High Performance ABS Products for Automotive Applications

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Jesse Wilson
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1 High Performance ABS Products for Automotive Applications

ELIX Polymers is a leading manufacturer of ABS (Acrylonitrile-Butadiene-Styrene) resins and derivatives in Europe.

ELIX Polymers has strong technical expertise in product formulation and color development and offers a range of high performance products that meet the stringent requirements of the Automotive

2 ELIX Polymers is a leading manufacturer of ABS (Acrylonitrile-Butadiene-Styrene) resins and derivatives in Europe. Operating from its head office in Tarragona, Spain, and with Sales support teams in all key markets, the company is a specialist provider of tailormade solutions for high quality thermoplastics applications. With a -year track record, ELIX Polymers is an expert in ABS polymers, and it has the resources, the expertise and the experience to create value for its customers through highly individual solutions. ELIX Polymers has strong technical expertise in product formulation and color development and offers a range of high performance products that meet the stringent requirements of the Automotive Industry and are suitable for general purpose, high heat, low emission, electroplating and pre-colored applications. The company counts leading global Tiers among its customers and the materials are used for interior and exterior applications of the main OEMs. ELIX Polymers has ISO 9001, ISO 1 and ISO certifications and fully underwrites the chemical industry s responsibilities. ELIX Polymers vision is to be the benchmark global leader in the specific thermoplastics market. As a customer-oriented company, the company offers a broad portfolio of products as well as personalized services. At the same time it is committed to addressing environmental sustainability and fostering the professional development of its employees. To achieve this, the company has placed emphasis on continuous improvement, innovation, state-of-the-art technology, high quality products and production as well as safe and environmentally responsible processes. Compromise Certifications Memberships The key factors are a high level of experience in the sales and technical marketing departments, as well as its team of professionals who make up the human capital of ELIX Polymers.

3 Applications Exterior Parts Electroplated Parts Interior Parts Exterior painted parts Radiator grilles Mirror housings Spoilers Rear light housings Painted tailgate handles Radiator grilles Logos Profiles Tailgate handles Decorative interior parts Seating parts Door panel parts Instrument panel parts Pillars Glove box compartments Center consoles Sun visors Air vents

4 Medium Heat Resistance Grades High Heat Resistance Grades Grades Typical properties Test condition Unit Standard P2M-V H604 H605 Grades Typical properties Test condition Unit Standard HH35 HH3 HH3114 Melt Volume Rate 2 C/kg cm 3 /min ISO Tensile Modulus 1mm/min MPa ISO 527-1, Izod Notched Impact Resistance 23 C kj/m 2 ISO 180-1A Izod Notched Impact Resistance - C kj/m 2 ISO 180-1A High Deflection Temperature (HDT) 1,80 MPa C ISO 75-1, High Deflection Temperature (HDT) 0,45 MPa C ISO 75-1, Vicat B50 C ISO Vicat B1 C ISO Melt Volume Rate 2 C/kg cm 3 /min ISO Tensile Modulus 1mm/min MPa ISO 527-1, Izod Notched Impact Resistance 23 C kj/m 2 ISO 180-1A Izod Notched Impact Resistance - C kj/m 2 ISO 180-1A High Deflection Temperature (HDT) 1,80 MPa C ISO 75-1, High Deflection Temperature (HDT) 0,45 MPa C ISO 75-1, Vicat B50 C ISO Vicat B1 C ISO High impact resistance Low emission and odor Medium to high flowability Excellent processability VICAT (B50) Excellent paintability 5 Yield Stress MPa 50 High heat resistance Well balanced mechanical properties Low emission and odor High flow Low density VICAT (B50) Excellent processability 1 Excellent paintability 12 Yield Stress MPa P2M-V H604 H HH35 HH HH HDT (0,45MPa) HDT (0,45MPa) IZOD Notched (-ºC) IZOD Notched (-ºC)

5 ABS (PC modified) Grades PC/ABS Blends Grades Typical properties Test condition Unit Standard H801 Ultra 45 Ultra HH 41 HI ELIX PC/ABS Grades Typical properties Test condition Unit Standard Melt Volume Rate 2 C/kg cm 3 /min ISO * 14* Tensile Modulus 1mm/min MPa ISO 527-1, Izod Notched Impact Resistance 23 C kj/m 2 ISO 180-1A Izod Notched Impact Resistance - C kj/m 2 ISO 180-1A High Deflection Temperature (HDT) 1,80 MPa C ISO 75-1, High Deflection Temperature (HDT) 0,45 MPa C ISO 75-1, Vicat B50 C ISO Vicat B1 C ISO Melt Volume Rate 260ºC/5kg cm 3 /min ISO Tensile Modulus 1mm/min MPa ISO 527-1, Izod Notched Impact Resistance 23 C kj/m 2 ISO 180-1A Izod Notched Impact Resistance - C kj/m 2 ISO 180-1A High Deflection Temperature (HDT) 1,80 MPa C ISO 75-1, High Deflection Temperature (HDT) 0,45 MPa C ISO 75-1, Vicat B50 C ISO Vicat B1 C ISO *260ºC/5kg Very high heat resistance Very high to extreme impact resistance Low emission and odor Medium to high flowability Good processability VICAT (B50) Lower density than PC/ABS 1 Good paintability Yield Stress 60 Extreme heat resistance Extreme high impact up to - C Low emission and odor High flow Excellent processability VICAT (B1) Excellent paintability Yield Stress MPa H ELIX PC/ABS 51 HH 41 HI ELIX PC/ABS HDT (0,45 MPa) HDT (0,45MPa) IZOD Notched (-ºC) IZOD Notched (-ºC)

