High Alternative in Polypropylene Compounds · (India) Nagpur (India) Kerikeri (New Zealand)...
Transcript of High Alternative in Polypropylene Compounds · (India) Nagpur (India) Kerikeri (New Zealand)...
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New Mineral Opportunities in Polymers
Mica A High Reinforcement Alternative in
Polypropylene Compounds
Jim Harper Applications Development ManagerImerys Performance Additives([email protected])770‐361‐1952
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Imerys Corporate Overview of Innovation and Development
San José (USA)
Roswell/Marietta(USA)
Sandersville, Georgia(USA)
Bras Cubas, near Sao Paolo(Brazil)
Changshu, Jiangsu province (China)
Zhangjiagang (China)
Kao-Shu Shiang (Taiwan)
Bangkok(Thailand)
Katni(India)
Nagpur(India)
Kerikeri(New Zealand)
Limoges (France) Aixe-sur-Vienne (France)
Colomiers (France)
La Guardia(Spain)
Castellon(Spain)
Saint Quentin Fallavier(France)
Par Moor (Cornwall)(UK)
Willebroek(Belgium)
Selb (Germany) Neuwied (Germany)
Hódmezõvásárhely (Hungary)
Toulouse(France)
Bodio (Switzerland)
Villach (Austria)
Sandersville, Georgia(USA)
Minerals for Ceramics, Refractories,Abrasives & Foundry
Performance Minerals & Filtration
Pigments for PaperMaterials & Monolithics
Regionallaboratories
R&DCenters
• Decentralised organization is optimum to support our customers worldwide– Divisions are responsible for innovation– Each operating own R&D resources
• 28 research centers: 8 main research centers and 20 regional laboratories• Network of 300 engineers and technicians
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Portfolio of Minerals
Alumina Andalusite Ball Clay Bentonite Bauxite Calcium Carbonate Ground Precipitated
Carbon Black Clinoptilolite Cordierite Diatomaceous Earth Dolomite Feldspar
Graphite Kaolin Hydrous Calcined
Magnesite Mica Muscovite Phlogopite
Olivine Perlite Silica Silicon Carbide Talc Vermiculite Zirconia
Kaolin Ball Clay
Diatomite
Dolomite
GCC
Mica
Perlite
Vermiculite
Talc
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Overview
• Key Mineral Characteristics of Mica
• Mica’s Key Function in Plastics
• Value Performance in Homopolymer Polypropylene
Compounds
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Performance Minerals InnovationMica – The Performance Additive Mineral
Suzorite® Phlogopite Mica – It is well recognized for its reinforcing and barrier properties, as well as its chemical inertness, phlogopite mica is also used as a sound and vibration-damping additive in polymeric and asphalt based coatings for under-the-carpet automotive applications.
Muscovite Mica Mined and processed in Kings Mountain, NC. It is suitable for applications requiring the reinforcement of coatings and where greater resistance to moisture, heat, light and chemicals is needed. It is a functional extender that improves crack resistance and reduced film permeability. It also promotes adhesion in both water and solvent-based formulations.
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Imerys North America Mica Locations
Kings Mountain, NC
Suzorite Mica Boucherville, Quebec
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Mica ‐ Phlogopite
KMg3(Si3Al)O10(F,OH)2
Suzorite, Quebec
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Mica ‐Muscovite
KAl2(Si3Al)O10(OH,F)2
Kings Mountain, NC
10 µm
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Talc vs. Phlogopite (Mica) Chemistry
OSiOH/FMgAlK
Phlogopite: KMg3(AlSi3)O10(OH/F)2Talc: Mg3Si4O10(OH)2
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Trioctahydral Mica (Brown or Black)Phlogopite: KMg3(AlSi3)O10(OH/F)2
Dioctahydral Mica (White or Off White)Muscovite: KAl2(AlSi3)O10(OH/F)2
Phlogopite vs. Muscovite (Mica) Chemistry
OSiOH/FMgAlK
*** F substitution for OH makes higher temperature micas
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Inherent Properties of Mica
Muscovite Phlogopite
Dehydroxylation Temperature (°C) 1200-1400 1800-1900
Specific Gravity 2.8 2.7
Refractive Index 1.6 1.6
Loss at 1,000°C (%) 4.2 < 1.0
Hardness (mohs) 2.5 3.0
Very High Aspect Ratio 50-90+ 50-90+
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Key Physical Characteristics
Shape - Platy (Highest Aspect Ratio Mineral) Aspect Ratio - Number denoting the average diameter vs the
thickness Flexible -Platelets are semi-rigid, and retain flexibility across all
Particle Size Distributions and grind techniques Dispersible - Mixes easily in formulations, requires low shear to
incorporate into plastics Chemically Resistant - Impervious to all chemicals, except
Hydrofluoric Acid
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Aspect Ratio
Aspect Ratio (Shape Factor) – Number relating the diameter (d) to the thickness (t) of the platelet.
5:1 10:1 60:1 80:1
0.73 µm
1:1sphere
0.5 µm 1.1 µm 1.9 µm 2.5 µm
t
d
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Function of Mica in Plastics
• Increase flexural modulus
• Increase heat deflection temperature
• Improves dimensional stability
•Decrease coefficient of linear thermal expansion
•Promote stable post‐molding isotropy
•Reduce distortion/warpage
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Details of Study
Minerals Used Mean Particle size, µm (Sedigraph)
Mean Particle Size, µm (Laser)
Typical Aspect Ratio
325 mesh lamellar talc 7.5 n/a 16:1
325 mesh phlogopite mica 8 25 85:1
200 mesh phlogopite mica 12 45 55:1
150 mesh phlogopite mica 34 150 90:1
The above mineral were used at 20 and 40% in a 4.3 Melt Flow, heat stabilized Polypropylene HomopolymerSamples were extruded
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Value Performance of Mica in Polypropylene Compounds
• Flexural Modulus is greatly impacted by the aspect ratio of the particles
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• Mean Particle Size as measured by Sedigraph
Value Performance of Mica in Polypropylene Compounds
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• Mean Particle Size as measured by Sedigraph
Value Performance of Mica in Polypropylene Compounds
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Value Performance of Mica in Polypropylene Compounds
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• Performance improves with larger particle size
Value Performance of Mica in Polypropylene Compounds
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• Shrinkage decreases as particle size increases
Value Performance of Mica in Polypropylene Compounds
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Summary of Properties
Phlogopite Mica • Provides optimum stiffness
• Achieved through the effect of high aspect ratios
•Improves thermal stability• Increasing particle size will increase heat deflection temperature
• Significantly reduces shrinkage• Improves dimensional stability
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Conclusions
•Physical properties such as Flexural Modulus, Notch Izod, HDT and Shrinkage are optimized using a 34 micron Phlogopite Mica
•Performance can be closely matched to coarse talc using a 8 micron Phlogopite Mica
•A balance of properties can be achieved through the use of 12 micron Phlogopite Mica
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Thank you for your attention!Any questions?
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