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9. 151006 陳育誠 臺灣pur產業之概況與發展機會
- 1. IEK產業經濟與趨勢研究中心 Copyright 2015 All Rights Reserved 工研院產業經濟與趨勢研究中心﹙IEK﹚ 陳育誠 產業分析師 2015年10月06日 臺灣PUR產業之概況與發展機會
- 2. IEK產業經濟與趨勢研究中心 Copyright 2015 All Rights Reserved 個人簡介 • 學歷： 1. 國立台灣科技大學化學工程系(2005.09-2007.06) 2. 國立台灣科技大學化學工程研究所，碩士(2007.09- 2009.06) • 工作經歷： 1. 工研院產經中心(IEK) 產業分析師(2009.11~) • 主要研究： 2009年進入IEK服務，曾參與經濟部技術處ITIS計畫石化 年鑑與特用化學品年鑑之編撰，並擔任多場產業趨勢研 討會之講師。主要研究全球特用化學品市場變化與綠色 化學產品趨勢，期許能為臺灣化學工業開拓新的契機。 1
- 3. IEK產業經濟與趨勢研究中心 Copyright 2015 All Rights Reserved 簡報大綱 2 臺灣PUR產業概述 PUR下游應用趨勢分析 PUR熱熔膠之全球前景展望
- 4. IEK產業經濟與趨勢研究中心 Copyright 2015 All Rights Reserved 臺灣PU樹脂之產量與售價呈現成長趨勢 • 根據經濟部工商生產統計碼1841355“PU合成樹脂”資料進行統計 • 在統計上包含發泡體（軟質、硬質、半硬質泡棉）、固態體（塗料用、 人造皮用、纖維用、彈性橡膠、彈性纖維，接著劑、填縫材料用） 3 0 10 20 30 40 50 60 70 80 90 100 0 2,000,000 4,000,000 6,000,000 8,000,000 10,000,000 12,000,000 14,000,000 16,000,000 18,000,000 20,000,000 生產量(公噸) 價格(新台幣/公斤) 資料來源：經濟部統計處；工研院IEK(2015/08)
- 5. IEK產業經濟與趨勢研究中心 Copyright 2015 All Rights Reserved 臺灣PU產業鏈概況 • 臺灣PU產業鏈發展已久，產業鏈完整，且應用廣泛 多元醇 異氰酸酯 PUR 合成皮 塗料 接著劑與 填縫膠 TPU PUD PU發泡 複合材料 彈性材料 日勝化、永捷、石 梅、双邦、高鼎…. 三芳、永光、永記、 南寶、大東、慶 泰…. 仰賴進口
- 6. IEK產業經濟與趨勢研究中心 Copyright 2015 All Rights Reserved 綠色環保是各PU下游應用的發展方向 5 節能、低碳、低VOC、低毒性、環保材料利 用 輕量化、材料無毒、低VOC、低碳、安全、 智慧化、環保材料應用 無溶劑、機能性、環保與回收材質應用 無鹵、材料無毒、可回收
- 7. IEK產業經濟與趨勢研究中心 Copyright 2015 All Rights Reserved 應用永續環保的方式生產PU原料也是產品發展趨 勢 • Mitsui與Bayer MaterialScience(現更名為Coverstro)皆有在2016年 量產生質PDI之計劃 • 中國大陸之凱賽生物科技(Cathay Industrial Biotech)因具備PDI前 驅物PDA之生產能力，也有意發展PDI 6
- 8. IEK產業經濟與趨勢研究中心 Copyright 2015 All Rights Reserved 環保多元醇並不局限於使用生質原料 • 除了生質的多元醇產品外，應用二氧化碳生產多元醇也是一條永續環 保的生產途徑 7 •耐磨 •耐化學反應 •抗污性 •耐水解 •高光澤
- 9. IEK產業經濟與趨勢研究中心 Copyright 2015 All Rights Reserved 不使用異氰酸酯來合成PU也正快速發展 • 加速反應速率是目前研究的重點 8
- 10. IEK產業經濟與趨勢研究中心 Copyright 2015 All Rights Reserved 9
- 11. IEK產業經濟與趨勢研究中心 Copyright 2015 All Rights Reserved 產線自動化也是PU下游應用的重要趨勢 • 在紡織貼合、食品包裝、電子產品組裝、汽車內裝與傳統木工等領域 以機械自動化生產，以減少人力需求已逐漸成為趨勢 • 自動化製造將增加PU類接著劑的使用機會 10
- 12. IEK產業經濟與趨勢研究中心 Copyright 2015 All Rights Reserved 以PU為樹脂的接著劑分類 11 PU接著劑 TPU熱熔膠 PUR反應型 熱熔膠 單組分 PUR反應 型接著劑 雙組分 PUR反應 型接著劑 PUD水性接 著劑 溶劑型TPU 接著劑 •木工接著 •板材接合 •製鞋 •皮革 •膠膜 •建築 •汽車內裝 •包裝 •汽車內裝 •食品包裝 •貼合 •木製地板 •鞋底 •製鞋 •皮革 •膠膜 •書本裝訂 •木製門板 •木製家具 •服飾與步料
- 13. IEK產業經濟與趨勢研究中心 Copyright 2015 All Rights Reserved PUR(Polyurethane Reactive)接著機制簡介 • 高接著強度、柔軟性以及寬廣的使用溫度是PUR接著劑的優勢 12 未反應的- NCO官能 基 分子結構 硬化機制
- 14. IEK產業經濟與趨勢研究中心 Copyright 2015 All Rights Reserved 反應性熱熔膠較非反應性熱熔膠具有優異的接著特 性 • 但安全性與成本是需要解決的問題 13 品項 非反應型熱熔膠(EVA) 反應型熱熔膠(PUR) 使用溫度 150ᵒC 120ᵒC 加工時間 快速 快速 耐熱性 差 佳 初始強度 佳 佳 接著強度 佳 優異 耐水解姓 差 優異 安全性問題 無 擔心有未反應完的異氰酸 酯單體 保存期限 長 3-6個月 成本 低 高
- 15. IEK產業經濟與趨勢研究中心 Copyright 2015 All Rights Reserved PUR是中高成本之接著劑產品 14
- 16. IEK產業經濟與趨勢研究中心 Copyright 2015 All Rights Reserved 相較於液態PUR接著劑，反應性PUR熱熔膠在高 速生產下具有優勢 品項 液態PUR接著劑 反應型PUR熱熔膠 加工設備 點膠機、塗佈機 塗佈機、噴膠槍 加工條件 室溫或加熱 加熱 工作時間 較長 較短 硬化機制 水氣或加熱 水氣 硬化時間 完全硬化約需24小時 完全硬化約需24小時 初始強度 無 佳 優勢 可朝回收之方向開發、可 在室溫使用、較長之開放 時間 不須烤箱去除溶劑、可與 高速生產線配合、零VOC 劣勢 較長的製程時間 不可回收、需在較高溫使 用 環保、健康與安全議題 未反應完之MDI 未反應完之MDI 成本 中等 高 15
