Performance ChemicalsNew 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 BalanceFlowability Control
Compatibility/Strength
Compound Design: Productivity and Cost EffectivenessProcess 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
22/03/2011INTERNAL4
BASF Joncryl® Functional Additives
Performance Balance – flowability control
ProblemsPoor MixingSurface RoughnessBad mold filling for thin or long flow length partsLong cycle time (filling time vs cooling time)Part warpage (from internal stress)
Conventional solutionExternal lubricant – migration, haze, drastic drop in HDT/impact, etc.Lower molecular weight blends by resin maker – drop in strength, production management of extra grades
22/03/2011INTERNAL5
Flow enhancement gives much better balance of performance for Eng Plastics
BASF Joncryl® Functional Additives
Performance Balance – flow enhancer vs plasticizer
Flow Enhancer PlasticizersIncreases 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
FreeVolumes
BASF Joncryl® Functional Additives
Performance Balance – internal flow enhancement
22/03/2011INTERNAL7
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
BASF Joncryl® Functional Additives
Performance Balance – PA6 - 30%GF enhancement
Joncryl® Flow Enhancer improves the flow of glass filled PA
22/03/2011INTERNAL8
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
BASF Joncryl® Functional Additives
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 fillingBetter wetting of PA onto fiber0%
20%
40%
60%
80%
100%
120%
140%
)
Tensile @ Yield
Tensile @ Break
Elong. @ Yield
Elong. @ Break
Flex Modulus
Impact Strength
PA66‐30%GF PA66‐30%GF + 1.5% ADF1300
ADF1300 balance properties of 30% GF filled PA66 wo risk of interactions
BASF Joncryl® Functional Additives
Performance Balance – internal flow enhancement
22/03/2011INTERNAL10
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
BASF Joncryl® Functional Additives
Performance Balance – TABS flow vs mechanical
22/03/2011INTERNAL11
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
Haz
e %
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
BASF Joncryl® Functional Additives
Performance Balance: TABS flow vs appearance
Flow balanced with appearance using Joncryl® Flow Enhancer ADP1200
12 2/9/2012
010203040
0 0.5 1 1.5 2 2.5 3 3.5
Dosage (%)
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
BASF Joncryl® Functional Additives
Performance Balance – PC flow vs transparency
00.20.40.60.8
1
0 0.5 1 1.5 2 2.5 3 3.5
Dosage (%)
Haziness of Flow Enhanced PCat 0.8mm thickness
ADF1300
0
0.5
1
1.5
0 0.5 1 1.5 2 2.5 3 3.5
Dosage (%)
Yellowness Index of Flow Enhanced PCat 0.8mm thickness
ADF1300
22/03/2011INTERNAL13
(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%
BASF Joncryl® Functional Additives
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 Softening Point
Control PC/ABS +3% of ADF1350
BASF Joncryl® Functional Additives
Performance Balance:– PC/ABS flow, mech, surface balance
PC/ABS mechanical properties balanced with surface gloss
PC/ABS Flow Increase with Full Properties Balance
BASF Joncryl® Functional Additives
12/01/2011 15
Stability of blend homogeneity and compatibility over time
Performance Balance – compatibility strength
Compatibility of Polymer Blends
12/01/2011 16
BASF Joncryl® Functional Additives
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
BASF Joncryl® Functional Additives
Performance Balance – compatibility/strength
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 CEElongation without CE
Tensile with CEElongation with CE
Rubbery Biopolymer % Increase Brittle Biopolymer % Increase
Blend CompatibilizationOf Biopolymers
Compatibilization by CEsignificantly 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
otched
Cha
rpy Im
pact (kJ/m^2)
Flexural M
odulus (M
Pa)
% 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
BASF Joncryl® Functional Additives
Performance Balance – compatibility/strength
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
@ 250*C
γ γ γ
β
PA
Joncryl® ADR
Compatibility brings synergistics performance of blend components
BASF Joncryl® Functional Additives
Performance Balance – PA-PBT Alloy in Progress
March 25, 2012 INTERN 20
Productivity: Cycle Time ReductionScrew 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%
KeyboardFrame 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 flowat same temperature
BASF Joncryl® Functional Additives
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
BASF Joncryl® Functional Additives
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, TPUγ = COOR, Ph-O-R, R-O-R, NCO + R-OH-R
Low Mw PET, PBT, PLA, PC, PA, TPUα = COOH, Ph-OH, R-OH, NH2
αα
α+ β β β
β
γ γ γβ
Joncryl® - ADR
β
β
Chain extender can rejoin the broken chain and form long chain branching
BASF Joncryl® Functional Additives
Productivity and Cost Effectiveness: Protection and Recycling
Repair by connecting broken chains
Protect by dropping acidity, hence dropping hydrolysis
12/01/2011 23
Chain extender repair and protect reground PA
BASF Joncryl® Functional Additives
Productivity and Cost Effectiveness: Protection and Recycling
12/01/2011 24
Chain extender can bring additional benefit to virgin and RPET
BASF Joncryl® Functional Additives
Productivity and Cost Effectiveness: Protection and Recycling
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 26
More Flow
Lower Melt Viscosity
Less Flow
Higher Melt Viscosity
EXTRUSION APPLICATIONS INJECTION APPLICATIONSfiber, sheet, film, strap, foam housings E/E, PET bottles
Chain Extender Flow Enhancer
BASF Joncryl® Functional Additives
ConclusionJoncryl Functional Additives can provide more design freedom for engineering plastics compound design through:
flow improvement
compatibility
process protection
structural modification