Chemical Foaming Agents Hydrocerol - Clariant/media/Files/Media/Previous-Events/… · · 2014-09-05BU Masterbatches -RBL Europe, Product Management Additives, 01.06.2013 Exothermic

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BU Masterbatches - RBL Europe

Product Management Additives

01.06.2013

Chemical Foaming AgentsHydrocerol®

BASICS

BU Masterbatches - RBL Europe, Product Management Additives, 01.06.2013

Table of Contents

2

What are chemical foaming agents? 3

Hydrocerol® in Extrusion 13

Hydrocerol® in Injection Molding 21

Direct Gassing = Physical Foaming 26

Tools 33

Contact 36

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01.06.2013

What are chemicalfoaming agents?


Why foaming?

– Cost reduction

– Weight reduction

– Material savings

– Reducing Carbon Footprint

– Better thermal insulation properties

– Higher stiffness-to-weight ratio

– Processing aid in injection molding

- Decreasing cooling times

- Higher Injection Speed

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Examples of use

5

BMW 3series dashboard carrier, PPO and PP-GF

Danone Activia yogurt cup, PS and PLA

Artificial wine corks, PE, TPE

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The principle


Exothermic and Endothermic chemical foaming agents

Exothermic

Exothermic CFA’s like

• azodicarbonamide

• sulfonylhydrazide

• 5-phenyltetrazole etc.

generate heat

Endothermic

Endothermic CFA´s like

• sodium bicarbonate

• citric acid and its salts

absorb heat

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Exothermic and Endothermic chemical foaming agents

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CFA (exo) + org. byproductsN2 + ∆E2+∆E1

CFA (endo) + inorg. byproductsCO2 + H2O+∆E

DSC-CurveEndothermic Decomposition

DSC-CurveExothermic Decomposition

T

E+

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Exothermic chemical foaming agentsChemistry

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Foaming Agent Chemical StructureDecomp.range [°C]

Gas yield[ml/g]

Maingases

Azodicarbonamide ADC 205 – 215 280 – 320N2, CO,

CO2, (NH3)

Modified ADC155 - 220 150 – 300

Oxybis( benzene-sulfonylhydrazide)

OBSH 140 – 165 120 – 150 N2, H2O

5-Phenyltetrazole 5 - PT 240 – 250 190 –210 N2

p-Toluylensulfonyl-semicarbazid

TSS 215 - 235 120 – 140 N2, CO2

p-Toluylensulfonyl-hydrazid

TSH 110 – 140 120 –140 N2, H2O

H3C SO2 NH NH CONH2

O SO2 NH NH2SO2NHH2N

C

NN

N

NH

H3C SO2 NH NH2

N N CO NH2COH2N

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Endothermic chemical foaming agentsChemistry

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+Na Cl NH3 H2O CO2 NaHCO3 NH4Cl+++

+NaHCO3 Na2CO3 H2O CO22 +

Production of Sodium bicarbonate

Decomposition of Sodium bicarbonate

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Decomposition of Citric acid

Citric Acid

H2C

C

H2C

COOH

COOHHO

COOHCO2 H2O+ +

H2C

C

H2C

COOH

COOHItaconic Acid


Endothermic chemical foaming agentsProperties

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I I I I I I I I I I I I I

I I I I I I I I I I I I I

Decomposition range Processing temperature of polymer

105 120 135 150 165 180 195 210 225 240 255 270 °C

Citrate

Citrate/Bicarbonate-Mix

Bicarbonate/Citrate-Mix

Bicarbonate

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What about Universal Chemical Foaming Agents?

– Melt temperature would have to be high enough to ensure a complete decomposition

– Carrier Polymer would have to fit into the matrix of the target resin

– Pressure of the polymer melt would have to be kept high enough to keep the gas dissolved

AND

– The different gasses (N2 , CO2) have differences in gas solubility in the polymer melt

– Incompatible gas / polymer combinations can cause problems

A tailor-made solution is needed for every process

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Hydrocerol® in Extrusion


Scope of use and applications

– Weight reduction: 10 - 50%

– Thermoforming of extruded sheets

– Co-Extrusion in all common layer structures

– Lower heat transfer

– Food contact approved grades

– Films, sheets, profiles and pipes, etc.

– PE, PP, PS, PET, PVC, PLA etc.

– Hydrocerol PEX standard range

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Parameters

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Rapid Pressure Build-up: High pressure is the key condition to keep the evolved gas dissolved in the melt

No Pressure-Drop: Pressure-Drop (e.g. at melt sieves) can cause pre-foaming problems

Sufficient Melt Strength : The dissolved gas decreases the melt viscosity. Lower MFI (2 - 3 times) may be required (co-extrusion !!)

