ThermoPlastic Composites (TPC) at Solvay November 12, 2019 Nicolas Cudré-Mauroux
WHAT IS A "COMPOSITE"? An heterogeous mixture of (at least) 2 materials: • a MATRIX • a REINFORCEMENT E.g. concrete: cement + stones Founding families event 2 November 12, 2019
WHAT IS A "COMPOSITE"? Wood: cellulose + hemicellulose (+ lignine): Founding families event 3 November 12, 2019
OUR COMPOSITE MATERIALS In Solvay, matrices we work with are POLYMERS (not metals or ceramics). Our polymers can be either THERMOSET or THERMOPLASTIC. We use 3 main types of reinforcements: Founding families event 4 Our focus for today November 12, 2019
WHAT IS A "POLYMER"? Macromolecule made of multiple repeating units (monomers) For example, the simplest one: Poly-ethylene [C-C] n Founding families event 5 November 12, 2019
THREE TYPES OF POLYMERS Elastomer Thermoplastic Thermoset Founding families event 6 November 12, 2019
TWO TYPES OF PROCESSING 1) THERMOSET Heat + Time 2 liquids Chemical reaction 1 solid (non reversible) E.g. epoxy or phenolic resins used today by our Composites GBU Founding families event 7 November 12, 2019
TWO TYPES OF PROCESSING 2) THERMOPLASTIC Heat Force No chemical reaction (reversible transformation) Founding families event 8 November 12, 2019
LOOKING INSIDE A THERMOPLASTIC POLYMER Founding families event 9 November 12, 2019
THE SECRET INGREDIENT THE INTERFACE Optimizing the interface is critical to optimize properties of composite materials ... and we have a lot of competencies in this area! Founding families event 10 November 12, 2019
THE ROLE OF THE INTERFACE HOW A COMPOSITE BREAKS "Perfect" (i.e. strong) adhesion: The crack barely "sees" the fiber rigid but brittle composite Founding families event 11 November 12, 2019
THE ROLE OF THE INTERFACE HOW A COMPOSITE BREAKS Optimized adhesion: Larger fracture area + Fiber pull-out friction MORE ENERGY CONSUMED BY THE FRACTURE PROCESS Founding families event 12 November 12, 2019
THERMOSET AND THERMOPLASTIC COMPOSITES Great properties but ... + • Long processing time THERMOSET: (chemical reaction) • Very hard to recycle Less rigid matrices but ... + • High productivity THERMOPLASTIC: processes • Recyclability Both are complementary and address different applications Founding families event 13 November 12, 2019
THERMOSET AND THERMOPLASTIC COMPOSITES High performance Thermoset TPCs Composites Combination of the benefits of thermoplastic processability and the exceptional properties of our Properties high performance polymers Standard TPCs Processing ( cost, recyclability) Founding families event 14 November 12, 2019
WHAT IS SPECIAL ABOUT OUR HIGH PERFORMANCE THERMOPLASTIC POLYMERS? In our high performance polymers, we eliminate weak chemical bonds to make them mechanically strong and highly resistant to heat and chemically agressive environments PEEK PPS PAEK Founding families event 15 November 12, 2019
WE HAVE THE "RIGHT TO WIN" IN TPC Broad portfolio of Fiber/Resin TP prepreg Application specialty polymers interface manufacturing Engineering Solvay thermoplastic composites PERFORMANCE FAST ENVIRONMENTAL AND DURABILITY CYCLE TIME RESILIENCE Robust cost-effective fabrication Resistance to aggressive fluids High strength Enables higher build-rates No corrosion Unrivaled toughness More efficient part assembly Improved recyclability Outstanding crash performance Founding families event 16 November 12, 2019
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UNMATCHED PORTFOLIO OF TECHNOLOGIES Unrivalled Compatible Extensive Bonding Field Technical and Adhesives Support & High Value Services Collaboration Materials COMPOSITE PRODUCTS COMPOSITE ECOSYSTEM Surfacing Carbon Application Resin & Polymer & Lightning & ENABLERS Fibers & Virtual Formulations Strike Engineering Thermoset & Protection Thermoplastic Prepregs Engineered Product Forms Process Tooling Materials Manufacturing Tools Founding families event 18 November 12, 2019
COMPOSITE MATERIALS RESEARCH & INNOVATION Multidisciplinary Structures & Multi-scale Application Engineering Fracture and Failure Analysis Manufacturing R&D Interfacial Properties Composite Toughening Product Architecture Formulation Chemistry Processing Science Product Forms Polymer Science Recycled Products Fiber Science Founding families event 19 19 November 12, 2019
