Composite Acrylic Impact Modifier: The Latest Innovation in PVC Window Profiles Impact Strengthening

Transcription

1 Composite Acrylic Impact Modifier: The Latest Innovation in PVC Window Profiles Impact Strengthening Philippe HAJJI,, Frédéric ric MARCHAND, Rosangela PIRRI ARKEMA / Functional Additives PVC 2008 Conference / Brighton April 23

2 SCOPE A little bit of AIM history AIM main action mechanisms Plateout issue Composite Acrylic Impact modifier: new innovative step in AIM Durastrength 360: first product from the C-AIM C platform

3 Acrylic Impact Modifier (AIM): a leading technology Among several impact modification technologies available on the outdoor U-PVC U market, AIMs are the most preferred, specially for Window Profile application

4 AIM successive innovation steps DURASTRENGTH range (Europe) 1 st generation 2 nd generation 3 rd generation 4 th generation 5 th generation D200 D300 D320 D529 D340 General purpose grade for various profiles, siding and injection molding Impact modifier for window profiles Standard impact modifier for window profiles Bifunctional modifier for window profiles High rubber impact modifier for window profiles Higher efficiency and continuous innovation explain AIM leading position

5 Typical AIM Core/Shell Structure -Crosslinked rubbery core of PBA (Tg = -45 C) -Rigid shell of PMMA (Tg = 100 C) PMMA rigid shell role: - powder flowability and bulk delivery - good compatibility with PVC matrix dispersion - PVC gelation promotion PBA rubbery core role: - The active phase for impact strengthening

6 From Core/Shell to AIM powder Core = X-linked PBA Shell = PMMA Primary particle = µm D 50 = 130 to 250 µm Primary particle Powder particle

7 PMMA Shell effects C Torque (g.m) e d c b a AIM % Time (s) (a)=4.5 phr; (b) = 5.5 phr; (c)=6.5 phr; (d)=7.5 phr; (e)=8.5 phr High dispersion level of primary particles in PVC matrix (window profile formulation) Role of PMMA shell in the gelation process.

8 Acrylic rubbery core effects Shear yielding mechanism Stress concentration Shear yielding of the PVC matrix is controlled by AIM particles through stress concentration

9 2 recent innovations in AIM High rubber D340 Bifunctional D529 Core = PBA Core = BA Shell = PMMA Shell = PMMA Process aid layer Higher core content allows to reduce AIM dosage (0.5 1 phr) Bifunctional nature allows to remove Process aid from the formulation (0.5-1 phr) Both approaches provide similar cost/performance ratio

10 Plateout: : nightmare and high cost - Unwanted deposits into die/calibrator - Stop production to clean high cost - More than ever an issue with Ca/Zn Shutdown cost rough estimation: Up to 500k for 20 kt window profile Design a high efficiency AIM with anti-plateout effect

11 New Composite AIM concept (C-AIM) An intimate association of an highly efficient AIM and a nano-sized inorganic additive. AIM -New dedicated high rubber AIM technology, -Ensures Nanofiller dispersion in PVC Nanofiller -Anti-plateout effect (gentle abrasion effect -> tool cleaning+ absorption of low molecular weight species), -Cavitation/stress concentration PVC matrix shear yielding (even if less efficient than AIM rubber) -Economical aspect (recovering of high rubber AIM at higher productivity)

12 Impact strengthening contribution of inorganic particles Morphology investigations after impact testing (ductile break) Cavitation Plastic deformation Dewetting of inorganic/pvc interfaces leads to cavitation that promotes shear yielding

13 C-AIM morphology options Outside type AIM core/shell particle Inside type AIM powder grain Nanofiller

14 D360: first of the C-AIM C series DURASTRENGTH range (Europe) 1 st generation 2 nd generation 3 rd generation 4 th generation 5 th generation 6 th generation D200 D300 D320 D529 D340 D360 General purpose grade for various profiles, siding and injection molding Impact modifier for window profiles: no longer in the range Standard impact modifier for window profiles Bifunctional modifier for window profiles High rubber impact modifier for window profiles Composite impact modifier for window profiles And many more to come, thanks to a continuous effort in innovation

15 Extrusion Behavior on Conical Twin Screw Cincinnati CMT45 PVC (K67): Lacovyl S110P 100 Ca/Zn one pack 3.7 Coated CaCO 3 8 TiO 2 4 AIM 6 Process aid (P551) 0.5 Melt temp ( C)* Mass pressure (bar) Torque (%) D High rubber AIM Standard AIM * As measured by DSC technique D360 provides very similar extrusion behavior than other AIMs: D360 can be used without altering extrusion conditions

16 EN Charpy Impact Strength 40 Impact strength (kj/m²) D360 High Rubber AIM Standard AIM 15 T1 T2 T3 T4 Extrusion temperature

17 BS-7413 Charpy Impact Strength 40 Impact strength (kj/m²) D360 High Rubber AIM Standard AIM 10 T1 T2 T3 T4 Extrusion temperature

18 RAL-GZ 716/1 Charpy Impact Strength 80 Impact strength (kj/m²) D360 High Rubber AIM Standard AIM T1 T2 T3 T4 Extrusion temperature

19 Surface Gloss (60 ) D320 D360 AIM comp Durastrength range provides the highest gloss level due to its unique design and specific chemical structure

20 Plateout resistance: lab scale prediction Plate-out rating scale 0 = NO PLATE OUT ; 1 = PLATE-OUT TRACES ; 2 = LOW PLATE-OUT ; 3 = MODERATE PLATE OUT ; 4 = SIGNIFICANT PLATE-OUT ; 5 = HEAVY PLATE OUT Standard AIM D360 Plate-out level* 3 1 Comment Moderate plate-out Plateout traces D360 provides strong anti-plateout effect to profile formulations * Details of the lab scale method available upon request

21 Conclusions Durastrength 360 is the first product of the new C-AIM technology platform It can be used at similar dosage to high rubber AIMs (up to 15% dosage saving) Similar or better impact performance than standard AIMs Fulfills all European impact strength requirements Provides similar high surface gloss levels of Durastrength AIMs Similar gelation and rheology patterns to standards AIMs Outstanding weatherability Significant plate-out reduction Less scraps and production downtime Improved powder properties allowing safe bulk delivery Attractive cost/performance (value-in-use) balance.

22 Acknowledgments R&D team: R. Pirri, F. Marchand, A. Wilhelm, C. Van den Bosch Business/Marketing: C. Granel, R. Quinson

23 Thank you very much for your attention