15, 2012 Slide 3

CONTENT

• Silicone elastomers – chemistry and classification

• Value chain and global market

• Characteristics of silicone elastomers in regard to sustainability

• Application examples

LED technology

Solar industry

Insulators in power, transmission & distribution

UV-curing silicone elastomers

Flame retardant silicone elastomers

Automotive/Transportation

• Summary

Quartz → Silicon metal → Silane → Polydimethylsiloxane

WHAT ARE SILICONES?

Si Si Si Si Si


SILICONE RUBBER FROM SAND TO THE OEM

SILOXANE SILICONE POLYMER

(GUM) BASE COMPOUND

RUBBER PART

(MOLDING)

OEM (CONSUMER) PRODUCT OR

TIER ½ COMPONENT

SAND SILICON


HIGH CONSISTENCY RUBBER ELASTOSIL® SILICONE ELASTOMERS

hardness (DIN 53505)

tensile strength (DIN 53504 S1)

elongation at break (DIN 53504 S1)

tear resistance (ASTM D 624)

compression set (DIN ISO 815-B)*

rebound resilience (DIN 53512)

very soft to 50 ShA

2–6 N/mm2

100–1000%

8–25 N/mm

40–70%

20–50%

* determined at 175 °C, 22 h

3–85 ShA

5–9 N/mm2

300–800%

15–45 N/mm

10–50%

40–60%

10–90 ShA

6–12 N/mm2

300–1200%

20–55 N/mm

10–40%

35–65%

RTV-2 LSR HTV


MECHANICAL PROPERTIES IN COMPARISON SILICONE ELASTOMER – ORGANIC RUBBER

EPDM NR VMQ

Hardness [Shore A] 42 37 40

Tensile strength [N/mm²] 15 15 11

Elongation at break [%] 670 610 710

Tear resistance [N/mm] 15 43 37

Rebound resilience [%] 67 73 63

Compression set [%] (150°C/3d) 64 n.a. 10


MINOR INFLUENCE OF THERMAL AGING ON MECHANICAL PROPERTIES OF SILICONE ELASTOMERS

EPDM NR VMQ

Hardness [Shore A] 0 d 40 40 40

14 d 53 n.a. 41

Tensile strength [N/mm2] 0 d 15 15 10

14 d 10 n.a. 10

Elongation [%] 0 d 670 610 600

14 d 200 n.a. 590

Weight loss [%] 14 d 10 12 1

Hot air storage (14 d / 150 °C)


SILICONE RUBBER PERFORMS MUCH BETTER IN REPEATED TEMPERATURE EXCHANGE

0

5

10

15

20

0 10 20 30 40 50 60Cycles

Silicone RubberEPDM

Tensile strength (N/mm²)

One Cycle: 1h/-60°C and 1h/200°C


HEAT- AND OILRESISTANCE ACCORDING ASTM-D 2000/SAE J 200)

maximum swell in oil IRM 903 (%)

heat

resi

stan

ce (°

C)

50

100

150

200

250

10 20 140

EPDM

MVQ

FPM

NBR

ACM HNBR

BR NR

SBR

30 40 60 80 100 120

40% VA 80% VA

34% ACN

18% ACN

44% ACN

48% ACN

NR

SBR

BR

IIR NBR

CR

EPDM

VMQ

EVM

FKM

HNBR

CM/CSM

ACM AEM

CO/ECO

HT-ACM FVMQ


SILICONE ELASTOMERS PROVIDE EXCELLENT LOW TEMPERATURE FLEXIBILITY AND HEAT RESISTANCE

-100 -50 0 50 100 150 200 250

VMQ

ACM

EPDM

FKM

HNBR

NR

Working temperature range [°C]


SILICONE RUBBER – WIDELY USED HIGH PERFORMANCE MATERIALS Dr. Udo Wachtler, Silicone Rubber, April 2006, Slide 12

OUTSTANDING DEEP TEMPERATURE FLEXIBILTY AND HEAT RESISTANCY

* Temperatur, bei der nach 1000 h 50 % der Ausgangsbruchdehnung verbleiben

0

Col

d Fl

exib

ilty

(°C

) acc

DIN

535

20

Heat resistance* (°C)

60 80 100 120 140 160 180 200

-20

-40

-60

-80 BR

SBR

CR HNBR

ACM

ECO

NR

SBR

BR

IIR

NBR CR

EPDM

CO/ECO

VMQ

CM/CSM

ACM

AEM EVM

FKM

HNBR

220 240 260

FVMQ

Compounding cristallization

ADVANTAGES OF SILICONE ELASTOMERS

Good long-term heat stability up to 180°C (with heat stabilizers up to 250°C and 300°C peak temperature)

