polyolefin additives: advances in performance extension · polyolefin additives: advances in...
TRANSCRIPT
Keith A. Keller, PhD
Research & Development Manager
Petrochemical Conclave 2016
Polyolefin Additives:
Advances in Performance Extension
©2016 Milliken & Company
Agenda
Introduction
Roadmap for the future
Recent products case studies
A glimpse inside the labs
Wrap up
©2016 Milliken & Company
Milliken & Company
H
H Headquarters
Technical center
• Founded in 1865. Headquartered in
Spartanburg, SC, USA
• 7,000+ associates
• Global presence - 45 facilities around
the world
Technical Innovation
• Community of innovators
• More than 5.000 patents
Segments served
• Floor Covering & Interiors
• Performance Materials
• Apparel & Specialty Fabrics
• Performance Solutions
• Specialty Chemicals
©2016 Milliken & Company 5
Milliken - Plastics Additives Business
• Clarity and Aesthetics
• Productivity improvement
• Energy savings
• CO2 savings
Millad Clarifying
agents
• Stiffness/impact balance
• Dimensional stability
• Productivity improvement
• Reduced cycle time
Hyperform HPN Nucleating agents
• Weight reduction
• Scratch improvement Hyperform HPR
Reinforcing agents
• Clearest and brightest colors for Clear PP
ClearTint colorants
©2016 Milliken & Company 6
Milliken Product/Technology Roadmap
Markets/End uses
Products/Projects
2014 2019 2016 2025
Housewares (PP; Clear)
Legacy
Millad 3988
Millad 3988i
Rigid Food Packaging (PP; Clear)
Millad
NX8000 EQ Millad
NX8000 UC
Hyperform
HPN68L
Thermoformed Disposable Packaging (PP; Nucleated)
Hyperform
HPN600ei
Automotive compounds (PP, Reinforced)
Hyperform
HPR803i Hyperform
HPN20e
High MFI, improved impact ICP
Improved
ICP
Barrier HDPE Film (PE; Nucleated)
Barrier LLDPE Film (PE; Nucleated)
Improved HDPE Rigids & Film (PE; Nucleated)
Improved Stiffness PP (PP; Nucleated)
HPN 210M
(PE) New PE
product
PO
Composites
Low
migration
AOX
Improved
cPP
Migration
Management
Improved
Stiffness PP HMS PP
PO Property
Extension
©2016 Milliken & Company 6
Key Definitions
Product
• Commercial and available for sale
• Production quantities of material are available
Technology
• New concepts under testing in the labs and not available for sale
• Commercialization dates are not yet determined
©2016 Milliken & Company
Millad® NX™ 8000 clearly leads the market because it is delivering value
across three overarching themes.
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Product: Millad® Clarifying Agents
1. Substantial energy savings and cycle time improvements
2. Superior performance in higher melt flow index resins
3. Enhanced clarity and appearance
©2016 Milliken & Company 8
Product: Millad® Clarifying Agents
•Household Industrial Chemical Packaging Application
•Extrusion Blow Molding Process
•North America Region
•New Product Launch that historically would have been in High Density Polyethylene (HDPE)
Material Replaced
•Excellent transparency
•Design flexibility of PP
•Reduction in raw material complexity (Inventory 1 bottle & add color to formulation)
Drivers for material
replacement:
Household Cleaner
Packaging
©2016 Milliken & Company 9
•Disposable drinking cup
•Food storage container Applications
•Thin wall injection molded Process
•Europe Region
•Polystyrene (PS), Polyethylene Terephthalate (PET)
Material Replaced
•Excellent transparency
•Lightweight packaging
•Boost impact resistance & avoid breakage
•Economics
•Microwaveable
Drivers for material
replacement:
Food Packaging
Product: Millad® Clarifying Agents
©2016 Milliken & Company 10
Product – Hyperform®
- Highest Tc of any nucleation technology
- Low warpage and improved molding performance
- Maximum part production and quality
- Low isotropic shrinkage and CLTE
- Unique shrinkage for dimensional control
- Good stiffness/impact balance (material optimization)
- Excellent aesthetics in sheet and formed parts
- Excellent thermal performance for fast forming times
- Good balance of physical properties
HPN-68L
HPN-20E
HPN-600ei
©2016 Milliken & Company
Hyperform is widely adopted across injection molding and
thermoforming processes globally
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Hyperform Global Use by Process
[CATEGORY NAME], [VALUE]
TWIM, 15%
[CATEGORY NAME], [VALUE]
[CATEGORY NAME], [VALUE]
Other, Pipe, Etc., 8%
Global Sales By Process
Global Hyper Nucleation Trends
• HPN-68L and HPN-20E growing fast for injection
molding applications
• HPN-600ei growing rapidly for clear and opaque
thermoforming applications
• Replacement of phosphate ester salts in
thermoforming and injection molding grades
• Enabling inter-material replacement of opaque
polystyrene
©2016 Milliken & Company
Hyperform is widely adopted across injection molding and
thermoforming processes globally
12
Hyperform Global Use by Process
Global Hyper Nucleation Trends
• HPN-68L and HPN-20E growing fast for injection
molding applications
• HPN-600ei growing rapidly for clear and opaque
thermoforming applications
• Replacement of phosphate ester salts in
thermoforming and injection molding grades
• Enabling inter-material replacement of opaque
polystyrene
[CATEGORY NAME], [VALUE]
[CATEGORY NAME], [VALUE]
[CATEGORY NAME], [VALUE]
[CATEGORY NAME], [VALUE]
[CATEGORY NAME], [VALUE]
Other, 12%
Global Sales By Markets
©2016 Milliken & Company 13
HPN in ICP Thermoforming
• ICP nucleated with Phosphate Ester Salt
Control
•Sealed, hot filled, microwavable rice containers
Application
•Thermoforming Process
• Isotropic shrinkage
•Reduced warpage in final parts during filling and sealing
•Reduced warpage after microwaving
• Improved part quality
•Reduced scrap rate
•Higher productivity
Polypropylene with
Hyperform® selected because:
©2016 Milliken & Company 14
HPN in Automotive Application
•Hyperform® HPN-20E Product
•Automotive Grill
•Automotive Door Panel Application
• Injection Molding Process
•Very low shrinkage and low CLTE for high-performance exterior automotive applications
• Allowed unpainted PP grill to match PC/ABS for shrinkage
• PP HPN-20E grill also achieved improved long-term exposure performance
•Part to part consistency
Polypropylene with
Hyperform® selected because:
20 mfr ICP
35 mfr ICP
©2016 Milliken & Company
Applying our ability to control polymer crystal orientation, we have
developed nucleator prototypes that maximize flexural modulus and
heat distortion temperature.
