NANOCOMPOSITES
Annual growth of 18% predicted up to 2008 / Layer-lattice silicate are a benchmark material / Boehmit as an alternative flame retardant? / Nanoparticles in demand as processing aids
In 2003, global consumption of polymer nanocomposites amounted to about 11,000 t at a value of USD 91m (around EUR 75m). A report published by Business Communication Company (Norwalk, Connecticut / USA; www.bcc.com) earlier this year predicts an average annual increase of 18% in global consumption of nanocomposites to a value of USD 210m by 2008. The most recent innovations displayed by suppliers of raw materials, compounds and masterbatches at K 2004 in October (see PIE 22, 2004) seem to confirm this forecast. Just as metallocene catalysis was the buzzword in the 1990s, the minuscule filler particles and their various applications are the talk of the plastics processing industry today.
At this year´s K exhibition in Düsseldorf, the German Fraunhofer institute for chemical technology (FhG ICT, D-76327 Pfinztal; www.ict.fraunhofer.de) showed a compound made from polyamide 6, supplied by Lanxess (D-51369 Leverkusen; www.lanxess.com), and “Nanofil”, a layer-lattice silicate supplied by Süd-Chemie (D-85368 Moosburg; www.sud-chemie.com) on a “ZSK 26 Mc” made by Coperion (D-70469 Stuttgart; www.coperion.com). In some cases, the addition of layer-lattice silicates markedly improves the most significant mechanical characteristics such as the modulus of elasticity, tensile strength, elongation at break and flexural modulus.
Most applications shown at K 2004 confirm that the functional properties of polymer materials can be improved by introducing as little as 5% by weight of nanoadditives. In addition to the positive effect on mechanical properties and a lower material density, nanofillers also improve the material´s heat distortion resistance, surface structure, permeability for gas and liquids, dripping during burning, UV-light absorption and antibacterial properties to name just a few.
Layer-lattice silicate compounds as a benchmarkLayer-lattice silicates have become widely established as the classic nanoparticle systems. They replace fillers such as talcum in polypropylene or partially replace additives such as aluminium hydroxide used as a flame retardant in cable compounds. Processing technology for this area of application is no longer in its infancy. At a price of EUR 5-15/kg, composites are an attractive option. Already, PP-based or PA 6-based nanoclay compounds are commercially available. Joachim Großman, vice president of sales and marketing for plastics additives at Süd-Chemie, estimates the global sales volume of these so-called organoclays at EUR 200m for all – including non-plastics – applications.
Boehmit particles may replace layer-lattice silicatesIn future, “Boehmit” may become established as an alternative to layer-lattice silicates. The material, a special aluminium hydroxide grade with the chemical name of AlO (OH), was presented by Sasol Germany (D-20537 Hamburg; www.sasolalumina.com) under the trade names “Dispal” and “Disparal”. Both the shape (platelet or needle) and the size of the particles can be manipulated to suit the application. Chemical surface modification is possible and the price, which starts at EUR 5/kg, is comparable to that of layer-lattice silicates. Extensive experience has been accumulated with processing compounds made from PA, PP or PS and with epoxy moulding compounds. Bayer uses Boehmit as a synergist for phosphanate amine-based flame retardants in PC/ABS blends.
Boehmit´s specific flame retardant properties result from the fact that in reaction to rising temperature rises the hydration water is split off, triggering the material´s transformation into aluminium oxide with a melting point of 2,000 °C. The improvement of flame retardant properties is also the target of Recam (D-73432 Aalen-Waldhausen; www.recan.de), a producer of “IPC” nanofibres made from AlO (OH) with an aspect ratio of 50 to 100.
Innovative nanoparticle systemsAt K 2004, Nordmann, Rassmann (NRC, D-20549 Hamburg; www.nrc.de) presented surface-modified silicate particles of only about 50nm in size. The nucleating agents “NGS 1000” and “NGS 2000”, produced by Nyacol Nano Technologies (Ashland, Massachusetts / USA; www.nyacol.com) and used in a concentration of between 0.1% and 0.2 % by weight, increase the crystallinity of PP. At the fair, NRC also showed indium tin oxide (ITO primary particles at a size of between 10 nm and 15 nm. ITO is an oxide blend widely used in the transparent conductive layers of electronic applications. At a price of EUR 1,000/kg, the material is mainly used as to block infrared light. ITO is produced by Nanogate Technologies (D-66121 Saarbrücken; www.nanogate.de).
