Hybrids and their potentials as tire reinforcement materials

Berrin Ylmaz Kordsa Global Endustriyel Iplik ve Kord Bezi San. ve Tic. A.S 17-19 November 2010, Mumbai - India

Sabanc Group: Turkeys Leading Industrial & Financial Conglomerate

Financial Services

Cement

Energy

Tire, Tire Reinforcement, Automotive

Retail

57,000 employees

69 companies 10 joint ventures

09 Revenues: $12.2 billion

2010 Kordsa Global

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Kordsa Global In Brief

Worlds leading producer of industrial nylon 6.6, polyester yarns, tire cord fabrics and single end cords Leading supplier of textile reinforcement materials for the tire industry 36 years of expertise in reinforcement technologies Only company in the industry with a globally approved product portfolio
2010 Kordsa Global

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Industry Leader *
Nylon 6.6 Global Market Share
Kordsa Global, 34% Other, 14%

Polyester Global Market Share

Kordsa Global, 7% Other, 32%

Producer A, 3% Producer B, 4% Producer C, 2% Producer D, 4% Producer E, 8% Producer H, 9% Producer I, 25% Producer G, 27%

Producer F, 31%

Only global company with a sizeable position in both industrial Nylon & PET Leading producer of Nylon 6.6 with 34% market share Worlds largest Tire Cord Fabric producer Growing in PET, 4th largest producer
* 2009 figures

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Worldwide Operations
Interkordsa GmbH Mhlhausen, Ger many

Kordsa Inc. USA Laurel Hill, N. Carolina; Chattanooga, Tenessee

SEC

Kordsa Global (Headquarters) Izmit, Trkiye

NY6.6, TCF

NY6.6, PET, SEC, TCF TCF

Nile-Kordsa Co. Cairo, Egypt

Kordsa China

NY6.6 TCF
Thai Indo Kordsa Ayutthaya, Thailand

Kordsa Brasil Salvador de Bahia

PET, SEC, TCF

NY6.6, PET, TCF

Indo Kordsa Jakarta, Indonesia

NY6.6, TCF
Kordsa Argentina Buenos Aires

Operations in 9 countries 11 plants More than 4,500 employees worldwide

2010 Kordsa Global

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USD 656 Million* Sales in 2009

North America USD 146 Mio.

USA

Europe Middle East Africa USD 267 Mio.

Turkey Germany Egypt

Asia Pasific USD 156 Mio.

Indonesia Thailand China

South America USD 103 Mio.

Brazil Argentina

*Annual Sales Revenue

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Product Portfolio

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Hybrid cords
Aramide (Ar)

Polyamide 6.6 (PA66) Polyester (PET)

Polyethylene naphthalate (PEN)

Rayon (Ry)

Tenacity , g/d Ar PA66 PET PEN Ry 20+ 9 8,5 - 9 9+ 5

Modulus, g/d 550 50 100 250 125

Elongati on at break,% 3,5 17-19 10-12 6 8-10

Shrinkag e, % 0,1 6-7 5-6 2,5-3,0 0,1

Thermal stability ~500 (DWM) 255/50 256/70 270/121 DWM

Density, g/cc 1,45 1,14 1,38 1,39 1,53

Thermal stability ~500 (DWM) 255/50 256/70 270/121 DWM

Price Index 100 11 9 47 9-22

DWM: decompose without melting

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Hybrid cords
Ply 1
Fiber A

Ply 2 Ply 3
Fiber B Fiber A or B

Ply 1
Fiber A

Ply 2 Ply 3
Fiber B Fiber A or B

RFL treatment S S

Cable
Fiber A+ Fiber B

Cable
Fiber A+ Fiber B

Hybrid Cords (HC)

