Commercial Applications of Bio- Based Polymers in Automotive Rick Bell – RS Development Manager SPE ACCE September 15, 2011 2 208 Years of Innovation and Success • A Dynamic Science Company • 60,000 employees in over 90 Countries • $32 Billion in Global Revenue • Above numbers do not reflect recent Danisco acquisition. • AA WorldWorld LeaderLeader inin RenewableRenewable MaterialsMaterials andand BiotechnologiesBiotechnologies Sept 15, 2011 3 Terminology • RENEWABLY SOURCED and BIO-BASED define the same thing. It refers to a material that contains carbon originating from a renewable plant source. DuPont™ Renewably Sourced™ materials contain a minimum of 20% renewably sourced ingredients by weight. • RENEWABLY SOURCED can include BIODEGRADABLE products that can be broken down by living organisms like bacteria. It also includes durable goods that are designed for long life. • Products discussed in this presentation are for durable good type applications. Sept 15, 2011 4 Renewable Materials from DuPont Sorona® for interior textiles Hytrel® RS thermoplastic elastomer for injection and Cerenol™ extrusion for polyurethane parts Zytel® RS polyamides for injection and extrusion BioFuels Sorona® Sorona® EP for carpets and mats PTT polyester for molded parts Sept 15, 2011 5 Next Generation Materials and Fuels from Biomass Automotive OEMs around the world are developing cars to be more environmentally friendly Biomass …to Products Green Chemistry & Engineering Wide range of products commercially available and under development. Deliver renewably sourced materials made from biomass instead of petroleum with uncompromised product performance Sept 15, 2011 6 DuPont Renewably Sourced Materials Broadest Portfolio for Engineering Polymers Sorona ® EP Thermoplastic Polymer • DuPont™ Sorona® EP is a PTT polyester with properties similar to PBT polyester. Hytrel ® RS Thermoplastic Elastomer • DuPont™ Hytrel® RS, is TPC-ET thermoplastic elastomer (TPE). Properties are similar to standard Hytrel®. Zytel ® RS 6,10 and 10,10 Long Chain Polyamides • Comprises all products based on PA 6,10 and 10,10 including copolymers, alloys, and reinforced grades. Product data sheets, brochures and processing guides available at: www.plastics.dupont.com and www.renewable.dupont.com Sept 15, 2011 7 Bio-PDO Provides Bio Content in Sorona® HOHO--CHCH2--CHCH2--CHCH2--OHOH Corn Starch Glucose Glycerol PDO Yeast Bacterium Combined in a Single Biocatalyst Current Production facility is sold out producing over 100 million lbs/year of bio- PDO. Over 30% Capacity Increase Underway LCA: 10 million gallons of gasoline/yr saved Sept 15, 2011 100 MM PPY, Loudon, TN 8 Sorona® Life Cycle Analysis Sorona ® vs nylon 6 Life Cycle Analysis (Cradle to gate) per ISO standards • 37% renewable content • 63% less green house gas emissions • 30% less energy and 21% less process water. Major ISO 14000-series documents: • ISO-14040 Environmental management- Life cycle assessment- Principles and framework • ISO-14044 Environmental management- Life cycle assessment- Requirements and guidelines • ISO-14047 Environmental management- Life cycle impact assessment- Examples of application of ISO-14042 • ISO-14048 Environmental management- Life cycle assessment- Data documentation format • ISO-14049 Environmental management- Life cycle assessment- Examples of application of ISO- 14041 to goal and scope definition and inventory analysis Holistic Approach: Evaluate the impact of all upstream and downstream products and processes. Third party certified. Sept 15, 2011 9 Sorona ®® Polymer - Product Properties Sorona® PET PBT Nylon 6 Nylon 6,6 PP PLA 0 Melt Temperature, Tm ( C) 228 260 225 222 262 160 130-175 0 Glass Transition, Tg ( C) 50-70 70 - 80 25 - 35 40 - 60 45 - 65 -30 55 - 65 Density 1.33 1.38 1.32 1.14 1.14 0.91 1.25 1,3-propanediol + DMT / TPA Catalyst Bio-PDO™ (Sb-free) O O 2GT 3GT 4GT -(-C C-OCH 2CH 2CH 2O)- PET PTT PBT n Sept 15, 2011 10 Sorona® EP Thermoplastic Polyester • PTT polyester similar to PBT in performance Applications and price. • Better surface appearance, UV resistance. • Electronic control module housings • Stronger and stiffer than PBT. • Headlamp bezels • Connectors, electrical, electronic parts • Lower shrink vs PBT, less warpage. • Handles, seat trim components • Improved hydrolysis resistance and laser • Any painted part (eliminate paint) weldability. Slightly better electrical properties PBT, 30%GR SoronaØ, 30%GR HDT (1.8 MPa) 1.5 Specific Gravity 1 Shrinkage 0.5 0 Flex Mod (150C) Tensile Strength Flexural Modulus Elongation Commercial at Toyota on interior parts Sept 15, 2011 11 Sorona® EP – Toyota Vent Louver - Commercial Cost reduction by eliminating painting process compared with glass reinforced PBT, former material Design freedom because