Kynar automotive applications - KYNAR

AUTOMOTIVE APPLICATIONS
Automakers are constantly striving
to make more reliable, attractive
and fuel-efficient vehicles at lower cost. This
drives the search for stronger, more durable
materials that are lighter or less expensive.
KYNAR®, KYNAR FLEX® and KYNAR 500® polyvinylidene fluoride (PVDF) resins exhibit high chemical and
abrasion resistance, have excellent thermal stability, are unaffected by UV radiation, and are resistant to
creep under mechanical stress and load. The resins can be used for molded parts, for extruded profiles,
or as protective coatings.
KYNAR® PVDF’s strength, durability and versatility make it suitable for automobile wiring harnesses, fuel lines and fuel line coatings, decals and decorative films, coatings, electrochromic
applications and plastic optical fibers (POF).
2
Melt Behavior of Select KYNAR® Grades
Property:
Melt Viscosity
Melt Flow Rate
Melt Flow Rate Load
Test Method/Conditions:
Units:
(ASTM D3835, 232°C)
K POISE @ 100 sec-1
(ASTM D1238, 232°C)
g/10 min
–
lb (kg)
KYNAR ® 370
8.0 – 13.0
–
–
KYNAR ® 460
23.5 – 29.5
6.0 –14.0
47.5 (21.6)
KYNAR ® 710
4.0 – 8.0
15.0 – 35.0
8.36 (3.8)
KYNAR ® 720
5.0 – 12.0
5.0 – 29.0
8.36 (3.8)
KYNAR ® 740
15.0 – 23.0
6.0 – 25.0
27.5 (12.5)
KYNAR 760
23.0 – 29.0
2.0 – 6.0
27.5 (12.5)
KYNAR 1000
15.0 - 20.0
1.5 – 2.5
11.0 (5.0)
KYNAR 6000
7.0 – 11.0
2.0 – 4.0
11.0 (5.0)
KYNAR 9000
5.0 – 8.0
16.0 – 40.0
11.0 (5.0)
KYNAR FLEX® 2750-01
20.0 – 25.0
4.0 – 14.0
27.5 (12.5)
KYNAR FLEX® 2800-00
23.0 – 27.0
3.0 – 8.0
27.5 (12.5)
KYNAR FLEX® 2800-20
12.0 – 20.0
1.0 – 6.0
11.0 (5.0)
KYNAR FLEX® 2850-00
23.0 – 27.0
3.0 – 8.0
27.5 (12.5)
KYNAR FLEX® 2850-02
16.0 – 20.0
10.0 – 20.0
27.5 (12.5)
KYNAR FLEX® 2850-07
16.0 – 20.0
10.0 – 20.0
27.5 (12.5)
KYNAR FLEX 3120-50
20.0 – 26.0
2.5 – 7.5
27.5 (12.5)
6.0 – 15.0
–
–
®
®
®
®
®
KYNAR SUPERFLEX 2500
®
General Property Profile(1) of
KYNAR® Fluoropolymer Resins
KYNAR® RESIN GRADE
Physical
Properties
Test Method
Units
460
700 Series
2500
2750/2950
2800/2900
2850
3120(2)
Melting Point Range
ASTM D3418
°F
°C
311-320
155-160
329-342
165-172
239-253
115-123
266-280
130-138
284-293
140-145
311-320
155-160
322-334
161-168
Specific Gravity
ASTM 792
--
1.75-1.77
1.77-1.79
1.80-1.82
1.78-1.80
1.76-1.79
1.77-1.80
1.76-1.79
Refractive Index
ASTM D542
--
1.42
1.42
1.40
1.41
1.41
1.42
1.41
Water
Absorption
ASTM D570
%
0.02-0.04
0.01-0.03
0.04-0.07
0.03-0.06
0.03-0.05
0.03-0.05
0.03-0.05
Tensile Strength at Yield
ASTM D638
psi
5,000-7,500
6,000-8,000
1,700-2,800
2,000-3,100
2,900-5,000
4,500-6,500
3,500-5,000
Tensile Strength at
Break
ASTM D638
psi
4,500-7,000
5,000-8,000
2,000-4,500
2,900-4,000
2,500-5,000
4,000-7,000
5,000-7,000
Elongation at Yield
ASTM D638
%
10-15
5-10
12-25
15-25
10-20
5-15
10-20
Elongation at Break
ASTM D638
%
40 min.
40 min.
200 min.
200 min.
150 min.
100 min.
100 min.
