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Plastics additives at NPE 2000
II
Plastics additives at N PE 2000 In this issue of Plastics Additives & Compounding we look at s o m e of the additives and t h e i r applications on show at the r e c e n t N P E 2000 in Chicago. The Polymer Additives Division of Ferro Corporation has developed Synpro Ca/Zn1550 - a polyolefin additive designed to eliminate die lip build-up. The company says that Synpro Ca/Zn-1550 is a hybrid calcium/zinc stearate blend designed to eliminate build up of die lip bleed in extruded polyolefin products. Its use in high density, polyethylene blown film where lost product and down time is cosily is described as particularly effective. Ferro adds that Synpro Ca/Zn-1550 combines the lower melting viscosity and external lubricity of zinc stearate with the stabilizing and later-stage melting contribution of calcium stearate. The Synpro Ca/Zn- 1550 lubrication package can enhance polyotefln processing and eliminate separation and build up of the low molecular weight fraction of polymer before it becomes a costly problem, says the company. Also new from Ferro is Therm-Chek ® PD888, a calcium/zinc powder heat stabi-
lizer that can provide improved UV stability for vinyl tiles. The company says that the product was formulated to aid flooring manufacturers in passing a proposed ASTM UV stability test. On the pigments front Ferro offers a complete line of GEODE ® complex inorganic colour pigments, which offer good heat and light stability, weatherability and chemical resistance. The pigments are recommended for use in PVC building products and engineering resins, but are also applicable for most plastics. Ferro says that each GEODE pigment is manufactured by calcining an intimate mixture of metal oxides at temperatures of 8001300°C. The resulting pigments have a special chemical compound and an individual crystal structure. Plastics additives from Struktol on show at NPE were claimed to provide good blending or mixing, as well as lubricant and flow enhancement properties for the compounder. Particularly efficient for
Plastics Additives & Compounding October 2000
34
compounding highly-filled polymers, Struktol additives act as compatibilizers or alloying agents, as well as providing improvements in surface appearance or mould release. The Struktol range includes TR 016, a dispersing agent for any inorganic filling system in PP, PE, TPO, PS, ABS and many PVC systems. Advantages claimed for this additive include lower viscosity and improved flow at processing temperatures. TPO blends and highly filled systems can be more homogeneously dispersed and other fillers and additives are more easily incorporated. Mould shrinkage is reduced and is more uniform, says Struktol, and there is a better surface appearance in finished parts. In talc-filled polypropylene compounds higher impact properties can be achieved with TR 016. The company adds that it provides mould release in olefin polymers and offers lower die swell. TR 016 has non-blooming properties that allow painting. Axel Plastics Research Laboratories has added a new internal lubricant and processing aid to its product line. MoldWiz INT-40DHT has been designed for PES and other engineering resins processed at high temperatures of 260-371°C (500700°F). The company says that the additive improves the release of parts from mould cavities and increases melt flow and enhances dispersion, as well. The product is particularly suitable for dispersing titanium dioxide, adds Axel. Applications for PPO SA120 resin from GE Plastics were highlighted at NPE, where it has been used in high performance laminated circuit boards. The product has been used to create a copper-dad laminate for use in high frequency antennas.