6 Electroplating Grades Technical Services ELIX Polymers offers top benchmark services to their customers including full technical support and special commitment in results and time. The company does care about customer s projects adapting their services and offering tailor-made solutions in terms of time, quality, color developments or additive packages. Grades Typical properties Test condition Unit Standard P2MC HHP2MC Ultra HH 41 PG Melt Volume Rate 2 C/kg cm3/min ISO * Color Development Technical Information Technical Support & Troubleshooting Tensile Modulus 1mm/min MPa ISO 527-1, Izod Notched Impact Resistance 23 C kj/m 2 ISO 180-1A Izod Notched Impact Resistance - C kj/m 2 ISO 180-1A High Deflection Temperature (HDT) 1,80 MPa C ISO 75-1, High Deflection Temperature (HDT) 0,45 MPa C ISO 75-1, Vicat B50 C ISO Vicat B1 C ISO *260ºC/5kg Request color chips Color match request Compounding capacities for color DVP Color translation Temporal commitment for color DVP deliveries Online technical knowledge center Product technical information Special test info (ask for availability) CAD/CAE data Regulation compliance support Temporal commitment for technical support Support in searching for cost saving opportunities Support during commisioning of new moulds Troubleshooting online and in customer s house New product development Adapt existing products Best in class plating ABS grade Special formulation, dedicated for galvanic process requirements High quality for class A surfaces Excellent flow Good processability Extreme impact resistance Ultra HH 41 PG High heat resistance HH P2MC Very high heat resistance Ultra HH 41 PG P2MC HHP2MC Ultra HH 41 PG VICAT (B50) 1 1 HDT (0,45 MPa) 45 IZOD Notched (-ºC) Yield Stress Environment, Health and Safety ELIX Polymers Innovation Strategy is clearly centered on environmental issues along with all aspects of Health and Safety. Over the last few years the company has adapted their manufacturing processes and technologies to ensure the highest level of environmental performance. As part of the product development process they use LCA (Life Cycle Assessment) and Carbon Footprint analysis in order to identify potentials of sustainability and measure the environmental impact of any new product. These changes in operating procedures and ecofriendly technologies have led to the following improvements during 14: - % reduction in Energy Consumption - 4% reduction in Carbon Footprint in Manufacturing - 23% reduction in Carbon Footprint in Transport- Distribution The introduction of added value to the ABS portfolio is an essential part of ELIX Polymers Innovation Strategy in terms of: More sustainable product portfolio Products based on renewable source raw materials. E.g. ABS with natural fibers (ABS-NF) and bio based ABS both of which are in the initial stages of development. Health impact awareness ELIX Polymers fulfill legal Health and Safety requirements (product hazard and risks). 00/53/EC End-of-Life Vehicle Guideline content of heavy metals. 11/65/EU and 12/19/EU RoHS and WEEE Directives 03/11/EC Marketing and use of certain dangerous substances and preparations. 5/09/EC Montreal Protocol (Ozone Depleting Substances) - 37/00 repealed. Absence of SVHC candidates in ELIX products.

Technical Information Painting ELIX grades show excellent performance as substrate for post-processes like painting, flocking or metallizing.

The high surface quality achievable with ELIX Automotive grades will support getting the best appearance for your parts.

companies. Eleven different paint systems for automotive have been selected, each of them with paint coats from well known suppliers.