- 17. IEK產業經濟與趨勢研究中心 Copyright 2015 All Rights Reserved 全球PU熱熔膠用量與售價穩定成長 • 不考慮匯率變動，以新台幣：美金＝30：1進行換算 • 反應型的PUR熱熔膠成長是主要驅動價格成長的因素 16 資料來源：Frost &Sullivan ；工研院IEK(2015/08) 0 50 100 150 200 250 0 20 40 60 80 100 120 2012 2013 2014 2015 2016 新 台 幣 / 公 斤 千 公 噸
- 18. IEK產業經濟與趨勢研究中心 Copyright 2015 All Rights Reserved 臺灣反應型PUR接著劑產品之產銷概況 • 臺灣PUR反應型接著劑之產量佔不到總體PU合成樹脂產量之1% • 臺灣反應型PUR接著劑產品之平均售價較國際PUR熱熔膠的平均售價低許 多 17 0 20 40 60 80 100 120 140 0 10,000 20,000 30,000 40,000 50,000 60,000 70,000 2011 2012 2013 新 台 幣 / 公 斤 公 噸 生產量 銷售單價 資料來源：台灣區合成樹脂接著劑同業公會；工研院IEK(2015/08)
- 19. IEK產業經濟與趨勢研究中心 Copyright 2015 All Rights Reserved 臺灣非EVA與彈性體之熱熔膠生產概況 • 臺灣非EVA與彈性體之熱熔膠之平均售價較國際PUR熱熔膠的平均售 價低許多 18 資料來源：台灣區合成樹脂接著劑同業公會；工研院IEK(2015/08) 0 20 40 60 80 100 120 140 160 0 500 1,000 1,500 2,000 2,500 3,000 3,500 4,000 4,500 5,000 2011 2012 2013 新 台 幣 / 公 斤 公 噸 生產量 銷售單價
- 20. IEK產業經濟與趨勢研究中心 Copyright 2015 All Rights Reserved 小結 • PU是具備環保永續特性與多元應用材料，在未來人類的生活中將較其 他材料更具有優勢 • 應用PUR作為接著劑在下游產品自動化高速生產的趨勢下，可以符合 高速生產要求並兼顧環保趨勢 • 配合下游產業朝向節能、環保、自動化與智慧化發展，臺灣廠商在 PUR反應型熱熔膠的發展上仍有許多可以發展的機會 19
- 21. IEK產業經濟與趨勢研究中心 Copyright 2015 All Rights Reserved • 研調領域涵蓋：半導體、資通訊、零組件、顯示器、電子材料、能源、石化 材料、特用化學、生技醫療、機械/車輛、兩岸產經與新興市場等領域
- 22. IEK產業經濟與趨勢研究中心 Copyright 2015 All Rights Reserved
- 23. http://ieknet.iek.org.tw/ IEK產業經濟與趨勢研究中心 Copyright 2014 All Rights Reserved 謝謝 陳育誠 產業分析師 電話：03-591-7019 E-mail：chenyuchen@itri.org.tw
Notas do Editor
- 從硬端(異氰酸酯分) : nMDI/pMDI/TDI/HDI/IPDI/H12MDI/NDI/XDI/TODI 從軟端(多元醇)分 : Polester/Polyther/Hybrid/Copolymer/Polycarbinate/Caplatum 從物性分 : Rigid :建材(浪板、工程鋼板、冷凍庫板、線板)、包裝(塑形避震) Flexible :泡棉(傢俱、汽車座椅、粉撲)、自結皮(方向盤、OA扶手、玩具) Coating :合成皮革、塗料、織物塗層、油墨 Adhesives :接著劑、硬化劑、密著劑 Sealant & Encapsulant :填充密封劑、防水劑、封裝材 Elastomers :熱固化發泡、不發泡彈牲體、熱塑性彈性體、彈性纖維
- 節能減碳 -保溫材料、隔熱材料 替代資源 -仿木建材、合成皮革、合成纖維 保存資源 -儲水泡棉、人造石、穀桿合板 潔淨製程 -無溶劑、無溫室氣體設計 回收減廢 -塑膠化、產品階級化、生物分解 生質取代 -生質材料發展
- http://www.mitsuichem.com/release/2014/141211.htm http://www.press.bayer.com/baynews/baynews.nsf/id/9SSDPM-New-milestones-in-polyurethanes
- http://www.nanotechindustriesinc.com/GPU.php
- 按化学性质，聚氨酯热熔胶可分为2类 ：一类是热 塑性聚氨酯热熔胶，另一类是反应型聚氨酯热熔胶。前 者加热液化后靠冷却固化，后者加热液化后通过冷却与 湿气反应交联固化。 Construction. One of the fastest growing segments in the construction market is hardwood flooring. Moisture-cure polyurethane adhesive is used for bonding. Also, polyurethane adhesives are used to make structural insulated panels (SIPS), where the adhesive is used to bond plywood, oriented strandboard (OSB) or particleboard to insulated foams like expandable polystyrene (EPS), rigid polyurethane foam and extruded polystyrene. Polyurethane adhesive is used to make interior and exterior panels that provide both insulation and structural strength. In some cases, the panels are built for decorative purposes in venues like refrigerated trucks, partition walls, cold storage rooms, containers and other areas. MDI-based adhesives are being used in place of formaldehyde resins in bonding of engineered wood products; thus, concerns over formaldehyde