Tensile Modulus
ASTM D638
psi
150-200x103
200-335x103
35-55x103
40-65x103
80-130x103
150-220x103
100-170x103
Flexural Modulus
ASTM D790
psi
200-260x103
240-335x103
28-40x103
40-60x103
90-120x103
150-180x103
90-120x103
Unnotched Impact
Strength
ASTM D256
ft-lb/in
15-40
20-80
Non Break
Non Break
Non Break
Non Break
Non Break
Notched Impact
Strength
ASTM D256
ft-lb/in
2-4
2-4
Non Break
Non Break
10-20
2-8
Non Break
Hardness
ASTM D2246
Shore
D
75-80
76-80
55-60
57-62
65-70
70-75
65-70
Limited Oxygen Index
ASTM D2868
% O2
44
44/60(3)
42/95(3)
43/95
42/75
43/75(3)
42/95(3)
UL94
--
V-O
V-O
N/A
V-O
V-O
V-O
N/A
Vertical Burn
(1) These are typical values, not to be construed as sales specifications
(2) 3120 available as 3120-10 (low viscosity) and 3120-50 (high viscosity)
(3) Optional product available with higher LOI
N/A = data not available
3
ROTOMOLDING
KYNAR® PVDF rotomolding grades have been used in industrial liners and tanks for many years. Rotomolding,
also known as rotational molding or rotocasting, is a low stress process that uses powdered resins and
an unfilled mold to produce large, hollow, seamless plastic parts such as drums, tanks, linings
and ducts. The newest addition to the KYNAR® PVDF rotomolding family is KYNAR®
3200 RG, which offers improved flow characteristics, excellent physical and mechanical properties, high chemical resistance, and low permeability. The excellent flow and processing characteristics of KYNAR® 3200 RG allow the molder
to produce KYNAR® PVDF rotomolded parts with extremely smooth inner
surfaces. KYNAR® 3200 RG is currently being used for fuel cells, ducts and
piping. KYNAR® 3200 RG is also suited for fuel tanks, particularly multilayer plastic fuel tanks where its chemical barrier properties and excellent
processing characteristics make it a preferred material.
PLASTIC OPTICAL FIBERS FOR
AUTOMOTIVE APPLICATIONS
Plastic optical fibers (POF) clad with KYNAR FLEX® fluoropolymer resin are
emerging as a new technology in automotive applications. They are less expensive,
require less power to operate than equivalent lengths of copper wire and can be
bundled together to allow for faster data transmission. Plastic optical fibers are
suited for carrying digital information and produce less signal degradation than
copper wire. As more sensors are added to monitor engine performance
and road conditions, POF systems are growing in importance.
Plastic optical fibers consist of three essential elements: 1) the core, a thin
center of polymethyl methacrylate (PMMA) through which light travels; 2) the
cladding, a special optical material (KYNAR FLEX® fluoropolymer) that reflects
light back into the core, allowing it to propagate through the length of the POF;
and 3) a protective RILSAN® polyamide coating to protect the fiber from damage
and moisture. The light in a POF travels through the PMMA core by a principle termed
total internal reflection in which light constantly bounces off of the KYNAR FLEX®
fluoropolymer cladding. The cladding does not absorb any light from the core, allowing the light
wave to travel distances with low signal loss. PMMA-based POF systems are specifically designed for short
distance applications found in homes and automobiles.
Arkema provides all elements of POF manufacture: high purity PMMA, KYNAR FLEX® fluoropolymer, and RILSAN®
polyamide. Technical support for material processing and design of POF systems is also available through
Arkema.
4
WIRING HARNESSES
KYNAR® PVDF is a thermoplastic fluoropolymer with a high melting point and
excellent mechanical properties, including cold flow and abrasion resistance.
KYNAR® resin also has exceptional chemical resistance, is unaffected by UV
radiation and is resistant to electrical arc tracking. Because of its
unique chemical structure, KYNAR® PVDF produces almost no
smoke when exposed directly to flame and does not propagate
fire like polyolefins and PVC. KYNAR® fluoropolymer can be extruded as primary insulation or used as a protective cover.
Its excellent chemical resistance and high melting point make
KYNAR® PVDF well suited for applications “under the hood.”
KYNAR® PVDF insulated wire is commonly cross-linked by electron-beam
radiation to further increase its toughness, cut-through resistance and
continuous-service use temperature.
