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PlasticAdditives1Ciba®IRGASTAB®NA287NewhighperformancenucleatorforPolypropylenePhilippWalter,NewBusinessDevelopmentFlorianStricker,SkillCenterMoldingCibaSpecialtyChemicalsPlasticAdditives2Therearetwogroupsofnucleatingadditives•Nucleatorsare“melt-insensitive“–Inorganicororganicsalts–Highmeltingpoint–Nucleiforcrystallization–E.g.sodiumbenzoate,phosphates,...•Clarifiersare“melt-sensitive“–Organiccompounds–Highmeltingpoint–SolubleinthePPmelt–Forminganetwork–Morehomogenousnucleation–E.g.sorbitols**********************************************************************************spherulitesfibrilsPlasticAdditives3It‘sachallengetomeetallrequirements•Highstiffness•Balancedstiffness/impact•Powertooverridenucleationeffects•Highefficacy•Potentialtoreducecycletime•Cost-effective•Improvedopticalproperties•Broadregulatoryapproval•Easydispersibility...withonenucleatingadditivePlasticAdditives4Commerciallyavailablenucleatorsare…•Lowcostnucleators–Sodiumbenzoate•Requireshigherloadings•Lowerperformancethanhighperformancenucleators•Highperformancenucleators–Ciba®IRGASTAB®NA11•“Best-in-class”inmechanicalperformance–HyperformHPN68•Cycle-timereductionandisotropicshrinkage–Ciba®IRGASTAB®NA287•NewDevelopmentfromCiba•CombinesbenefitsofhighperformancenucleationwithcostattractivenessPlasticAdditives5Newhigh-performancenucleatorforPPCiba®IRGASTAB®NA287…•Enablesmaterialsavingsthroughgoodmechanicalproperties•Improvesoutputofpolypropyleneconversionprocesses•Helpsmanagewarpage–Broadenchoicesincoloration–Reducedscrapformation•Improves“see-through”qualitythroughhazereduction•Excellentcost/performancebalancePlasticAdditives6Ciba®IRGASTAB®NA287ina“nutshell”•Freeflowingpowder•Foodcontactclearance•Nointeractionswithcommonpolypropyleneco-additives•ActiveatlowloadingsPlasticAdditives7MaterialandcostsavingsthroughgoodmechanicalpropertiesPlasticAdditives8TheoreticalAnalysis:Materialsavingsresult…05010015020025030035040045000.010.020.030.040.050.06Wallthicknessreduction(mm)intons02004006008001,0001,2001,400in1000$MaterialsavingsperyearCostsavingsperyear-0.75%-20%-38%Assumptions:Consumptionof10,000tonsperyearSampleform:injectionmoldedcupsSampledimensions:radius1=7.5cm;radius2=10cm;heigth=17cmSamplethickness:1mm…incostsavingsPlasticAdditives9IRGASTAB®NA11provideshighstiffness…12201410171015401530100011001200130014001500160017001800ControlNa-benzoateIRGASTABNA11IRGASTABNA287HPN-68Flexuralmodulus(MPa)@500ppmPPhomopolymerInjectionmoldedplaques,4mm…inPPhomopolymerPlasticAdditives10990122013601330132090010001100120013001400ControlNa-benzoateIRGASTABNA11IRGASTABNA287HPN-68Flexuralmodulus(MPa)IRGASTAB®NA287iscompetitive…@500ppmPPblockcopolymer,MFI35Injectionmoldedplaques,4mm…inPPimpactcopolymerPlasticAdditives11Outputimprovementthroughcycle-timereductionPlasticAdditives12CoolingtimedominatescycletimesandlinespeedThin-walledpartsTechnicalparts70%Coolingtime50%InjectiontimeHoldingpressureDemoldingCycletimeanalysisbyJohannaber&Michaeli,HandbuchSpritzgiessen,Hanserpubl.2002PlasticAdditives13Coolingtimesdependonvariousparameters•Wallthickness•Melttemperature0204060801001201400123456Wallthickness(mm)Coolingtime(s)70°C80°CInfluenceofwallthickness&demoldingtemperature•Moldtemperature•Demoldingtemperature–Crystallizationspeed–CrystallizationtemperaturePlasticAdditives14Nucleatorsaffectcoolingtimeby...•Increasingcrystallizationtemperatureandspeed0.00.51.01.52.02.53.090110130150Temperature(oC)HeatFlow(mW/mg)NucleatedVirginpolymerPlasticAdditives15Theoreticalanalysis:CoolingtimereductionOutputimprovementvs.coolingtimereduction020040060080010001200140001020304050CoolingTimeReduction(%)#parts/year*#cavities020406080100120140(%)TechnicalPartPackagingPart(%)(%)Assumptions:Technicalpart(30seccycle-time)Packagingpart(5seccycle-time)PlasticAdditives16IRGASTAB®NA287increasescrystallizationspeed117133131128051015202530Na-BenzoateIRGASTABNA11IRGASTABNA287HPN-68Timeinminutes115120125130135Temperaturein°CHalftimeTemperaturePPhomopolymer,0.1%nucleatingagentCrystallizationhalf-timeCrystallizationtemperaturePlasticAdditives17WarpagemanagementforbroaderchoiceincolorationandreducedscrapformationPlasticAdditives18Differentialshrinkagecauseswarpage•Shrinkage–Changesinvolumeoncrystallization•Warpage–DistortionofthefinalinjectionmoldedpartPlasticAdditives19Testforscreeningwarpagepotential•Judgementofwarpagebasedondifferentialshrinkage•Wellestablishedforpigments•RectangularInjectionmoldedplates–Measureshrinkageinlengthandtransversedirection–PlotDeltaLengthversusDeltaWidth–Providesa“Diamond-shapedscale“forwarpageNeatmaterialDeltaWidth(‰)DeltaLength(‰)PlasticAdditives20IRGASTAB®NA287withhighestability...…tomanagewarapgeHeterophasicPP,MFR=35-14.00-5.00-3.00-1.001.003.00-20.00-18.00-16.00-12.00-10.00-8.00-6.00-4.00-2.000.00DeltaL(‰)Ciba®IRGASTABNA287Ciba®IRGASTAB®NA11Ciba®IRGASTAB®NA04DeltaW(‰)NeatPPPlasticAdditives21…andoverridesnucleationbypigmentsHPN-68w/andw/opigments-Yellow110Blue15:1--18-10-4++-20-6-8DeltaL(‰)IRGASTABNA287w/andw/opigmentsNeatPlasticAdditives22Enhancementof“see-through”qualit