Plastics Overview Gary Phillips

Transcription

1 Plastics Overview Gary Phillips Wollastonite Business Unit Manager

2 Company Business Overview World s largest wollastonite supplier for reinforced and filled polymers Family of specialty reinforcements Tier approved global supplier State-of-the-art mining and processing operations Willsboro, New York Hermosillo, Mexico Extensive chemical modification technology Customer-focused global technical support Product stewardship program Superior world-wide distribution network Plastics Overview 2

3 Properties of Wollastonite Calcium Silicate (CaSiO 3 ) Naturally occurring non-metallic white mineral Acicular crystal structure ph = 10 Mohs hardness = 4.5 Specific Gravity = 2.9 High Melting Point = 1540 C Plastics Overview 3

4 Properties of Wollastonite vs E-Glass and Carbon Fiber Product Elastic Modulus Tensile Strength Wollastonite (GPa) (MPa) E-Glass 72 (GPa) 3445 (MPa) Carbon Fiber 138 (GPa) 3.5 (GPa) Plastics Overview 4

5 Electrical Conductivity (ASTM D257) (units are ohm-cm) DC 60hz khz Mhz NYGLOS x x x x NYGLOS M x x x x Coefficient of Linear Thermal Expansion (CLTE) up to 1000 C (average value) NYGLOS 4 NYGLOS x 10-5 in/in 1.2 x 10-5 in/in NYGLOS M x 10-5 in/in NYAD M x 10-5 in/in Thermal Conductivity up to 1000 NYGLOS W/(cm-K) 1.8 BTU/(hr-ft²- F) Specific Heat (W-sec/gm-K) 23 C 100 C 500 C 1000 C NYGLOS PHYLLOCOAT Dielectric Constant 50 C applied at 2.45 Ghz 2.5 Thermal Diffusivity (cm²/sec) 23 C 100 C 500 C 1000 C NYGLOS Plastics Overview 5

6 Relative Particles Sizes Plastics Overview 6

7 Chemical Modification Improved Processing - Composite Properties Functional Silanes Amino Methacrylate Vinyl Epoxy Mercapto Hydrophobic & Reactive Blends Emulsions Wetting/Non-Dusting Polymers Oligomers Alkyl/Ester Modified Siloxane Siloxane polyolefin Antimicrobial Silyl quat agent-3 (trimethyoxysilyl) propyl octadecyldimethyl ammonium chloride Plastics Overview 7

8 High Value Product Applications Commercial OEM Composites (Reinforced Plastics) Fenders, claddings, fascia, and rocker panels Mirror housings, roof racks, wheel covers Headlamp housing bezels Instrument panels, pillars, rub strips Engine covers, fan shrouds and blades Electronic housings Electrical connectors Plastics Overview 8

9 High Aspect Ratio, Fine Particle Size Wollastonite Grades NYGLOS 8 (x500) NYGLOS 4W (x500) New - NYLITE (x500) D50 = 12 microns Average length 156 microns Tapped bulk density = 0.48 g/cc D50 = 7 microns Average length - 63 microns Tapped bulk density = 0.35 g/cc D50 = 8 microns Average length microns Tapped bulk density = 0.54 g/cc Plastics Overview 9

10 Key Benefits of Wollastonite in Engineering Polymers HAR grades improve properties versus competitive materials LAR grades equal or improve properties versus competitive minerals Tailored chemical modification Compounding conditions versus competitive minerals Straight mineral or glass/ mineral compounds No splaying during injection molding Improved knit/weld line strength Increased extruder output Excellent surface appearance, Improved surface appearance paintability-plateability Low raw material cost Increased extruder output Excellent glow wire performance Reactive and nonreactive modifications based on polymer and composite requirements Reduced dusting Increased extruder output Stable at high temperature compounding conditions No shift in color during compounding Full replacement for milled glass Partial replacement for chopped glass Excellent creep and tortional shear properties Plastics Overview 10