If specifically formulated and processed, the cross-linked polymer makes lightweight, flame-retardant wire insulation that offers a temperature rating of
approximately 175°C (347°F), does not melt and is resistant to most solvents, fuels,
lubricants and other hydrocarbon fluids. Cross-linked KYNAR® PVDF insulation is commonly used in automotive T4 wire (150°C, 3000 hrs). This KYNAR® PVDF-based insulation has become a construction standard for major original equipment manufacturers
(OEMs) in North America. Originally developed for aerospace and military requirements
as Mil Spec 81044 wire, cross-linked KYNAR® PVDF insulation is widely used where en-
KYNAR® PVDF offers corrosion
and chemical resistance coupled
with excellent mechanical properties for wire coatings.
vironmental conditions demand high performance, such as in commercial and military
electronics, satellites, ships, trains, automobiles and in aerospace applications.
DECORATIVE FILMS
KYNAR® PVDF decorative films for automotive accessories are
both aesthetically pleasing and highly resistant to corrosion and
weathering. These films are used on a variety of parts, such as
rocker panels, roofing strips, tail lamp housings, bodyside moldings, front and rear bumpers, mirror housings and pillars. The
films can be processed with standard plastics equipment and
general polymer knowledge, thus requiring little capital investment. Durable KYNAR® PVDF films are applied to PVC, PC, TPO
and ABS, and can be supplied with a heat-activated adhesive
for bonding to polyolefins. The films can be thermoformed to a
shape, trimmed and then placed into an injection mold. They
can also be laminated to flat stock sheets, then thermoformed
into the required shape. Films are also available with pressuresensitive adhesives for lamination under ambient conditions.
KYNAR® films are available in virtually any color, including solid,
metallic, pearlescent, chrome and brushed aluminum.
KYNAR® fluoropolymer films provide an attractive,
corrosion-resistant alternative to paint.
5
FUEL LINES
KYNAR® polyvinylidene fluoride resin provides a barrier layer in lowpermeation automotive fuel lines. The tubing is a multilayer
construction consisting of five layers; the innermost and outermost
layers are made from Arkema’s RILSAN® polyamide 11 or 12.
Between these polyamide layers is a layer of KYNAR® PVDF resin,
which resists alcohol permeation in fuels and helps carmakers meet strict EPA guidelines for hydrocarbon emissions.
ADHEFLON® tie resin is used to bond the KYNAR® PVDF barrier
to the RILSAN® polyamide layers, resulting in durable, flexible,
low-permeation tubing.
In addition to being easily processed on conventional
co-extrusion equipment, this innovative fuel line construction
exhibits excellent cold temperature impact strength (-40°C), chemical resistance and dimensional stability. It is also compatible with a
wide range of fuel-alcohol blends and is available in a conductive version.
KYNAR® PVDF can also be used as a protective coating over carbon steel fuel and
brake fluid lines, and in under-chassis applications. KYNAR® PVDF can be applied in
very thin layers and maintains durability and corrosion resistance. It can also be
applied as a liquid coating, as a powder coating, or by cross-head extrusion.
KYNAR® PVDF
RESISTS
GASOLINE,
ROAD SALT,
OILS,
LUBRICANTS,
BRAKE FLUID,
TRANSMISSION FLUID,
WINDSHIELD
WASHER FLUID,
COOLANTS,
AND BATTERY ACID
KYNAR FLEX®
2850 PC FUNCTIONAL
POWDER COATING
KYNAR FLEX® 2850 PC functional powder coating is a new addition to the KYNAR® coating
family. This fluoropolymer coating resists gasoline, road salt, oils, lubricants, brake fluid,
transmission fluid, windshield washer fluid, coolants, and battery acid. KYNAR FLEX®
2850 powder coating may be used to coat carbon steel parts as a low-cost alternative to
stainless steel. This powder coating is durable and may be applied in very thick coatings
(up to 100 mils).
KYNAR FLEX® resin is corrosion resistant and unaffected by UV radiation, making it especially suitable for exterior applications. Excellent chemical and mechanical properties allow
KYNAR FLEX® powder coating to be used in chemical processing applications such as tank
linings, valve and flange coatings, and pipe coatings (exterior or interior). The powder is
currently supplied in a natural, unpigmented form, though pigmented versions can be
prepared. KYNAR FLEX® 2850 PC is typically applied by electrostatic spray over a powder
primer.