NPE The company says that circuit boards made with the additive offer a good cost/performance ratio compared with existing electrical materials, such as PTFE. The dielectric constant and dissipation factor can be significantly improved through the use of PPO SA120, according to GE Plastics, which are two of the most important properties for circuit board materials. The material also offers improved fracture toughness, shrinkage and dimensional stability, chemical resistance, fire resistance and moisture absorption. Laminates using this material are expected to be used in new high speed digital computer and wireless telecommunications applications. PPO SA120 is a low molecular weight version of PPO resin that has been specifically created to act as an additive to bring new properties to thermoset products, such as epoxy-based composites and electronics components, as well as moulding compounds. Entex International says that its range of chemical foaming agents can ensure high quality thermoplastic foamed products by generating fine, closed-cell foams. The company adds that they can act as processing aids to improve flow and compatibilize mixed polymers, reduce moulding cycle times and increase extrusion rates. They can also improve weld line strength and reduce warp and sink marks. The foaming agents can be used in a wide range of processes, including injection moulding, blow moulding, rotational moulding and extrusion of sheet, film and profiles. New applications for polymer processing additives from Dyneon were highlighted at the exhibition. The company has developed several new grades of additives that are applicable for resins other than LLDPE. Dynamar FX9613 and FX5920A have been used to eliminate melt fracture in blown film applications in LLDPE. New grades can be used in other resins and in applications other than melt fracture elimination. New Dynamar processing additives are available for use in nylon, polystyrene, polypropylene, acrylic, PVC and PET. The additives are being used for gel reduction, die build-up reduction, reduced back pressure, colour change-
over, improved gauge control and/or pigment dispersion. Two new grades of Engage polymer modifier were introduced by DuPont Dow Hastomers. Both are high performance, ethylene-octene co-polymers designed to meet higher flow and enhanced cold temperature impact requirements and can be used in a number of applications. Engage 8842 has a 1 melt index and a 0.857 density and is claimed to show the same qualities only found in ultra-low density elastomers. These include good flow characteristics and impact properties in blends with polypropylene and polyethylene. The company says that it performs particularly well in TPO applications where low temperature impact properties are required. Engage 8130 has a 13 melt index and 0.864 density and has been developed by DuPont Dow Elastomers to respond to the market interest in compounds with enhanced flow properties. It has good toughness and flexibility, which allows thin-walled parts to be made and improves processability. The company adds that Engage 8130 offers good performance as an impact modifier in polyolefin compounds or as an injection moulding component. A new purging compound was introduced at NPE by Shuman Plastics. Dyna-Purge O has been added to the company's line of thermoplastic blends. The product is designed for moulders of optical media resins processed at 204-310°C (400590°F) The company says that DynaPurge O is ideal for demanding applications such as CDs and DVDs. The compound is made of completely clear ingredients and Dyna-Purge O eliminates colour contamination in clear end-products. Shuman Plastics adds that regular use of Dyna-Purge O eliminates carbon build-up and deposits and allows for efficient resin changeovers, which minimizes scrap and machine downtime. DayGlo Color Corporation introduced high performance fluorescent colours suitable for use in polyolefins, without causing plateout during processing, at NPE. The company says that the product has been developed with the masterbatch manufacturer in mind. DayGlo are claimed to be clean, brilliant colours that
2000
also offer improved processing properties. DayGlo says that it has developed new technology that minimizes the problem of plate-out at the blownpin and in the mould cavity. This means that continuous high speed production is now possible with minimum downtime. Masterbatch formulations can now be simplified, claims the company, because expensive or hard to handle additives for controlling plateout can now be eliminated. In addition, an intermix palette allows the custom blending of multiple shades of DayGlo colours from just four blending colours. The colorant is available in a dust-free form in a high strength prill. They can be used at full strength for lowest cost in use or as a replacement for melt-in colorants for custom colour matches. At normal moulding temperatures