11 Benefits of NYGLOS HAR Wollastonite vs Milled Glass in Nylon 6 30% Loading in Straight Mineral Formulations - Data based on Ultramid B-27 Resin Properties Milled Glass Fiber NYGLOS 12 Treated NYGLOS 8 Treated NYGLOS 4W Treated Tensile Break (MPa) Break (%) Flexural Modulus (MPa) psi ( C) Notched Izod (KJ/Sqm) Unnotched Izod (KJ/Sqm) Key Benefits: Lower raw material costs Assists in meeting UL94 VO,V1,V2 flameability rating based on polymer, additives, application requirements and glow wire testing Superior surface appearance Improved feeding and dispersion Reduces orientation of chopped glass in glass/mineral compounds Improved flexural and tensile strength Higher HDT with no loss of charpy impacts Primary mineral reinforcement in glass/mineral compounds Improved Knit/Weld Line Strength Plastics Overview 11

12 Product Mix Study Low and High Aspect Ratio Wollastonite Nylon 6 Ultramid B mm. ZSK Extruder Screw Design Z Properties NYAD G Uncoated NYAD MG Uncoated MD400 WOLLASTOCOAT WOLLASTOCOAT NYGLOS MD1000 Ash - % Tensile Yield - MPa Tensile Yield - % Flex Secant Modulus - MPa Flex Peak STress - MPa Impact Resistance Notched Izod J/m NYAD G and NYAD MG are essentially equivalents MD400 WOLLASTOCOAT and 400 WOLLASTOCOAT are equal in physical properties. Wollastonite grades fed in barrel # Plastics Overview 12

13 Product Mix Study Low and High Aspect Ratio Wollastonite Nylon 6 Ultramid B-27 (cont d) 40 mm. ZSK Extruder Screw Design Z Properties Translink 445 NYGLOS 4W ASPECT 3914 NYGLOS 4W µm Talc Ash - % Tensile Yield - MPa Tensile Yield - % Flex Secant Modulus - MPa Flex Peak STress - MPa Impact Resistance Notched Izod J/m NYGLOS 4W and ASPECT Equivalent in physical properties NYGLOS 4W and ASPECT Far superior to competitive products no splaying during plaque molding - Large formulation window NYGLOS 4W Exhibited highest stiffness, lower impact to any product. Attractive for high stiffness, low density, thin wall composites. Candidate for the extension of chopped glass. Treatment is best to meet glow wire and heat deflection temperature requirements. Treatment stable at processing temperatures > 290 NYGLOS /ASPECT wollastonite grades fed in barrel #6 via side feeder Plastics Overview 13

14 Glass/Mineral and Straight Mineral Nylon 6 (Screw Design Z40-220) PA 6 BASF Ultramid B27 E01 Ratio - PA/ Mineral/Glass % Ash Break (MPa) Break (%) Notch Izod (KJ/SqM) Unnotch Izod (KJ/SqM) Flex Mod (MPa) 264 psi ( ) Translink Control 60/25/ NYGLOS MD1000/1000 Uncoated 60/25/ NYGLOS 4W /25/ NYGLOS MD Low cost alternative with comparable properties to expensive coated calcined clay Glass/Mineral formulations - Cost down Superior performance to coated calcined clay Glass/Mineral formulations - High stiffness - Improved ductility - Improved surface NYGLOS 4W Control 60/25/ NYGLOS 4W /30/ NYGLOS /30/ NYGLOS 4W and NYGLOS Represent potential to replace approximately 33% of glass loading in a glass/mineral formulations Comparable or improved performance - Improved surface appearance - Reduction in extruder abrasion - Reduced unit/compounding costs Plastics Overview 14

15 Wollastonite Product Study Effect of Particle Size/Aspect Ratio on Izod Impact (Nylon 66 40% Mineral System) Plastics Overview 15

16 Wollastonite Product Study (cont d) Effect of Particle Size/Aspect Ratio on Flexural Modulus (Nylon 66 40% Mineral System) Plastics Overview 16

