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Rilsan® HT - The First Flexible PPA Confidential Arkema Property – Duplication prohibited
Introduction to Rilsan HT
1
ARKEMA
Rilsan® HT - The First Flexible PPA Confidential Arkema Property – Duplication prohibited
Castor seed
Castor plant
harvesting
grinding
Long chain PAPA11
monomer
Castor oil
Long chain PAPA12
Mid-chain PAPA612
Petroleum base
PA elastomerPEBA
Process flow of high performance PA
Rigid PA
High heat resistance PA
Aminoundecanoic acid
Sebacic acid
Decanediamine
H2N-(CH2)10-COOH
HOOC-(CH2)8-COOH
H2N-(CH2)10-NH2
Mid&long chain PA
PA610, 1010, 1012
PA elastomerPEBA
polymerization
45~100%Up to 95%
Amorphous PA
100% Up to 53%56% Up to 70%
Rilsan® XD
Rilsan® HT - The First Flexible PPA Confidential Arkema Property – Duplication prohibited
150°°°°C
110-120°°°°C
250°°°°C
110-120°°°°C
150°°°°C
220-200°°°°C
Metal
Metal & Rubber
Complex solutions (i.e. reinforced Rubber / FKM)
Cooling: PA11
HPPA MLT solutionPA12 Special Grade
Air IntakeTEEE, PA6, PA6-Alloy, Rubber
MetalMetal / / RubberRubber SolutionSolution Flexible Flexible ThermoplasticThermoplastic SolutionSolution
-
no solution
no solution
220-200°°°°C
A Breakthrough in Metal Replacement
Rilsan® HT creates opportunities to replace metal in tubing that were previously unthinkable !
Rilsan® HT New class of flexible PPA
Rilsan® HT - The First Flexible PPA Confidential Arkema Property – Duplication prohibited
What makes Rilsan® HT so different ?
�is the first flexible PPA to replace metal in tubing for high temperature applications
� surpasses other high-temperature thermoplastics with superior long-term resistance to thermo-oxidative and chemical aging at high temperatures
� is the only PPA being spin- weldable on aliphatic PA
� naturally fits into eco-design concepts
� can be easily manufactured on standard processing equipment
� offers cost-efficient manufacturing and system cost reduction
� features high design flexibility
� is a light- weight PPA resin
� offers exceptional dimensional stability
► Flexibility
► Processability: ► processing similar to aliphatic polyamides
► no need for special heating & cooling system
► excellent thermoforming and fitting insertion
►Long term heat resistance ► (thermooxidation) and chemical ► resistance at high temperature
► Integrity of mechanical properties ► at high temperature
► Spin-welding
► Low density
► Low moisture uptake
► Biobased
High Temperature Resistance…. PLUS : Rilsan® HT…..
Rilsan® HT - The First Flexible PPA Confidential Arkema Property – Duplication prohibited
Rilsan® HT: The optimum synergy of both
Rilsan® HT – The First Flexible PPA
LimitationsTemperature resistance
up to 150°C
LimitationsOnly available as injection grades due to intrinsic brittleness / stiffness of material
Poorer Long-Term Aging Resistance
Difficult overall processing
Rilsan® PA11 Classical PPA resins
Key Points:High melting point
High temperature resistance
Key Points:►Flexibility
►Excellent Long-Term Aging
► Resistance
►Ease of processing
►BioBased
Rilsan® HT - The First Flexible PPA Confidential Arkema Property – Duplication prohibited