Low temperature flexibility down to -50°C

Constant mechanical and electrical properties over a wide temperature range

Excellent weathering, UV and ageing resistance Outstanding electric properties (excellent insulation)

Low flammability (no toxic products evolved, insulating silica dioxide remains)

High transparency Pigmentable in nearly every color


Silicone Elastomers

Room Temperature Curing High Temperature Curing

1-Component (RTV-1)

2-Component (RTV-2)

High Consistency Rubber (HTV)

Liquid Silicone Rubber (LSR)

peroxide cure platinum cure platinum cure platinum cure

condensation cure condensation

cure

SILICONE ELASTOMERS CAN BE CATEGORIZED INTO HIGH AND ROOM TEMPERATURE CURE SILICONES


Other Applications

Automotive

Electrical Energy

Electronics Photonics

MachineryMedical and Health Care

SILICONE ELASTOMERS REPRESENT ONE FIFTH OF THE GLOBAL SILICONES MARKET 2009 OF 8.0 BILLION EURO*

20%

20%

10%

15%

25%

10%

Silicone Elastomer

Market 2009 1.8 BN EUR*

* Source: WACKER estimates


SILICONE ELASTOMERS EXHIBIT A WEALTH OF UNIQUE MATERIAL CHARACTERISTICS

Characteristics with special focus on sustainability and durability

• Excellent heat-stability (standard grades: 200 °C; special grades: 250 - 300 °C)

• Low glass transition temperature (standard grades: -50 °C; special grades: -120 °C)

• Excellent long-term flexibility paired with very good mechanical properties

• Excellent long-term stability vs. wheathering and irradiation

• Excellent biocompatibility & physiological inertness

• Low flammability (no toxic combustion products)

• Free of plasticizers


WACKER‘S LSR AND HTV PORTFOLIO INCLUDES GENERAL PURPOSE AND SPECIALTY GRADES

General purpose

HTV LSR

High tear

Media resistant

Self-adhesive

Flame retardant

Heat resistant

Oil bleeing

LOW COF

Electrical conductive

Healing free

Highly trransparent

Colored

Low Compression set

General purpose

High tear

Media resistant

Self-adhesive

Flame retardant

Heat resistant

Oil bleeding

LOW COF

Electrical conductive

Fatique resistant

High green strength

Low temp. flexibility

High elasticity

High damping

Steam resistant

Colored


WACKER SILICONE ELASTOMERS SHOW PERFORMANCE IN MEDICAL APPLICATIONS

Pourable silicone elastomers for medical devices, for example podology, liners, breast

prothesis, dental or wound care

Silicone elastomers for the fabrication of rubber parts, for example medical tubings, seals and

gaskets, masks or valves and baby care articles

Megatrend: Growing and Ageing Population

Silicone Elastomers in Medical and Health Care Applications

Medical Care Health Care Fabricator


WACKER SILICONE ELASTOMERS SHOW PERFORMANCE IN ENERGY, ELECTRICS & ELECTRONICS

Various cable applications,

for example ignition cables, safety cables

or sleevings

Wire & Cable

Encapsulation, potting, coating, sealing and bonding of electronic

components and devices

Electronics & Photonics

Sealing, bonding, potting in photovoltaic

modules or fresnel lenses in

concentrator modules

Solar Industry

Medium and high voltage insulation, for example insulators,

arresters, cable accessories or transformers

Transmission & Distribution

Silicone Elastomers in Electrical and Electronic Applications

Megatrend: Renewable Energy and Energy-Efficiency


SILICONE ELASTOMERS SHOW EXCELLENT PERFORMANCE IN MANY OTHER INDUSTRIES

Silicone elastomers for encapsulation,

potting, coating, sealing and bonding in various industry

application

Machinery & Transportation

Fabrication of rubber parts or textile coat- ings for automotive applications and the

transportation industry

Automotive Rubber

Rubber parts for various applications,

for example household, sports,

fashion, construction or machinery

Rubber

Silicone elastomers for moldmaking, rapid prototyping, pad

printing or composite manufacturing

Mold Making

Silicone Elastomers are Used in a Broad Field of Applications

Megatrend: Rapid Growth of Emerging Markets Infrastructure and Mobility


Gold wire Silicone lens

Silicone encapsulation LED chip

Heatsink Reflector

WACKER SILICONE ELASTOMERS IMPROVE THE MANUFACTURING PROCESS AND THE PRODUCT

Applications

• Encapsulation of LED chips

• Manufacture of highly transparent LED optics

• Encapsulant for sensitive LED chips with bond wire

• Resistant to UV radiation

• Heat-resistant (> 250 °C)