blownpin plateout or in-mould residue is reduced to virtually zero, says DayGlo. The company adds that the colorants are completely formaldehyde-free and are highly cost effective compared with conventional fluorescent colorants. Two new grades of Ultramarine Violet pigments, Premier VB and Premier VX, were introduced by Holliday Pigments. The company says that Premier VX is a blue-shade Ultramarine Violet and is 10% stronger than existing violet grades. Premier VB is an intermediate blue-shade violet that complements the existing redshade violet Premier VU. It is 25% stronger than its Standard equivalent grade 13. All the grades have FDA approval. Milliken Chemical used the NPE to launch its expanded global support capability for the clarified polypropylene market. The company says that there are a growing number of products and parts made using polypropylene clarified with MILLAD® 3988. New thermoforming equipment to be employed in the company's applications laboratory demonstrated the manufacture of pressure formed cups from clarified polypropylene sheet. MILLAD 3988 is the latest of the company's clarifying agents for polypropylene and offers good clarity, gloss, processing and organoleptic performance. CK Witco Corporation highlighted its full range of additives for PVC corn-
PlasticsAdditives & Compounding October 2000
35
l/
NPE
2000
pounding at NPE. These include heat stabilizers based on mixed metals, phosphites and organotin. The company has a series of liquid and solid mixed metal stabilizers for flexible and semi-rigid PVC compounds. The Mark®range are non-cadmium stabilizers that offer heat stability with plate-out resistance, as well as moderate
temperature heat ageing performance and low volatility. In addition they are claimed to offer good initial colour control, impart appropriate levels of lubrication and result in good clarity and length of stability. The Mark phosphite heat stabilizers are used in combination with the mixed metal stabilizers and are said to be
highly efficient in both rigid and flexible PVC formulations. The company's organotin heat stabilizers are based on alkyltin mercaptides and carboxylates that are particularly effective in the stabilization of rigid PVC compounds. Products based on methyl, butyl or octyl and sulphur-containing or sulphur-free are all available. Drapex epoxy plasricizers from CK Witco, used as co-stabilizers with Mark mixed-metal stabilizers are claimed to provide good heat and light stability. This is achieved because they act synergistically with primary stabilizers, in particular barium-zinc and calcium-zinc mixed-metal stabilizers. The company also supplies PVC lubricants, including metal stearates, amide waxes and fatty acids, as well as UV absorbers, antistatic agents, blowing agents and antifogging agents. In forthcoming issues of Plastics Additives & Compounding we will report on some developments highlighted at N P E in masterbatches and compounding, as well as compounding equipment.
PLEASE INSERT 011 ON READER ENQUIRY CARD Plastics Additives & Compounding October 2000
36
Plastics additives at N PE 2000 In this issue of Plastics Additives & Compounding we look at s o m e of the additives and t h e i r applications on show at the r e c e n t N P E 2000 in Chicago. The Polymer Additives Division of Ferro Corporation has developed Synpro Ca/Zn1550 - a polyolefin additive designed to eliminate die lip build-up. The company says that Synpro Ca/Zn-1550 is a hybrid calcium/zinc stearate blend designed to eliminate build up of die lip bleed in extruded polyolefin products. Its use in high density, polyethylene blown film where lost product and down time is cosily is described as particularly effective. Ferro adds that Synpro Ca/Zn-1550 combines the lower melting viscosity and external lubricity of zinc stearate with the stabilizing and later-stage melting contribution of calcium stearate. The Synpro Ca/Zn- 1550 lubrication package can enhance polyotefln processing and eliminate separation and build up of the low molecular weight fraction of polymer before it becomes a costly problem, says the company. Also new from Ferro is Therm-Chek ® PD888, a calcium/zinc powder heat stabi-
lizer that can provide improved UV stability for vinyl tiles. The company says that the product was formulated to aid flooring manufacturers in passing a proposed ASTM UV stability test. On the pigments front Ferro offers a complete line of GEODE ® complex inorganic colour pigments, which offer good heat and light stability, weatherability and chemical resistance. The pigments are recommended for use in PVC building products and engineering resins, but are also applicable for most plastics. Ferro says that each GEODE pigment is manufactured by calcining an intimate mixture of metal oxides at temperatures of 8001300°C. The resulting pigments have a special chemical compound and an individual crystal structure. Plastics additives from Struktol on show at NPE were claimed to provide good blending or mixing, as well as lubricant and flow enhancement properties for the compounder. Particularly efficient for