APPLICATIONS - Aerospace Reaching new heights with composites Empennage Interiors Composites FST composites Adhesives Adhesives Radii filler Thermoplastic films and resins Wing Engines High service temp composites Composites Fuselage Manufacturing Enablers Impact resistant resins Liquid resin infusion Tailored textiles and preforms Sealants and adhesives Damage tolerant composites Composite tooling OoA prepregs Bonding primers Process materials Lightning strike protection Surfacing films Ancillaries Adhesives Founding families event 20 November 12, 2019
APPLICATIONS – Oil and Gas Composite materials that go deeper and further MATERIALS Lightweight thermoplastic composites Evolite F1050 PVDF Carbon Fiber prepreg. BENEFITS THAT COMPOSITES BRING • Weight reduction • Resistant to corrosion • High fatigue performance • Design optimization • Enables lower total installed costs • Enables access to ultra-deep water Founding families event 21 21 November 12, 2019
APPLICATIONS - Automotive Driving the world towards a more sustainable future Closures: Body in White: hood, trunklid, doors Pillars, bulkheads, floor pan, body side, roof rails, door sill Design freedom Meet crash and safety performance Class A finish Structural integration Meet crash and safety performance More flexible around vehicle architecture Trim: Secondary Dashboard, door structures / Battery tray: inner, rocker panel transmission tunnel, leafspring, spoilers, diffusers, wings, seats Stiffness and impact performance Fatigue performance Stiffness and impact performance Design freedom High energy absorption levels Noise and vibration reduction Founding families event 22 November 12, 2019
Up to 75% of race cars are composites. APPLICATIONS - Motorsport • Stiffness • Lightweight • Impact strength Composite materials that • Energy absorption • Temperature resistance help boost performance • Strength • Design freedom Engine cover HANS device Exhaust • Rapid prototyping & components (on driver) shielding • Manufacturing flexibility Rear wing Monocoque & support Rear impact structure Front Rear suspension suspension Side impact Front impact Front wing Air ducts Floor pan structure structure Founding families event 23 23 November 12, 2019
HOW DO WE ANTICIPATE AND DEVELOP SOLUTIONS Application Engineering Products Novel for Chemistry Automation TOTAL COST SPEED ECOSYSTEM Modelling External Testing Collaborations Life Cycle More than a material supplier we are a technology integrator Founding families event 24 24 November 12, 2019
TO GROW FURTHER, COMPOSITES MUST DELIVER MORE VALUE Beyond lightweighting, composites bring additional benefits: Aerodynamics Fatigue life Corrosion resistance Design freedom Part integration Function integration Increased passenger comfort CHALLENGES MANUFACTING JOINING SIMULATION FOR THE FUTURE TECHNOLOGIES Founding families event 25 25 November 12, 2019
WHY DO WE HAVE THE "RIGHT TO WIN" IN TPC? Best portfolio of high performance Differentiated properties for high thermoplastic polymers value-in-use applications Strong presence in composites Ability to adapt fibers and access and carbon fibers to composite experts Core competencies in surface and Unique solutions protected by interface engineering strong IP Founding families event 26 November 12, 2019
DISCLAIMER This presentation may contain forward-looking information. Forward-looking statements describe expectations, plans, strategies, goals, future events or intentions. The achievement of forward-looking statements contained in this presentation is subject to risks and uncertainties relating to a number of factors, including general economic factors, interest rate and foreign currency exchange rate fluctuations, changing market conditions, product competition, the nature of product development, impact of acquisitions and divestitures, restructurings, products withdrawals, regulatory approval processes, all-in scenario of R&D projects and other unusual items. Consequently, actual results or future events may differ materially from those expressed or implied by such forward-looking statements. Should known or unknown risks or uncertainties materialize, or should our assumptions prove inaccurate, actual results could vary materially from those anticipated. The Company undertakes no obligation to publicly update or revise any forward-looking statements This document does not constitute an offer to sell, or the solicitation of an offer to subscribe for or buy, any securities. Founding families event 27 27 November 12, 2019
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