3M Microspheres Performance Enhancements. Applications

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1 3M Microspheres Performance Enhancements Innovative Solutions fordemanding Applications 3

2 3M Microspheres 3M Microspheres offer a variety of inherent advantages over many traditional irregularly shaped mineral fillers. 3M can offer engineered microspheres with different sizes, strength, density and composition. Combining the inherent advantages with engineered features provides a wide choice of unique potential enhancements to help you meet specific processing and end use requirements. Possible enhancements using microspheres from 3M are improved flow, lower resin demand, low viscosity/high filler loading, and reduced warpage and shrinkage. 3M Glass Bubbles are an ideal choice to help reduce weight and improve machinability and sandability, increase thermal insulation, and lower dielectric constant. 3M Ceramic Microspheres are ideal options for increasing hardness gloss control, and may improve corrosion resistance, or if you need fine particle size filler. Engineered for a wide choice of unique enhancements Low viscosity/ high filler loading One effect of low resin demand and the ball-bearing action of spheres is lower viscosity at equivalent filler loading, or higher filler loading at equivalent viscosities. The following are viscosity curves for various typical fillers in a polyester resin*. A = Talc (3 26 C. B = CaCO 3 (19 26 C. C = 3M Ceramic Microspheres 26 C. D = 3M Glass Bubbles, grade 25 C * Resin = Ashland Aropol Viscosity (cps) A 160 0% 10% 20% 30% 40% 50% Improved flow Percent volume loading Unlike many irregularly shaped fillers, 3M microspheres roll easily over one another, similar to ball bearings. This can help improve the flow of many materials to which microspheres are added. Flow of Filled/Reinforced Polypropylene B C D Low Resin Demand With the lowest surface area to volume ratio of any shape, 3M microspheres can help reduce resin demand in a variety of applications. Specific Surface Area m 2 /g m 2 /cc 3M Glass Bubbles K/S Series Floated Series M Ceramic Microspheres 3M Ceramic Microspheres Traditional Mineral Fillers Talc Clay CaCO Finger flow mold, inches* of flow Filler/reinforcement None 30% glass fiber 40% glass fiber 30% glass with 10% Zeeospheres Finger thickness (mils) * 500 F (260 C) melt temp. at 1400 psi. 2

3 Weight Reduction The low density of 3M Glass Bubbles can help reduce the weight of a wide variety of finished products. Potential Weight Reduction with 3M Glass Bubbles (based on reported customer results) Automotive PVC Sealer 40-50% SMC (Sheet Molding Compound) 32-47% Thermoplastics 10-22% RIM fascia (Reaction Injection Molding) 10-16% Reduced shrinkage and warpage The high filler loading possible with 3M Microspheres can often result in reduced shrinkage. 3M glass bubbles help reduce cracking and shrinkage in spackling compound. In some types of reinforced thermoplastics, adding either 3M Ceramic Microspheres or high-strength grades of 3M glass bubbles can also help reduce shrinkage. Plus, 3M Microspheres provide more uniform stress distribution to help reduce or eliminate warpage in many molded plastics filled with fibers or other high aspect ratio materials. Spackling compound without 3M glass bubbles. Reinforcement Warpage mm Shrinkage in./in. Floated Series % GF % GF/10% G % GF/10% G % GF/15% G GF = Glass fiber G-600 = 3M Ceramic Microspheres G-600 Reduced weight Better performance Spackling compound with 3M glass bubbles. NOTE: Technical information and data shown throughout this brochure should be considered representative or typical only and should not be used for specification purposes. 3

4 3M Microspheres Water resistance 3M Glass Bubbles are soda-lime borosilicate (true glass) with inherently greater water resistance than borosilicate glass bubbles (water glass), maintaining integrity even when boiled in water for more than 40 minutes. In the photo at right, 3M glass bubbles are at left; borosilicate glass bubbles at right. Both are floating on the surface. After boiling (bottom photo), borosilicate glass bubbles dissolved while 3M glass bubbles were still floating on the surface, virtually unchanged. 3M ceramic microspheres offer even greater water resistance but not the same degree of weight reduction and thermal insulation as 3M glass bubbles. Both float on surface After boiling for more than 40 minutes 3M Glass Microspheres 3M Glass Bubbles Borosilicate glass microspheres Borosilicate glass microspheres Continues to float Dissolves in water 3M Glass Bubbles Borosilicate glass microspheres True glass integrity 4

5 Machinability and sandability Parts or tooling compounds containing 3M Glass Bubbles can often be easier to cut, sand, machine, and shape. Note the threads in the cone at below. With 3M glass bubbles in autobody filler, filing and sanding is easier and there is very little gouging. And there s less clogging of tools, which can help extend the service life of sandpaper and files. Easier to work with 5