Plastics Additives & Compounding October 2000
34
compounding highly-filled polymers, Struktol additives act as compatibilizers or alloying agents, as well as providing improvements in surface appearance or mould release. The Struktol range includes TR 016, a dispersing agent for any inorganic filling system in PP, PE, TPO, PS, ABS and many PVC systems. Advantages claimed for this additive include lower viscosity and improved flow at processing temperatures. TPO blends and highly filled systems can be more homogeneously dispersed and other fillers and additives are more easily incorporated. Mould shrinkage is reduced and is more uniform, says Struktol, and there is a better surface appearance in finished parts. In talc-filled polypropylene compounds higher impact properties can be achieved with TR 016. The company adds that it provides mould release in olefin polymers and offers lower die swell. TR 016 has non-blooming properties that allow painting. Axel Plastics Research Laboratories has added a new internal lubricant and processing aid to its product line. MoldWiz INT-40DHT has been designed for PES and other engineering resins processed at high temperatures of 260-371°C (500700°F). The company says that the additive improves the release of parts from mould cavities and increases melt flow and enhances dispersion, as well. The product is particularly suitable for dispersing titanium dioxide, adds Axel. Applications for PPO SA120 resin from GE Plastics were highlighted at NPE, where it has been used in high performance laminated circuit boards. The product has been used to create a copper-dad laminate for use in high frequency antennas.
NPE The company says that circuit boards made with the additive offer a good cost/performance ratio compared with existing electrical materials, such as PTFE. The dielectric constant and dissipation factor can be significantly improved through the use of PPO SA120, according to GE Plastics, which are two of the most important properties for circuit board materials. The material also offers improved fracture toughness, shrinkage and dimensional stability, chemical resistance, fire resistance and moisture absorption. Laminates using this material are expected to be used in new high speed digital computer and wireless telecommunications applications. PPO SA120 is a low molecular weight version of PPO resin that has been specifically created to act as an additive to bring new properties to thermoset products, such as epoxy-based composites and electronics components, as well as moulding compounds. Entex International says that its range of chemical foaming agents can ensure high quality thermoplastic foamed products by generating fine, closed-cell foams. The company adds that they can act as processing aids to improve flow and compatibilize mixed polymers, reduce moulding cycle times and increase extrusion rates. They can also improve weld line strength and reduce warp and sink marks. The foaming agents can be used in a wide range of processes, including injection moulding, blow moulding, rotational moulding and extrusion of sheet, film and profiles. New applications for polymer processing additives from Dyneon were highlighted at the exhibition. The company has developed several new grades of additives that are applicable for resins other than LLDPE. Dynamar FX9613 and FX5920A have been used to eliminate melt fracture in blown film applications in LLDPE. New grades can be used in other resins and in applications other than melt fracture elimination. New Dynamar processing additives are available for use in nylon, polystyrene, polypropylene, acrylic, PVC and PET. The additives are being used for gel reduction, die build-up reduction, reduced back pressure, colour change-
over, improved gauge control and/or pigment dispersion. Two new grades of Engage polymer modifier were introduced by DuPont Dow Hastomers. Both are high performance, ethylene-octene co-polymers designed to meet higher flow and enhanced cold temperature impact requirements and can be used in a number of applications. Engage 8842 has a 1 melt index and a 0.857 density and is claimed to show the same qualities only found in ultra-low density elastomers. These include good flow characteristics and impact properties in blends with polypropylene and polyethylene. The company says that it performs particularly well in TPO applications where low temperature impact properties are required. Engage 8130 has a 13 melt index and 0.864 density and has been developed by DuPont Dow Elastomers to respond to the market interest in compounds with enhanced flow properties. It has good toughness and flexibility, which allows thin-walled parts to be made and improves processability. The company adds