February 1, 2007 MITSUI CHEMICALS, INC. February 1, 2007 MITSUI CHEMICALS, INC. Functional Polymeric Materials Group - - Specialty Resins Div. Specialty Resins Div. Functional Polymeric Materials Group
Contents Contents ◆ Needs and expectations of polymer processing ◆ Needs and expectations of polymer processing ◆ EXCEREX ◆ TM - EXCEREX TM - the new generation processing aid the new generation processing aid ◆ Examples of various ◆ Examples of various moldings moldings ◆ Molded product properties ◆ Molded product properties ◆ Summary ◆ Summary
Contents Contents ◆ Needs and expectations of polymer processing ◆ Needs and expectations of polymer processing ◆ EXCEREX ◆ TM - EXCEREX TM - the new generation processing aid the new generation processing aid ◆ Examples of various moldings ◆ Examples of various moldings ◆ Molded product properties ◆ Molded product properties ◆ Summary ◆ Summary
Needs and expectations of polymer Needs and expectations of polymer processing processing Blown films Sheets Bottles Containers ① Increased productivity ③ Molded high quality products screw speed, cooling cycle time… mechanical strength, optical ② Decreased productivity loss properties, heat sealing, lamination… scorching, die build-up, energy loss...
Conventional processing aids Conventional processing aids Fatty Amide Fatty Amide Fatty Acid Soap Fatty Acid Soap Fluoropolymer Fluoropolymer Olefin Wax Olefin Wax F F （ （ R-COO) 2 Me R- Chemical R- R-CONH Chemical -CH 2 -CH 2 - 2 structure structure F F Me: Ca, Mg, etc. Function Function Lubricant Lubricant 1- Increased productivity 2- Decreased productivity loss Content Content < 0.5 % < 0.5 % Limitation Limitation Poor compatibility Poor compatibility Low molecular Low molecular weight ingredient weight ingredient Disadvantage Disadvantage Bleed out Bleed out Lowering mechanical and optical properties Lowering mechanical and optical properties ③ Molded high quality products
Contents Contents ◆ Needs and expectations of polymer processing ◆ Needs and expectations of polymer processing ◆ EXCEREX ◆ TM - EXCEREX TM - the new generation processing aid the new generation processing aid ◆ Examples of various molding conditions ◆ Examples of various molding conditions ◆ Molded product properties ◆ Molded product properties ◆ Summary ◆ Summary
EXCEREX TM TM - - the new generation EXCEREX the new generation processing processing aid aid “EXCEREX EXCEREX TM ” “ TM ” high performance olefin oligomer oligomer. . is a high performance olefin is a It was commercialized for the first time in the world in 2004 It was commercialized for the first time in the world in 2004 by using metallocene metallocene catalyst catalyst technology. technology. by using TM has many advantages as follows: EXCEREX TM EXCEREX has many advantages as follows: � � Productivity improvement Productivity improvement � Low process temperature � Low process temperature � Decrease in scorching and die build- -up up � Decrease in scorching and die build � � Shortening the turnover time between process changes Shortening the turnover time between process changes
Narrow Molecular Weight Distribution Narrow Molecular Weight Distribution Narrow Composition Distribution Narrow Composition Distribution Relation of composition distribution and M.W. distribution Relation of composition distribution and M.W. distribution Sharper elution temperature range means narrower composition distribution EXCEREX TM Olefin wax (Mv 4000, D 930 kg/m -3 ) (Mv 4000, D 930 kg/m -3 )
Features of EXCEREX TM TM Features of EXCEREX EXCEREX TM TM EXCEREX Nonsticky solid solid Nonsticky Olefin Oligomer Olefin Oligomer at room temperature at room temperature Mv: Under 10000 Mv: Under 10000 Pellet EXCEREX TM Powder EXCEREX TM EXCEREX TM is easy to handle
Expected Main Effects Expected Main Effects － Characteristics of an Olefin Oligomer － － － Characteristics of an Olefin Oligomer Characteristics of an olefin oligomer Olefin oligomer Low viscosity Low surface tension Low friction Functions in the extruder Internal and external lubrication Good wettability Improvement of flow quality 1- Increased productivity 2- Decreased productivity loss
Expected Effects Effects Expected － 1. Increased － － Productivity － 1. Increased Productivity Internal and external lubrication Improvement of flow quality Less torque Cylinder set at lower temp. Less pressure Higher screw speed Shortening of cooling cycle Increased Productivity
