11:00 am – 11:30 am:
Resorcinol Formaldehyde Aerogel Nano-network Structural Assembly and its Thermal Properties Correlation
Mohammed Alshrah, University of Toronto
When organic aerogel particles are polymerized, a complex three-dimensional (3-D) nano-network is generated. This network is composed of randomly assembled nanoparticles, which form many-branched nanoclusters with unique morphological features. The organic aerogels that result from this process have exceptional properties, which supersede those of the current materials used. We studied the morphological features of an organic aerogel (resorcinol-formaldehyde, RF) and correlated each feature to the sample thermal insulation properties. Several RF aerogels were synthesized with different morphological features and structural assemblies. This was done by changing the catalyst percentages and the void fractions at the polymerization stage. Then, each morphological feature was assessed and categorized using two scales: the macro scale and the micro scale. We found that the macro-features were independent of the catalyst percentages and depended only on the void fractions. However, the micro-features were highly sensitive to any changes during the polymerization process. These changes altered the samples’ three main structural factors: (i) The structural assembly, (ii) The porous structure, and (iii) The fractal parameters. Thus, we characterized and quantified each component within these areas. Then, we assessed the structure’s heat transfer modes and classified them as follows: (i) Solid conductivity through the solid particles, (ii) Gas conductivity through the gas molecules, and (iii) Thermal radiation. We identified the morphological features that governed each mode. For example, the samples’ solid conductivity was highly dependent on the fractal parameters of our structure; that is, the particles’ roughness, the structural complexity, and the structural homogeneity. For those samples with extremely rough particles and a complex structure, the solid conductivity reached the lowest possible point. We also found that the total thermal conductivity was mainly controlled by the micro-morphological features, and that the solid conductivity was the most dominant heat transfer mode.
8:00 am – 12:00 pm:
W8-Technical Marketing: Additives
(Moderator: Joe Golba)-Room S320C
8:00 am – 8:30 am:
A Novel Synergist for Halogen Free Flame Retardants
Amit Paul, Paxymer
Paxymer AB has developed a novel halogen-free flame retardant system based on a multi-mechanistic approach including a unique synergist based on functional polymers. The challenge for formulators aiming to achieve halogen-free flame retardant performance is high dosage of additives resulting in low processing and mechanical properties and high prices. Paxymer’s synergistic line of products address this. Enabling formulators to reduce their total amount of flame retardant additive using functional polymers gives benefits in all aforementioned aspects. For example: cost reductions of 10% with retained mechanical performance and improved processing performance. Paxymer’s functional polymers eliminate dripping and can therefore act as a halogen free replacement of the commonly used PTFE. The company has also developed a analytical toolkit for characterisation and formulation prediction for halogen free flame retardants. The presentation will introduce the new line of products based on the company’s 2016 patent submission. It will give some insight into the mode of action of the functional polymers, briefly outline the analytical approach of the toolkit and present a comparative case study between Paxymer containing products and a reference.
8:30 am – 9:00 am:
New Technology for Improving Halogen Free Flame Retardant Performance in Polymer Application
Ido Offenbach, Evonik
The recent health-risk and environmental concerns of using Halogen Flame Retardant (HFR) is driving companies to use Halogen Free Flame Retardant (HFFR) in their products. However, several challenges must be overcome to utilize HFFRs in polymer matrixes. Many of those challenges are related to the HFFR large dosing level, its low compatibility, and its poor dispersibility. These characteristics lead to impaired mechanical properties in the final product. Due to the health-risk and environmental concerns, Interface and Performance, which is a division of Evonik, has developed new technologies to enhance the properties of HFFR in polymer applications. Organo-Modified Siloxane (OMS) is an example of this technology. This technology is made up of unique polymeric substances that improve the compatibility of HFFR particles with polymer matrixes such as polyolefin and engineering polymers. Therefore, Combining OMS with HFFR improves UL 94 results at lower HFFR usage levels, mechanical properties of highly filled HFFR polymer compounds, melt flow indexes (improving the processing ability of highly filled HFFR compounds), amperage level use, and prevention of die drool. The OMS technology also improves the hydrophobicity of the compound, resulting in lower water absorption and better CTI values. This paper focuses on Evonik state-of-the-art OMS additives for filled HFFR (melamine cyanurate, phosphorus based materials, and others) in engineering polymer compounds (PBT, polyamide 6 and polyamide 6,6). These OMS additives can be used while compounding as well as in surface treated HFFR. The improvement of UL 94, CTI, mechanical properties, and melt flow indexes of filled HFFR in engineering polymer compounds will be demonstrated in this paper.
9:00 am – 9:30 am:
New Generation Flame Retardants Based on Ionic Liquids
Yanjie “Jeff” Xu, Inovia Materials LLC
Ionic liquids — salts in a liquid state at ambient conditions — make up a fascinating family of materials whose unique physical properties have made them highly sought after for many challenging applications. Inovia Materials LLC is the first company in the world to patent and commercialize ionic liquids for polymer additive applications. Inovia Materials LLC is positioned to replace and expand the applications of traditional flame retardants with high “green chemistry” qualities, superior performance and enhanced properties. Some advantageous features include: • Negligible volatility and a benign environmental presence; • Better flame retarding performance and longer period of effectiveness; • Milder effects on thermal, mechanical, optical properties of polymers treated; • Significant reduction of polymer melt viscosity, allowing polymers to be processed or recycled at a lower temperature and in a more efficient manner. Inovia flame retardants can find applications in plastics, textiles, and elastomers in the building & construction, electronics & appliances, automotive & transportation, wires & cables, textiles, and other end-use industries. Inovia flame retardants can be applied using different methods: • Mixing with monomers or oligomers before polymerization • Compounding with plastics • Surface modification and coating application.
