New Mineral Opportunities in Polymers Mica

Transcription

1 New Mineral Opportunities in Polymers Mica A High Reinforcement Alternative in Polypropylene Compounds Jim Harper Applications Development Manager Imerys Performance Additives (jim.harper@imerys.com)

2 Imerys Corporate Overview of Innovation and Development Decentralised organization is optimum to support our customers worldwide Divisions are responsible for innovation Each operating own R&D resources 28research centers: 8 main research centers and 20 regional laboratories Network of 300 engineers and technicians San José (USA) Roswell/Marietta (USA) Par Moor (Cornwall) (UK) Aixe-sur-Vienne (France) Limoges (France) Colomiers (France) Sandersville, Georgia (USA) Sandersville, Georgia (USA) La Guardia (Spain) Castellon (Spain) Willebroek (Belgium) Neuwied (Germany) Selb (Germany) Villach (Austria) Bodio (Switzerland) Saint Quentin Fallavier (France) Toulouse (France) Hódmezõvásárhely (Hungary) Nagpur (India) Katni (India) R&D Centers Zhangjiagang (China) Bangkok (Thailand) Regional laboratories Changshu, Jiangsu province (China) Kao-Shu Shiang (Taiwan) Minerals for Ceramics, Refractories, Abrasives & Foundry Performance Minerals & Filtration Pigments for Paper Materials & Monolithics Bras Cubas, near Sao Paolo (Brazil) Kerikeri (New Zealand)

3 Portfolio of Minerals Alumina Andalusite Ball Clay Bentonite Bauxite Calcium Carbonate Ground Precipitated Carbon Black Clinoptilolite Cordierite Diatomaceous Earth Dolomite Feldspar Graphite Kaolin Hydrous Calcined Magnesite Mica Muscovite Phlogopite Olivine Perlite Silica Silicon Carbide Talc Vermiculite Zirconia Kaolin Diatomite GCC Dolomite Vermiculite Talc Ball Clay Mica Perlite

4 Overview Key Mineral Characteristics of Mica Mica s Key Function in Plastics Value Performance in Homopolymer Polypropylene Compounds

5 Performance Minerals Innovation Mica The Performance Additive Mineral Suzorite Phlogopite Mica It is well recognized for its reinforcing and barrier properties, as well as its chemical inertness, phlogopite mica is also used as a sound and vibration-damping additive in polymeric and asphalt based coatings for under-the-carpet automotive applications. Muscovite Mica Mined and processed in Kings Mountain, NC. It is suitable for applications requiring the reinforcement of coatings and where greater resistance to moisture, heat, light and chemicals is needed. It is a functional extender that improves crack resistance and reduced film permeability. It also promotes adhesion in both water and solvent-based formulations.

6 Imerys North America Mica Locations Suzorite Mica Boucherville, Quebec Kings Mountain, NC

7 Mica Phlogopite KMg 3 (Si 3 Al)O 10 (F,OH) 2 Suzorite, Quebec

8 Mica Muscovite 10 µm KAl 2 (Si 3 Al)O 10 (OH,F) 2 Kings Mountain, NC

9 Talc vs. Phlogopite (Mica) Chemistry O Si OH/F Mg Al K Talc: Mg 3 Si 4 O 10 (OH) 2 Phlogopite: KMg 3 (AlSi 3 )O 10 (OH/F) 2

10 Phlogopite vs. Muscovite (Mica) Chemistry O Si OH/F Mg Al K Trioctahydral Mica (Brown or Black) Phlogopite: KMg 3 (AlSi 3 )O 10 (OH/F) 2 Dioctahydral Mica (White or Off White) Muscovite: KAl 2 (AlSi 3 )O 10 (OH/F) 2 *** F substitution for OH makes higher temperature micas

11 Inherent Properties of Mica Muscovite Phlogopite Dehydroxylation Temperature ( C) Specific Gravity Refractive Index Loss at 1,000 C (%) 4.2 < 1.0 Hardness (mohs) Very High Aspect Ratio

12 Key Physical Characteristics Shape - Platy (Highest Aspect Ratio Mineral) Aspect Ratio - Number denoting the average diameter vs the thickness Flexible -Platelets are semi-rigid, and retain flexibility across all Particle Size Distributions and grind techniques Dispersible - Mixes easily in formulations, requires low shear to incorporate into plastics Chemically Resistant - Impervious to all chemicals, except Hydrofluoric Acid

13 Aspect Ratio Aspect Ratio (Shape Factor) Number relating the diameter (d) to the thickness (t) of the platelet. d t sphere 1:1 5:1 10:1 60:1 80:1 0.5 µm 0.73 µm 1.1 µm 1.9 µm 2.5 µm

14 Function of Mica in Plastics Increase flexural modulus Increase heat deflection temperature Improves dimensional stability Decrease coefficient of linear thermal expansion Promote stable post molding isotropy Reduce distortion/warpage

15 Details of Study Minerals Used Mean Particle size, µm (Sedigraph) Mean Particle Size, µm (Laser) Typical Aspect Ratio 325 mesh lamellar talc 7.5 n/a 16:1 325 mesh phlogopite mica :1 200 mesh phlogopite mica :1 150 mesh phlogopite mica :1 The above mineral were used at 20 and 40% in a 4.3 Melt Flow, heat stabilized Polypropylene Homopolymer Samples were extruded

16 Value Performance of Mica in Polypropylene Compounds Flexural Modulus is greatly impacted by the aspect ratio of the particles

17 Value Performance of Mica in Polypropylene Compounds Mean Particle Size as measured by Sedigraph

18 Value Performance of Mica in Polypropylene Compounds Mean Particle Size as measured by Sedigraph

19 Value Performance of Mica in Polypropylene Compounds

20 Value Performance of Mica in Polypropylene Compounds Performance improves with larger particle size

21 Value Performance of Mica in Polypropylene Compounds Shrinkage decreases as particle size increases

22 Summary of Properties Phlogopite Mica Provides optimum stiffness Achieved through the effect of high aspect ratios Improves thermal stability Increasing particle size will increase heat deflection temperature Significantly reduces shrinkage Improves dimensional stability

23 Conclusions Physical properties such as Flexural Modulus, Notch Izod, HDT and Shrinkage are optimized using a 34 micron Phlogopite Mica Performance can be closely matched to coarse talc using a 8 micron Phlogopite Mica A balance of properties can be achieved through the use of 12 micron Phlogopite Mica

24 Thank you for your attention! Any questions? Slide 24