emissions are eliminated. The polyurethane industry has introduced isocyanates with low monomer content of <0.1%. These low levels are achieved by process engineering (e.g., monomer stripping) or formulation techniques. Electronics. Polyurethane adhesives are used in the electrical/electronics industry for mass casting of electronic components. The miniaturization of electronics has increased demand for adhesives since they fill gaps between the component and spaces in circuit boards, thus anchoring the component. Most demand for this market is in Asia, where electronic goods are now made. Polyurethane adhesives are also used to bond loudspeakers and particles to magnetic tape and other media. Some adhesives are thermally conductive to help dissipate heat in the assemblies. Footwear. Polyurethane adhesives are used to bond soles to the uppers in footwear. Most of the PU adhesives are one-component solvent-based systems, as these adhesives are easy to use, cure rapidly and provide good bond strength. However, as a result of concerns regarding worker safety and solvent emissions, they are being replaced by hot-melts and PUD adhesives. Most footwear is now made in Asia, but there is some production of military and safety footwear in North America, and high-end goods in Europe. Packaging. Polyurethanes are used for both food and medical flexible packaging because of their good flexibility, excellent chemical resistance and adhesion to dissimilar materials. They can be used for filmto- film, film-to-foil and film-to-paper lamination. In food packaging, PU adhesives are used for bags, pouches, and wraps for snack items, meat, and cheese on substrates such as polyolefins, polyester (PET), nylon, and aluminum foil. The flexible packaging industry is converting from solvent-borne adhesives to PUDs and waterborne acrylic emulsions in response to regulatory pressures. The moisture-cure urethanes typically have VOC levels that are less than 50 grams per liter, while traditional solvent-borne adhesives based on elastomers contain at least 25% organic solvent. The price of one-part moisture-cure urethanes is usually comparable to that for solvent-borne adhesives. The drawbacks to the urethanes are that their performance can be degraded by wet substrates or high humidity, and they tend to yellow if made from MDI or TDI. The flexible packaging industry has been growing as a result of greater demand for food, especially for ready-to-eat foods, as consumers are tending to eat at home more than dining out in restaurants. Another growing market is retortable packaging, which is used to deliver drinks that are processed by aseptic processing. In addition, demand for pharmaceuticals and medical goods continues to grow. Transportation. Polyurethane adhesives are used for bonding substrates such as plastics, metals and glass. Urethanes are suited to bonding plastic to metal or plastics that are dissimilar in coefficient of thermal expansion. Some of the