17 PHYLLOCOAT F Chemically Modified Lamellar Amorphous Aluminosilicate Typical Property Typical Value G.E. Brightness 82 Oil Absorption (lbs./100 lbs.) 56 PHYLLOCOAT F (x750) Bulk Density Loose (lbs./cu.ft.) (g/cc) Tapped (lbs./cu.ft.) (g/cc) (17) (0.27) (25) (0.40) Median Particle Size (µm) 6.0 Surface Area (m 2 /g) 3.6 Minus 325 U.S. Mesh Screen 99.9 Moisture (%) 0.19 Appearance White Specific Gravity (g/cc) 2.4 ph 8.5 Mohs Hardness 5.5 Melting Point ( C) theoretical 980 Patent Pending Plastics Overview 17

18 PHYLLOCOAT F012 (cont d) New High Strength Non-Directional Reinforcement for Engineering Alloys Nylon 6 20% Straight Mineral and 15% Glass/25% Mineral Compounding Data Property Test Method Calcined Clay PHYLLOCOAT F012 Glass and Calcined Clay Glass and PHYLLOCOAT F012 Filler Content (%) ISO Tensile Strength,50 mm/min (MPa) ISO Tensile Break, 50 mm/min (%) ISO Flexural Modulus Chord, 2 mm/min (MPa) ISO Flexural Strength, 2 mm/min (MPa) ISO Notched Charpy 23 C (KJ/m 2 ) ISO Unnotched Charpy 23 C (KJ/m 2 ) ISO HDT@ 1.8 MPa ( C) ISO Density (g/cm 3 ) ISO Mold Linear Shrinkage, 4 x 8 Plaque (%) Internal Mold Transverse Shrinkage, 4 x 8 Plaque (%) Internal Compounding Conditions: PHYLLOCOAT F012 Powder Feeder (Properties will be improved if fed downstream in the mix via side feeders) Surface Modified Calcined Clay Powder Feeder PA6 10 micron Chopped Glass Fiber Glass Feeder Patent Pending Plastics Overview 18

19 PHYLLOCOAT F012 (cont d) New High Strength Non-Directional Reinforcement for Engineering Alloys Nylon 6 20% Straight Mineral and 15% Glass/25% Mineral Compounding Data Major Benefits: Higher Stiffness and HDT Improved Surface Appearance Reduced Dusting During Compounding Comparable Shrinkage With Existing Tooling Comparable or Reduced Raw Material Cost Reduced Warpage in Glass/Mineral Compounds Partial Replacement of Glass Fiber in Glass/Mineral Compounds Patent Pending Plastics Overview 19

20 Key Benefits of Wollastonite in Polyolefins Improved mar and scratch resistance Lower loading level = lower density High stiffness - improved impacts Further improvement in mar/scratch resistance Excellent balance in stiffness and impact Excellent surface appearance and color retention Odorless (Rating 2.4, Neat PP 2.0) vs Talc (5.0) Low CLTE (no gap) Improved HDT Excellent plateability Plastics Overview 20

21 New NYGLOS 4W STO105 and NYLITE High Strength Wollastonite Reinforcements for Polyolefin Applications Automotive Transportation Appliance Furniture Braskem T16200Q Hi Impact Copolymer 20 MFR-NB 15% Mineral By Weight Neat Resin Modulus 793 MPa Property Test Method Measure Neat PP Talc (0.5µm) Talc (2µm) NYGLOS 4W STO105 NYLITE Melt Flow Rate (g/10 mins) ISO C /2.16kg Filler Content (%) ISO F/10 mins Moisture (%) ASTM D C Density ISO 1183 g/cm VW Odor Test Scale (1-5) Tensile Strength (MPa) ISO mm/min - CH Tensile Elongation (%) ISO mm/min - CH Flex Strength (MPa) ISO mm/min MPa ( C) ISO 75 na Flex Modulus Chord (MPa) ISO mm/min Charpy Notched, 23 C ISO 179 kj/m Charpy Notched, -30 C ISO 179 kj/m x 8 Shrink Plaques With Flow Transverse Flow Average CLTE, with flow (10-6/mm/mm C) CLTE, cross flow (10-6/mm/mm C) Differential ISO to 120 C DSC (Tc) 2 cycles ISO na NYGLOS and NYLITE Fed Downstream Barrel #8 ZSK Coperion Downstream side feeding into the melt is required to optimize NYGLOS /NYLITE performance Talc Fed Barrel #6 ZSK Coperion Percent loading levels by weight vary depending on the engineering standard/composite requirements Plastics Overview 21

