Organised by Munich, Germany 12-13 March 2008 ISBN: 978-1-84735-069-5 © Smithers Rapra, 2008 All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form by any means, electronic, mechanical, photocopying, recording or otherwise, without prior written permission of the publisher, Smithers Rapra Ltd., Shawbury, Shrewsbury, Shropshire, SY4 4NR, UK. The views expressed in this publication are those of the individual authors and do not necessarily correspond to those of Smithers Rapra Technology Ltd. This publication is published on the basis that no responsibility or liability of any nature shall attach to Smithers Rapra Technology Ltd. arising out of or in connection with any utilization in any form any material contained in this publication. 12-13 March 2008 Munich Marriott Hotel, Munich, Germany Contents SESSION 1 MARKET TRENDS FOR SILICONE ELASTOMERS Paper 1 Global expansion for the silicone rubber market Dr Hans Peter Wolf, Dow Corning GmbH, Germany SESSION 2 LIQUID SILICONE RUBBER Paper 2 Liquid silicone rubber, the material of your choice Marco Pagliani, Dow Corning SpA, Italy & Fabien Virlogeux, Dow Corning France SAS Paper 3 Real fluorosilicones combined with LSR processing: new product family FFSL Oliver Franssen & Dr Stephan Bosshammer, Momentive Performance Materials GmbH, Germany SESSION 3 APPLICATIONS FOR SILICONE ELASTOMERS Paper 4 Silicone elastomers in medical applications Andre Colas, Dow Corning SA, Belgium Paper 5 Adding colour to medical devices using pigment masterbatches Patrick Peignot & Stephen Brunerm NuSil Technology Europe, France Paper 6 Silicone elastomers for outdoor electrical power transmission and distribution applications Dr Hans-Jörg Winter, Wacker Chemie AG, Germany Paper 7 Corpo Fibre Reinforcement for Elastomer Applications Siebe Nooij, Coen Ten Herkel & Soren Blomaard, Taniq BV, The Netherlands SESSION 4 TESTING SILICONE ELASTOMERS Paper 8 A single testing instrument with multiple testing capabilities for silicone elastomers Laurent Perier & Arnaud Favier, DMA Products and Consulting, 01dB-Metravib, France SESSION 5 FILLERS FOR SILICONE ELASTOMERS Paper 9 Carbon nanotubes/silicone elastomer nanocomposites: multi-fuctional and high performance products; review and trends of their applications Michael Claes & Daniel Bonduel, Nanocyl SA, Belgium & Philippe Dubois, Université of Mons-Hainaut, Belgium Paper 10 Structure modified fumed silica-a clear solution for silicone rubber Dr Mario Scholz, Evonik Degussa GmbH, Germany Paper 11 Improvements in reinforcement with diatomaceous earth in silicone systems Julian Danvers,World Minerals, UK SESSION 6 CROSSLINKING SILICONE ELASTOMERS Paper 12 Peroxide curing of silicone elastomers Leo Nijhof, Akzo Nobel Polymer Chemicals BV, The Netherlands Paper 13 Crosslinking in PDMS particulate composites Dr Catarina Esteves, Dr J Brokken-Zijp, Dr J Laven & Dr G de With, Technische Universiteit Eindhoven, The Netherlands SESSION 7 PROCESSING SILICONE ELASTOMERS Paper 14 Silicone mixing and extrusion processing Ubaldo Colombo, Colmec SpA, Italy Paper 15 Carbon dioxide: good news for silicone rubber Thomas Christensen, Nanon A/S, Denmark Paper 16 Silicone composites Dr Jürgen Weidinger & Dr Jürgen Ismeier, Wacker Chemie AG, Germany Paper 17 Bonding silicone elastomers Aissa Benarous, Chemical Innovations Ltd, UK Paper 18 Bubbling modelization, a help for the development of low density RTV foams Dr Delphine Blanc, Bluestar silicones, France SESSION 8 INJECTION MOULDING LIQUID SILICONE RUBBER Paper 19 Physical foaming of liquid silicone rubber in the injection moulding process Prof Dr-Ing Dr-Ing Eh W Michaeli & Dipl-Ing Kai Openwinkel &, IKV Aachenm Germany Paper 20 High quality LSR moulding Kurt Manigatter, Elmet GmbH, Austria 12-13 March 2008-Munich, Germany Silicone Elastomers 2008 SILICONE EXPANSION: TREND INDICATORS FOR GROWTH IN THE SILICONE ELASTOMER MARKET Dr. Hans Peter Wolf, author and conference speaker Silicone Rubber S&T Manager - Europe, Dow Corning GmbH Rheingaustrasse 34, 65201 Wiesbaden, Germany Tel: +49 –611237293, Fax: +49 611 237 62, Email: [email protected] BIOGRAPHICAL NOTE Dr. Hans Peter Wolf joined Dow Corning in 1998, when he joined a Dow Corning research team as part of his post-doctoral work on the direct synthesis of phenychloro silanes. He holds an undergraduate degree in chemistry and a Ph.D. in inorganic chemistry from the University of Frankfurt. Dr. Wolf has extensive experience in silicone research and is an expert in engineered elastomers. Dr. Wolf’s career with Dow Corning in Europe has included positions in research, engineering, TS&D and leadership. In January 2008, he was named Rubber S&T Manager for Europe in the Engineered Elastomers Industry. ABSTRACT In recent years, the use of silicone elastomers has grown exponentially. Silicone's versatility and consistent proven performance when exposed to extreme temperature ranges, moisture or other adverse conditions, makes it the material of choice across a