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The performance of reinforced polymers depends not only on the filler
characteristics, but also on its dispersion and the interactions formed at the
polymer-filler interface. By using a dispersing aid and coupling agents, ultimate
performance of composites can be optimised. Today, silanes are widely used
as coupling agents, adhesion promoters, but also as a dispersing aid of fillers
in polymeric matrices. Valerie Smits, Pierre Chevalier, Damien Deheunynck
and Scott Miller of Dow Corning review the effect of silane treatment on
the performances of composites and introduce a new family of dispersing
aid products.
P
erformance of filled or reinforced or even to improve the reinforcing effect of the expected performance improvement
plastics generally depends on the the filler. Indeed, silanes could also be added is good filler dispersion and appropriate
characteristics of the filler, such as to a compound formulation as coupling polymer-filler interactions. This can be
its shape and size also known as the agents improving both filler dispersion achieved through a filler treatment using
aspect ratio and its surface characteristics. and interactions between the filler and the silane technology. This is closely linked to
For a given system, one of the most important polymeric matrix. the intrinsic reactivity of the silane and its
parameters which will affect the mechanical, Today, silanes represent the most widely ability to react onto the surface of the filler
optical and/or electrical properties of a used coupling technology together with either before or during the different steps of
reinforced polymer is the filler dispersion. maleic anhydride grafted polyolefins. Among composite processing. It is also important that
It is known that large agglomerates tend to a large number of applications, silanes are the organic functionality of the silane provides
form a flaw which leads to mechanical failure. traditionally used to treat silica and improve compatibility and improved interaction with
A second key parameter is the polymer- the reinforcement of tyre tread rubber the resin.
filler interaction, and more specifically the formulation. Silane is also a critical component
properties and thickness of the interphase in glass fibre reinforced polymer composites. Dispersion mechanism
between polymer and filler. The final As mentioned before one of the key The first challenge of processing a
performance of the composite depends upon conditions that must be met in order to obtain compound is the dispersion of the filler.
the capabilities of the interphase to transmit
the stress from the matrix to the filler.
Silanes are widely used as dispersing
aids. They enhance filler compatibility with Cluster size 5–30 nm 40–100 nm 1–500μm
the polymer matrix by making the filler
hydrophobic and less polar (lower surface Agglomeration
energy), and thus more compatible with a
polymeric resin, which is mainly apolar by
mixing
nature. As an example, silanes are used to treat
Primary particle Aggregate Agglomerate
fillers such as halogen-free flame retardants,
titanium dioxide etc to make them more
compatible and dispersible in the polymer Figure 1: Filler aggregation and dispersion.
0034-3617/08 ©2008 Elsevier Ltd. All rights reserved December 2008 REINFORCEDplastics 37
Feature
120 44
Torque[Nm]
80
Untreated 40
60 Treated
38
40
36
20
0 34
GCC TALC SILICA Pure PP Untreated Treated
talc talc
Figure 5: Surface hydrophobation – contact angle data for untreated and n-octyl silane treated fillers. Figure 6: Processing energy reduction for T2 at 7 wt%
of talc.
condensation reactions with filler surface Figure 5 clearly illustrates that fillers are
Chemical name (R) Chemical structure
forms a siloxane monolayer around the filler becoming more hydrophobic after octylsilane O CH3
Methyl- H3C Si O CH3
particle leading to a clear interface between treatment. The results are explained as O CH
3
filler and polymeric matrix. However, inter- follows. The interaction and/or reactivity Vinyl- MeO
CH2
CH
diffusion phenomenon and inter-penetrated of the alkoxy groups of the n-octyl silane MeO
Si
network (IPN) formation occurs leading to with the filler particles through hydrolysis- OMe
H H
the creation of an interphase, rather than an condensation allows the silane anchorage on Phenyl- O CH3
H Si O CH3
interface, as illustrated in Figure 4. the filler surface, whereas n-octyl functionality O CH
3
H H
gives a hydrophobic character to the filler Methacryloxypropyl- H2C CH3
Treating fillers using silane technology treated filler more compatible with an apolar OMe
N-octyl
can improve processing, performance and polymeric matrix such as polypropylene (PP) EtO
EtO
durability of mineral-modified products by: of low surface energy. Si
r JNQSPWJOH XFUUJOH PG UIF NJOFSBM CZ UIF Two kinds of talc (T1 and T2) were OEt
O
Glycidoxypropyl
polymer; surfaced treated using n-octyl silane and were
O
r SFEVDJOHUIFWJTDPTJUZPGUIFGJMMFSQPMZNFS then compounded in a lab-scale twin screw
mix; FYUSVEFS 5PSRVF PWFS UJNF XBT SFDPSEFE MeO
Si
OMe
r JNQSPWJOHEJTQFSTJPOPGUIFNJOFSBMJOUIF EVSJOH DPNQPVOEJOH 5IF UPSRVF MFWFM JT MeO
and the polymer; UIF MPXFS UIF QSPDFTTJOH FOFSHZ SFRVJSFE UP Figure 7: Chemical structures of studied alkoxysilanes:
r JNQSPWJOHFMFDUSJDBMQSPQFSUJFTBOE R-Si(OX)3.