6 3M Microspheres Thermal insulation Because 3M Glass Bubbles are hollow, they provide low thermal conductivity as shown below. Thermal 32 F (0 C): W/mK Low dielectric constant 3M glass bubbles are hollow, providing low dielectric constant as shown below. Dielectric Constant (@ 100 mhz) 3M Glass Bubbles Varies w/grade Cost effectiveness In the photo, 3M glass bubbles in the flask at right are the same weight as the calcium carbonate at left. Since 3M glass bubbles obviously occupy more space, a comparison of filler cost effectiveness must consider cost per unit volume instead of cost per pound. With low resin demand, 3M glass bubbles can often maintain viscosity while replacing more of the costly resin than traditional mineral fillers. Results are similar to those illustrated in the autobody filler example below. Cost-effective product enhancement Cost evaluation Autobody Putty Current Formulation Cost/lb Density Weight Weight Volume Volume Total Cost $/Can* Component $ g/cc lbs % gal % $ Polyester Resin Thixotrope TiO Talc Totals Suggested Formulation with 3M Glass Bubbles 3.69/80% filled Cost/gal=$4.61 Cost/lb Density Weight Weight Volume Volume Total Cost $/Can* Component $ g/cc lbs % gal % $ Polyester Resin Thixotrope TiO Talc K1 Glass Bubbles Totals /80% filled Cost/gal= 4.35 % Change: Density = -34.9% Cost/gal = -5.8% NOTE: As indicated in the chart, 3M glass bubbles can lower the raw material costs while reducing the density by 38%. Which can help reduce shipping costs! Important Notice and Disclaimer: The formulations, calculations and recommendations contained in this Cost Evaluation are suggestions only and the user of this information must thoroughly evaluate any such formulation, calculation and recommendation to determine whether it is fit for a particular purpose and suitable for the user s method of application. 3M makes no warranties, expressed or implied, including, but not limited to any implied warranty of merchantability or a fitness for a particular purpose or any implied warranty arising out of a course of dealing, custom, or usage of trade. Limitations of Liability: 3M shall not be liable for any losses or damages resulting from the use or inability to use this Cost Evaluation whether direct, indirect, special, incidental, or consequential, regardless of the legal or equitable theory asserted, including contract, negligence, warranty, or strict liability. * 1 can = 0.8 U.S. gallons 6

7 Hardness Mohs 7 hardness and the spherical shape of 3M Ceramic Microspheres contribute to increased hardness of a variety of compounds. Despite such hardness, 3M ceramic microspheres have been shown to be less abrasive to equipment than many irregularly shaped mineral fillers of equal or lower hardness. Mohs Value Talc 1 Fingernail 2.25 Copper coin 3 Iron 4.5 Titanium dioxide M Ceramic Microspheres 7 Topaz 8 Sapphire 9 Diamond 10 Gloss control Many gloss control materials can increase viscosity. But increasingly higher levels of 3M ceramic microspheres can help incrementally lower gloss without significantly increasing viscosity in many applications. Corrosion resistance In general, the tight particle packing of 3M ceramic microspheres can produce coatings with increased corrosion resistance via reduced film permeability in many applications. In salt spray testing of a water-reducible epoxy primer, the following results were observed on test panels. With 5% by volume of 3M Ceramic Microspheres added, 60 gloss is 66, and viscosity is essentially unchanged. Salt Spray Testing of Water-Reducible Epoxy Primer 3M Ceramic Filler Barium Sulfate Microsphere G-200 Hours to fail PVC Application solids Control...without 3M Ceramic Microspheres exhibits 60 gloss of 85. 7

8 3M Microspheres Beyond microsphere enhancements...technical support and worldwide service It can take more than quality products to help you solve complex problems. That s why 3M also provides technical support, a proven global service network, and ongoing R&D to help you meet your ever-evolving needs. R&D... expanding our capabilities to serve you With a focus on continuous improvement and innovation, 3M R&D takes you beyond our current microsphere technology microencapsulation, surface treated products and metal coated products. Technical support Tur technical support team offers the expertise and depth of 3M. Together with our technically trained authorized distributor network, we field the largest team in the industry to help you solve problems, optimize formulations and simplify material handling. Resources 3M Microspheres are supported by global sales, technical and customer service resources, with fully-staffed technical service laboratories in the U.S., Europe, Japan, Latin America and Southeast Asia. Users benefit from 3M s broad technology base and continuing attention to product development, performance, safety and environmental issues. For additional technical information on 3M microspheres in the United States, call 3M Energy and Advanced Materials Division, For other 3M global offices, and information on additional 3M products, visit our web site at: United States 3M Energy and Advanced Materials Division Brazil 3M do Brasil Ltda Canada 3M Canada Company Europe 3M Belgium N.V India 3M India Limited Bangalore China 3M China Ltd China 3M Hong Kong Limited Taiwan 3M Taiwan Limited Korea 3M Korea Limited Japan Sumitomo 3M Limited Philippines 3M Philippines, Inc Singapore 3M Singapore Pte. Ltd Malaysia 3M Malaysia Sdn. Berhad New Zealand 3M New Zealand Ltd Australia 3M Australia Pty., Ltd Other Areas (U.S.) Important Notice to Purchaser: The information in this publication is based on tests that we believe are reliable. Your results may vary due to differences in test types and conditions. You must evaluate and determine whether the product is suitable for your intended application. Since conditions of product use are outside of our control and vary widely, the following is made in lieu of all express and implied warranties (including the implied warranties of merchantability and fitness for a particular purpose): Except where prohibited by law, 3M s only obligation and your only remedy, is replacement or, at 3M s option, refund of the original purchase price of product that is shown to have been defective when you received it. In no case will 3M be liable for any direct, indirect, special, incidental, or consequential damages (including, without limitation, lost profits, goodwill, and business opportunity) based on breach of warranty, condition or contract, negligence, strict tort, or any other legal or equitable theory. 3 Energy and Advanced Materials Division 3M Center Building 223-6S-04 St. Paul, MN Please recycle. Printed in USA. Issued: 9/07 3M All rights reserved. 5922HB M is a trademark of 3M. Used under license by 3M subsidiaries and affiliates.