9:30 am – 10:00 am:
Novel Approach to Controlled Migration of Antifog Additives in Multilayer Packaging Films
Michal Schreiber, Tosaf
One of the biggest applications of polymers is food packaging. Downgaging and multilayer structures are the main trends which lead the food packaging in the recent years. This is the main reason why multilayer polymer films rapidly increase their share in the global food packaging market. Controlling the surface properties of polymer films is of outmost importance for both the packaging process and package quality. The most accepted way of keeping up with market requirements when surface properties need to be altered is the use of migrating additives. Slips, antistatics and antifogs are most widely used. These migrating additives migrate throughout the film and form a thin layer on the surface, this way decrease the coefficient of friction (slip), dissipate the electrostatic charge (antistatic) or increase the surface energy of the film (antifog). Antifog additives mainly used in packaging of refrigerated food. Water droplets on the clear packaging impair product’s appearance and decrease its shelf life. Antifog additives migrate to films’s surface and dissolve in the condensate. Droplets are transformed into continuous and transparent water layer. The migration rate of the antifog additives is often influenced by a range of factors for example corona or flame treatment, lamination, tie layers and polar polymers, forcing the migrating additive to migrate towards an undesired direction. This can compromise other vital film properties, such as printability, lamination strength etc’… The ability of film producers to control the migration of antifog additives is of outmost importance. Tosaf’s novel barrier additive will direct the migration to the desired direction thus significantly decrease or completely prevent the migration throughout this additive containing layer. The BR7483PE is incorporated into the layer adjacent to the antifog containing layer (the inner layer). BR7483PE increases the rigidity of the amorphous phase, preventing antifog migration to the undesired direction.
10:00 am – 10:30 am:
Novel Dispersants Enabled by Natural Oil Metathesis
Frederyk Ngantung, Elevance Renewable Sciences
One of the major challenges in polymer composites is the identification of reliable dispersants, or filler surface treatments, that improve the compatibility of dissimilar materials (e.g. minerals and polymers). The filler-polymer interface, to a large extent, determines the bulk properties of polymer composites. Elevance’s building block produced from natural oil is well-suited for the design of novel polar dispersants with improved compatibility for PVC, a moderately polar amorphous thermoplastic. In this talk, we will demonstrate how our developmental product improves dispersion of calcium carbonate in a model system for PVC versus stearic acid. The data is also applicable to other fillers such as aluminum trihydrate, magnesium hydroxide, and titanium dioxide.
10:30 am – 11:00 am:
Advances in Thermal Stability
Bradley Sparks, Ascend Performance Materials
Ascend Performance Materials is a vertically integrated polyamide producer, strategically positioned to provide reliable and value adding solutions for Automotive and other Industries. Thermal management in under-the-hood (UTH) applications continues to be a focus for the industry. As a result, it has become a part of the core competencies of Ascend. The company continues to invest in the development of new products expanding the capabilities for thermal management in terms of temperatures and long term property retention. In order to provide a comprehensive product offering for UTH applications, Ascend now offers a high performance PA66 based solution that exhibits excellent thermal stability up to 230°C.
11:00 am – 11:30 am:
Tuball™ Single Wall Carbon Nanotubes for Thermoplastics
Maus Christian, Product Development Leader, OCSIAL
OCSIAL has developed Single Wall Carbon Nanotubes (SWCNT) which are now available at industrial scale under TUBALL tradename. SWCNT’s are the ultimate material for conductivity: they are only one carbon atom thick with a diameter of around 2 nanometers and a length of 5-10 microns. Traditional fillers used to bring electrical conductivity in plastics typically need to be added at a high dosage. The unique morphological characteristics of SWCNT’s enable the creation of conductive networks at much lower dosages than those required by CB’s or MWCNT’s for example. As a result, it is now possible to achieve high electrical conductivities without compromising the mechanical properties and other characteristics of plastics. In order to enable the full development of their benefits the SWCNT’s need to be very well dispersed and distributed inside the polymer matrix. Two routes related to melt mixing are considered for the SWCNT’s incorporation. From one side the compounding of SWCNT powder into polymers is envisaged, general recommendations for a two-step compounding approach involving high specific mechanical energy input are summarized. On the other side, OCSIAL has started to develop several concentrates of SWCNT’s that are designed for compounding into specific thermoplastics. Those concentrates have typically a high dosage of SWCNT (up to 10%) and are based on fluid carrier systems. Proposed under the MATRIX tradename, they facilitate the dispersion and eliminate the SWCNT powder handling. Details about dilutions parameters and examples of performances that have been recently achieved by a selection of MATRIX grades are given. The results obtained in ABS, PC, PE rotomolding and PVC plastisols are covered and the specific benefits enabled by the implementation of SWCNT’s are discussed. From those practical cases it can be concluded that SWCNT’s can be incorporated into plastics by melt mixing and that the pre-dispersed SWCNT concentrates provide opportunities for differentiation through new product development.
11:30 am – 12:00 pm:
Surface Enhancement via Polypropylene Metallic Compounds
Tanmay Pathak, A. Schulman
Light weighting and low emissions are desirable aspects for any compound developed for automotive applications. In addition the enhancement of an automotive surface for visual appeal and improved aesthetics is also a key area of research in polymer composites targeted for such applications. There has been considerable development on surface appeal via metallic polymer compounds using effect pigments which allows reduction of weight by metal replacement. However, during injection molding, these compounds could lead to weld line imperfections in parts especially where the flow fronts come together. This is essentially due to poor metallic pigment distribution. The current work shows the development of a Polypropylene metallic composite with the focus on weld line improvement by proper choice of material and tool design to allow injection molded metallic TPO for exterior class A. This development also provides lower costs and lower emissions as it eliminates painting of such TPO compounds.