Flexural modulus of Rilsan® HT compared to classic HT polymers –a breakthrough amongst HT materials
Rilsan® HT – Unprecedented Flexibility
Rilsan® HT: <<<< is the only PPA to combine the high-temperature resistance of conventional PPA grades with flexibility
Rilsan® HT
PA 11
9T6/6T
66/6T
6I/6T
46
1000
1500
2000
2500
3000
3500
150 170 190 210 230 250 270 290 310 330
Melting point (°°°°C)
Fle
xu
ral
mo
du
lus (
MP
a)
Classic PPA
New class of
flexible PPA
PA 6
(neat resins)
Rigid
Flexible
500
Rilsan® HT extrusion grades
Rilsan® HT - The First Flexible PPA Confidential Arkema Property – Duplication prohibited
Weight reduction by Rilsan® HTWeight savings, through
Metal replacement and substitution of rubber & other polymeric materials Low density
Rilsan® HT:
<<<< lowers total system weight by min. 50% (factor 2 to 3 vs Al, 6 to 8 vs steel)
<<<< is a light- weight PPA resin
<<<< helps to reduce emissions
and fuel consumption
8.67.8
7.1
2.21.7 1.7
1.4 1.3 1.2 1.2 1.1 1.1 1.0
0
2
4
6
8
10
Bra
ss
Ste
el
Zin
c
PT
FE
ET
FE
PV
DF
PP
S
PE
EK
PP
A 6
T
PA
46
PA
66
Rils
an®
HT
PA
11
MetalFluorinated Polymers
Other HT/HP
PolymersClassic
HT Materials
Densi
ty [
g/c
m3]
Ril
sa
n®
HT Rubber
1,15 – 1,3
1.211.18
1.14
1.08
1.02
0.85
0.95
1.05
1.15
1.25
Density of Rilsan® HT compared to metal, rubber and other polymeric materials
Rilsan® HT
is more
than 10%
lighter than
classic PPA
EnvironmentalEnvironmental
Metal assembly / 1000g � Rilsan® HT / 350gWeight gain: Rilsan® HT 3 times lighter
Blow-by @ VW
Alu tube w/ Brass QC (280g) resp. w/ Alu QC (110g) --> Rilsan® HT tubing / 50gWeight gain: Rilsan® HT 2 to 6 times lighter
EGR vacuum tubing @ PSA
Alu assembly / 270g � Rilsan® HT / 110gWeight gain: Rilsan® HT 2.5 times lighter
TOC @ Hyundai
Rilsan® HT - The First Flexible PPA Confidential Arkema Property – Duplication prohibited
System Cost reduction by Rilsan® HT
Rilsan® HT vs. metal based tubing assembly:
Rilsan® HT: <<<< generates up to 50% cost savings vs. metal tubing assemblies
0
10
20
30
40
50
60
70
80
90
100
Syst
em
cost
s[
Base
100 o
f M
eta
l Ass
em
bly
Syst
em
Cost
]
Assembly
Processing(Extrusion,Thermoforming)
Material
Component / system cost
Metal Tubing Assembly
Rilsan® HT Tubing Assembly
EconomicalEconomical
Rilsan® HT - The First Flexible PPA Confidential Arkema Property – Duplication prohibited
Rilsan® HT product line up
Extrusion grade
Rilsan® HT CESV P010TL
Rilsan® HT CESV Bk P010TL HP
Rilsan® HT CESV Bk P223TL
Rilsan® HT CESV P123TL
Rilsan® HT CZM30 Bk TLD
Rilsan® HT CSR13
Injection grade
feature (flexural modulus)
Standard (820MPa)
High pressure (1530MPa)
Flexible (520MPa)
Improved hydrolysis (820MPa)
feature (flexural modulus)
GF30% (7300MPa)
Conductive (7600MPa)
Rilsan® HT CMFO High flowability, non-filled (1800MPa)
Rilsan® HT CMNO TL Standard, non-filled (1370MPa)
Rilsan® HT CMNO Standard, non-filled (1800MPa)
Rilsan® HT - The First Flexible PPA Confidential Arkema Property – Duplication prohibited
… already been selected by many OEM
Rilsan® HT – …
Rilsan® HT - The First Flexible PPA Confidential Arkema Property – Duplication prohibited
Rilsan® HT – with best fit ….
