more design freedom for engineering plastics compound via

Performance Chemicals New Business Development

More design freedom for engineering plastics compound via Joncryl® functional additives – IPI Chennai Joseph Hui April 26, 2013

AGENDA

Elements for Good Compound Design

Compound Design: Performance Balance Flowability Control

Compatibility/Strength

Compound Design: Productivity and Cost Effectiveness Process temperature vs flow improvement

Use of regrind materials – more recycling

Q&A

12/01/2011 2

BASF Joncryl® Functional Additives

Performance balance: strength ~ appearance ~ processibility

Productivity and cost effectiveness

Better dispersive and distributive mixing flow improvement

Optimal temperature flow improvement

Optimal residence time flow, extent reaction

Process stability viscosity, melt strength

Usage of regrind protect, repair

12/01/2011 3

Solution to allow better control of flow and strength good compound

Elements for Good Compound Design

22/03/2011 INTERNAL 4


Performance Balance – flowability control

Problems Poor Mixing Surface Roughness Bad mold filling for thin or long flow length parts Long cycle time (filling time vs cooling time) Part warpage (from internal stress)

Conventional solution External lubricant – migration, haze, drastic drop in HDT/impact, etc. Lower molecular weight blends by resin maker – drop in strength, production management of extra grades

22/03/2011 INTERNAL 5

Flow enhancement gives much better balance of performance for Eng Plastics


Performance Balance – flow enhancer vs plasticizer

Flow Enhancer Plasticizers Increases flow

Same Modulus and Strength

Same Tg

Same or Slightly Reduced Heat Resistance

Very Few Effective Additives

Not Often Used

Concentration: 0.5 to 3%

Strongly Increases Flow

Lower Modulus and Strength

Strongly Reduced Tg

Strongly Reduced Heat Resistance

Multitude of Additives-> Liquids

Frequently Used

Concentration: 5 to 60%

22/03/2011 INTERNAL 6

Joncryl® Flow Enhancer (FE) Polymer Chains

Joncryl® FE enchorage structure creates more free volume for resins to flow without migration.

Polymer matrix chains

Free Volumes


Performance Balance – internal flow enhancement

22/03/2011 INTERNAL 7

Shear rate VS. Shear viscosity @245

100

1000

100 211.0640564 448.7344055 949.3031616 2007.379761

Shear rate (/s)

Shea

r vis

cosi

ty (P

a.s)

PA +GF T245 Shear Viscosity VS Shear rate

PA +GF 0.5% ADD3310T245 Shear Viscosity VS Shear rate 1

PA +GF 1.0% ADD3310T245 Shear Viscosity VS Shear rate

PA +GF 1.5% ADD3310T245 Shear Viscosity VS Shear rate 1


Performance Balance – PA6 - 30%GF enhancement

Joncryl® Flow Enhancer improves the flow of glass filled PA

22/03/2011 INTERNAL 8

0

10

20

30

40

50

60

70

PA/30%GF 0.5% ADD-3310 1.0% ADD-3310 1.5% ADD-3310

Tens

ile S

treng

th (M

Pa)

0

1000

2000

3000

4000

5000

6000

Impa

ct S

treng

th (J

/m^2

)

Tensile Strength @ Yield Tensile Strength @ Break Impact Strength


Performance Balance – PA6 - 30%GF enhancement

Mechanical properties are preserved while flow was improved

9 2/9/2012

Flow of glass fiber filled PA can be increase by 20%:

Better mold filling Better wetting of PA onto fiber 0%

20%

40%

60%

80%

100%

120%

140%(275C/kg)

Tensile @Yield

Tensile @Break

Elong. @Yield

Elong. @Break

FlexModulus

ImpactStrength

PA66-30%GF PA66-30%GF + 1.5% ADF1300

ADF1300 balance properties of 30% GF filled PA66 wo risk of interactions


Performance Balance – internal flow enhancement

22/03/2011 INTERNAL 10

Joncryl® ADP-1200 gives high flow improvement of about 40% with high retention of mechanical properties to TABS

Flow balanced with mechanical properties using Joncryl® Flow Enhancers


Performance Balance – TABS flow vs mechanical

22/03/2011 INTERNAL 11

Joncryl® ADP-1200 gives superior flow improvement and transparency maintenance than EBS (ethylene bis-esteramide)

Change in MFR of T-ABS After Flow Improvement (220C@10kg)

05

10152025303540

0 3% 5%

Dosage

MFR

(g/1

0 m

ins.