22 New NYGLOSS 4W STO105 and NYLITE High Strength Wollastonite Reinforcements for Polyolefin Applications (cont d) Automotive Transportation Appliance Furniture Key Benefits: Odorless not associated with any volatiles Non-Toxic, safe and recyclable Improved physical property performance Lower compound density Premier reinforcement for weight reduction Superior scratch performance and surface appearance Improved weld line strength Plastics Overview 22

23 New NYGLOS 4W STO105 and NYLITE High Strength Wollastonite Reinforcements for Polyolefin Applications Erichsen Cross-Cut Test Delta L-10N Plaques Property Measure Talc (0.5µm) Talc (2µm) NYGLOS 4W STO105 Five Finger Scratch 15N FORD Grain Erichsen Cross-Cut Test Delta L-10N-Smooth Plaques >3 >3 <1 <1 Erichsen Cross-Cut Test Delta L-10N- Coarse Plaques >5 >5 <2 <2 NYLITE Coarse Plaques Talc (2 micron) 5.50 Talc (0.5 micron) 6.50 Wollastonite (NYGLOS 4W STO105) 1.80 Wollastonite (NYLITE ) 1.95 Smooth Plaques Talc (2 micron) 3.25 Talc (0.5 micron) 3.89 Wollastonite (NYGLOS 4W STO105) 0.75 Wollastonite (NYLITE ) Plastics Overview 23

24 Polypropylene Interior High Impact Co-Polymer NYGLOS /ASPECT Wollastonite (Neat Resin Modulus 760 MPa) Properties NYGLOS 4W NYGLOS 4W NYGLOS 4W ASPECT 3992 ASPECT 3992 ASPECT 3992 Fine Talc (0.5µm) Ash - % Flexural Modulus Yield Yield MPa Scratch Rating 15n FLTM BN Melt Flow Multiax, Impact - 30 C (DUCT/Brit - J) 4D/1B 39J 5D -37J 5D -37J 3D/ 2B - 36J 5D -37J 5D -36J 5D -37J Impact - Notched 0 C hours R.T Key Benefits: Tailored chemical modifications Can alter the balance of stiffness, impact and gloss. Chemical modifier (10992) - Exhibits good balance of overall mechanical properties with improved feeding and higher elongation Plastics Overview 24

25 NYGLOS Wollastonite Chemical Modification Study High Impact Polypropylene Interior Co-Polymer (Neat Resin Modulus 800 MPa) Properties Test Method Fine Talc NYGLOS 4W NYGLOS 4W NYGLOS Ash - % ASTM D5630A Flexural Mod. (Chord) 2MM/MIN 64 MM SPAN (MPa) ISO Yield 50MM/MIN (MPa) ISO Yield 50MM/MIN ISO MPa 264 PSI FLATWISE ISO Mar & 4, 5, 7, 10, 15 & 20 Newtons GMN , 2, 4, 5, 5 2, 2, 3, 4, 4 2, 2, 3, 4, 4 2, 2, 3, 4, 4 Melt Flow 230 C/2.16KG ASTM D1238A Max - 30 C to 110 C ASTM E831 40/150 32/164 33/160 33/166 Multiax, Impact - 30 C/2.2M/S ASTM D3763 5D 37J 3D 2B 39J 2D 3B 38J 2D 3B 36J Impact - Notched 0 C KJ/SQM ISO Impact - Unotched 0 C KJ/SQM ISO 180 N/B hours R.T. % ISO Gloss 60 Degree ASTM D Plastics Overview 25