Intercooler
EGR cooler EGR valve
Injector
Blow-by
Turbo
Air
Fuel
SCR
DPF
DOC
AdBlueTank
Exhaust Gas
DPF (Diesel Particulate Filter)
SCR (catalyst)
AdBlue®Tank
and InjectionDOC(Diesel OxydationCatalyst)
EGR
EGR Valve
Tubing
Mixer
SCR / AdBlue®
Air
Ma
na
ge
me
nt
Ag
gre
ssiv
e
Me
dia
Mn
gt.
Oil
Mn
gt.
Aq
ue
ou
s
Me
dia
Mn
gt.
EGR EGR (exhaust gas recirculation)
Air IntakeAir Intake
TOC TOC (Transmission Oil
Cooling)
BlowBlow--byby
AdBlueAdBlue®® / SCR / SCR (selective catalytic
reduction)
CoolingCooling
Fu
el
Mn
gt.
High High
TemperatureTemperature
Fuel LinesFuel Lines
… to Euro 6 & key powertrain technologies
Rilsan® HT - The First Flexible PPA Confidential Arkema Property – Duplication prohibited
� GradeGradeGradeGrade: Rilsan® HT CESV P010TL� Case studyCase studyCase studyCase study: Powertrain Powertrain Powertrain Powertrain ---- Aggressive Media ManagementAggressive Media ManagementAggressive Media ManagementAggressive Media Management
Blow By LineBlow By LineBlow By LineBlow By Line� Replaced:Replaced:Replaced:Replaced: Aluminium tubing / HPPA with heat shield� Status:Status:Status:Status: Approved and in series prod. since Q3 2010
at VW (PV 3936) / AUDI / SEAT / Porsche / Bentley; Daimler, Mahindra, Ferrari / Maserati / Alfa Romeo, Chrysler
� Models:Models:Models:Models: VW VW VW VW groupegroupegroupegroupe: : : : <<<<all diesel engines (having a diesel particle filter, due to new Euro 5/6 regulation), models/platforms starting with 2,0l & 1,6l engines, eg. Golf, Passat, Tiguan, A3, Skoda, …) <<<< all new 12 cyl. gasoline engines (e.g.A8, Phaeton, Bentley)Fiat Fiat Fiat Fiat groupegroupegroupegroupe: <<<< e.g. for new V6 engines of Ferrari & Chrysler for Maserati, Alfa Romeo, Chrysler
� Example: Example: Example: Example:
Rilsan® HT Tubing
AirBlow By GasExhaust Gas
Combustion Chamber
Piston
Connecting rod
Crankshaft
Oil pan
Blow-by tubing
Air IntakeExhaust gaz
Rilsan® HT CESV P010TL
Crankcase
2 temp. classes:►160°°°°C
►180°°°°C
Case: Aggressive M. / Blow By
Rilsan® HT - The First Flexible PPA Confidential Arkema Property – Duplication prohibited
IntercoolerIntercooler
FilterFilterClean air tube
Outside Intercooler Tube
OUTSIDE TURBO TUBE
Exhaust
gas pipeAIRAIR GAS
Turbo -Compressor
Outside Turbo TubeOutside Turbo Tube
4 cylinders engine4 cylinders engine
Rilsan® HT
180°°°°C < T < 200°°°°C
P~2-4bar, T ~ 180-200°C
P~2-4bar, T ~ 110°C
T ~125 to 150°°°°C
T ~125 to 150°°°°C
P~0.7-1 bar, T ~ 20-40°C
Orgalloy® LT
Orgalloy® LT
� GradesGradesGradesGrades: Rilsan® HT CESV P010TLRilsan® HT CESVO P223TL (“ultra-flexible”)
� Case studyCase studyCase studyCase study: Powertrain Powertrain Powertrain Powertrain –––– Air / Pressure ManagementAir / Pressure ManagementAir / Pressure ManagementAir / Pressure ManagementAir IntakeAir IntakeAir IntakeAir Intake
� Replaced:Replaced:Replaced:Replaced: Metal, Rubber� Status:Status:Status:Status: Under development� ExampleExampleExampleExample:
Rilsan® HT Tubing Case: Air Mngt. / Air Intake