wide range of markets, including power and utilities, transportation, healthcare, and consumer. As developing nations look for greater ways to expand, silicone technology has become a critical player in promoting greater economic growth, improved energy and cost efficiencies, while maintaining regulatory and safety standards. This paper will take a closer look at the driving forces behind this global heightened demand. The use of such advancing technologies in key developing regions, specifically Asia, will be analyzed. As business activity continues to grow in these areas, a greater cross- sharing of knowledge and expertise is needed to educate audiences on the limitless potential of silicone elastomers in the development and globalization of regions throughout the world. INTRODUCTION In recent years, the use of silicone materials has grown dramatically in a variety of industries because of their high-performance advantages such as wide in-use temperature range, chemical resistance, good electrical properties and environmental benefits. Use of silicone elastomers in particular has increased globally as nations and industries recognize their processing and cost efficiencies as a way to grow through advances in productivity and improved performance standards. Additional growth factors include the need to manage overall costs and the globalization of manufacturing as industries transplant operations to developing countries. With this trend, manufacturers will seek partners offering a global presence and local expertise as well as access to international supply chains, market information, and government regulations and standards. Steady increases in raw material and energy costs since 2006, which are expected to continue in 2008 and beyond, are putting many industries under stress. Innovation in solutions to increase performances and limit energy consumption and waste will be critical success factors to survive in the new industrial era. The silicone rubber industry is innovating to offer solutions that help industries overcome these new challenges: development of formulations for improved performance and longer service life parts, and improved processability for more effective manufacturing, like the fluorosilicone elastomers, liquid silicone elastomers Page 1 of 10 Paper 1 Silicone Elastomers 2008 12-13 March 2008-Munich, Germany and liquid fluorosilicone elastomers. The use of silicone rubber in demanding solutions has continued to grow in recent years, and one can expect that this is the start of a long term trend. This paper provides an overview of trends that drive the need for silicone rubber solutions, in industries like automotive, electrical distribution, imaging equipment, consumer and healthcare product markets. I. Industry Overview - Historic Growth & Global Consumption Automotive, electrical and consumer applications lead global consumption of silicone rubber as well as materials industry growth. Global consumption and growth figures show that silicone markets continue to outpace average global economic growth. Between 1995 and 1998, the average global growth rate of the silicone industry was 6 percent, driven largely by developing Asian countries. In 2002, the global market for silicones totaled approximately €8 billion, based on a production volume slightly above 2 million tons. Major sales areas included Europe, representing 33 percent of the global total in 2002, and North America, representing 34 percent.1 (Figure 1) Regional Share of € 8 Billion Silicone Sales based on 2,000,000 tons production volume 5% 33% 28% Western Europe North America Asia Rest of the World 34% Figure 1 Source: CES In 2005, global elastomer consumption grew by an estimated 2.5 percent to 20.68 million tons. In 2006, World Rubber Summit & Assembly of Nations member states predicted that global elastomer utilization will grow by about 3.3 percent in 2006.2 The markets for natural rubber (NR) and synthetic rubber (SR) are projected to increase by 2.6 percent and 3.8 percent, respectively.3 As shown in Figure 2, growth in the global elastomer and rubber market is slated at 5 percent per year. Specialty elastomers are expected to exceed this growth rate by 2 percent while silicone elastomers are expected to nearly double the total elastomer and rubber growth rate with an anticipated increase of 9 percent per annum. 