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Polymer-Clay Nanocomposites - Better Plastics

Tie Lan
General Manager Nanocor, Inc. 1500 Arlington Heights, IL 60004 USA

Outline
Plastic-Nanoclay Technology Commercial Applications Environmental Benefits

Nanotechnology
From composite to nanocomposite:
One continuous phase and at least one discontinuous phase At least one dimension in 100-nm scale

Nanoclay

Nanocomposite Benefits
Mechanical properties improvement Increase stiffness without loss of flexibility Increased dimensional stability Enhanced barrier properties Chemical and thermal stability Flame retardation in combination with FR agents Easy processing and recycling
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Nanoclay
BENTONITE: FDA 21CFR184.1155 GRAS: Generally Recognized as Safe
High aspect ratio Silicate layers 200-300 Possible inner layer chemistry
Nanoclay platelets are one-ten thousandth the diameter of a human hair!!

From Nanoclay to Nanocomposite

- H2O

15~25 Microns
Na-Bentonite

Nanos
Water Dispersion

BEST DISPERSED NANOCLAY

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From Nanoclay to Nanocomposite

Cationic surfactants

1st Step
Surface Treatment Hydrophilic Hydrophobic

From Nanoclay to Nanocomposite Nanomer

Monomer

Nanocomposite
Polymerization

Hydrophobic

Melt Compounding Polymer Melt

From Nanoclay to Nanocomposite

nanoMax Masterbatch Products
Nanomer Powder

Twin Screw Compounding Nanocomposite

Compatibilizer

Twin Screw Compounding

(Film, Engineering & FR)

nanoMax

Polyolefin Pellets

Polyolefin Pellets

Single Screw Extruder Injection Molder (Engineering, FR Only) Nanocomposite

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From Nanoclay to Nanocomposite

TEM of Nanoclay Dispersed in Plastics Polymer degradation

400 nm

Nanoclay layers are encapsulated in the polymer only

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From Nanoclay to Nanocomposite Nano-PA6

In situ polymerization process with patented technology FDA/EU approval status for direct food contact
H H H N+

H H H N+ O C C N+ H H H O OH N+ H H H OH O C OH

O C NH e-caprolactam M onom er

C O HN O C H N O C N H

O C NH O C H N O C NH

I.24T L

N+ H H H

N+ H H

N ylon 6 N anocom posite

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Barrier Improvement of nano-PA6

Oxygen Water Vapor

3
O T R (c c m i l / 1 0 0 i n 2 .d a y )

W V T R ( g m il/m

day)

400 300 200 100 0 0% 2% 4% -48% -68% -82% 6%

2 1 0 0

-48% -64% -71% -82%

I.24TL Loading (%)

I.24TL loading (%)

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Film Mechanical Properties of Nano-PA6

Cast Monolayer Films (20-30 micron)
Flow Direction
Testing Sample Nylon 6 B135WP Nano-PA6 %Nano Loading n/a 3% Youngs Modulus (Mpa) 150 270 Yield Strength (Mpa) 12 35 Strain @ break (%) 700 650

Perpendicular Direction
Testing Sample Nylon 6 B135WP Nano-PA6 %Nano Loading n/a 3% Youngs Modulus (Mpa) 200 380 Yield Strength (Mpa) 16 28 Strain @ break (%) 600 550

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Nanocomposites
Same Tm, Tg ---Same processing Smart design Use less resin ---same strength and barrier
PE//PA6//PE = 40//20//40 PE//nano-PA6// = 40//10//40 10% saving in film weight

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Nanocomposites
Applications of Nano-PA6: Stand-up pouch

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Nanocomposites
Nano-Nylon MXD6
H2NCH2 CH2NH2 + HOOC(CH2)4COOH

MXDA

Adipic acid

HNCH2

CH2NHC(CH2)4C OH O O
n

H2O

Nylon-MXD6

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Imperm Barrier Properties

Property
OTR (23oC, 60%RH) CO2TR (23oC, 60%RH) WVTR (40oC, 90%RH)