Rilsan® HT - The First Flexible PPA Confidential Arkema Property – Duplication prohibited
� GradesGradesGradesGrades: Rilsan® HT CESV P010-HP TL (tubing)Rilsan® HT GF reinforced (QC)Connection by spin-welding
� Case studyCase studyCase studyCase study: Powertrain Powertrain Powertrain Powertrain ---- Oil Oil Oil Oil MngtMngtMngtMngt. / Transport. / Transport. / Transport. / TransportTOC TOC TOC TOC (Transmission Oil Cooling)
� Replaced:Replaced:Replaced:Replaced: Metal, Rubber Tubing� Status:Status:Status:Status: Approved at BMW, Greatwall
� Models:Models:Models:Models: will be in series for new platforms
� ExampleExampleExampleExample:
Metal, Rubber Tubing
replaced by:
Rilsan® HT CESV P010-HP TLRilsan® HT GF reinforced
(QC)
Gearbox
Transmission Fluid Cooler
Radiator
Transmission Oil Cooler Hose
Rilsan® HT CESV P010-HP TL
Specification:►3000h oil 150°°°°C / peak 175°°°°C►Burst resistance: hot oil at 220°°°°C
Rilsan® HT Tubing Case: Oil Mngt. / TOC
Rilsan® HT - The First Flexible PPA Confidential Arkema Property – Duplication prohibited
Case: Cooling
� GradesGradesGradesGrades: Rilsan® HT CESV P010 TL (medium temp.)Rilsan® HT CESV black P123 TL (high temp.)
� Case studyCase studyCase studyCase study: Powertrain Powertrain Powertrain Powertrain ---- Aqueous Media Aqueous Media Aqueous Media Aqueous Media MngtMngtMngtMngt....Cooling linesCooling linesCooling linesCooling lines
� Replaced:Replaced:Replaced:Replaced: Aluminium tubing / Rubber� Status:Status:Status:Status:
Current grade: Current grade: Current grade: Current grade: RilsanRilsanRilsanRilsan®®®® HT CESV P010 TLHT CESV P010 TLHT CESV P010 TLHT CESV P010 TL� BMWBMWBMWBMW
� Mini, series 3, 5, 7 / new Hybride� SOP end 2013
� DAIMLERDAIMLERDAIMLERDAIMLER� e.g. Mercedes Class “C”� SOP end 2013
� VOLVO Truck (US)VOLVO Truck (US)VOLVO Truck (US)VOLVO Truck (US)
New grade: CESV black P123 TL New grade: CESV black P123 TL New grade: CESV black P123 TL New grade: CESV black P123 TL � Under evaluations
(technical feedback from customer to pass VW specification)
125 - 130°°°°C (temp. class rating) (current grade CESV P010TL)
135 - 145°°°°C (temp. class rating) (new grade CESV P123L)
Rilsan® HT Tubing
Rilsan® HT - The First Flexible PPA Confidential Arkema Property – Duplication prohibited
� GradeGradeGradeGrade: Rilsan® HT CESVO P223 TL – “ultra-flexible” Rilsan® HT Grade� Case studyCase studyCase studyCase study: Industrial Applications Industrial Applications Industrial Applications Industrial Applications –––– Air / Vacuum ManagementAir / Vacuum ManagementAir / Vacuum ManagementAir / Vacuum Management
e.g. High Temperature Pneumatic TubingHigh Temperature Pneumatic TubingHigh Temperature Pneumatic TubingHigh Temperature Pneumatic Tubing� Replaced:Replaced:Replaced:Replaced: Metal, ETFE, PTFE� Status:Status:Status:Status: Under evaluation at customer / OEM� ExampleExampleExampleExample:
Temperature class:> 150°C
Key Benefits:
▶ Flexibility (520MPa) !
▶ “ultra-flexible”
Rilsan® HT Grade
Rilsan® HT Tubing Case: Industrial Tubing