Hyperform HPN-20Edocuments.specialchem.com/documentsshared/shared/web...Up to 20% increased anisotropic stiffness/impact balance Higher tenacity and better draw down in nonwovens •Improved

Improving the Properties of Polyethylene through Advanced

Nucleation

April 26, 2012

Hyperform® HPN-20E

©2011 Milliken & Company

Agenda

• Milliken & Company

• Polyethylene Nucleation: The How and Why’s

• Introduction to HPN-20E

• Case Studies (By Application)

Blown Film

Extrusion Blow Molding (Drums & IBC’s)

Injection Molding (Caps & Closures)

Rigid Tubes

Nonwovens

2


Milliken & Company

• Since 1865, Milliken has sought to

Provide products that exceed customers’ expectations in

quality and value

Manufacture and conduct business with responsibility and

absolute integrity

• Milliken has evolved into a diversified innovator and

manufacturer

• Divisions:

Chemical

Floor Covering

Technical Textiles

Research

Specialty Apparel

• Our focus remains on basic principles of:

Innovation

Excellence

Integrity

3

Our Legacy of Innovation


Milliken’s extensive experience in PP nucleation

Hyperform® nucleating agents

General injection molding

HPN-68L or HPN-20E

• Pigment leveling

• Productivity improvements

• Balanced physical properties

TWIM packaging

HPN-20E

• Balanced physical properties

• Low level efficacy & Good dispersion

• High productivity

Thermoforming

HPN-600ei

• Improved

quality/output ratio

• Excellent aesthetics

• Sustainable usage of resources

ECM

HPN-20E / HPN-68L /

blends

• Tunable shrinkage

• Pigment leveling

• Productivity improvement

Pipe Extrusion

HPN-20E

• Balanced Physical properties

• Low level efficacy

• Increased throughput

We are expanding this knowledge into PE nucleation

4


Advancing the Use of Polyolefins

5

Innovation

Opening new applications and

material substitution

opportunities for polyolefins

Millad® 3905

Millad® 3940

Hyperform® HPR-803i

ClearTint®

Millad® 3988i

Hyperform® HPN-20E

Millad® NX™ 8000

Hyperform® HPN-600ei

Hyperform® HPN-68L


Agenda





Blown Film



Rigid Tubes

Nonwovens

6


Formation of a new crystal phase

PE Nucleation: The How

Cooling

Melt Primary nucleation

= Chain folding

7


Formation of a new crystal phase with a nucleator

PE Nucleation: The How

Nucleating agent crystal surface

positive

energetic

interaction

epitaxial match

of surface to polymer crystal topology

polymer chain

Onset of Crystallization

by DSC is a direct

measurement!

8


DSC: Higher Peak Tc = Productivity

Control HDPE

HPN-20E

Cooling

Temperature

Heat

Flo

w E

ndo U

p

Description Peak Tc (oC)

Control HDPE 118.5

HDPE + HPN-20E 121.4

• Increasing Peak Tc

can result in up to

25% Improvement

in Productivity.

PE Nucleation: The Why

9


Controlled crystallization allows for enhanced physical properties


100 mm

PE control film PE + HPN-20E

• Nucleation effects the crystal structure

Decreased crystal size = Better Optics

Specific crystal orientation = Improved Properties

10


Summary of Property Enhancements – Flexible Applications


• Passive Barrier improvement (25-50%)

• Optics improvement

Improved LLDPE film haze and gloss

• Potential for increased throughput

• Increased anisotropic stiffness (+5-20%)

Increase in MD modulus

Slight/No loss in tear or impact properties

11


Summary of Property Enhancements – Rigid Applications


• Passive Barrier improvement (25-50%)

• Improved contact clarity (EBM)

• Cycle time reduction/increased output

• Increased anisotropic stiffness/impact

balance (+5-20%)

Material reduction

Stronger parts in radial/round

applications

• Anisotropic shrinkage

Ideal for radial/round applications

12


Agenda





Blown Film



Rigid Tubes

Nonwovens

13


What is HPN-20E?

