Silicone Elastomers 2008 : second International Conference, 12th-13th March 2008, Munich, Germany : conference proceedings

244 Pages·17.351 MB·English

by  Rapra Technology

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: [phone], Fax: [phone], 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