1. Kaneka Core-Shell Toughening Systems for Thermosetting Resins
Douglas J. Sober
Kaneka Texas Corp
2 Northpoint Drive
Suite 200
Houston, TX

2. What is Core-Shell Rubber (CSR) ?
Co-Polymer I designed for impact resistance. This is the core.
Co-Polymer II designed to be compatible with thermosetting resin.
This is the shell.
2-Layer CSR

3. What is Core-Shell Rubber (CSR) ?
2-Layer CSR
100nm

4. How does CSR toughen resins?
Core polymer cavitates on impact dissipating energy .
Small, evenly dispersed particles act as a crack terminator.

5. Applications of CSR? Thermosplastic resins systems.
Thermosetting resins systems for:
- Adhesives.
- Composites.
- Potting Compounds & Encapsulants
- Coatings
- Copper-Clad Laminates

6. Core Shell Rubber Advantages:
Outstanding Toughness Improvement:
- Fracture Toughness
- T-Peel Strength
- Lap-Shear Strength
No Depression of Tg.
Wide Cure Window.
Consistent Morphology.
Low Ionic and Surfactant Content.
Extremely Stable.

7. What is Kane Ace MX:
Kane Ace MX are concentrates comprised typically of 25% by weight of CSR dispersed in various thermosetting resins. The liquids are easily poured after heating and the individual CSR domains remain uniformly dispersed during storage and formulating.

8. Viscosity vs. CSR Content
Basic Properties of MX system
Rubber particles are homogeneously dispersed in epoxy resin. Available as Concentrate containing 25 wt% of CSR.
Appearance
Viscosity vs. CSR Content
Conventional CSR
(10wt%) in epoxy
New CSR
(25wt%) in epoxy

9. Comparison of the Kane Ace MX and Conventional CSR
TEM observation - Cured system
Appearance - Cured system
“Transparent”
1mm

10. Kane Ace MX Products: MX 120 Standard Liquid Bis A Epoxy Resin
MX 120LV Low Viscosity Liquid Bis A Epoxy Resin
MX Standard Liquid Bis F Epoxy Resin
MX Epoxidized Phenol Novolac Resin
MX Epoxidized Cresol Novolac Resin
MX Multifunctional Epoxy Resin (TGMDA)
MX Multifunctional Epoxy Resin (TGPAP)
MX Cyclo-Aliphatic Epoxy Resin*
MX Polypropylene Glycol
MX XYZ Proprietary Resins as supplied by customer
* May contain less than 25% CSR

11. T-Peel Strength Kane Ace MX

12. T-Peel Strength of DGEBA Epoxy/MX 120 System

13. Lap-Shear Strength OF Kane Ace MX
Adhesive layer

14. Lap-shear Strength of DGEBA Epoxy/MX 120

15. Toughening Effect of Epoxy/ Kane Ace MX System
Three-Point Bending
strength
force
stress
energy
strain
specimen: 6cm x 1.2cm x 0.5cm
pre-crack: 0.6cm depth by blade-tapping
head speed: 1mm/min.
ASTM 5095

16. Fracture Toughness of DGEBA Epoxy/MX 120

17. Fracture Toughness of DGEBA Epoxy/MX 120

18. T-peel Strength of MX 120 vs. CTBN in DGEBA Epoxy

19. Comparison of CSR and CTBN
Lap-shear Strength of MX 120 vs. CTBN in DGEBA Epoxy

20. Comparison of CSR and CTBN
Fracture Toughness and Glass Transition Temperature of MX 120 vs. CTBN in DGEBA Epoxy Tg

21. Kaneka Corporation
Today Kaneka is a world leader in the creation of innovative technologies in areas such as polymers, construction materials, and pharmaceuticals.
Kaneka is a global organization with production facilities on four continents and approximately 7000 employees.
Revenue for our latest fiscal year (ended March ‘04) is estimated worldwide at approximately $4.3 billion.

22. Kaneka Global Manufacturing
Kaneka currently manufactures “Modifiers” at four sites around the world. These include:
Kaneka Japan Asia Takasago, Japan
Kaneka Texas USA Pasadena, Texas
Kaneka Belgium Europe Oevel, Belgium
Kaneka Malaysia Asia Kuantan, Malaysia
These four sites provide Kaneka with an annual capacity of modifiers of approximately 350 million pounds.

23. Kaneka Texas Corporation
A wholly owned subsidiary opened in 1983, Kaneka Texas (KTC) is responsible for marketing several Kaneka product lines throughout the Americas.
Business operating at KTC include:
1.) Polymer Modifiers (Kane Ace)
2.) CPVC Resins (Kanevinyl)
3.) Foamed Olefins Resins (Eperan, Eperan PP)
4.) Modified Silicone for Sealants (MS Polymer)
5.) Polyimide Film (Apical)
6.) Nutrients (CoQ10)