Expected Effects Expected Effects － 2. Decreased － － Productivity Loss － 2. Decreased Productivity Loss Internal and external lubrication Good wettability Improvement of flow quality Good Less torque Cylinder set Good dispersability at lower temp. dispersability with other materials with pigments Lower resin temp. Conserved Decreased scorching, Shortening of Improvement of electric power die build-up and pigment and resin pigment screen exchange grade turnover dispersion frequency
Mechanism Mechanism － Local Torque in the Barrel － － Local Torque in the Barrel － Extruder: φ 36 mm single extruder Resin: PP (MI 3 g/10 min., Density 910 kg/m 3 ) 100 phr EXCEREX TM : 2 phr Torque is lowered at feed zone and compression zone
Contents Contents ◆ Needs and expectations of polymer processing ◆ Needs and expectations of polymer processing ◆ EXCEREX ◆ TM - EXCEREX TM - the new generation processing aid the new generation processing aid ◆ Examples of various ◆ Examples of various moldings moldings ◆ Molded product properties ◆ Molded product properties ◆ Summary ◆ Summary
Examples Examples of of Extrusion Molding Extrusion Molding
Performance on PP Sheet Sheet Performance on PP － 1. Less － － Torque and Resin Pressure － 1. Less Torque and Resin Pressure Increased output is over 30% Decreased motor torque and resin pressure
Performance on PP Sheet Sheet Performance on PP － 2. Lower － － Resin Temp. － 2. Lower Resin Temp. Resin is protected from heat degradation
Performance on PP Sheet Sheet Performance on PP － 3. Lower － － Set Temp. － 3. Lower Set Temp. Lower process temp. from 230 ℃ to 210 ℃ Resin is protected from heat degradation
Examples Examples of of Blown Film Molding Blown Film Molding
Performance on HDPE Blown Film Performance on HDPE Blown Film － Less Torque and Improved Output － － Less Torque and Improved Output － Output is increased by 16% with 0.5 phr EXCEREX TM Does not affect film properties (Tensile, impact, optical, heat seal, etc.) Does not affect heat sealing and printability
Examples Examples of of Blow Molding Blow Molding
Performance on PP Blow Molding Performance on PP Blow Molding － Lower Set Temp. and Shortened Cooling Cycle － － Lower Set Temp. and Shortened Cooling Cycle － Processability is improved by 13%. (Shot number 144 → 164 pieces/hr)
Examples Examples of of Injection Molding Injection Molding
Performance on HDPE Injection Molding Performance on HDPE Injection Molding － Lower Set Temp. and Shortened Cooling Cycle － － Lower Set Temp. and Shortened Cooling Cycle － Processability is improved by 6%.
Contents Contents ◆ Needs and expectations of polymer processing ◆ Needs and expectations of polymer processing ◆ EXCEREX ◆ TM - EXCEREX TM - the new generation processing aid the new generation processing aid ◆ Examples of various ◆ Examples of various moldings moldings ◆ Molded product properties ◆ Molded product properties ◆ Summary ◆ Summary
Bleed- -out out Bleed － PP Film － － PP Film － Mono- Mono -PP PP cast film TM cast film EXCEREX TM EXCEREX Conventional Conventional No additive No additive 48070BT 3 phr phr Olefin wax 3 phr phr 48070BT 3 Olefin wax 3 （ 120 ） Aging （ days ） Aging 120 ° ° C C × × 3 3 days No change Hazing No change Hazing Does not affect bleed-out
Heat Seal Strength Heat Seal Strength PP sheet ： 650 μ m Top sheet film ： 40 μ m Top sheet film PP sheet container Does not affect heat seal strength
Mechanical Strength Mechanical Strength － PP Sheet － － PP Sheet － Sheet 0.5 mm homo- ＰＰ （ MI 0.5 g/10 min ） Resin EXCEREX TM 48070BT (Mv 4600, Density 902 kg/m 3 ) Does not affect tensile and impact strengths
Haze Haze － PP Sheet － － PP Sheet － Sheet 0.5 mm homo- ＰＰ （ MI 0.5 g/10 min ） Resin EXCEREX TM 48070BT (Mv 4600, Density 902 kg/m 3 ) Does not affect optical properties
Lamination Lamination Base material OPP Lamination layer randam- ＰＰ （Ｍ I 25 g/10 min ） EXCEREX TM 30200BT (Mv 2900, Density 913 kg/m 3 ) Does not affect lamination
TM Grades EXCEREX TM Grades EXCEREX Units 30200BT 48070BT 40800T Molecular Mv 2900 4600 4000 weight kg/m 3 Density 913 902 980 Melting ° C 102 90 128 point Viscosity mPa ･ s 265 1300 750 (140 ° C) Applied resins LLDPE, LDPE, PP HDPE These figures are representative data.
Recommend
More recommend