26 NYGLOS M2992 A Non-Directional Wollastonite Medium Impact Polypropylene Co-Polymer (Neat Resin Modulus 1035 MPa, 35 Melt Flow) Key Benefits: Improved impact strength Excellent balance in stiffness and impact Improved stiffness = lower CLTE = higher HDT Higher elongation at break Comparable shrinkage differentials in both directions Excellent surface appearance and improved mar/scratch resistance Utilize existing tooling Ideal reinforcement for vertical body panels Plateability and direct metallization properties Properties Talc 2µm (20%) Talc 7µm (20%) NYGLOS M2992 (20%) Melt Flow (g/10 min) Tensile Yield (MPa) Elongation Break (%) Flexural Modulus (MPa) Flexural Strength (MPa) Notched Charpy, 23 C (kj/m 2 ) Notched Charpy, -30 C (kj/m 2 ) MPa ( C) Tool Shrinkage, 24 hours 4x6 shrink (w/flow) x6 shrink (x/flow) x6 shrink (avg) Shrinkage Differential Plastics Overview 26

27 NYGLOS M3 Wollastonite A Cost Performance Additive Versus Talc in Polypropylene Key Benefits : 20% By Weight Mineral Filled Physical Property Comparison Cost reduction in raw materials Improved notched impact properties Excellent balance in stiffness and impacts Better mar and scratch resistance Lowers CLTE Low fogging properties Plastics Overview 27

28 Wollastonite vs Calcium Carbonate and Talc (35 Melt Flow Polypropylene Copolymer) Properties Test Method CaC0 3 (6µm) NYAD 450 WOLLASTONITE NYGLOS 1000 WOLLASTONITE NYGLOS STPO WOLLASTONITE Talc (7µm) Melt Flow (g/10min) ISO Filler Content (%) ISO Tensile Yield (MPa) ISO Break (%) ISO Flexural Modulus, 2mm/min (MPa) ISO Flexural Strength, 2mm/min (MPa) ISO Notched Charpy Impact, 23 C (kj/m2) ISO Notched Charpy Impact, -30 C (kj/m2) ISO MPa ( C) ISO Mold Shrinkage (with flow) (mm/mm) ISO Mold Shrinkage (cross flow) (mm/mm) ISO CLTE-30 to 100 C (with flow) (10-6/ C) ASTM E CLTE-30 to 110 C (cross flow) (10-6/ C) ASTM E Finger Scratch ( 5, 7, 10, 15, 20N) INTERNAL 3, 3, 4, 5, 5 2, 2, 3, 4, 5 2, 2, 2, 3, 4 2, 2, 2, 3, 4 3, 3, 4, 5, Plastics Overview 28

29 Polypropylene Copolymer 20% Loading (CLTE 10x6/ C - ASTM E ) Plastics Overview 29

30 NYGLOS /ASPECT - Wollastonite Improves Scratch Resistance in Polyolefins Key Benefits : Improved scratch resistance on soft and coarse plaques Higher flexural modulus and heat distortion temperature Good cold temperature impacts Lower CLTE Optimum reinforcement for lower density and thin wall composites Excellent painted surface appearance and color retention Plastics Overview 30

31 Product Development Study NYGLOS /ASPECT Wollastonite Cost Effective Replacement for Glass Fiber High Impact Polypropylene Interior Co-Polymer (Neat Resin Modulus 800 MPa) Properties Test Method UltrafineTalc NYGLOS 4W ASPECT /8 in. Glass Ash - % ASTM D530A Flexural Mod. (Chord) 2MM/MIN 64 MM SPAN (MPA) ISO Yield 50MM/MIN (MPA) ISO Yield 50MM/MIN ISO MPa 264 PSI FLATWISE ISO N/A Mar & 5, 7, 10, 15 and 20 Newtons GMN , 2, 3, 5, 5 2, 2, 3, 4, 4 2, 2, 3, 4, 4 N/A Melt Flow 230 C/2.16KG ASTM D1238A N/A Max - 30 C to 110 C ASTM E831 40/150 32/164 33/166 26/190 Multiax, Impact - 30 C/2.2M/S ASTM D3763 5D 37J 4D 1B 39J 2D 3B 37J N/A Impact - Notched 0 C KJ/SQM ISO Impact - Unotched 0 C KJ/SQM ISO 180 N/B hours R.T. % ISO N/A Gloss 60 Degree ASTM D N/A Reduce costs, improve surface appearance and reduce warpage compared to glass fiber Plastics Overview 31

