Product Commercialization One Nanostep at a Time

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Product Commercialization One Nanostep at a Time

• Karl Kamena
• Southern Clay Products

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FF Conference-1998

• The critical pieces are now in place to broadly
  move the concept forward to commercial
  applications.

3
Murphys Corollary 1

• Nothing ever gets built on schedule or within
  budget.

4
FF Conference-2002

• Timing-wise, I believe were still a few years
  away from a robust marketyes, I do believe there
  will be a nano in your future.

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Murphys Corollary 2

• To spot the expert, pick the one who predicts
  the job will take the longest and cost the most.

6
FF Conference-2004

• Developing products and technologies from concept
  to the production floor
• Evolving nanocomposite products and applications
• Commercialization timelines

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SOUTHERN CLAY PRODUCTS

• A Global Leader in
• Functional, Specialty Natural and
• Synthetic Smectite Clays

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SCPs Rheological Additives
Water based
Solvent based
Manufactured Silicate
Laponite
Claytone
Organically Modified Bentonites
Gelwhite
Garamite
Mined Bentonites
Mineral Colloid
Perchem
Bentolite Permont
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SOUTHERN CLAY PRODUCTS
GONZALES, TEXAS
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• Rockwood Specialties November 2000 former Laporte
  PLC
• HQ Princeton, NJ
• 2.5 billion sales
• Major investor Kohlberg, Kravis, Roberts Co.

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Nanocomposites at SCP

• Began early 90s with resin suppliers
• SCP clay experts (knowledge)
• Partner with resin suppliers expertise
  (knowledge)
• Provide clays to nanocomposite technology
  developers
• Partner with other interested parties

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Nanocomposites Concept

• The incorporation of single-digit percentages of
  high surface-area nanoclays into host polymer
  systems improves the performance of the specific
  polymer matrix without significant deterioration
  of properties.

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Nanocomposite Benefits

• Lower Density
• Reinforcement
• Increased Dimensional Stability
• Increased HDT
• Improved Barrier Properties
• Synergistic Flame Retardant Approach
• Increased melt strength
• Thermoplastic Recyclable

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Clay Terminology

• Bentonite
• A rock
• A mixture of several minerals (one is smectite)
• Billions of tons worldwide
• Smectite
• Component of bentonite
• Known as a 21 layered clay
• Clays in the smectite family
• Montmorillonite (di-octahedral)
• Hectorite (tri-octahedral)
• Others

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SEM of Unrefined Bentonite
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TEM of Refined Montmorillonite M
1 micron
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Smectite Crystal
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Smectite Aggregate
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Key Properties of Montmorillonite

• Shape Platelet
• Size 1nm thick, 75-150 nm across
• Charge unit cell 0.5-0.75 charge 92 meq/100g
  clay
• Surface Area gt750 m2/g
• High Modulus 170 GPa
• Particle robust under shear, not abrasive

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Smectite Clay Chemistry

• Smectite (dioctahedral)
• 2-dimensional arrays of silicon-oxygen tetrahedra
  and 2-dimensional arrays of aluminum- or
  magnesium-oxygen-hydroxyl octahedra

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Organoclay Chemistry
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Quat Ion Exchanged Montmorillonite
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SCP CLOISITE Products
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C18

N
HOCH2CH2
CH2CH2OH
CH3
Methyl, Tallow, bis-2-Hydroxyethyl, Quaternary
Ammonium X
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Cloisite 93A (90 MER)
C18

N
H
CH3
C18
Methyl, Dihydrogenatedtallow, Ternary Ammonium X
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C18

N
CH3
CH2
CH3
Dimethyl, Hydrogenated tallow, Benzyl, Quaternary
Ammonium X
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C18

N
CH3
CH2CH(CH2)3CH3
C2H5
CH3
Dimethyl, Hydrogenated tallow, 2-Ethylhexyl,
Quaternary Ammonium X
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C18

N
CH3
CH3
C18
Dimethyl, Dihydrogenated tallow, Quaternary
Ammonium X
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Nanocomposite Language
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From concept to production

• Concepts lead to new technologies and products,
  but its all academic until you bring it to and
  through the production floor.

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Murphys Corollary 3

• If it works in theory, it wont work in practice.
• If it works in practice, it wont work in theory.