• HPN-20E is an organic salt

• Its typical particle

morphology is ruler shaped

which has consequences on

its performance in

polyolefins

• Nucleates both

polypropylene and

polyethylene

D50 = 2.8 microns

D97 = 9 microns

Introduction to Hyperform® HPN-20E

14


These rulers orient very strongly in the polymer melt, along the machine direction.

The degree of orientation depends on the process (favored by non-turbulent laminar flow)

MD

TD

Particle Morphology and Melt Flow Orientation

• What We Know: HPN particles are shaped like long rulers

Hyperform® HPN-20E

15


Crystalline morphology of PE nucleated with HPN

Hyperform® HPN-20E

16


Agenda





Blown Film



Rigid Tubes

Nonwovens

17


Blown Film - HDPE

Hyperform® HPN-20E

• Barrier improvements: 25-50% passive barrier improvements (WVTR, OTR,

Solvent, etc)


• Markets: meat/cheese/poultry; dry food; cereal

Up to 50% higher passive barrier improvements

Barrier

18


Blown Film - LLDPE

Hyperform® HPN-20E

Control HPN-20E

Up to 50% improvement in optics

• Optical improvements: Significant improvement C4 gas phase

• Barrier improvements: 15-35% passive barrier improvements (WVTR, OTR,

Solvent, etc)

• Markets: LLDPE/LDPE blend solutions: vegetable/fruit bags

Optics

19


EBM - Industrial drum & IBC

Hyperform® HPN-20E


Faster cycle time (>10%)

• Physical Property improvements

Potential for improved top load, burst strength and ESCR

Improved productivity and quality

Top Load

20


Crystallization Temperature

IM - Caps & Closures

Hyperform® HPN-20E

• Pigment leveling and increased productivity

• HPN out nucleates most pigments, as shown by crystallization

temperature.

Easier processing and improved productivity

21


IM - Caps & Closures

Hyperform® HPN-20E

• ‘Leveling’ effect provided by HPN results in more consistent

processing.

• Improved dimensional stability at increased productivity

31,13

31,11

31,06

31,18

31,14

31 31,2

Control at Standard Speed

31,22

31,23

31,24

31,23

31,22

31 31,1 31,2 31,3

With HPN-20E at High Speed

Colo

r

Colo

r

Closure E-Dimension Closure E-Dimension

22


Rigid Tubes

• WVTR: 60 mil industry standard = 40 mil Hyperform Nucleated solution

• 30% reduction in weight possible with 35% improvement in WVTR

Hyperform® HPN-20E

Lightweighting potential

23


Nonwovens

• Productivity and Increased Tenacity

Increases MD modulus by 25%

Maintains other physical properties

Increases Output

Decreased denier

– HDPE/HPN 20E denier = Homo PP denier

Hyperform® HPN-20E

24


0 5 10 15 20 25 30

Bicomp - 25% HDPE / 75%PP

Bicomp - 25% HDPE + HPN20E / 75% PP

Modulus - psi

Nonwovens Bicomponent Modulus

TD

MD

Hyperform® HPN-20E

• Improved drawdown over unnucleated material

• 25% Increase in MD modulus

Bicomponent Nonwoven (similar results to monocomponent)

25


Hyperform® HPN-20E can bring the following benefits to Polyethylene

• Improved Performance

25-50% improvement in passive barrier performance.

Improvements in optics (Haze, Gloss, Contact Clarity)

Up to 20% increased anisotropic stiffness/impact balance

Higher tenacity and better draw down in nonwovens

• Improved Processing

Productivity

– Potential for increased output/cycle time reductions (up 1o 15%)

Quality

– Pigment leveling

– Warpage control

In Summary

26

Any Questions?

Documents

Hyperform HPN-20Edocuments.specialchem.com/documentsshared/shared/web...Up to 20% increased anisotropic stiffness/impact balance Higher tenacity and better draw down in nonwovens •Improved