32 Processing Information and Guidelines Excellent color retention and surface appearance - compounding conditions All coated products eliminated or reduced dust during feeding Extruder torque rates (throughput) increased at equal loading levels by 20% Increased throughput demonstrates potential to reduce compounding cost Powder grades can be processed and compounded same conditions as talc High Aspect Grades NYGLOS and ASPECT downstream feeding Recyclable - Pelletized material fed into main feed exhibited 98% retention Tailored modification to further enhance processing, properties and reduce dusting Plastics Overview 32

33 Combination Twin Screw Process Setup For Compounding W & P ZSK-40 TALC NYGLOS/ASPECT PROPERTIES can be further improved by moving the side feeder farther downstream Plastics Overview 33

34 NYGLOS 4W Wollastonite A Cost-Effective Partial Replacement to Chopped Glass in General Purpose PBT Key Benefits: Cost reduction in raw materials Comparable properties to chopped glass Excellent thermal and dimensional stability Reduced warpage versus chopped glass Improved molded surface appearance and finish Reduction in glass read out Increased extruder throughput Excellent chemical resistance Plastics Overview 34

35 NYGLOS 8 Wollastonite Improved Performance Versus Fine Talc in General Purpose PBT/PET Key Benefits: Significant improvement in notched impacts 50% increase in flexural modulus Improved thermal and dimensional stability Better tensile strength Superior molded surface appearance and finish Enhanced dielectric properties versus talc Improved chemical resistance Plastics Overview 35

36 NYGLOS Wollastonite Cost-Effective Extender for Chopped Glass in Bulk Molding Compounds Compound Barcol Hardness Specific Gravity Shrinkage (In./In.) Cure Time (Sec.) Water Absorption (%) Standard (All Glass) NYGLOS (30% Replacement) Compound Tensile Strength (103 psi) Flexural Strength (103 psi) Flexural Modulus (106 psi) Notched Izod Impact (ft.-lb./in.) Compression Molded NYGLOS ¼ Chopped Glass Screw Injected NYGLOS ¼ Chopped Glass Plunger Injected NYGLOS ¼ Chopped Glass Key Benefits: Reduced compounding and end unit cost Improved spiral flow Improved long-term ageing Improved surface appearance Plastics Overview 36

37 Key Benefits of Wollastonite in Plastics Cost-effective replacement for milled glass Cost-effective extension for chopped glass and synthetic reinforcements Cost-effective replacement to milled carbon fiber (NYLITE ) Reduced weight/density Increased flexural modulus Excellent balance stiffness - impact Lower coefficient of linear thermal expansion Improved heat distortion temperature Improved dimensional stability Odorless, no volatiles Improved mar-scratch resistance Improved creep resistance tortional shear HAR grades E-Coat compatible (depending on polymer) Tailored chemical modification Plastics Overview 37

38 New Application Development OEM vertical body panels PPE/PA Non directional product NYGLOS M2000 treated Polypropylene NYGLOS M2000 treated Interior, exterior and under the hood applications Thin wall lower density composites Engineering alloys Straight mineral & mineral/glass compounds Milled glass replacements for UL94 glow wire applications Head lamp housings (bezels) PBT, BMC, PPS Computer housings and ultra books PC/ABS LCP (Electrical connectors) Extension/replacement of milled carbon fibers (NYLITE ) Plastics Overview 38

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