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Hybrid cords
Hybrid cord features Combination of different materials Broad range of constructions are possible Properties can be engineered by changing Material, dtex, ply number, single and cable twist, dipping conditions PEN-NY hybrid cords Dtex PEN = 1100, 1670, 2200 Dtex NY66 = 940, 1400, 1880, 2100 Twist, tpm = 150 450 PEN ply number = 1 2 NY ply number = 1 2 Total ply number = 2 - 3 RY-PET hybrid cords Dtex RY = 1220, 1840, 2440 Dtex PET = 1100, 1440, 1670, 2200 Twist, tpm = 150 450 RY ply number = 1 2 PET ply number = 1 2 Total ply number = 2 - 3
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Ar-NY Hybrid cords Dtex Ar = 1100, 1670 Dtex NY66 = 940, 1400, 1880, 2100 Twist, tpm = 150 450 Ar ply number = 1 2 NY ply number = 1 2 Total ply number = 2 - 3 PET-NY Hybrid Cords Dtex PET = 1100, 1440, 1670, 2200 Dtex NY66 = 940, 1400, 1880, 2100 Twist, tpm = 150 450 PET ply number = 1 2 NY ply number = 1 2 Total ply number = 2 - 3

Hybrid cords

Ar-NY hybrids cords

Twisting effects Load elongation (%) behaviour of Ar and NY

Aramide ~30 40 % loss in break str ~ 25 - 35% loss in modulus ~ 40 - 50% loss in LASE2% ~30 40% increase in brk.elongation >100% increase in EASL 66N

Nylon ~ 7-10% loss in break str ~ 30-40% loss in modulus ~ 15 - 40% loss in LASE2% ~ 7 - 30% increase in brk.elongation ~ 25 - 60% increase in EASL 66N

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Hybrid cords

Ar-NY hybrid cords

Load elongation (%) curves of single ply twisted Ar and NY enables a broad range of hybrid cord structure

Contribution of aramide Tire production Running performance Low modulus at low elongations High modulus at high elongations
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Contribution of nylon

Hybrid cords

Ar-NY hybrid cords

Hybrid ar dtex/ply ny dtex/ply Hybrid A 1100/2-2100/1 Hybrid B 1100/2-1880/1 Hybrid C 1100/1-1880/2 Hybrid D 1100/1-940/2 Hybrid E 1670/2-2100/1 Hybrid F 1670/2-1880/1 Hybrid G 1670/1-1880/2 Hybrid H 1670/1-940/2

Twist, tpm, ar/ny/cable 250/350/150 350/150/250 350/150/250 450/450/450 250/350/150 350/150/250 350/150/250 450/450/450

Breaking Strength, N 426 454 344 266 605 633 456 351

Elongation at 66N,% 1,1 2,8 4,3 6,6 1,0 2,8 4,8 6,4

Elongation at break,% 4,3 7,8 10,6 13,4 4,6 8,9 13,7 16,3

Shrinkage, % 0,9 1,5 2,8 2,5 0,9 1,6 2,7 1,9

Thickness, mm 0,84 0,77 0,82 0,65 0,97 0,88 0,93 0,77

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Hybrid cords
Data Means
NY dtex 350 A R twist

Ar-NY hybrid cords

Main Effects Plot for Elongation at Break
Data Means
NY twist

Main Effects Plot for Breaking Strentgh

10

NY dtex

AR twist

NY twist

8
300

6
250

Mean

Mean

4 940 10 1400 1880 C able twist 2100 150 250 350 A R ply 450 150 250 350 NY ply 450

940

1400 1880 Cable twist

2100

150

250 350 A R ply

450

150

250 350 NY ply

450

350

8
300

6
250

4
150 250 350 450 1 2 1 2

150

250

350

450

Based on Delta values and P values of response of means of Breaking Strength

Based on Delta values and P values of response of means of Elongation at Break

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Hybrid cords

Ar-NY hybrid cords

Main Effects Plot for %Retained Breaking Strength

Data Means
NY dtex 100 A R twist NY twist

80

60

Mean

40 940 100 1400 1880 Cable twist 2100 150 250 350 A R ply 450 150 250 350 NY ply 450

80

60

40 150 250 350 450 1 2 1 2

Based on Delta values and P values of response of means of %Retained Break. Str. after Fatigue

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Hybrid cords

Ar-NY hybrid cords

1100*1+940*1, 250/250/250 tpm

1100*2+940*1, 350/350/350 tpm

1100*2+1400*1, 150/250/350 tpm

1100*1+1880*1, 250/450/350 tpm

1100*1+940*2, 450/450/450 tpm

1100*1+2100*2, 150/450/250 tpm

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Hybrid cords

Ar-NY hybrid cords

Ar-NY hybrids provide ;

vs 100% aramide Improved fatigue resistance Controlled shrinkage Higher elongation/lower modules Lower raw material cost Dual modulus behaviour Low noise (important PCR) vs 100%NY Ply reduction in tyres (lighter tire) Lower shrinkage/lower growth Reduced flat spotting contribution Improved handling/cornering Increased high speed performance Good rolling resistance Good comfort Property retention at elevated temperatures Higher raw material cost Higher dipping cost