4 Of note, Western Europe is also showing growth in silicone elastomer consumption after several flat years (Figure 3). Within silicone elastomers, high consistency silicone rubber (HCR) consumption remains significant due to the wide range of custom HCR compounds available. However, while consumption of HCR has leveled during the past decade, liquid silicone rubber (LSR) and fluorosilicone rubber (FSR) consumption has practically doubled based on two key trends: market demand for increased performance and durability; and the demand for increasingly cost-effective processes. According to presentations during the LSR Forum 2005 in Lyon, even though LSR still represents less than 2 percent of all rubbers and elastomers, it has experienced a two-figure increase in demand. Considering ongoing investments, LSR capacity is expected to triple by 2009. LSR is becoming a key technical material class, particularly as cost pressures drive the need for materials that perform in highly automated manufactured applications.5 Paper 1 Page 2 of 10 12-13 March 2008-Munich, Germany Silicone Elastomers 2008 Figure 2 Figure 3 Source: World Rubber Summit & Assembly Source: CEH Report, SRI Consulting Estimated Elastomer Growth Per Year Western Europe by Segment of Market Consumption of Silicone Elastomers (thousands of metric tons) 10% 140 8% 9% 120 6% 7% 100 4% 5% 80 60 2% 40 0% 20 Total All Specialty Silicone Elastomer Elastomers Elastomers 0 Market 1986 1994 1999 2001 2007 The available data confirms that consumption of silicones, particularly LSR and FSR, has increased steadily over the last 20 years. This trend towards higher performance and easy-to-process silicone elastomers is expected to continue (Figure 4).6 Figure 4 Source: CEH Report, SRIConsulting 200 180 160 140 RTV 120 HCR 100 LSR & Fluorosilicone 80 Total 60 40 20 0 1986 1991 1995 1998 2002 2005 2010 LSR, known for its processability, enables manufacturers in developed countries to reduce labor time and therefore compete with manufacturers in low labor cost nations. FSR provides a reliable level of performance when used in extreme temperature and aggressive chemical environments. As large OEMs source from emerging economies to achieve higher performance and lower delivered cost, the long-term trend towards globalization is becoming visible. With silicon-based materials and global technical service support, manufacturers can improve their processes, increase productivity and create better, more cost-effective products. As local economies grow, local consumption increases. Developing countries are rapidly adopting new technologies and are demonstrating the same level of acceptance of silicone elastomers as in more developed nations. Overall, China and India represent the strongest opportunities for the silicone market. There have already been massive investments in the petrochemicals sector in both countries, although investments are now migrating rapidly to downstream segments, including specialty chemicals Another market showing great promise for silicone is Southeast Asia, particularly Thailand, Indonesia, the Philippines and Vietnam. The 2002 CEH Marketing Research Report 'Silicones' projected a 4 – 15 percent Page 3 of 10 Paper 1 Silicone Elastomers 2008 12-13 March 2008-Munich, Germany growth in overall silicone consumption in developing nations compared to 2 percent and 3 percent for the United States and Western Europe, respectively. China, for example, is predicted to have a 15 percent average annual consumption growth rate between 2005 and 2010, far higher than any other region of the world.7 Table 1 Source: CEH Report, SRI Consulting Average Annual Consumption of Silicone - Growth Rate by Region (percent) USA Western Europe Japan Rest of the World Total 2002-2007 4% 2% 1-1.5% 5-10% 2.2% 1. AUTOMOTIVE INDUSTRY TRENDS a) Geographic expansion Historically, Tier suppliers in the automotive industry have typically installed their production close to their OEM customers. As OEMs expand their activities in developing or emerging countries, to achieve cost gains or reach new markets, the whole automotive supply chain needs to follow. This leads to the need for suppliers to offer global solutions. b) Emission Regulations: The European Union (EU), Japan and United States have recently implemented more stringent emission standards. The drive to reduce emissions is leading to increasingly closed engine systems. This creates a harsher environment with increased presence of fuels, oils and chemicals as well as higher temperatures under the hood. This trend is forcing car makers and their parts suppliers to evaluate new materials that are able to withstand these harsher environments. Many traditional materials are being replaced by more resistant materials, and silicone rubbers such as fluorosilicone rubbers are becoming a preferred solution.. c) Higher Performance Requirements: With the presence of aggressive oils and higher temperatures under the hood, car makers and suppliers must look to higher performance materials, such as fluorosilicone rubber (FSR). Compared to most organic rubbers, FSR offers superior mechanical properties at elevated temperatures. In addition to its heat resistance, silicone rubber can offer chemical resistance and superior acoustic behavior, lending it to many uses. d) Increased Use of Electronics in Motor Vehicles: The increased use of electrical components in automobiles demands long-term functionality, which requires protection from the outside environment. Liquid silicone rubber is the primary material suitable for producing weather