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CHAPTER 15 COMMERCIAL POLYMER BLENDS M. K. AKKAPEDDI Honeywell Inc., EAS R & T, Morristown, USA 15.1 Abstract In this chapter, an overview of the commercially important blends is presented with a particular emphasis on the rationale for their commercial development, the compatibilization principles, their key mechanical properties and their current applica- tions and markets. To facilitate the discussion, the commercial polymer blends have been classifi ed into twelve major groups depending on the type of the resin family they are based on, viz. (i) polyolefi n, (ii) styrenic, (iii) vinyl, (iv) acrylic, (v) elastomeric, (vi) polyamide, (vii) polycarbonate, (viii) poly(oxymethylene), (ix) polyphenyleneether, (x) thermoplastic polyester, (xi) specialty polymers, and (xii) thermoset blends. Within each major category, the individual polymer blends of industrial signifi cance have been described with relevant data. Since the discussion is limited only to those blends that are actually produced and used on a commercial scale, the relevant cost and performance factors that contribute to the commercial viability and success of various types of blends have been outlined. In comparing the different blends, the specifi c advantages of each type, as well as any potential overlap in performance with other type of blends have also been discussed. The fundamental advantage of polymer blends viz. their ability to combine cost-effectively the unique features of individual resins, is particularly illustrated in the discussion of crystalline/amorphous polymer blends, such as the polyamide and the polyester blends. Key to the success of many commercial blends, however, is in the selection of intrinsically complementing systems or in the development of effective compatibilization method. The use of reactive compatibilization techniques in commercial polymer blends has also been illustrated under the appropriate sections such as the polyamide blends. In many commercial blends, rubber toughening plays an important and integral part of the blend design. Combining high impact strength with other useful properties such as heat and solvent resistance can signifi cantly enhance the commercial value of a blend. Hence, the nature of the impact modifi ers used and the role of morphology on properties have been discussed under the appropriate cases of commercial blends. The chapter concludes with an outline of the potential trends in the commercial polymer development. L.A. Utracki (Ed.), Polymer Blends Handbook, 1023-1115. © 2003 Kluwer Academic Publishers. Printed in the Netherlands. 1024 M. K. Akkapeddi 15.2 Introduction 6. Blends can be formulated, optimized and com- mercialized generally at a much faster rate Polymer blends have gained signifi cant com- (from concept to commercialization) than new mercial growth in the last two decades outpacing polymers, provided there are no major techni- the growth rate of existing polymers by at least cal hurdles for the compatibility development 2 to 5%. The current worldwide market volume between the components. for polymer blends and alloys is estimated to be 7. The development of an effective compatibiliza- more than 700,000 metric ton/y, with an average tion technology, whenever needed, allows the growth rate of 6 to 7%. Although this pace of resin supplier to establish a proprietary and growth slightly slackened during the ‘90’s, the competitively advantageous position. demand for polymer blends is expected to be 8. Blends offer useful and economic means of maintained due to the possibility of adjusting upgrading recycled and off-specifi cation polymers. the cost-performance balance and tailoring the technology to make products for specifi c end-use The terms “polymer blends” and “polymer applications [Utracki, 1998]. A combination of alloys” are defi ned in Chapters 1 and 2 of this the following important factors contribute to the Handbook. In the trade literature, they have been continued commercial interest in the polymer used interchangeably. In the context of current blends: discussion, we will treat all of them simply as 1. The blending of commercially available poly- polymer blends, except specifying, where pos- mers is a more cost-effective method of devel- sible, the origin of the technological compat- oping a new product that meets the customer or ibility between the components in each type market requirements, as opposed to developing of blend. Table 15.1 lists the commercially avail- a totally new polymer what generally involves able polymer blends according to their primary prohibitively high research, development and structural categories (Figure 15.1). capital costs. 