Nanoparticles as processing aidsThe new nanoparticle-modified compounds also have a positive effect on processing conditions during the production of structural components. “Schulamid 6.6 MNF 2510”, a new compound launched by A. Schulman (D-50143 Kerpen; www.aschulman.de) at K 2004, will reduce the shrinkage of nano scale particles to levels similar to those of materials with a 40% glass-fibre content. “SE 2000” and “SE 3010”, new Nanofil products supplied by Süd-Chemie, improve the mechanical properties as well as the melt viscosity of polymer materials. Raw material experts are convinced that in future, the introduction of suitable nanoparticle systems could also significantly shorten injection moulding cycle times.
At this year´s K exhibition in Düsseldorf, the German Fraunhofer institute for chemical technology (FhG ICT, D-76327 Pfinztal; www.ict.fraunhofer.de) showed a compound made from polyamide 6, supplied by Lanxess (D-51369 Leverkusen; www.lanxess.com), and “Nanofil”, a layer-lattice silicate supplied by Süd-Chemie (D-85368 Moosburg; www.sud-chemie.com) on a “ZSK 26 Mc” made by Coperion (D-70469 Stuttgart; www.coperion.com). In some cases, the addition of layer-lattice silicates markedly improves the most significant mechanical characteristics such as the modulus of elasticity, tensile strength, elongation at break and flexural modulus.
Most applications shown at K 2004 confirm that the functional properties of polymer materials can be improved by introducing as little as 5% by weight of nanoadditives. In addition to the positive effect on mechanical properties and a lower material density, nanofillers also improve the material´s heat distortion resistance, surface structure, permeability for gas and liquids, dripping during burning, UV-light absorption and antibacterial properties to name just a few.
Layer-lattice silicate compounds as a benchmarkLayer-lattice silicates have become widely established as the classic nanoparticle systems. They replace fillers such as talcum in polypropylene or partially replace additives such as aluminium hydroxide used as a flame retardant in cable compounds. Processing technology for this area of application is no longer in its infancy. At a price of EUR 5-15/kg, composites are an attractive option. Already, PP-based or PA 6-based nanoclay compounds are commercially available. Joachim Großman, vice president of sales and marketing for plastics additives at Süd-Chemie, estimates the global sales volume of these so-called organoclays at EUR 200m for all – including non-plastics – applications.
Boehmit particles may replace layer-lattice silicatesIn future, “Boehmit” may become established as an alternative to layer-lattice silicates. The material, a special aluminium hydroxide grade with the chemical name of AlO (OH), was presented by Sasol Germany (D-20537 Hamburg; www.sasolalumina.com) under the trade names “Dispal” and “Disparal”. Both the shape (platelet or needle) and the size of the particles can be manipulated to suit the application. Chemical surface modification is possible and the price, which starts at EUR 5/kg, is comparable to that of layer-lattice silicates. Extensive experience has been accumulated with processing compounds made from PA, PP or PS and with epoxy moulding compounds. Bayer uses Boehmit as a synergist for phosphanate amine-based flame retardants in PC/ABS blends.
Boehmit´s specific flame retardant properties result from the fact that in reaction to rising temperature rises the hydration water is split off, triggering the material´s transformation into aluminium oxide with a melting point of 2,000 °C. The improvement of flame retardant properties is also the target of Recam (D-73432 Aalen-Waldhausen; www.recan.de), a producer of “IPC” nanofibres made from AlO (OH) with an aspect ratio of 50 to 100.
Innovative nanoparticle systemsAt K 2004, Nordmann, Rassmann (NRC, D-20549 Hamburg; www.nrc.de) presented surface-modified silicate particles of only about 50nm in size. The nucleating agents “NGS 1000” and “NGS 2000”, produced by Nyacol Nano Technologies (Ashland, Massachusetts / USA; www.nyacol.com) and used in a concentration of between 0.1% and 0.2 % by weight, increase the crystallinity of PP. At the fair, NRC also showed indium tin oxide (ITO primary particles at a size of between 10 nm and 15 nm. ITO is an oxide blend widely used in the transparent conductive layers of electronic applications. At a price of EUR 1,000/kg, the material is mainly used as to block infrared light. ITO is produced by Nanogate Technologies (D-66121 Saarbrücken; www.nanogate.de).
Nanoparticles as processing aidsThe new nanoparticle-modified compounds also have a positive effect on processing conditions during the production of structural components. “Schulamid 6.6 MNF 2510”, a new compound launched by A. Schulman (D-50143 Kerpen; www.aschulman.de) at K 2004, will reduce the shrinkage of nano scale particles to levels similar to those of materials with a 40% glass-fibre content. “SE 2000” and “SE 3010”, new Nanofil products supplied by Süd-Chemie, improve the mechanical properties as well as the melt viscosity of polymer materials. Raw material experts are convinced that in future, the introduction of suitable nanoparticle systems could also significantly shorten injection moulding cycle times.
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09.12.2004 Plasteurope.com [201457]
Published on 09.12.2004