r JODSFBTJOHNFDIBOJDBMQSPQFSUJFT
39
In this section silane effect on filler 38
37
hydrophobation and dispersion will be
36
illustrated and more specifically how silanes
Torque (Nm)
35
enhance filler compatibility and dispersion
34
within a polypropylene (PP) matrix. 33
Talc together with calcium carbonate 32
and silica were initially treated using n-octyl 31
silane at a level of 15 wt%. The efficiency 30
yl-
yl
l
ed
l-
yl-
l-
l-
ny
ty
op
op
en
at
de
Oc
Vi
et
pr
tre
Ph
pr
ta
M
n-
xy
y
Un
Oc
id
cr
yc
ha
Figure 9: SEM picture of T2 reinforced PP composites: effect of silane treatment on Figure 10: SEM picture of silica reinforced organic rubber: effect of silane treatment on
filler dispersion. filler dispersion.
9.00 0.18
8.00 Treated Talc/PP 0.16
Untreated Talc/PP Treated Talc/PP
7.00 0.14
Pure PP Untreated Talc/PP
6.00 0.12 Pure PP
Tan Delta
E (GPa)
5.00 0.10
4.00 0.08
3.00 0.06
2.00 0.04
1.00 0.02
0.00 0.00
100 50 0 50 100 150 200 100 80 60 40 20 0 20 40 60 80 100 120 140 160 180
Temp (°C) Temp (°C)
Figure 11: Thermomechanical properties – Storage modulus E and loss tangent Tan δ – for 30 wt% T2 filled-polypropylene composite.
produce the filled composite. Figure 6 shows simple observation of the images. As illustrated as illustrated in Figure 12, enhancing the
UIBU CZ USFBUJOH UBMD 5
UIF UPSRVF MFWFM JT in Figure 9, there is no clear dispersion rigidity-toughness balance.
reduced by 10%. It is observed that n-octyl improvement of the talc in polypropylene From these results, one can see the
TJMBOF USFBUNFOU SFEVDFT UIF UPSRVF MFWFM UP matrix after n-octyl silane treatment. This is positive influence of silane treatment on the
UIFFRVJWBMFOUMFWFMPGQVSFQPMZQSPQZMFOF most likely due to the fact that talc is already performance of filler reinforced-plastics:
A series of different silane surface treating fairly dispersible into polypropylene. On the the silane treatment reduces the processing
agents were investigated on T1 talc: methyl-, contrary, silica dispersion was evaluated in energy at the compounding stage by up to
vinyl-, phenyl-, methacryloxypropyl-, another study and we clearly observed the 10% and improves the energy dissipation
n-octyl-, glycidoxypropyl- and octadecyl- dispersion improvement of silica in organic while maintaining composites stiffness.
trialkoxysilane. The chemical structures rubber via sulphido-silane treatment as Those observations are most likely due to
of those various silanes are illustrated in illustrated in Figure 10. an improved filler wetting and compatibility
'JHVSF 5IF UPSRVF MFWFMT PCTFSWFE EVSJOH Mechanical performances of the with the polypropylene matrix.
the compounding step are reported in polypropylene composites were evaluated by
Figure 8. their viscoelasticity performance measured on A new family of dispersing aids
5IF UPSRVF SFEVDUJPO JT FYQMBJOFE PO temperature sweep mode. Storage modulus, Dow Corning is developing a new line of
the basis of relative solubility parameters. as well as tan δ, was recorded as a function of dispersing aid products. The first product
The different silanes used in this study have the temperature. of the series is Dow Corning® Z-6173
different polarities and compatibilities with Figure 11 summarises the results for Filler Dispersion Aid. This product is a
QPMZQSPQZMFOF 5IF MPXFTU UPSRVF MFWFM XBT the 30 wt% talc reinforced-polypropylene. multifunctional siloxane product that
obtained with octadecyl-trimethoxysilane We clearly observe that elastic modulus is can improve filler dispersion, improve
for which filler/filler interaction is reduced higher at low temperature, improved at room compatibility between materials, and provide
MFBEJOHUPBMPXFSUPSRVFMFWFM temperature and preserved within the service application-specific benefits. Dow Corning
The dispersion of the filler in the polymer temperature range. At the same time tan Z-6173 Filler Dispersion Aid contains alkoxy
NBUSJY XBT RVBMJUBUJWFMZ FWBMVBUFE VTJOH δ is increased. This increase in tan δ is and alkyl functional groups which improves
scanning electron microscopy (SEM) by leading to improved impact performance, the dispersion of inorganic fillers such as
40 180
160
35 140
Contact Angle(°)
120
KJ/m2
30 100 Untreated
80 Treated
25
60
20 40
20
15 0
CaCO3 ATH Talc Silica Mica
Untreated Treated
talc talc
Figure 13: Surface hydrophobation – contact angle data for untreated and Z-6173 treated fillers.
