New Mineral Opportunities in Polymers Mica A High Reinforcement Alternative in Polypropylene Compounds Jim Harper Applications Development Manager Imerys Performance Additives ([email protected]) 770‐361‐1952 Imerys Corporate Overview of Innovation and Development • Decentralised organization is optimum to support our customers worldwide – Divisions are responsible for innovation – Each operating own R&D resources •28research centers: 8 main research centers and 20 regional laboratories R&D Regional • Network of 300 engineers and technicians Centers laboratories Minerals for Ceramics, Refractories, Abrasives & Foundry Performance Minerals & Filtration Pigments for Paper Willebroek Materials & Monolithics (Belgium) Neuwied (Germany) Par Moor (Cornwall) Selb (Germany) (UK) Villach (Austria) Aixe-sur-Vienne (France) Limoges (France) Hódmezõvásárhely (Hungary) Colomiers (France) Roswell/Marietta Bodio (Switzerland) (USA) Zhangjiagang (China) La Guardia San José (USA) (Spain) Saint Quentin Fallavier Katni (France) Changshu, Jiangsu province Castellon (India) (China) (Spain) Toulouse (France) Kao-Shu Shiang Sandersville, Georgia (Taiwan) (USA) Sandersville, Georgia (USA) Nagpur (India) Bangkok (Thailand) Kerikeri (New Zealand) Bras Cubas, near Sao Paolo (Brazil) Portfolio of Minerals . Alumina . Graphite . Kaolin . Andalusite . Hydrous . Ball Clay . Calcined . Bentonite . Magnesite Kaolin Dolomite Ball Clay . Bauxite . Mica . Calcium Carbonate . Muscovite . Ground . Phlogopite . Precipitated . Olivine . Perlite Diatomite Vermiculite Mica . Carbon Black . Silica . Clinoptilolite . Silicon Carbide . Cordierite . Talc . Diatomaceous Earth . Vermiculite . Dolomite . Zirconia GCC Talc Perlite . Feldspar Overview • Key Mineral Characteristics of Mica • Mica’s Key Function in Plastics • Value Performance in Homopolymer Polypropylene Compounds Performance Minerals Innovation Mica –The Performance Additive Mineral Suzorite® Phlogopite Mica – It is well recognized for its reinforcing and barrier properties, as well as its chemical inertness, phlogopite mica is also used as a sound and vibration-damping additive in polymeric and asphalt based coatings for under-the-carpet automotive applications. Muscovite Mica Mined and processed in Kings Mountain, NC. It is suitable for applications requiring the reinforcement of coatings and where greater resistance to moisture, heat, light and chemicals is needed. It is a functional extender that improves crack resistance and reduced film permeability. It also promotes adhesion in both water and solvent-based formulations. Imerys North America Mica Locations Suzorite Mica Boucherville, Quebec Kings Mountain, NC Mica ‐ Phlogopite KMg3(Si3Al)O10(F,OH)2 Suzorite, Quebec Mica ‐ Muscovite 10 µm KAl2(Si3Al)O10(OH,F)2 Kings Mountain, NC Talc vs. Phlogopite (Mica) Chemistry O Si OH/F Mg Al K Talc: Mg3Si4O10(OH)2 Phlogopite: KMg3(AlSi3)O10(OH/F)2 Phlogopite vs. Muscovite (Mica) Chemistry O Si OH/F Mg Al K Trioctahydral Mica (Brown or Black) Dioctahydral Mica (White or Off White) Phlogopite: KMg3(AlSi3)O10(OH/F)2 Muscovite: KAl2(AlSi3)O10(OH/F)2 *** F substitution for OH makes higher temperature micas Inherent Properties of Mica Muscovite Phlogopite Dehydroxylation Temperature (°C) 1200-1400 1800-1900 Specific Gravity 2.8 2.7 Refractive Index 1.6 1.6 Loss at 1,000°C (%) 4.2 < 1.0 Hardness (mohs) 2.5 3.0 Very High Aspect Ratio 50-90+ 50-90+ Key Physical Characteristics . Shape - Platy (Highest Aspect Ratio Mineral) . Aspect Ratio - Number denoting the average diameter vs the thickness . Flexible -Platelets are semi-rigid, and retain flexibility across all Particle Size Distributions and grind techniques . Dispersible - Mixes easily in formulations, requires low shear to incorporate into plastics . Chemically Resistant - Impervious to all chemicals, except Hydrofluoric Acid Aspect Ratio Aspect Ratio (Shape Factor) – Number relating the diameter (d) to the thickness (t) of the platelet. d t sphere 1:1 5:1 10:1 60:1 80:1 0.5 µm 0.73 µm 1.1 µm 1.9 µm 2.5 µm Function of Mica in Plastics • Increase flexural modulus • Increase heat deflection temperature •Improves dimensional stability •Decrease coefficient of linear thermal expansion •Promote stable post‐molding isotropy •Reduce distortion/warpage Details of Study Mean Particle size, Mean Particle Size, Typical Aspect Minerals Used µm (Sedigraph) µm (Laser) Ratio 325 mesh lamellar talc 7.5 n/a 16:1 325 mesh phlogopite mica 8 25 85:1 200 mesh phlogopite mica 12 45 55:1 150 mesh phlogopite mica 34 150 90:1 The above mineral were used at 20 and 40% in a 4.3 Melt Flow, heat stabilized Polypropylene Homopolymer Samples were extruded Value Performance of Mica in Polypropylene Compounds • Flexural Modulus is greatly impacted by the aspect ratio of the particles Value Performance of Mica in Polypropylene Compounds • Mean Particle Size as measured by Sedigraph Value Performance of Mica in Polypropylene Compounds • Mean Particle Size as measured by Sedigraph Value Performance of Mica in Polypropylene Compounds Value Performance of Mica in Polypropylene Compounds • Performance improves with larger particle size Value Performance of Mica in Polypropylene Compounds •Shrinkage decreases as particle size increases Summary of Properties Phlogopite Mica • Provides optimum stiffness • Achieved through the effect of high aspect ratios •Improves thermal stability •Increasing particle size will increase heat deflection temperature • Significantly reduces shrinkage • Improves dimensional stability Conclusions •Physical properties such as Flexural Modulus, Notch Izod, HDT and Shrinkage are optimized using a 34 micron Phlogopite Mica •Performance can be closely matched to coarse talc using a 8 micron Phlogopite Mica •A balance of properties can be achieved through the use of 12 micron Phlogopite Mica Thank you for your attention! Any questions? Slide 24.