Units
ccmm/m2dayatm

MXD6 a) 0.09 0.30 1.36

Imperm a) 0.02 0.15 0.58

ccmm/m2dayatm

gmm/m2day

a) Non-oriented monolayer film

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O2 and CO2 Sensitive Products

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Nanocomposites for Military Food Packaging

Objectives
Eliminate Foil Layer in Meal Ready to Eat (MRE) Packaging Capability of Microwave Processing, High Pressure Pasteurization, Radio Frequency Sterilization. Reduction of Stress-Cracks and PinHoles Reduce Processing Steps (No-lamination required) Decrease MRE weight Reduce Solid Waste

MRE Barrier Specifications: OTR 0.06cc/m-day-atm WvTR 0.01g/m-day-atm

Shelf Life = 3 Years at 80F, 6 Months at 100F

US ARMY NATICK SOLDIER RD&E CENTER. The Science Behind the Warrior: Warrior: Yesterday, Today and Tomorrow

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Nanocomposites for Military Food Packaging

Oxygen Transmission of Multilayer MXD6 and Imperm Films
2.5

2.02
2

Multilayer MXD6 - 11.5 m il Multilayer Im perm Nano MXD6 - 10.0 m il

OTR (cc/m2-day)

1.5

0.97 0.61

Regular nano
< 0.05

0.5

MRE Relative Humidity (%) Specification 0.06 US ARMY NATICK SOLDIER RD&E CENTER. The Science Behind the Warrior: Warrior: Yesterday, Today and Tomorrow

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Nanoclay as FR Additives
Low Nanomer loading level Reduction of Traditional FR Agents Dripping Control Anti-Blooming Good Mechanical Properties Easy Processing Regulation Favorable
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Nanoclay as FR Additives
Brominated systems

Reduce toxicity Metal Hydroxide-MDH, ATH Easy processing, high productivity Intumescing systems Easy processing

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WWW.NANOCOR.COM

Nanocomposite Applications
Wire and Cable Application

Non-Hal, low smoke jacket Slow burning Low heat release rate

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Nanocomposite Applications
Auto Parts

Nano-PP replace GF Filled PP 25% weight reduction, easy processing CP Polymer CRESS-ALON A Nano Nano Resin Brand name - Cress-Alon Injection grade - NE2740, NE6040ST

nanoSEAL barrier resin

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Nanocomposite Applications
Marine Fuel Tank

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Nanocomposite Applications

nano Regular
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Nanocomposite Applications
Agriculture Film Application

Reduce MeBr emission

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Nanocomposite Market
Data Source: BCC Research www.bccresearch.com

Global Consumption of Nanocomposites

Global Consumption (million $) $900 $800 $700 $600 $500 $400 $300 $200 $100 $0 2004

$857

$288 $252

Average Annual Growth Rate (AAGR) 24.4%

2006

2008 year

2010

2012

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Nanocor Markets
Transportation FR Compounds

Packaging

Coating

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Summary
Nanoclays are effective additives to make better
plastics Nanocomposite resins offer same processing and recycle Use of nanocomposite have good environmental impact Lower weight auto parts Less toxic flame retardant compounds Thinner plastic package Durable/impermeable fuel tanks
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Company Information
www.amcol.com (NYSE: ACO)

AMCOL International Corp., through its operating subsidiaries, is a leading international producer and marketer of value-added, specialty minerals and related products. The Companys products serve 12 major markets, includingmetalcasting, detergents, pet products, building materials and personal care. AMCOL operates a transportation segment that acts as a servicing operation for other business segments and outside customers. Headquartered in Arlington Heights, Ill., AMCOL operates 68 facilities in Asia, Australia, Europe and North America. The Company employs 1,750+ employees in more than 26 countries. The Company, established in 1927,

American Colloid

CETCO

ASM/AME

HBS

Nanocor

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Thank You

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