common applications are glass roof lights, acrylic taillights, vinyl roofs and body side moldings. Polyurethane adhesives are used increasingly to bond parts to the body after painting. For example, Opel and Volkswagen are using a polyurethane adhesive to bond the cockpit area into the body of some models. Some companies use polyurethane adhesives for certain low-bond-strength applications, such as roof bows, sliding roofs, header rails on car roofs, wheel arches or, in the case of Renault’s allcomposite Espace, body panels (acrylic foam tape is often used in these applications). Urethanes are also used to bond polycarbonate automotive headlight assemblies in place (synthetic rubber–based hot-melt adhesive is often used in this application). Polyurethanes are used in sheet molded compound (SMC) applications in vehicles, typically for the assembly of square-back station wagons and sport utility vehicle (SUV) rear doors. Polyurethane adhesives contribute rigidity to the vehicles; by doing so, there is a significant savings in weight. Semistructural polyurethane adhesives are also used in recreational vehicles and commercial vehicles, particularly in delivery vans (e.g., for bonding the cargo compartment to the driver’s cabin). In the latter case, they also serve as sealants. PU adhesives are also used to bond metal and composite panels to frames and roofs in buses, trucks, railroad cars and armored vehicles. In commercial vehicles and buses, polyurethanes are used to bond steel and aluminum panels to steel frames, composite roofs and side panels, glass and plastic dome lights, and structural glazing. In railway rolling stock, polyurethanes are employed in bonding the components to the body. Interior applications include instrument panel assembly, decorative trim and carpeting, and sealing door windows. Under-the-hood applications include air filter bonding. Polyurethane adhesives are also used to bond metal and composite panels to frames and roofs in buses, trucks, trains, recreational vehicles and armored vehicles. Textiles and fibers. Reactive hot-melt urethane adhesives are used for the high-speed lamination of textiles used in sportswear, beachwear, outdoor protective garments and other applications. PU adhesives allow the production of breathable fabrics, as the adhesive is permeable to moisture. Industrial/other. Polyurethane adhesives are used in a variety of miscellaneous uses such as white goods, furniture, mattressses and general plastic bonding. Polyurethane reactive hot-melts have been penetrating the furniture market and continue to replace solvent-based polyurethane adhesives. One of the most demanding applications is in the insulation of tanks for transporting liquefied gas in large oceangoing ships. Adhesives are used to bond sandwich elements to each other and to the metallic hull. Adhesives used have to withstand temperature differences in the range of –160°C to 60°C as well as have high mechanical resistance. Polyurethane products have established themselves as the adhesive of choice. PU adhesives are also being considered for use for wind turbine construction, specifically for rotor blade bonding. Epoxies are generally used for this application, but urethanes offer more efficient, automated production since PU adhesives cure much quicker than epoxies, and also generate less heat.