of higher mechanical property than glass reinforced PBT Material chosen and Why Sorona® 2045G , 45% glass filled grade was chosen because 45% glass filled Sorona®EP of its excellent combination of Sorona®2045G good appearance and mechanical property. Sept 15, 2011 12 Comparative Properties – Glass Reinforced 12000 Sorona® 3030G PA66 PA6 10000 PBT DAM DAM 8000 PA66 50%RH Sorona® 3015G PA6 PA6 PBT PA66 6000 DAM 50%RH DAM Tensile Modulus, MPa Modulus, Tensile PA66 4000 PA6 50%RH 50%RH 2000 0 13-15% Glass 30% Glass Datasheets at www.plastics.dupont.com Sept 15, 2011 Contact Rick Bell for detailed product comparisons 13 DuPont™ Sorona ® Fibers • Currently available in apparel, commercial and residential carpet. • Commercial today as carpet pad on five different car lines. • Provides improved stain resistance vs nylon. • Significantly improved crush resistance and durability vs. polyester fibers • Superior softness compared to nylon and polyester. • Resistant to mold, mildew and odor without surface treatments. If only 20% of the residential carpet sold in the U.S. were made from Sorona®, the energy equivalent of approximately 50 million gallons of gasoline would be saved per year. Sept 15, 2011 14 Sorona® Fiber Commercial Examples Toyota SAI Sustainable compact luxury car 60 percent of the interior fabrics use DuPont™ Sorona® renewably sourced fiber • headliner • sun visor • other fabric covered surfaces • floor mats. (Also on Prius). Sept 15, 2011 15 Zytel® RS Long Chain Polyamides • Based on biofeedstock derived from castor plant. Includes various grades of PA10,10 (100% biobased) and PA6,10 (60% biobased). • Commercial in monofilaments, consumer products, sporting goods, hand held devices, automotive. Radiator end-tanks – Comm’l • High performance polyamides that provide high flexibility, toughness and thermal properties with superior chemical and hydrolysis resistance • Provides competitive cost options vs nylon 11 and 12. Fuel lines – Comm’l Pneumatic/air brake tubing Comm’l Fuel Connectors Coolant pipes Sept 15, 2011 16 Renewable Sourcing for Long Chain Polyamides Castor Oil Petrochemicals Sebacic acid Hexamethylene Diaminodecane diamine PA10,10 PA6,10 100% Renewable Carbon 62% Renewable Carbon Sept 15, 2011 17 Comparative properties of base polymers TENSILE MODULUS 2500 PA610 PA612 2000 PA1010 PA12 1500 PA11 MPa 1000 500 0 Mechanical Properties ( dry as moulded ) PA610 PA612 PA1010 PA11 PA12 Yield Stress (Mpa) 62 61 50 43 45 Yield Strain (%) 4.3 4.6 5 5.2 Strain at Break (%) >50 >50 >50 >50 >50 Tensile Modulus (MPa) 2250 2100 1550 1350 1400 Unnotched Charpy Impact Strength -50C (kJ/m2) NB NB NB NB NB Notched Charpy Impact Strength -50C (kJ/m2) 2.4 3.5 6.3 5.2 Sept 15, 2011 18 Positioning of Various Polyamides Hydrocarbons resistance Barrier Properties (fuel, CO2) PA12 PA11 PA1010 PA612 PA610 Polar Fluids resistance Chain length Chain Flexibility Moisture resistance PA66 Hydrolysis resistance Stress Cracking resistance Sept 15, 2011 19 Radiator End-Tanks - Denso Commercial example of better performance at lower cost while reducing carbon footprint • Zytel® RS (PA 610) commercial in radiator end tanks • First use of this renewably sourced plastic in a mechanical component exposed to the hot, chemically aggressive underhood environment • DuPont won Denso's "Innovative Technology of the Year" award and SPE 2009 automotive award “Most Innovative Use of Plastics for the Environment” Lower cost vs PA11, PA12 or PA6,12 Sept 15, 2011 20 Hytrel® RS Thermoplastic Elastomer Properties similar to standard Hytrel ® • Excellent elasticity & low In Hytrel ® RS, petroleum sourced polyether temperature flexibility glycols in the soft segments are replaced by • Excellent flex fatigue and cut Renewably Sourced polyether glycols made growth life from non-food biomass. • Good chemical & oil resistance 70 60 • High tear strength, 50 toughness, resilience, impact 40 resistance 30 • Commercial in sporting 20 goods, furniture and % renewable content 10 consumer products. 0 Air bag door covers 30 40 50 60 70 shore D hardness The renewably sourced content of Hytrel ® RS varies with the hardness of the grade Sept 15, 2011 21 Hytrel ® RS – Potential Applications Properties similar as regular Hytrel® TPE Any thermoplastic CVJ boot elastomer, soft touch application ABD Covers Overmolded parts CVJ, shifter boot, seat shift (Driver) (Door latches) dust covers Hose & tubing Air duct Air brake hose (vacuum hoses) Sept 15, 2011 22 DuPont Renewably Sourced Materials Our goal is to provide performance and functionality equivalent to or better than today’s fully petroleum based materials while reducing the environmental footprint. Enhanced Sustainable Performance Solutions Total Lowest System Cost Sept 15, 2011 www.renewable.dupont.com.