)

ADP-1200 EBS

Change in Clarity of T-ABS After Flow Improvement

0123456789

0 3% 5%

Dosage

Haze

%

ADP-1200 EBS

Change in Colour of T-ABS After Flow Improvement

0

0.5

1

1.5

2

2.5

3

3.5

4

0 3% 5%

Dosage

Del

ta E

ADP-1200 EBS


Performance Balance: TABS flow vs appearance

Flow balanced with appearance using Joncryl® Flow Enhancer ADP1200

12 2/9/2012

0

10

20

30

40

0 0.5 1 1.5 2 2.5 3 3.5Dosage (%)

Melt Flow of Flow Enhanced PC @ 250C, 1.2kg

ADF1300

Note: 1. Control PC sample at 0% dosage was also

compounded once

2. If measured at 300C, 1.2kg; MFR at 2% dosage > 100 g/10min

PC transparency was well maintained up to 2% of dosage of Joncryl®ADF1300


Performance Balance – PC flow vs transparency

00.20.40.60.8

1

0 0.5 1 1.5 2 2.5 3 3.5Dosage (%)

Haziness of Flow Enhanced PC at 0.8mm thickness

ADF1300

0

0.5

1

1.5

0 0.5 1 1.5 2 2.5 3 3.5Dosage (%)

Yellowness Index of Flow Enhanced PC at 0.8mm thickness

ADF1300

22/03/2011 INTERNAL 13

(MFI - 300°C; 1.2 kg; HDT - 264 psi reported in °C)

0

2

4

6

8

10

12

14

16

18

Control ADF-1300 ADF-1350

Mel

t Flo

w R

ate

(g/1

0min

)

100

105

110

115

120

125

130

135

HD

T (C

)

+33% +23%

-3% -3%


Performance Balance – PC flow vs HDT

ADF1300 allows minimal HDT drop of 3% when flow is increased by 36%

Melt Flow Increase vs HDT Drop in PC using ADF1300

12/01/2011 14

ADF-1350 increases flow of PC by about 20-30% while mechanical properties are highly preserved

Angle of Ray (60 )

Angle of Ray (20 )

Control PC/ABS

94.3 76.2

+ 3% of ADF1350

97.9 83.1

PC/ABS Gloss Improvement

0%20%40%60%80%

100%120%140%

MFR (260C, 5kg)

Tensile @ Yield

Tensile @ Break

Elong @ Yield

Elong @ BreakFlex Modulus

Flex Strength

Izod Impact

Vicat SofteningPoint

Control PC/ABS +3% of ADF1350


Performance Balance: – PC/ABS flow, mech, surface balance

PC/ABS mechanical properties balanced with surface gloss

PC/ABS Flow Increase with Full Properties Balance


12/01/2011 15

Stability of blend homogeneity and compatibility over time

Performance Balance – compatibility strength

Polymer 1

Polymer 2

compounding

Polymer 1

Polymer 2

reactivecoextrusion

with Joncrylcompatibilizer

w/o Joncryl

Loss of propertiesSynergistic effectBefore processing

Before processing Synergistic effect Maintain properties

time

timePolymer 1

Polymer 2

compounding

Polymer 1

Polymer 2

reactivecoextrusion

with Joncrylcompatibilizer

w/o Joncryl

Loss of propertiesSynergistic effectBefore processing

Before processing Synergistic effect Maintain properties

time

time

Compatibility of Polymer Blends

12/01/2011 16

+

Chain extender can be used as a compatibilizer for forming alloys: e.g. PC-PET, PA-PBT, etc.

Polycondensate APolycondensate B

Joncryl® ADR

New Alloy of Polycondensates

A-B

+

Chain extender can be used as a compatibilizer for forming alloys: e.g. PC-PET, PA-PBT, etc.

Polycondensate APolycondensate BPolycondensate APolycondensate B

Joncryl® ADRJoncryl® ADR


A-B


A-B


Performance Balance – compatibility/strength

Blend homogeneity and compatibility stabilized using ADR chain extender

Compatibility using Joncryl® ADR Chain Extender (CE)

17 11/30/2012

of the blend without sacrificing



0

5

10

15

20

25

30

35

40

0 10 20 30 40 50 60 70 80 90 100

% Brittle Polymer

MPa

0

200

400

600

800

1000

1200

1400

1600

% E

long

.