Decomposition temperature of the CFA has to be reached at least once during the process

Temperature:

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Pressure Profile

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conventionalextruder

extruder withgrooved feedingzone

pressure

pressure

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Temperature Profile

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foam

plastic

Hydrocerol ®

tem

pera

ture

decomposition temperatureof the foaming agent

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Chemical Foaming

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Plastification

Foaming

DispersionReaction

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plasticHydrocerol ®


Example of use:PS sheets and trays

– Mono or co-ex films

– Slot die for chemical foaming, 10-30% weight reduction

Suitable Formulation:

– GPPS 50%

– HIPS 50%

– SBS copolymers as modifiers

– Nucleation: e.g. talc

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Foam structure in Extrusion

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01.06.2013

Hydrocerol® in Injection Molding


Advantages

For the plastic part:

– Reduction of weight

– Elimination of sink mark

– Elimination of warpage / Improved dimensional accuracy

For the process:

– Improvement of flowability

– Reduction of injection pressure

– Reduction of clamping force (enables to use smaller machines)

– Faster cycle time

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compact

foamed

Hydrocerol ITP product range


Equipment and Process

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Hydrocerol® can usually be processed on every common injection molding machine.

The advantages are:

– Shut-of-nozzle to avoid premature foaming

Gates and flow path should be configured in a way as to allow a fast and even mold filling

– A very good venting at the end of the flow path

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Case Study:Mold venting

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- Floater (PA66)

- HYDROCEROL ITP825

Weight reduction 5%

Drastic reduction ofclamping force

(improved venting)

Weight reduction 50%

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Important parameters

– Back Pressure

- A specific pressure of 40bar should be applied to avoid premature foaming

- Recommendation: use of shut-off nozzle/position control of the screw

– Holding Pressure

- Should be as low as possible (ideally zero) to allow nucleation and expansion of the dissolved gas

– Shot weight

- Reduced, to give room for the gas to expand (needed if weight reduction is required)

– Injection Speed

- As high as possible, to prevent premature expansion of the gas and forming of silver streaks

– Temperature profile

- Dependent on HYDROCEROL® grade - information can be extracted from technical datasheet

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Direct Gassing =Physical Foaming


Scope of use

– Extremely light foam (15 kg / m³)

– Special machinery

– Gas dosing unit

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Applications

– Food trays (PS)

– Pipe insulation (PE)

– Cable insulation (PE, PVC)

– XPS-boards

– Seals

– Profiles

– Food-trays

– Insulation boards

– CFA as a nucleant

– Hydrocerol NUC series

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Physical Foaming

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GAS

plastic


Hydrocerol in Direct Gassing Nucleation

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Without or poor passive nucleation

With active Nucleation

Nucleating Agents create centers for foam cells.

Interruption of resin matrix leads to irregular “spots” where the dissolved gas starts separating easily.

The result are more and smaller cells.

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Hydrocerol in Direct Gassing Active versus Passive Nucleation

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foaming gasgas from decompositionsolid particles

Passive Nucleation Active Nucleation

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foaming gassolid particles

HYDROCEROL

decomposition


Hydrocerol in Direct Gassing Different dosages

32

– 2% Hydrocerol NUC 5510 (50% talc MB)

– 0,5% HYDROCEROL NUC 5540 (active/passive mixture)

– 0,3% HYDROCEROL NUC 5535 (active)

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Tools


Questionnaire

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Cost calculator

– Helps to create a commercial scenario for weight reduction and cost savings

– Finds break even point for balance of weight reduction and additional costs of CFA

– Can be discussed with customer or used as an internal back up for monitoring projects

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Contact


Contact

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CLARIANT MASTERBATCHESRBL EUROPE

Clariant SE

BU Masterbatches

Am Unisys-Park 1

D-65843 Sulzbach am Taunus

Tel: +49 6196 757 6276 / +49 6196 757 60

Fax: +49 6196 757 6113

WWW.CLARIANT.MASTERBATCHES.COM

[email protected]


Disclaimer

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This presentation contains certain statements that are neither reported financial results nor other historical information. This presentation also includes forward-looking statements.

Because these forward-looking statements are subject to risks and uncertainties, actual future results may differ materially from those expressed in or implied by the statements. Many of these risks and uncertainties relate to factors that are beyond Clariant’s ability to control or estimate precisely, such as future market conditions, currency fluctuations, the behavior of other market participants, the actions of governmental regulators and other risk factors such as: the timing and strength of new product offerings; pricing strategies of competitors; the Company's ability to continue to receive adequate products

from its vendors on acceptable terms, or at all, and to continue to obtain sufficient financing to meet its liquidity needs; and changes in the political, social and regulatory framework in which the Company operates or in economic or technological trends or conditions, including currency fluctuations, inflation and consumer confidence, on a global, regional or national basis.

Readers are cautioned not to place undue reliance on these forward-looking statements, which speak only as of the date of this document. Clariant does not undertake any obligation to publicly release any revisions to these forward-looking statements to reflect events or circumstances after the date of these materials.

Documents

Chemical Foaming Agents Hydrocerol - Clariant/media/Files/Media/Previous-Events/… · · 2014-09-05BU Masterbatches -RBL Europe, Product Management Additives, 01.06.2013 Exothermic