6
KYNAR POWERFLEX® COPOLYMER
PROVIDES ELECTROCHROMIC TECHNOLOGY
FOR THE AUTOMOBILE
Advances in polymer and electrochromic technology have allowed the development
of electrochromic windows — windows that darken or lighten to control the amount of light
permitted inside a vehicle. Electrochromic windows, which control solar radiation transmission
and modulate glare, increase passenger comfort and safety and are manufactured using
a patented inner layer of KYNAR POWERFLEX® copolymer film (US Patent 6,620,342). These
unique windows contain a core of transparent polymer layers and electrolyte sandwiched
between sheets of glass. The KYNAR® layer allows exchange of ions within the system. When a
voltage is applied to the system, ions migrate through the KYNAR® PVDF film, causing a change
in opacity. The result: windows and mirrors with controllable optical properties.
The lack of easily manufactured, durable, low-cost materials of construction has prevented
widespread use of electrochromic devices. However, Arkema’s patented KYNAR POWERFLEX®
film is inexpensive, easily processed and possesses the necessary electrochromic
properties. The polymer (or matrix) must meet strict requirements for use in electrochromic
devices, including high electrochemical stability to allow for thousands of charge/discharge
cycles, stability to acid (H+), stability to ultraviolet (UV) light, stability to thermal degradation,
good electrical conductivity (whether the film is rigid or plasticized) and high optical clarity.
The KYNAR polymers developed by Arkema exhibit outstanding UV stability and retain their
mechanical integrity at elevated temperatures and in the presence of solvents. They are well
suited for use in electrochromic windows, mirrors and devices used to control both UV and
visible light. Arkema’s KYNAR POWERFLEX® copolymer films have low solubility in organic
solvents and plasticizers and high thermal stability to minimize or eliminate electrolyte leakage
from the device. These new films will not soften in the heat of direct sunlight or electromagnetic
radiation and have excellent transparency.
KYNAR POWERFLEX® can be used
to control the transmission of
visible and UV light through
automotive windows.
KYNAR POWERFLEX® LBG copolymer and
KYNAR® homopolymer are also used in
lithium ion batteries which can be used in
hybrid electric vehicles (HEV). A unique
polymer structure of carbon, hydrogen
®
and fluorine atoms, gives KYNAR® PVDF
excellent thermal and chemical stability.
The chemical nature of KYNAR® PVDF allows
good adhesion to metallic collectors and
good cohesion between active material
particles. KYNAR® resin is very soluble in
industrial solvents and produces uniform
INTRODUCING
KYNAR ADX RESIN:
®
New KYNAR® ADX resin is designed to bond to
nylons, polyolefins and metals. This melt
processible resin bonds to various substrates,
allowing cost effective engineering solutions,
and maintains nearly all of the
performance properties offered by
KYNAR® PVDF.
slurries at room temperature. KYNAR® PVDF
has electrochemical properties, such as
good initial capacity and cycling
behavior which make it an excellent
electrode. KYNAR® resins also possess
performance characteristics, such as high
electrochemical stability, high polymer
purity, high molecular weight and a high
melting point.
7
The statements, technical information and recommendations contained herein are believed to be accurate as of the date hereof. Since the conditions and methods of use of the product and
of the information referred to herein are beyond our control, Arkema expressly disclaims any and all liability as to any results obtained or arising from any use of the product or reliance on such information; NO WARRANTY OF FITNESS FOR ANY PARTICULAR PURPOSE, WARRANTY OF MERCHANTABILITY OR ANY OTHER WARRANTY, EXPRESS OR IMPLIED, IS MADE CONCERNING THE GOODS DESCRIBED OR
THE INFORMATION PROVIDED HEREIN. The information provided herein relates only to the specific product designated and may not be applicable when such product is used in combination with other
materials or in any process. The user should thoroughly test any application before commercialization. Nothing contained herein constitutes a license to practice under any patent and it should not be
construed as an inducement to infringe any patent and the user is advised to take appropriate steps to be sure that any proposed use of the product will not result in patent infringement.
KYNAR®, KYNAR FLEX®, KYNAR POWERFLEX® are registered trademarks belonging to Arkema Inc.
ADHEFLON® and RILSAN® are registered trademarks belonging to Arkema.
© 2005 Arkema Inc. All rights reserved.
See MSDS for Health and Safety Considerations.
Americas
Arkema Inc.
2000 Market Street
Philadelphia, PA 19103-3222
U.S.A.
Tel.: 215-419-7000
www.arkemagroup.com
www.kynar.com
Europe
Arkema
4-8 Cours Michelet
La Defense
Cedex 92091
´
France
Tel.: 33.2.32.46.68.53
Asia
Arkema Pte Ltd
53, Tuas Crescent
Singapore 638732
Tel.: 65.64.19.90.18
Visit us at
www.kynar.com
for the latest information
on KYNAR® PVDF