Blend homogeneity and compatibility stabilized using chain extender

Tensile without CE Elongation without CE

Tensile with CE Elongation with CE

Rubbery Biopolymer % Increase Brittle Biopolymer % Increase

Blend Compatibilization Of Biopolymers

Compatibilization by CE significantly raised elongation of blend without sacrificing tensile strength

18 11/30/2012

0

5

10

15

20

25

0

500

1000

1500

2000

2500

3000

3500

4000

4500

5000

0 10 20 30 40 50 60 70 80 90 100

Unn

otch

ed C

harp

y Im

pact

(kJ/

m^2

)

Flex

ural

Mod

ulus

(MPa

)

% of Glass FIber filled PET

Flexural Modulus MPa 0.65% CE Flexural Modulus MPa

Unotched Charpy Impact kJ/m^2 0.65% CE Unnotched Charpy Impact kJ/m^2

of the blend without sacrificing



Compatibility brings synergistics performance of blend components

Blend Compatibilization Of PBT with Recycled Glass Fiber Filled PET (RGF-PET)

PBT RGF-PET

Data Source: Journal of Appliced Sciences 12 (3) 296-300, 2012

Improved flexural modulus and impact after compatibilization

100% RGF-PET did not break in impact test because of 30% GF

12/01/2011 19

PBT 100

1000

100 1000

PBT/PA ControlPBT/PA + 0.5% ADR-4368PBT/PA + 1.0% ADR-4368

Shear Rate (1/sec)

@ 250*C

γ γ γ

β

PA

Joncryl® ADR

Compatibility brings synergistics performance of blend components


Performance Balance – PA-PBT Alloy in Progress

March 25, 2012 INTERN 20

Productivity: Cycle Time Reduction Screw back Melting/Mixing Inject Pack Hold Cool Open

Melting / Cycle Time Production

Screw back Mixing Injection Packing Holding Cooling Release Total % Reduction Increase

Duration (sec) (sec) (sec) (sec) (sec) (sec) (sec) (sec) Hammer Handle 8 4 3 3 2 30 2 52

Flow enhance 8 4 3 3 2 18 2 40 23% 30%

Keyboard

Frame 8 4 6 4 4 2 2 30

Flow enhance 8 4 4 2 1 2 2 23 23% 30%

Drop of molding tempearture

Higher flow at same temperature


Productivity and Cost Effectiveness: Cycle Time Reduction by More Flow or Lower Temperature

Productivity can be increased by more flow or by optimal process temperature

March 25, 2012 INTERN 21


Productivity and Cost Effectiveness: Protection and Recycling

Water, Heat, Impurities initiate hydrolysis

-COOH -OH R-COO-R

Hydrolysis breakup polyester chains and destroy mechanical properties of condensation polymers

e.g. PA, PET, PC, etc

Hydrolysis takes place during repeated processing and regrinding

Chain Extender as Hydrolytic Stabilizer

12/01/2011 22

High Mw PET, PBT, PLA, PC, PA, TPU γ = COOR, Ph-O-R, R-O-R, NCO + R-OH-R

Low Mw PET, PBT, PLA, PC, PA, TPU α = COOH, Ph-OH, R-OH, NH2

α α

α + β β β

β

γ γ γ β

Joncryl® - ADR

β

β

Chain extender can rejoin the broken chain and form long chain branching



Repair by connecting broken chains Protect by dropping acidity, hence dropping hydrolysis

12/01/2011 23

0

2

4

6

8

10

0.00 0.25 0.50

Melt Flow Index

Melt

Flow

Inde

x (g/

10")

J-ADR-4368 % (w/w)0

500

1000

1500

2000

2500

3000

0.00 0.25 0.50

Viscosity

Mel

t Vis

cosi

ty (P

a-S)

J-ADR-4368 % (w/w)50

51

52

53

54

55

56

57

58

0.00 0.25 0.50

Tensile Strength

Tens

ile S

treng

th (M

Pa)

J-ADR-4368 % (w/w)

Chain extender repair and protect reground PA



12/01/2011 24

Chain extender can bring additional benefit to virgin and RPET



PET Food Tray with >30% RPET

Ovenable:

Heat Stability: 190C for 30 mins

Frozenable: Impact better than CPET and PP at -20 C

Productivity and Cost Effectiveness

Less sheet necking

Faster thermoforming cycle

12/01/2011 25


Improve Resin Processibility

12/01/2011 26

More Flow

Lower Melt Viscosity

Less Flow

Higher Melt Viscosity

EXTRUSION APPLICATIONS INJECTION APPLICATIONS fiber, sheet, film, strap, foam housings E/E, PET bottles

Chain Extender Flow Enhancer


Conclusion Joncryl Functional Additives can provide more design freedom for engineering plastics compound design through:

flow improvement

compatibility

process protection

structural modification

12/01/2011 27


Q&A

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more design freedom for engineering plastics compound via

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