2. Polymer blends can fi ll the cost-performance 15.2.1 Compatibilization Mechanisms in gaps in the existing commercial polymers. Commercial Polymer Blends Several properties can be uniquely combined in a blend that a single resin often cannot To be useful, most commercial polymer blends provide. In some cases, synergistic improve- are either designed or selected to have some ments in properties such as toughness and heat degree of the technological compatibility between resistance are achievable. the components to resist delamination and loss 3. Polymer blending can be done at a relatively in ductility. Compatibility is defi ned here as the low cost using an extruder. Production of new ability for the polymer components to co-exist polymers, on the other hand, requires capital- either as molecularly miscible or as morphologi- intensive plants and reactors that must operate cally distinct phases, but interfacially stabilized, on a reasonably large scale for reasons of without a tendency for delamination. economics. The technological compatibility in polymer 4. The fl exibility of extruder blending enables blends can result from any of the following custom production of different blends in a wide mechanisms: range of production volumes. Polymerization 1. Thermodynamic miscibility between the com- plants are generally not as fl exible and not ponents such as in the case of polystyrene (PS) economical for small volume production. and poly(2,6-dimethyl 1,4-phenylene ether) 5. Polymer blends provide an avenue for diversi- (PPE) blends. fying and expanding the product line for resin 2. Segmental miscibility between the compo- producers and suppliers, without signifi cant nents, even when they are phase separated, investment risks. imparting a low interfacial tension and an Commercial Polymer Blends 1025 Table 15.1. Commercial polymer blends Blend Producer Trade Name Compatibilization Blend Type Mechanism(a) Polyolefi n Blends Elastomeric Polyolefi n blends PP/EPDM Monsanto Santoprene® None (b); Dynamic Crystalline/ Amorphous Novacor Sarlink 3000® Vulcanization (c) PP/NBR Advanced Elastomer Geolast® Grafting/Dynamic Crystalline/ Amorphous Systems Vulcanization PP/EPDM/NBR Japan Synthetic Rubber Dynafl ex P® Grafting/Dynamic Crystalline/ Amorphous Vulcanization PP/PBD Monsanto Vyram® None; Dynamic Crystalline/ Amorphous Novacor Sarlink 1000® Vulcanization PP/Butyl Novacor Sarlink 2000® None; Dynamic Crystalline/ Amorphous Advanced Elastomer Systems TPE-3000® Trefsin® Vulcanization Ethylene DuPont Alcryn® Partial miscibility(d) Amorphous/ Amorphous terpolymer/PVC Thermoplastic Polyolefi n blends (TPO) PP/EP or EPDM BP Performance None Crystalline/ Amorphous polymers; Bayer; D&S International; Ferro; Himont Hoechst; ISR; Mitsubishi Petrochem; Republic Polymers; A. Schulman; Teknor Apex; Tonen and others HDPE/Polyisobutylene Paxon Polymer Co. Pax-Plus 3200® None Crystalline/ Amorphous Styrenic blends ABS blends ABS/PC Monsanto Triax 2122® Partial miscibility Amorphous/ Amorphous General Electric Cycoloy EHA® Mobay Bayblend® ABS/PBT General Electric Cycovin® - - Monsanto Triax 4000® Daicel (Japan) ABS/PA Monsanto Triax 1000® Grafting(R) Amorphous/ Crystalline ABS/PVC General Electric Cycovin® Partial miscibility Amorphous/ Amorphous ABS/SMI Denka (Japan) Malecca K® Partial miscibility Amorphous/ Amorphous 1026 M. K. Akkapeddi Table 15.1. continued Blend Producer Trade Name Compatibilization Blend Type Mechanism(a) SAN blends AES (SAN/AES blend) Dow Rovel® Miscibility Amorphous/ Amorphous SAN/PVC Vista Suprel® Partial Miscibility Amorphous/ Amorphous Vinyl blends PVC/PMMA Polycast Royalite® Partial Miscibility Amorphous/ Amorphous PVC/Nitrile rubber B.F. Goodrich Hycar® Miscibility occurs with Amorphous/ Amorphous Showa Denka Denka LCS® NBR containing Polysar, etc. Krynac® >25% AN PVC/polyurethane D & S International Vythene® None Amorphous/ Amorphous Acrylic blends PMMA/PV DFRexham Fluorex® Miscibility Crystalline/ Amorphous PMMA/PVC Kleerdex Kydex® Partial miscibility Amorphous/ Amorphous PMMA/acrylic core Rohm & Haas Plexiglas® Miscibility Amorphous/ Amorphous shell elastomer CYRO Cyrex® Miscibility Elastomeric blends EPDM/PP Advanced Elastomer Systems Santoprene® Dynamic Vulcanization Amorphous/ Amorphous Novacor Sarlink® NBR/PP Advanced Elastomer Systems Geolast® Dynamic Vulcanization Amorphous/ Amorphous Novacor Sarlink® Dynamic Vulcanization Amorphous/ Amorphous Butyl rubber/PP Novacor Trefsin® Dynamic Vulcanization Amorphous/ Amorphous PBD/PP Novacor Vyram® Dynamic Vulcanization Amorphous/ Amorphous Polyamide blends PA/ABS Monsanto Triax 1000® Graft-coupling(e) Crystalline/ Amorphous PA/Acrylic rubber DuPont Zytel FN® Grafting/controlled Crystalline/ Amorphous crosslinking PA/Elastomer DuPont Zytel ST® Graft-coupling Crystalline/ Amorphous Zytel Z408® Polar interactions(f) AlliedSignal Capron® 8350, 8351 EMS-American A28®, BT40X® Grilon PA/ Polypropylene
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