- http://www.prnewswire.com/news-releases/global-pur-hot-melts-adhesives-market---segmented-by-application-type-and-geography---trends-and-forecasts-2014-2020---reportlinker-review-300145378.html
- Prices rose significantly from 2004 through the first half of 2008. Polyurethane adhesive prices in 2008 ranged from about $4 per kilogram to more than $20 per kilogram in the United States, while the average price of formulated reactive polyurethane adhesives was about $5 per kilogram in 2011. Urethane hotmelt adhesives are more expensive, ranging from $15 to $25 per kilogram; however, they are typically composed of 100% active ingredients. In Western Europe, in late 2008 and 2009, prices dropped and only started to increase in 2011 and 2012. In 2012, prices were in the range of $4.70-6.50 per kilogram for direct glazing adhesives, $6-7 for semistructural adhesives, $8-9 for adhesives for bonding structural composites, and $13-15 for solventfree adhesives used in foil laminating. Reactive hot-melt adhesive prices are in the range of $16-22 per kilogram.When evaluating adhesives, it is advisable to compare the cost of products on a unit output basis. For example, solvent-free polyurethane adhesives used in foil lamination are more expensive than solvent-borne products, but only 50% by weight of the solvent-free product is required. In addition, productivity is higher because laminating machines using solvent-free systems can run at rates up to 300 meters per minute, compared with about 200 meters per minute with solvent-borne adhesives. In 2011, the average unit sales price from adhesive manufacturers for polyurethane solvent-type adhesives in Japan was ¥500 ($6.30) per kilogram; the average unit sales price of waterborne isocyanate oligomer adhesives was ¥180 ($2.20) per kilogram. The estimated market prices of polyurethane adhesives were as follows: liquid type, ¥500-700 ($6.30-8.80) per kilogram; hot-melt type, ¥1,000-1,100 ($12.60-13.90) per kilogram; and waterborne polymer isocyanate, ¥220-350 ($2.70-4.40) per kilogram. In 2008, the price of solvent-based polyurethane adhesives in China was 16-25 renminbi ($2.30-3.60) per kilogram. The average price of water-based polyurethane adhesive was 20-30 renminbi per kilogram, equal to $2.88-4.30 per kilogram. In 2011, the price of solvent-based polyurethane adhesives in China was 20-28 renminbi ($4.48-6.28) per kilogram. The price of domestic water-based polyurethane adhesive was 30-35 renminbi ($6.73-7.85) per kilogram. The price of exported water-based polyurethane was about 40-60 renminbi ($8.97-13.45) per kilogram.