pack connector grommets and seals because it provides the required thermal, electrical, and humidity resistance properties. Because liquid silicone rubber can be self-lubricating, it is easier to thread the cables and wires during assembly. Long-term connector seal performance is maximized due to the low compression set and a range of fuel-, oil- and chemical-resistant liquid silicone rubber options. e) Increased Safety Systems: The silicone elastomer industry worked closely with a leading airbag manufacturer to develop a silicon-modified, organic, elastomeric coating that controls inflation/deflation timing and dependability. It also has a high resistance to gases and retains flexibility and resilience over wide temperature and humidity ranges and over extended periods of time. In addition, the thinness of the coating ensures the airbag cushion can easily be folded and complies with both regulatory requirements and vehicle manufacturers’ specifications. g) Reduction of Noise & Vibration: What used to be considered luxury is now being demanded by the average consumer as a standard of performance. This is especially true for noise control in vehicles; some degree of noise control is now is expected for nearly all vehicles. The use of silicone elastomers increases soundproof performance by reducing noise and vibration through the frame of the car. In fact, silicone rubber’s specific properties make it an ideal material for sound and vibration damping applications because of its consistent behavior in a wide range of harsh environments. Paper 1 Page 4 of 10 12-13 March 2008-Munich, Germany Silicone Elastomers 2008 f) Lengthened Warranty: Higher operating temperatures in automobiles can cause premature failure of existing materials. Silicone rubber can help extend the life time of under-the-hood components to meet these new challenges. One well known example solution is the use of silicone rubber for charge air coolers—part of a high tech induction system that increases engine combustion efficiency by cooling compressed air that is forced through the intake side of the engine. When operating correctly, the cool air improves horsepower and fuel efficiency while also reducing emissions. g) News Fuels:: Modern fuels often contain oxygenates like alcohols or ethers, which may negatively affect sealing materials, causing degradation, loss of sealing integrity, and eventual failure. The polymer industry has responded with innovations in fuel-contact materials and processing technology. In many instances, fluorosilicone and liquid fluorosilicone elastomers, which possess outstanding chemical resistance and sealing characteristics, are increasingly specified to help achieve emissions and fuel systems requirements. 2. ELECTRICAL INDUSTRY TRENDS Silicone is gaining ground in the electrical industry for its proven insulation performances, long lasting properties, and resistance to external factors such as humidity, pollution, temperature changes. a) Network reliability: Everywhere in the world is the need to guarantee more reliable electricity supply and distribution. We have seen in the recent years numbers of network failures in developed countries that drive decision makers to look for more reliable systems. The Electrical industry has moved towards Silicone Rubber for high voltage transmission systems and power insulators. This transition to silicone rubber is due to its good electrical insulation properties, durability, ease of installation and low weight as compared to porcelain transmission and insulator systems. In parallel, the huge growth of electricity consumption in developing countries requires new and reliable networks to be installed. The electrical power industry is expected to show significant growth in China. The China Electricity Council predicts that China's power sector will maintain an annual growth rate of 7 percent over the next ten years, signaling an enormous investment in the industry. During the past five years the electrical power industry has increasingly moved towards composite high voltage transmission systems and power insulators; silicone rubber is expected to comprise at least 30 percent of the global electrical insulators by 2010, up from 20 percent in the previous decade. Silicone rubber is expected to comprise at least 30 percent of the global electrical insulators and transmissions materials market by 2010, up from 20 percent in the previous decade8. Silicone rubber electrical transmission products maintain compounded growth rates of 15 percent per year.9 b) Fire Safety Regulations: Regulations for wire, power and control cables, and communication cables, as well as new low smoke density and low toxicity requirements are increasing the demands of silicone rubber, which provide high temperature resistance, good dielectrics and fire resistance. Certain commonly used materials such as PVC, fluorocarbons and other halogenated or halogen containing compounds do not meet Safety Instruction