• Lead-free soldering possible (above 260 °C)

• Lens production directly on LED chip in a single step

Benefits of WACKER LUMISIL® / SEMICOSIL®


SILICONE ELASTOMERS PLAY A MAJOR ROLE IN POWER GENERATION, TRANSMISSION AND DISTRIBUTION

• UV-Beständigkeit • thermische Stabilität

• Schwerbrennbarkeit

• Hydrophobie

• Erosions- und Kriechstromfestigkeit

• Korona- und Ozonbeständigkeit

• Unempfindlich gegenüber mechanischer Belastung

Advantages of Silicone Elastomers in Power Generation, -Transmission and -Distribution

Germany’s Electricity Grid

The network of high-voltage and extra-high-voltage lines has a length of over 100,000 km.

It is estimated that about 3.75 million insulators are in use. In Europe, tens of millions of insulators are therefore in use.*

• UV resistance • Heat resistance

• Fire resistance

• Hydrophobicity

• Erosion and tracking resistance

• Corona and ozone resistance

• Unaffected by mechanical loading

Advantages of Silicone Elastomers in Power Generation, Transmission and Distribution

*Source: WACKER estimate


OPTIMIZED POTTING PROCESSES WITH UV-ACTIVATED SILICONES IMPROVE EFFICIENCY

Application Example in Electronics

Potting/Coating of Power Modules

Replaced process: two subsequent coating/potting processes with each step requiring 30 minutes curing at 150 °C

Optimized continuous process with 5 minutes curing at room temperature

Application Example in Photovoltaics Potting of Junction Boxes

Optimized process: 1K system - no mixing or dosing equipment needed

From 4 hours curing at room temperature to 10 minutes curing at room temperature


LOW DENSITY / NON ABRASIVE FULFILLS UL 94 V0 0.75 MM ELASTOSIL® LR 3011/50 FR

LR 3011/50 FR

pc

LR 3001/55 FR oil resistant

npc

LR 3001/60 FR oil resistant

npc

LR 3170/40 self adhesive

npc Viscosity (0.9 s-1 ) [mPas] 1 000 000 250 000 280 000 1 500 000

Density [g/cm³] 1.14 1.37 1.38 1.12

Hardness Shore A 50 51 60 44

Tensile strength [N/mm²] 8.9 5.5 5.4 8.8

Elongation [%] 470 340 300 480

Tear resistance [N/mm] 28 17 17 22 Compression set (22h/175°C) [%] 17 40 35 40 (22h/150°C)

Color dark grey dark grey whitish beige dark grey

Processing non abrasive abrasive abrasive non abrasive

UL Yellow Card UL 94 V0 0.75 + 3 mm

UL 94 V0 0.75 + 3 mm

UL 94 V0 4 mm

UL 94 V0 3 mm

New!


USE OF FIRE SAFETY CABLES


SILICONE RUBBER Dr. Thomas Frese, S-E-R, June 2011, Slide 26

FLAME RETARDANT HCR-SERIES EL R 770 CERTIFIED ACCORDING TO EUROPEAN RAILWAY STANDARDS

HARD/SOFT COMPOSITES CAN BE GENERATED BY USING UNDERCUTS AND PRIMERS

• additional processing step

• restricted design

• solvents included

Drawbacks of undercuts and primers

Silicone Substrate

undercut

priming, surface treatment

self-adhesion

Current technologies for hard/soft composites


SELF-ADHESIVE SILICONE RUBBER INCREASES THE PRODUCTION EFFICIENCY

Adhesion to a variety of rubbers, plastics and metals

• No undercut, no primer needed

• No solvents

• Join and seal in one step

• Suitable for various designs

Higher efficiency in the production process:

• One-step process (adhesion during cure)

• High degree of automation, no assembly (2k injection molding, coextrusion, molding)

Benefits of Self-Adhesive HTV and LSR Silicone Rubber


ENERGY-EFFICIENT SOLUTIONS WITH SILICONE ELASTOMERS FOR LONG-TERM USE

Their special characteristics and excellent properties make silicone elastomers the ideal material in many applications:

• Ingredients not known to be harmful in any way

• End product is ideal for long-term use: durability and flexibility

• Manufacturing efficiency is boosted: reduction in energy consumption and costs

Silicone elastomers help conserve energy and save on resources thanks to durable end products.

Summary


THANK YOU FOR YOUR ATTENTION!

ENERGY-EFFICIENT SOLUTIONS WITH SILICONE ELASTOMERS


energy-efficient solutions with silicone...

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