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Technology – Improved Stiffness PP
12 MFR HPP 26 MFR ICP
Milliken EXP-715
Phosphate Ester
©2016 Milliken & Company
A different nucleator prototype shows improvement across multiple
dimensions of physical properties, providing a highly balanced material.
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Technology – Improved Polypropylene
12 MFR HPP 26 MFR ICP
Milliken EXP-705
Phosphate Ester
©2016 Milliken & Company
In designing an impact copolymer, there are fundamental tradeoffs
among MFR, impact resistance, and stiffness.
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Technology – Improved ICPs
©2016 Milliken & Company
0
50
100
150
200
250
300
350
400
0 20 40 60 80 100 120
23°C
ISO
Izod Im
pact
Mean (
J/m
)
Melt Flow Rate (dg/min)
Izod Impact at 23°C of ISO Bars vs Melt Flow Rate
Starting Resin
Commercial Resins
EXP-Milliken
Non-Breaks
Error bars are ± One Measurement Standard Deviation
This technology can significantly change the balance of properties.
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Technology – Improved ICPs
Value Proposition
16 to 50 MFR
Same impact
Value Proposition
2X MFR
50% better impact
Value Proposition
2X MFR
Non-break
©2016 Milliken & Company
©2016 Milliken & Company
It is possible to access very different regions of performance space from
the same flake starting point, shifting the balance of what was previously
accessible.
20
Technology – Improved ICPs
Low MFR
ICP
Experimental
Additive
RO
Vis-broken
ICP
High Impact
High MFR ICP
©2016 Milliken & Company 21
Product – PE Nucleators
• Barrier improvement - 25 – 70% lower transmission rates in
HDPE and LLDPE (all permeants)
• Optics improvement - Reduction in LLDPE haze up to 40%
- Improvement in HDPE clarity and haze
- Higher gloss in both HDPE and LLDPE
• Increased Tc - Faster freeze-off / increased output
• Physical Properties - Higher MD and TD modulus with slight
to no loss in tear and impact
properties
• Barrier improvement - Various permeants (H2O, O2, grease,
hydrocarbons, etc.)
• Optics improvement - HDPE sheet clarity and gloss
• Increased Tc - Cycle time reduction / increased
output
• Higher Productivity
• Increased stiffness/impact
balance - Material reduction in radial/round
applications
- Stronger parts in radial/round
applications
• Improved ESCR (drums), HDT
& pigment leveling (closures)
Flexible Applications
Rigid Applications
©2016 Milliken & Company
Milliken’s expertise in controlling the crystalline orientation of polymers
has led to a new PE nucleator: HPN 210M
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Product – PE Nucleators
Polyethylene normally self-nucleates
into large spherulitic structures.
Molded article
Spherulites (random crystal growth)
Molded article
MD crystal growth
HPN 210M
With HPN 210M, PE crystals grow in the
machine flow direction of the polymer.
©2016 Milliken & Company 23
Product – PE Nucleators
Nucleated with HPN 210M at reduced cycle
time: no warpage, original dimensions
improved mechanical properties – both
stiffness & HDT are increased
Reduced cooling time 10- 20%
Nucleated with HPN 210M at the same
cycle time: no warpage and larger parts
©2016 Milliken & Company
This long-term development arc is driven on the core of an innovation
culture.
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Conclusion
Innovation
Opening new
applications and
material substitution
opportunities for
polypropylene &
polyethylene
Millad 3905
Millad 3988
Hyperform HPN-68L
Millad NX8000
Hyperform HPR-803i
Millad 3940
Hyperform HPN-600ei
Hyperform HPN-20E
Opening new applications and
material substitution
opportunities for polypropylene &
polyethylene
Innovation