that Engage 8130 offers good performance as an impact modifier in polyolefin compounds or as an injection moulding component. A new purging compound was introduced at NPE by Shuman Plastics. Dyna-Purge O has been added to the company's line of thermoplastic blends. The product is designed for moulders of optical media resins processed at 204-310°C (400590°F) The company says that DynaPurge O is ideal for demanding applications such as CDs and DVDs. The compound is made of completely clear ingredients and Dyna-Purge O eliminates colour contamination in clear end-products. Shuman Plastics adds that regular use of Dyna-Purge O eliminates carbon build-up and deposits and allows for efficient resin changeovers, which minimizes scrap and machine downtime. DayGlo Color Corporation introduced high performance fluorescent colours suitable for use in polyolefins, without causing plateout during processing, at NPE. The company says that the product has been developed with the masterbatch manufacturer in mind. DayGlo are claimed to be clean, brilliant colours that
2000
also offer improved processing properties. DayGlo says that it has developed new technology that minimizes the problem of plate-out at the blownpin and in the mould cavity. This means that continuous high speed production is now possible with minimum downtime. Masterbatch formulations can now be simplified, claims the company, because expensive or hard to handle additives for controlling plateout can now be eliminated. In addition, an intermix palette allows the custom blending of multiple shades of DayGlo colours from just four blending colours. The colorant is available in a dust-free form in a high strength prill. They can be used at full strength for lowest cost in use or as a replacement for melt-in colorants for custom colour matches. At normal moulding temperatures blownpin plateout or in-mould residue is reduced to virtually zero, says DayGlo. The company adds that the colorants are completely formaldehyde-free and are highly cost effective compared with conventional fluorescent colorants. Two new grades of Ultramarine Violet pigments, Premier VB and Premier VX, were introduced by Holliday Pigments. The company says that Premier VX is a blue-shade Ultramarine Violet and is 10% stronger than existing violet grades. Premier VB is an intermediate blue-shade violet that complements the existing redshade violet Premier VU. It is 25% stronger than its Standard equivalent grade 13. All the grades have FDA approval. Milliken Chemical used the NPE to launch its expanded global support capability for the clarified polypropylene market. The company says that there are a growing number of products and parts made using polypropylene clarified with MILLAD® 3988. New thermoforming equipment to be employed in the company's applications laboratory demonstrated the manufacture of pressure formed cups from clarified polypropylene sheet. MILLAD 3988 is the latest of the company's clarifying agents for polypropylene and offers good clarity, gloss, processing and organoleptic performance. CK Witco Corporation highlighted its full range of additives for PVC corn-
PlasticsAdditives & Compounding October 2000
35
l/
NPE
2000
pounding at NPE. These include heat stabilizers based on mixed metals, phosphites and organotin. The company has a series of liquid and solid mixed metal stabilizers for flexible and semi-rigid PVC compounds. The Mark®range are non-cadmium stabilizers that offer heat stability with plate-out resistance, as well as moderate
temperature heat ageing performance and low volatility. In addition they are claimed to offer good initial colour control, impart appropriate levels of lubrication and result in good clarity and length of stability. The Mark phosphite heat stabilizers are used in combination with the mixed metal stabilizers and are said to be
highly efficient in both rigid and flexible PVC formulations. The company's organotin heat stabilizers are based on alkyltin mercaptides and carboxylates that are particularly effective in the stabilization of rigid PVC compounds. Products based on methyl, butyl or octyl and sulphur-containing or sulphur-free are all available. Drapex epoxy plasricizers from CK Witco, used as co-stabilizers with Mark mixed-metal stabilizers are claimed to provide good heat and light stability. This is achieved because they act synergistically with primary stabilizers, in particular barium-zinc and calcium-zinc mixed-metal stabilizers. The company also supplies PVC lubricants, including metal stearates, amide waxes and fatty acids, as well as UV absorbers, antistatic agents, blowing agents and antifogging agents. In forthcoming issues of Plastics Additives & Compounding we will report on some developments highlighted at N P E in masterbatches and compounding, as well as compounding equipment.
PLEASE INSERT 011 ON READER ENQUIRY CARD Plastics Additives & Compounding October 2000
36