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Hybrid cords

PET-NY hybrids

Twisting effects Load elongation (%) behaviour of PET and NY

Broad range of PET-NY hybrids cord properties

PET (based on dtex) ~10-25% loss in break str ~25-40% loss in modulus ~10-15% increase in brk.elongation ~ 40 - 50% increase in EASL 66N

Nylon ~7-10% loss in break str ~30-40% loss in modulus ~7 - 30% increase in brk.elongation ~ 25 - 60% increase in EASL 66N

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Hybrid cords
Effect of twist level on 1 ply PET-1 ply NY hybrid cord tensile, thermal and adhesion properties

PET-NY hybrids

Hybrid ny dtex/ply pet dtex/ply Hybrid I 1400/1-1670/1 Hybrid J 1400/1-1670/1 Hybrid K 1400/1-1670/1 Hybrid L 1400/1-1670/1 Nylon cord 1400/2 Polyester cord 1670/2

Twist, tpm, ny/pet/cable 200/200/200 200/350/350 200/470/470 350/350/470 350 310

Breaking Strength, N 215 219 191 177 227 209

Elongation Elongation Shrinkage, at 66N,% at break,% % 5,6 7,1 9,1 7,9 9,9 4,0 15,1 18,6 21,2 15,5 25,0 12,6 1,8 2,3 2,6 2,3 3,3 1,5

Thickness, mm 0,69 0,72 0,76 0,67 0,70 0,69

Adhesio n, N 165 188 186 204 191 203

Ref: Aye Ayta, Design of Nylon6.6/Polyester Hybrid cords and their properties, The Degree of Doctor of Philosophy, Kocaeli University, Kocaeli-2007 Strictly Confidential

Hybrid cords
Effect of twist level on 1 ply PET-1 ply NY hybrid cord fatigue properties - High twist level contributes
more to the fatigue performance

PET-NY hybrids

Fatigue behavior of polyester nylon hybrids changes based on twist level of the components and dtex. -1400*2 NY cords , twist range 270 470 tpm; breaking strength retention is above 80 95 %. - 1670*2 PET cords, twist 160, 310; breaking strength retention 20, 40%, twist 430 tpm strength retention 80 - 90 %. - PET-NY hybrid cords breaking strength retention 40 90 %.
Ref: Aye Ayta, Design of Nylon6.6/Polyester Hybrid cords and their properties, The Degree of Doctor of Philosophy, Kocaeli University, Kocaeli-2007

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Hybrid cords
Effect of NY and PET ply number on 2 ply PET-1 ply NY and 1 ply PET-2 ply NY hybrid cord tensile, thermal and adhesion properties

PET-NY hybrid cord

Hybrid ny dtex/ply pet dtex/ply Hybrid M 1100/2-1400/1 Hybrid N 1100/1-1400/2 Hybrid O 1100/2-1880/1 Hybrid P 1100/1-1880/2 Hybrid R 1670/2-1400/1 Hybrid S 1670/1-1400/2

Twist, tpm, ny/pet/cable 250/250/250 250/250/250 350/350/350 350/350/350 350/450/150 350/450/150

Breaking Strength, N 233 232 218 188 307 301

Elongation at 66N,% 4,6 5,9 5,7 6,8 3,6 5,0

Elongation at break,% 14,5 15,0 15,7 14,4 14,6 16,2

Shrinkage, Thickness, % mm 2,0 2,5 2,1 3,0 1,9 2,4 0,70 0,68 0,72 0,88 0,84 0,82

Adhesion, N 142 190 172 196 197 171

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Hybrid cords

PET-NY hybrid cords

Effect of NY and PET ply number on 2 ply PET-1 ply NY and 1 ply PET-2 ply NY hybrid cord fatigue properties
- High NY content increases breaking strength retention

Hybrid M 1100/2-1400/1, 250/250/250

Hybrid N 1100/1-1400/2, 250/250/250

Hybrid O 1100/2-1880/1, 350/350/350

Hybrid P 1100/1-1880/2, 350/350/350

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Hybrid cords
Finite Element Analysis; Load distribution;