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Processing Nanocomposites
Nanocomposite processing is different from
processing traditional fillers!
Criteria Choice of Organoclay How the process
is run
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The Processing Challenge
8µm Particle gt1 Million
Platelets
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Nanocomposite Exfoliation
The Good
The Ugly
The Bad
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Dispersion Mechanisms
8 µm Particle 1MM Platelets
(1)Chemistry (2)Chemistry/Processing
(3)Processing
Tactoids/ Intercalants
Tactoids/ Intercalants
Tactoids/ Intercalants
Dispersion
Partial Dispersion
Dispersion
Tactoids/ Intercalants
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Dispersion Mechanism
Particles Shear Apart
Platelets Peel Apart
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Dispersion Particles Shear ApartPlatelets
Peel Apart
Particles Shear Apart
Platelets Peel Apart
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XRD Examples 15A/PA6
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TEM Examples 15A/PA6
Single Screw
Co Rotating, Low Shear
Co Rotating, Medium Shear
Tangential, Medium Shear
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Factors to Achieve Performance

• Intercalation (Surfactant Polymer)
• Interfacial Adhesion or Wetting
• Exfoliation (Dispersion and Delamination)

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Exfoliation in nylon and PP
Polymer/ Modulus No Clay GPa Low Exf. Improvement Medium Exf. Improvement High Exf. Improvement
PA6 (Tensile) 2.7 38 48 63
PP (Tensile) 1.26 30 48 ---
PP (Flex) 1.31 11 29 ---
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Evolving Nanocomposite Products

• Polyamides
• Polyolefins
• Styrenics
• Epoxies
• UPR
• TPU
• PLA
• EVA
• Rubbers
• Synergistic FR additive
• Others

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Evolving Application Areas

• Reinforcement
• Thermal
• Barrier
• Synergistic Flame Retardant

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Partnering Relationships-General Motors Basell

• GM Research-go nano
• TPO nanocomposites
• Ran first experiment late 97
• JDA with SCP in 98
• 1st generation technology products
• Compete with talc-filled TPO

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Partnering Relationships-General Motors Basell

• Commercial applications
• M-Van Step Assist, 08/01
• Impala side moldings, 02/04
• Hummer H2 SUT trim, panels (05/04)

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Impala side moldings
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General Motors-Technical Challenges and Roadmap

• Different shrinkage rate
• Different part thickness
• Coloring recipe revisions
• Developed and qualified new nanocomposite to meet
  requirements

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General Motors/Basell/SCP-Critical Issue

• Surface defects
• Painting problems
• 8 micron CLOISITE nanoclay
• 100-200 micron clay clumps
• Causes?
• Solutions?

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General Motors/Basell/SCP-Critical Issue

• Clay agglomeration caused by processing
  conditions
• Clay feed position
• Screw design/speed
• Temperature
• Pressure

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General Motors/Basell/SCP-Critical Issue

• Clay agglomeration resolved by processing
  conditions
• Clay feed position
• Screw design/speed
• Temperature
• Pressure

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Murphys Corollary 4

• New systems generate new problems

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General Motors-more to come

• Additional applications
• Exterior trim, range of models
• Announcements not news
• Second generation nanoproducts developments

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Commercialization Timelines

• Wise men talk because they have something to
  say fools talk because they have to say
  something.
• Plato (427-347 BC)

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Others-more to come

• Additional products
• Additional applications
• Some nano announcements
• Second generation nanoproducts developments

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SPE Plastics Engineering, May 2004

• Nanocomposites
• Microscopic Reinforcements Boost Polymer
  Performance,
• Nanocomposites Market Starts To Pick Up Steam,
• The long-awaited potential of nanocomposites is
  being realized.

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Plastic in Packaging, June 2004

• Nanocomposites a world of opportunity?
• Nanocomposite technologies are still in their
  infancythere are promising opportunities for
  nanomaterials, which have the potential to offer
  flexible and rigid packaging producers improved
  properties at lower costs.

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Modern Plastics, August 2004

• Promise of compounds containing nanoclays
  becoming reality?
• Nanocomposites have been the Next Big Thing in
  the plastics industry for several years now. What
  has been lacking in all that time is the killer
  application to prove out the hype.
• What has happened instead is a slow trickle of
  relatively modest applications.

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Commercialization Timelines

• Nano is happening now
• One nanostep at a time
• Part of the polymer system
• Cost, performance, value

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Commercialization Strategies

• Pay attention
• Get started (restarted)
• Do something nano
• One nanostep at a time
• Multiple nanosteps

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Karls Corollary

• Do it right the last time, over and over again.

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THANK YOU

• Karl Kamena
• Visit us at www.nanoclay.com