Figure 12: Un-notched impact strength for 30 wt% T2
filled-polypropylene composite.
25
these benefits, one can expect mechanical
20
performance durability over time; indeed
15
thanks to the lower water uptake better
10
durability will be achieved and mechanical
5
properties maintained longer.
0
Reference WPC gMA-PE Vinyl-functionnal
(No coupling agent) Processing Aid
Halogen-free flame retardant
compound
3 For a variety of market segments, it is
2.5
critical to improve the flame retardant (FR)
properties of a polymer. Several technologies
Elong. at break (%)
2
are used today to improve fire retardancy,
1.5
however due to environmental and safety
1 aspects the fastest growing technology is the
0.5 use of halogen-free flame retardant (HFFR)
0
additives. Among the different HFFRs,
Reference WPC gMA-PE Vinyl-functionnal aluminium trihydrate (ATH) is by far the
(No coupling agent) Processing Aid
most used flame retardant. For example,
Figure 16: Mechanical performances of polyethylene-based WPC: effect of coupling agent. ATH is the flame retardant of choice for wire
and cable application. However the lower FR
(gMA-PE), which represents the benchmark Scanning electron microscopy with efficiency of HFFRs compared to halogenated
today. Polyethylene was extruded in a twin X-ray microanalysis (SEM/EDS) is used for FRs remains a critical limitation and higher
screw extruder with 30 wt% wood flour; recording the SEM analysis of wood particles concentrations are needed to achieve
when applicable prototype vinyl functional dispersion in plastic and the corresponding SFRVJSFE GMBNF SFUBSEBOU QFSGPSNBODF 5IJT
dispersing aid and gMA-PE were added at SEM/EDS analysis on the right-hand side to higher concentration of HFFR affects both
a level of respectively 3 wt% and 5 wt%. determine where the silicon-based coupling processability and mechanical performances
Both products were added directly into the agent is located. As shown on Figure 14 of a HFFR compound. To prevent the
extruder for in situ reaction between the filler silicon atoms from the dispersing aid are performance loss, a silane coupling agent
and the polymer. located on the surface of the wood particles, is typically used such as Dow Corning
When using our vinyl functional i.e. as expected at the interface filler/polymer. aminopropyltrimethoxysilane Z-6011.
dispersing aid prototype, peroxide additive This observation is even more remarkable The performances of the prototype,
was added to the mixture allowing a coupling knowing that the coupling agent was added amino functional dispersing aid from the
through covalent bonding between vinyl in situ in the twin screw extruder. new Dow Corning filler dispersing aid family
functionality of the dispersing aid and the Water absorption over time of various was investigated in comparison to Z-6011 in
polyethylene matrix. composites is measured by weight increase. ethylene vinyl acetate (EVA) HFFR compound.
Torque [N.m]
1.2 phr
%VSJOH QSPDFTTJOH
UPSRVF SFRVJSFE
Amino
to compound the mixture at 250 rpm was Functional
recorded and data are recorded in Figure 17. 50 Dispersing Aid
1.2 phr
This data clearly illustrates the advantage
Amino
of the new dispersing aid on the extrusion, Functional
UPSRVFCFJOHSFEVDFECZDPNQBSFEUPUIF Dispersing Aid
1.6 phr
benchmark coupling technology Z-6011. The 45
0:14:24 0:17:17 0:20:10 0:23:02 0:25:55 0:28:48 0:31:41 0:34:34
MPXFS UPSRVF MFWFM BMMPXT UIF DPNQPVOEFS Time [h:m:s]
either to reduce energy consumption for
FYUSVEJOH UIF TBNF RVBOUJUZ PS UP JODSFBTF Figure 17: Torque level during compounding.
extruder throughput.
To evaluate mechanical performances 18
16
of the various compounds, namely tensile
14
strength and elongation at break, ‘dog bone’
Fmax [MP a]
12
1.2 phr
tensile specimens were cut from sheets 10
1.6 phr
which were prepared in a platen press. 8
6
Minimum target values were 10 MPa and
4
150% for tensile strength and elongation at 2
break respectively. Results are summarised 0
Z6011 Z6173 Z6178
in Figure 18 and clearly show that Z-6173
250
filler dispersion aid does not meet the
mechanical targets for both tensile strength 200
and elongation at break. Adding amino
E [%]