PET-NY hybrid cords

-one ply NY fiber in NY-PET hybrid carries more load and absorbs more energy compared to the one ply of two ply NY cord with same twist levels. -one ply PET fiber in NY-PET hybrid carries less load and absorbs less energy compared to the one ply of two ply PET cord with same twist levels. - The difference between NY and PET fibers lateral rigidness and modulus, PET resist more to the lateral deformation due to tension. Fracture Energy distribution; - PET contributes to fracture energy more than that of NY - Balance twist of single ply and cable donot effect the distribution - Same distribution was calculated for different balanced twist levels. - Unbalance twist levels may effect the load and breaking energy distributions.

Ref: Doan Sevim, Kordsa Global, Finite Element Analysis of Nylon-Polyester Hybrid Cords, Tire Strictly Confidential Technology

Hybrid cords

PET-NY hybrids

Hybrids vs 100% Polyester

Improved fatigue resistance (especially with high nylon content) Controlled shrinkage Higher elongation/lower modules Higher dipping cost Better aged adhesion results Better for high temperature adhesion Increased high speed performance

Hybrids vs 100%nylon66
Lower shrinkage/lower growth Lower raw material cost due to PET Reduced flat spotting contribution Good comfort

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Hybrid cords

PEN-NY hybrid cords

Comparision of PEN-NY and PET-NY hybrid cord tensile, thermal and adhesion properties

- PEN-NY hybrids have lower breaking strength and breaking elongations -PEN-NY hybrids have higher modulus (autoyoung) - PEN-NY hybrids 70 g/denier , - PET-NY hybrids 60 g/denier. - PEN-NY hybrid have lower partial load elongation (66N) - PEN-NY and PET-NY have the same thermal shrinkage - PEN-NY and PET-NY have acceptable adhesion levels

Hybrid ny dtex/ply pet or pen dtex/ply Hybrid T 1400/1-1670/1 nypet Hybrid U 1400/1-1670/1 nypen

Twist, tpm, ny/pet/cable 200/350/350

Breaking Strength, N 219

Elongation at 66N,% 7,1

Elongation at break,% 18,6

Shrinkage, Thickness, % mm 2,3 0,72

Adhesion, N 188

200/350/350

188

5,3

12,2

2,2

0,72

168

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Hybrid cords

RY-PET hybrid cords

RY-PET hybrid cord ovendry tensile, thermal and adhesion properties

Combination of two dimensional stable material - The breaking strength and elongation at break values of hybrids are between RY and PET cords. - Partial load elongation (EASL 66N) of hybrids are closer to PET. - Hybrids have moderate thermal shrinkage. - Hybrids have balanced moisture sensitivity - Breaking strength retention and adhesion retention after fatigue testing of RY-PET hybrids with different cord constructions stay in the range of 60 85%. Reference rayon cord retentions stay within the same range.
Hybrid pet dtex/ply ry dtex/ply Hybrid V 1670/1-1840/1 Hybrid Y 1670/1-1840/1 Hybrid Z 1670/1-1840/1 Rayon, 1840*2 Polyester, 1670*2, Twist, tpm, pet/ry/cable 320/350/350 360/400/400 360/470/470 420 430 Breaking Strength, N 188 171 168 172 195 Elongation at 66N,% 4,0 4,4 5,1 Elongation at Shrinkage, break,% % 11,8 11,4 12,3 0,8 0,8 1,0 0,1 2,0 Thickness, mm 0,68 0,68 0,70 0,62 0,68 Adhesion, N 102 101 90 158 201

2,4 10,3 4,8 13,8 Strictly Confidential

Hybrid cords

RY-PET hybrids

In summary; Ar- NY hybrids provide a big mechanical property range between aramid and nylon. Better breaking strength, variable modulus, moderate shrinkage, good adhesion and optimized fatigue are achievable. PET-NY hybrids provide comparable breaking strength, variable modulus between polyester and nylon, controlled shrinkage, optimized dimensional stability. PEN-NY hybrid provides higher modulus compared to PET-NYhybrids. RY-PET hybrid provide better breaking strength, dimensional stability, less moisture sensitivity.

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Hybrid cords

Thank you

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