7 Technical Information Painting ELIX grades show excellent performance as substrate for post-processes like painting, flocking or metallizing. Every ELIX grade has high wettability and surface energy assuring low scrap rates and high adhesion without the need of pretreatments. The high surface quality achievable with ELIX Automotive grades will support getting the best appearance for your parts. For demonstration purposes paintability tests were done at Thierry GmbH, a leading company which supplies the highest quality color standards and precision painting services to OEMs and paint companies. Eleven different paint systems for automotive have been selected, each of them with paint coats from well known suppliers. For testing the adhesion of the different paint systems used, cross-cut tests were done according to DIN EN ISO 29. Painting System Layer Paint Supplier Film Thickness K Primer SB* PETER-LACKE K Primer WB* MANKIEWICZ K Topcoat SB PETER-LACKE K Topcoat WB WÖRWAG Base Coat SB TECHNICOAT Base Coat WB SCHRAMM K Clear Coat SB SCHRAMM Technical Information Processing TECHNICOAT *SB= Solvent Based Number of layers *WB= Water Based Total thickness µm Drying Conditions Recommended drying conditions for and PC/ABS grades ELIX Grade Drying Temperature (ºC) Permitted Residual Moisture Content (% weight) Circulation Dryer (50% Fresh air) Drying Time (h) Fresh Air Dryer (High speed) Dried Air System According to DIN EN ISO 29, a classification is obtained from the cross-cut tests. All ELIX Automotive grades tested had a score of 0, the best possible in the standard, which means that the edges of the cut are completely smooth with optimal adhesion. A minimal score of 1 is required to pass the test. CLASSIFICATION AFFECTED CROSS-CUT AREA 80 <0, % H801 ELIX PC/ABS 90 <0, % % For process parameters consult the ELIX Injection Moulding Guideline (available in the corporate web site) 3-35% % Injection Conditions 5 >65% SCORE 0 SCORE 3 ELIX Grade Melt Temperature (ºC) Mould Temperature (ºC) Feeding Section Processing Temperature ( C) Metering Section Compression Section Nozzle Injection of Plaques Painting with different paint systems Adhesion tests according to DIN EN ISO 29 H ELIX PC/ABS

8 Grades table Medium Heat Resistance High Heat Resistance ABS (PC modified) PC/ABS blends Electroplating Property Test Condition Unit Standard P2M-V H604 H605 HH 35 HH 3 ELX ABS HH 3114 H HH 41 HI ELIX PC/ABS 51 ELIX PC/ABS 51 P2MC HH P2MC HH 41 PG Density - g/cm 3 ISO ,03 1,04 1,05 1,03 1,03 1,04 1,07 1,07 1,07 1,11 1,13 1,03 1,04 1,07 Rheological properties Melt Volume Rate 2 C; kg cm 3 /min ISO Melt Volume Rate 260 C; 5kg cm 3 /min ISO Mechanical properties (23ºC /50% H.R.) Yield Stress 50mm/min Mpa ISO Yield Strain 50mm/min % ISO ,2 2,6 2,5 2,6 2,6 2,6 3,0 3,7 7 4,9 5,1 2,4 2,6 7 Tensile Strain at break 50mm/min % ISO > > > > > Tensile modulus 1mm/min Mpa ISO Flexural Strength 2mm/min Mpa ISO Flexural modulus 2mm/min Mpa ISO Izod Notched Impact Resistance 23 C kj/m 2 ISO 180-1A Izod Notched Impact Resistance - C kj/m 2 ISO 180-1A Izod Notched Impact Resistance - C kj/m 2 ISO 180-1A Charpy notched impact strength 23 C kj/m 2 ISO 179-1eA Charpy notched impact strength - C kj/m 2 ISO 179-1eA Ball identation hardness N/mm 2 ISO Thermal properties High Deflection Temperature (HDT) 1,80 Mpa C ISO 75-1, High Deflection Temperature (HDT) 0,45 Mpa C ISO 75-1, Vicat softening temperature 50N; 1 C/h C ISO Vicat softening temperature 50N; 50 C/h C ISO Burning behavior UL 94 (1,6 mm) 1.6 mm Class UL 94 HB HB HB HB HB HB HB HB HB HB HB HB HB HB Burning rate (US-FMVSS) 2,0 mm mm/min ISO <50 <55 < < < 80 < < Coeff. Lin. ther. expansion, parallel 23 to 55 C -4 /K ISO ,-2 1,0 0,8 0,9 0,99 0,92 0,92 0,8 0,9 0,89 0,8 0,77 1 0,92 0,89 Molding shrinkage, normal 60x60x2 % ISO ,4-0,7 0,5-0,7 0,4-0,6 0,6-07 0,6-07 0,6-07 0,5-0,7 0,6-0,8 0,65-0,75 0,6-0,7 0,6-0,7 0,4-0,7 0,4-0,7 0,65-0,75 Molding shrinkage, parallel 60x60x2 % ISO ,4-0,7 0,5-0,7 0,4-0,6 0,6-07 0,6-07 0,6-07 0,5-0,7 0,6-0,8 0,65-0,75 0,6-0,7 0,6-0,7 0,4-0,7 0,4-0,7 0,65-0,75 IM melt temperature - C ISO IM mold temperature - C ISO IM velocity - mm/s ISO

9 ABS Manufacturer Global presence, covered by extensive ELIX Polymers sales force, distributors and agents Automotive Industry Tel: ELIX Polymers, S.L. Polígono Industrial Crta. Vilaseca-La Pineda s/n 43 La Canonja (Tarragona) - España Fax: info@elix-polymers.com ELIX Polymers, S.A. All rights reserved. The content of this publication may not be reproduced in whole or in part, nor may it be transmitted by or saved in any kind of information retrieval system, without the prior written permission of ELIX Polymers, S.L. For comprehensive technical information on our products, or processing advice please visit: Last updated: May 17

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