IS 23, Rev 2.10. Consequently, silicone rubber maintains a unique role as a material which meets the needs of this application. c) Cost Pressures: Silicone elastomers are providing manufacturers and end users with new opportunities to meet the challenges of competitive pressures to reduce costs, further driving growth in silicone consumption in this market. High Voltage Insulators Silicone Coatings reduce the maintenance costs of ceramic insulators thanks to their long lasting capabilities. Salt spray, industrial pollutants, and even desert sand can lead to costly power interruptions due to arcing and flashover. In areas of moderate to high contamination there has been a strong trend towards the use of silicone housed composite insulators due to the increased performance in the suppression of leakage currents and the reduced maintenance of the line. While numerous attempts with other protective methods have displayed limitations, RTV coating solutions are providing a new level of performance that is driving silicone demand. Silicone composite insulators can also help in the reduction of the total line cost due to their lower weight in new constructions. The lower weight may allow for more environmentally sensitive line designs as well as the upgrading of existing lines to higher voltage without the need for extending the right of way access.11 Page 5 of 10 Paper 1 Silicone Elastomers 2008 12-13 March 2008-Munich, Germany Table 2: Conventional vs. Silicone Breaker Weights Conventional 550 kV Breaker New 550 kV Breaker with with Porcelain Insulators Composite Insulators Interrupter Head Weight 100% 50% Support Column Weight 100% 23% Weight of Base 100% 100% Total Weight 100% 62% 550kV breakers made with composite insulators are approximately 62 percent lighter than conventional porcelain insulators.12 These unique properties have made silicone rubber the material of choice for polymeric insulators. 3. IMAGING EQUIPMENT MARKET TRENDS Silicone elastomers address trends in the imaging equipment market, such as reducing machine costs, simplification of design, and environmental friendliness. Ultra low-duro LSR and sponge technologies allow high performance while also permitting the downsizing of machines. Furthermore, the semi-conductive and anti-static properties of silicone rubber also facilitate high speed printing better than other organic rubber applications. Finally, the low thermal conductivity in pressure roller applications and controlled thermal conductivity for heat rollers provides increased potential for further energy savings. 4. CONSUMER INDUSTRY TRENDS Manufacturers are finding that wherever long life, visual appeal, texture and comfort are important, silicone rubber can provide the solution. The fashion and accessories market has adopted silicone rubber as a given for smooth texture and trendy look. Kitchenware and cookware designers are now incorporating silicone rubber for its flexibility, color options, and for its ability to perform in a wide range of temperature, from the oven to the freezer. Sports gears include silicone rubber for its feel, the comfort and the added performance it can help achieve. Design and manufacturing for consumer goods are today vastly made in Asia, and brand owners selling in developed countries, in particular in Europe because of REACH, will have to be knowledgeable of the materials used in their products, to limit their quality assurance costs, from control to recall. Silicone Rubber suppliers who operate globally will help in this trend. Through 2010, liquid silicone rubber growth is expected to continue to be higher than the 3 percent global average largely due to new developments in consumer goods, where LSR competes with other injection molding materials such as urethanes.13 Additionally, new advances in LSRs are providing improved processability to increase automation cost effectiveness for manufacturing. a) Skin Contact Applications: Although silicone rubber is a higher cost material than many natural rubber or latex alternatives, it is often specified in fashion, leisure and sports applications that require skin contact due to its aesthetic and non-allergic characteristics. b) Productivity Improvements: When compared with solid silicone rubber compounds, Silastic® LSR can help manufacturers increase their productivity up to 50 percent. The two-component system for Silastic® LSR has a one-to-one ratio that’s easy to mix and pigment. Only very limited environmental controls are needed in the manufacturing area because Silastic® LSR is a non-toxic material with low odor. Molding with Silastic® F-LSR also eliminates scrap and flashes, helping to save on waste disposal costs. Manufacturers can take advantage of substantial reductions in labor costs because Silastic® LSR has excellent hot tear strength for easy de-molding, making it highly suitable for automated production and robotic handling. No secondary operations are required. Paper 1 Page 6 of 10