New Mineral Opportunities in Polymers

Mica A High Reinforcement Alternative in 

Polypropylene Compounds

Jim Harper Applications Development ManagerImerys Performance Additives(jim.harper@imerys.com)770‐361‐1952

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

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

Overview

• Key Mineral Characteristics of Mica

• Mica’s Key Function in Plastics

• Value Performance in Homopolymer Polypropylene 

Compounds

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.

Imerys North America Mica Locations

Kings Mountain, NC

Suzorite Mica Boucherville, Quebec

Mica ‐ Phlogopite

KMg3(Si3Al)O10(F,OH)2

Suzorite, Quebec

Mica ‐Muscovite

KAl2(Si3Al)O10(OH,F)2

Kings Mountain, NC

10 µm

Talc vs. Phlogopite (Mica) Chemistry

OSiOH/FMgAlK

Phlogopite: KMg3(AlSi3)O10(OH/F)2Talc: Mg3Si4O10(OH)2

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

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+

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

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

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

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

Value Performance of Mica in Polypropylene Compounds

• Flexural Modulus is greatly impacted by the aspect ratio of the particles

• Mean Particle Size as measured by Sedigraph

Value Performance of Mica in Polypropylene Compounds

• Mean Particle Size as measured by Sedigraph

Value Performance of Mica in Polypropylene Compounds

Value Performance of Mica in Polypropylene Compounds

• Performance improves with larger particle size 

Value Performance of Mica in Polypropylene Compounds

• Shrinkage decreases as particle size increases

Value Performance of Mica in Polypropylene Compounds

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

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

Thank you for your attention!Any questions?

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