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Polymers and composites

R&D activities on polymers and composites
by

Materia Nova

on 20 November 2013

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Transcript of Polymers and composites

Developing new fire resistant formulations
Reactive extrusion applied to bioplastics

COMPATIBILIZATION OF TALC / ECOFLEX® MELT BLENDS
BIOPOLYMERS
New fire resistant formulations
Partially hydrated dolomitic lime : Ca(OH)2. Mg(OH)2. MgO
Completely hydrated dolomitic lime : Ca(OH)2. Mg(OH)2
Example 2: Flame retardant
PLA/PBS 60/40 (w/w) nanocomposites
4wt% compatibilizer
3wt% nanofiller
4 in 1
TAILORING OF CO-CONTINUOUS
BIOPOLYMER BLENDS MORPHOLOGY :
THE JOINT ACTION OF COMPATIBILIZERS OBTAINED BY REACTIVE EXTRUSION AND NANOCLAYS.
REx for BIOPLASTICS
Continuous production of aliphatic polyesters by catalyzed ROP;
Polyester chemical modification (self-branching) and chain-functionalization (maleation);
Compatibilization of polyester-based composites with different naturally occurring fillers;
Functionalization of thermoplastic starch and production of melt-blends and nanocomposites.
...

BIODEGRADABLE (BIO)POLYMERS AND RELATED COMPATIBILIZED BLENDS & (NANO)COMPOSITES :

USING SILICA NANOPARTICLES TO STABILIZE PA6/PP BLEND MORPHOLOGY IN ORDER TO OBTAIN AN ALLOY COMBINING BOTH PP AND PA INHERENT PROPERTIES.

UNTREATED silica “HYDROPHILIC” (300 m2/g)
TREATED SILICA (HexaMethyldiSilazane) “HYDROPHOBIC” (225 m2/g)
SILICA NANOPARTICULES TO STABILIZE BLENDS
EXAMPLE 1
Recycling implies separation and polymer treatment
Immiscible Polymer blends : Necessity of compatibilization to prevent phase separation
Research programs in collaboration with industrial partners
Tests et analyses (Problem solving, product development)
Scientific advice and consultancies




Help companies to maintain high efficiency
Support innovation inside companies
OUR MISSION

Biopolymers : technical application
Murariu M, Bonnaud L, Fontaine G, Bourbigot S, Dubois Ph., Pol. Deg. Stab. 2010; 95(3):374-381

Thermal resistance during processing increased
Mechanical properties not affected despite of high filler content
Flame retardant : burning rate decreased
Blends & (Nano)Composites


Mechanical behavior
Fire resistance
Thermal characterization methods

Mixing of polymers
Dispersion of (nano)fillers
Dubois, Narayan et al., Macromol. Mater. Eng., 298, 310 (2008)

STEP 3 : Film blowing in a single-screw extruder

STEP 1 : free-radical maleation of Ecoflex®

Compatibilization of talc/ecoflex melt blends
MAG-Ecoflex®
with 0.94 wt% MA
+ T : 180°C
+ L101: 0.05 wt% (Free Radical Initiator )
co-rotating intermeshing twin-screw extruder
130 rpm
Residence time < 5min

STEP 2 : Melt blending of talc (30wt%; 6mm) with MAG-Ecoflex®

PA6/PP blends
+

+

NANOFILLER (3wt%)

Polymer Degradation and Stability 2013, DOI: 10.1016/j.polymdegradstab.2013.06.020

Fire resistant formulations

FORMATION OF COHESIVE RESIDUE


EVA / Hydrated & semi hydrated dolimes


pHRR
FORMATION OF COHESIVE RESIDUE
Fire resistant formulation
Ca(OH)2.Mg(OH)2. MgO


MDPE / Hydrated & semi-hydrated dolimes

Modelisation
Synthesis
Devices
Structured surfaces
Nanotechnologies
Plasma technologies
Electrochemistry
Sol-gels
Biodegradation
Biotechnology
FIELDS OF EXPERTISE

! Nanoparticles are not specific to one polymer blend !
Compatibilizing agent is specific to each polymer blend
- ↓ Interfacial tension
- ↓Size of the dispersed phase
- ↑Stress transfer

+ NP

Blends & (Nano)Composites

- Interfacial energy
- ↓total free energy of the system

Persenaire, O., Raquez, J.-M., Bonnaud, L., Dubois, P.; 2010
Macromolecular Chemistry and Physics 211 (13) , pp. 1433-1440

Destructuration of nodules
Clay is located in PBS and at the interphase

PBS

Clay is located in PLA and at the interphase

Dispersed phase
PBS

PLA

MA-g-PLA (4 wt%)

EXAMPLE : 4 in 1
Clay is mainly located at the interphase

Co-continuous morphology

Uncompatibilized blends

MA-g-PBS (4 wt%)

Reactive Extrusion
PROCESSING
PERFORMANCE EVALUATION
COMPATIBILIZATION OF IMMISCIBLE BLENDS
Organic compatibilzation
Inorganic compatibilization (nanoparticles - NP)
PLASTICS IN AUTOMOTIVE
= 17wt% !
Macromolecular Materials and Engineering 298 (3), pp. 328-338
EVALUATION OF THE POTENTIAL FLAME RETARDANT EFFECT OF DOLIMES:
Ca(OH)2 fraction may be of interest:
Its endothermic dehydration occurs at higher temperatures
the T range action of the FR system
over 400°C
Ca(OH)2.Mg(OH)2


BIO-NANOCOMPOSITES
+
+
Nanofiller
(3 wt%)
NANOCLAYS
ADVANTAGES
Solvent free;
Continuous processing;
Control over the residence time;
Integration of other extrusion streams with the polymerization process…

for polymer processing including :
Melt blending, Filler dispersion, Chemical modification (branching, functionalization,…) & (Co)polymerization reaction

REACTIVE EXTRUSION (REx)
ATTRACTIVE ROUTE
REx for BIOPLASTICS
To permit their COMMERCIAL SCALE-UP, appropriate, inexpensive and easy process to manufacture biodegradable polymers is highly desirable for their commercial viability (bulk commodity materials) and cost-competitiveness.

PLA
Polymer
Biopolymers : example
By-product from LA fabrication process : MICROFILLER
(40wt%)

Reactive extrusion
How can production and compounding of polymer materials be integrated in a one-stage processing?
(Nano)Composites
& Blends

Bioplastics
SMPC
Thank you for your attention
(Nano-)composites
Bioplastics
Partial substitution of hydrated minerals by synergistic additives to produce thermally stable residue in order to ensure better shielding effect and extend their efficiency over 400 °C
Broaden the temperature range of the FR system action
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