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Product Commercialization One Nanostep at a Time

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Product Commercialization One Nanostep at a Time Karl Kamena Southern Clay Products FF Conference-1998 The critical pieces are now in place to broadly move the ... – PowerPoint PPT presentation

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Title: Product Commercialization One Nanostep at a Time


1
Product Commercialization One Nanostep at a Time
  • Karl Kamena
  • Southern Clay Products

2
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.

5
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

7
SOUTHERN CLAY PRODUCTS
  • A Global Leader in
  • Functional, Specialty Natural and
  • Synthetic Smectite Clays

8
SCPs Rheological Additives
Water based
Solvent based
Manufactured Silicate
Laponite
Claytone
Organically Modified Bentonites
Gelwhite
Garamite
Mined Bentonites
Mineral Colloid
Perchem
Bentolite Permont
9
SOUTHERN CLAY PRODUCTS
GONZALES, TEXAS
10
  • Rockwood Specialties November 2000 former Laporte
    PLC
  • HQ Princeton, NJ
  • 2.5 billion sales
  • Major investor Kohlberg, Kravis, Roberts Co.

11
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

12
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.

13
Nanocomposite Benefits
  • Lower Density
  • Reinforcement
  • Increased Dimensional Stability
  • Increased HDT
  • Improved Barrier Properties
  • Synergistic Flame Retardant Approach
  • Increased melt strength
  • Thermoplastic Recyclable

14
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

15
SEM of Unrefined Bentonite
16
TEM of Refined Montmorillonite M
1 micron
17
Smectite Crystal
18
Smectite Aggregate
19
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

20
Smectite Clay Chemistry
  • Smectite (dioctahedral)
  • 2-dimensional arrays of silicon-oxygen tetrahedra
    and 2-dimensional arrays of aluminum- or
    magnesium-oxygen-hydroxyl octahedra

21
Organoclay Chemistry
22
Quat Ion Exchanged Montmorillonite
23
SCP CLOISITE Products
24
C18

N
HOCH2CH2
CH2CH2OH
CH3
Methyl, Tallow, bis-2-Hydroxyethyl, Quaternary
Ammonium X
25
Cloisite 93A (90 MER)
C18

N
H
CH3
C18
Methyl, Dihydrogenatedtallow, Ternary Ammonium X
26
C18

N
CH3
CH2
CH3
Dimethyl, Hydrogenated tallow, Benzyl, Quaternary
Ammonium X
27
C18

N
CH3
CH2CH(CH2)3CH3
C2H5
CH3
Dimethyl, Hydrogenated tallow, 2-Ethylhexyl,
Quaternary Ammonium X
28
C18

N
CH3
CH3
C18
Dimethyl, Dihydrogenated tallow, Quaternary
Ammonium X
29
Nanocomposite Language
30
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.

31
Murphys Corollary 3
  • If it works in theory, it wont work in practice.
  • If it works in practice, it wont work in theory.

32
Processing Nanocomposites
Nanocomposite processing is different from
processing traditional fillers!
Criteria Choice of Organoclay How the process
is run
33
The Processing Challenge
8µm Particle gt1 Million
Platelets
34
Nanocomposite Exfoliation
The Good
The Ugly
The Bad
35
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
36
Dispersion Mechanism
Particles Shear Apart
Platelets Peel Apart
37
Dispersion Particles Shear Apart Platelets
Peel Apart
Particles Shear Apart
Platelets Peel Apart
38
XRD Examples 15A/PA6
39
TEM Examples 15A/PA6
Single Screw
Co Rotating, Low Shear
Co Rotating, Medium Shear
Tangential, Medium Shear
40
Factors to Achieve Performance
  • Intercalation (Surfactant Polymer)
  • Interfacial Adhesion or Wetting
  • Exfoliation (Dispersion and Delamination)

41
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 ---
42
Evolving Nanocomposite Products
  • Polyamides
  • Polyolefins
  • Styrenics
  • Epoxies
  • UPR
  • TPU
  • PLA
  • EVA
  • Rubbers
  • Synergistic FR additive
  • Others

43
Evolving Application Areas
  • Reinforcement
  • Thermal
  • Barrier
  • Synergistic Flame Retardant

44
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

45
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)

46
Impala side moldings
47
General Motors-Technical Challenges and Roadmap
  • Different shrinkage rate
  • Different part thickness
  • Coloring recipe revisions
  • Developed and qualified new nanocomposite to meet
    requirements

48
General Motors/Basell/SCP-Critical Issue
  • Surface defects
  • Painting problems
  • 8 micron CLOISITE nanoclay
  • 100-200 micron clay clumps
  • Causes?
  • Solutions?

49
General Motors/Basell/SCP-Critical Issue
  • Clay agglomeration caused by processing
    conditions
  • Clay feed position
  • Screw design/speed
  • Temperature
  • Pressure

50
General Motors/Basell/SCP-Critical Issue
  • Clay agglomeration resolved by processing
    conditions
  • Clay feed position
  • Screw design/speed
  • Temperature
  • Pressure

51
Murphys Corollary 4
  • New systems generate new problems

52
General Motors-more to come
  • Additional applications
  • Exterior trim, range of models
  • Announcements not news
  • Second generation nanoproducts developments

53
Commercialization Timelines
  • Wise men talk because they have something to
    say fools talk because they have to say
    something.
  • Plato (427-347 BC)

54
Others-more to come
  • Additional products
  • Additional applications
  • Some nano announcements
  • Second generation nanoproducts developments

55
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.

56
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.

57
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.

58
Commercialization Timelines
  • Nano is happening now
  • One nanostep at a time
  • Part of the polymer system
  • Cost, performance, value

59
Commercialization Strategies
  • Pay attention
  • Get started (restarted)
  • Do something nano
  • One nanostep at a time
  • Multiple nanosteps

60
Karls Corollary
  • Do it right the last time, over and over again.

61
THANK YOU
  • Karl Kamena
  • Visit us at www.nanoclay.com
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