- Future trends and strategic issues Trends and opportunities in urethane adhesives are as follows. ● Growth of reactive hot-melt adhesives. These represent an attractive technology that is becoming increasingly popular, with annual growth rates of 4-5% in Western Europe and North America. In Japan, the growth of reactive hot-melts stagnated, because of competition from other specialty thermoplastic resins such as high-molecular-weight polyester hot-melts and polyamide hot-melts, which are better in handling and processability. ● Increasing use for car and other vehicle assembly. As more automakers move to modular assembly, polyurethane adhesives are being used in place of epoxy and PVC products because of their flexibility. ● Increased use of MDI formulations as replacements for TDI formulations because of toxicity concerns. ● Development of “multifunctional” adhesives with higher green strength, higher modulus, low electrical conductivity ● Greater use of one-component systems in place of two-component to eliminate mixing requirements and to reduce waste and worker exposure to potentially hazardous materials (e.g., isocyanate curing agents). Nonsolvent-type moisture-curable one-component systems are increasing in interior construction applications in Japan. ● Lower curing time and temperature. Continuing research efforts, as with other adhesives, to decrease the time and energy required for cure. ● Solvent-free urethane adhesives. More importance will be placed on the development of these adhesives; however, they are still deficient in cost and performance compared with solvent-based adhesives. In packaging, hot water resistance has been improved by the development of new polyurethane dispersions used in combination with a water-based cross-linker. In footwear adhesives, solvent-free formulations are important for a safer working environment. ● More frequent use of urethanes in the form of hybrids. In the area of high-performance structural adhesives, urethanes will be used more frequently in the form of hybrids to balance desirable properties with costs. These hybrids will likely claim an increasing share of the market over the next five years. An example of such hybrids are the silane-end-capped polyurethane products developed by Sivento, a division of Degussa, and also by Konishi. Epoxy-urethane adhesives have been developed by Yokohama Rubber. ● Development of new polyurethane adhesives for bonding of plastics with low surface energy. Plastics like polypropylene, polyethylene, PTFE, silicone-coated plastics and some grades of ABS are difficult to bond. Generally, modification of the surface energy of the plastic is the method used to overcome the problem, either by flame treating, corona treatment, electrostatic treatment or plasma treatment. Companies are working on improved adhesives that eliminate the need for pretreatment. Development of more effective primer systems for engineering plastics (i.e., a universal primer system) is needed. ● Development of water-based acrylics for one-component adhesives. In the field of film-tofilm lamination, two-component polyurethanes, either as solution in organic solvents or as solventless formulations, are currently widely used in Europe. However, the toxicity of organic solvents and isocyanates threatens polyurethane use in food packaging applications. Water-based acrylics for one-component adhesives are being developed by BASF and Rohm and Haas as environmentally friendly and toxicologically safe alternatives to polyurethane-based adhesives. In Japan, high-solids two-component polyurethanes are used for laminate adhesives. A waterborne polyurethane laminate adhesive was developed in the past, but was not widely used because of the cost. In China, water-based polyurethanes should grow significantly, especially for footwear as replacements for traditional chloroprene rubber adhesives. ● Improved waterborne dispersions (PUDs). The major disadvantage of two-component waterborne polyurethane adhesives is slow setting speed. Rongalit catalyst (formaldehyde sulfoxylate salt) is a potentially good catalyst to accelerate the cure of two-component reactive systems; however, the use of rongalit catalysts will be regulated in Japan because of formaldehyde emission concerns. Another major concern over the use of PUDs has been the presence of n-methyl pyrrolidone (NMP) as a solvent, which presents toxicity concerns. Newer versions of PUDs are being made without NMP. ● Mercury-free hardeners. Several producers now offer polyurethane hardeners that are mercury free, but with no loss in bonding properties