Processing and Performance Additives For Plastics
Processing and Performance Additives For Plastics
References 379
O
H3C CH3
O O CH3
O H3C O
O H3C CH3
O
Dibenzoyl peroxide
tert-Butyl peroxyneodecanoate
O O
OH
O
O C O O C O
tert-Amyl hydroperoxide (formula reproduced with the
kind permission of chemBlink,
Dicyclohexyl peroxydicarbonate [Link]
OH
O
CH3
O
O 2.2�-Azobisisobutyronitrile
HO O C O OH
O
C2H5 OH
Monomer Dimer
Methyl ethyl ketone peroxide
Figure 1 Typical initiators for free radical polymerization.
Surface tension
Figure 2 Schematic representation of surface tension and wetting. Adapted from the Chem1 Virtual Textbook by Stephen Lower, Simon Fraser
University, Vancouver, [Link] with kind permission.
372 Polymer Processing: Environmentally Benign & Safe | Processing and Performance Additives
10.21.4 Additives for Polymer Processing • Fluoropolymers, such as polytetrafluoro ethylene (PTFE).
Lead soaps
Synergism of
Ca/Zn stabilization
Organo-Sn
stabilizers
Epoxidized vegetable
oil
Capturing of HCl
Figure 3 Stabilization mechanisms for PVC. Höfer, R.; Hinrichs, K. In Polymers: Opportunities and Risks II: Sustainability, Product Design and
Processing; Handbook Environmental Chemistry; Eyerer, P., Weller, M., Hübner, C., Eds.; Springer Verlag: Berlin, Heidelberg, 2010; Vol. 12; Höfer, R. In
Perspektiven nachwachsender Rohstoffe in der Chemie; Eierdanz, H., Ed.; VCH: Weinheim, 1996; p 91.1d,14c
stabilization of PVC against thermal stress is achieved by Acid scavengers may also act as co-stabilizers, as can be seen
addition of the following: in Figure 3 for the case of epoxidized vegetable oils in PVC
stabilization.
• Mixed metal salts (formerly Ba/Cd, now largely replaced
because of toxicity concerns by Ba/Zn and Ca/Zn salts of
fatty acids or phenolates, mainly used in flexible and semi
rigid PVC) [Link] Polymeric Processing Aids
• Organotin stabilizers (e.g., dibutyltin maleate or di Polymeric processing aids are particularly important to
n-alkyltin mercaptides, preferentially used for rigid PVC) solve productivity issues, to overcome problems due to
• Lead stabilizers (tribasic, dibasic, or neutral lead stearate, stick and slip conditions during extrusion, to improve the
dibasic lead phthalate; inorganic lead sulfates, carbonates, optical properties such as haze and transparency, and to
or phosphites, mainly used in wire and cable applications) avoid surface defects usually called surface melt fracture or
• Epoxidized vegetable oils (e.g., epoxidized soybean oil sharkshrink in polyolefin films. For that purpose, fluoro
polymer and so-called fluoroelastomer22 processing aids
(ESO), epoxidized linseed oil, or butyl epoxystearate).1d,19
are traditionally used in blown film extrusion of linear
Primary heat stabilizers may advantageously be used in combi low-density polyethylene (LLDPE) and HDPE, usually at
nation with organic co-stabilizers, such as β-aminocrotonates, a very low addition rate between 200 and 1500 ppm in
β-diketones, or β-ketocarboxylic esters, or inorganic weight.23 The most widely used fluoropolymer is a
co-stabilizers, such as zeolites or hydrotalcites. hexafluoropropylene-vinylidene fluoride copolymer
(Figure 4)
Being immiscible with polyolefins, fluoropolymers tend to
build up on metal die surfaces and form a slippery surface
[Link] Acid Scavengers
coating that increases the flow stability.24
Trace amounts of acidic or halogen-containing impurities may
remain in a polymer after manufacturing or processing. Such
impurities may derive from catalysts such as in the case of
polyolefins or from other additives such as flame retardants.
-(CF2-CF)n-(CH2-CF2)m
Metal soaps such as calcium stearate or calcium lactate,
hydrotalcite [Mg6Al2(CO3)(OH)16•4(H2O)] or hydrocalumite
CF3
{Ca2Al(OH)6[Cl1−x(OH)x]•3(H2O)}, and zinc oxide may be
used as acid scavengers in polyolefins.21 Figure 4 Hexafluoropropylene-vinylidene fluoride copolymer.
374 Polymer Processing: Environmentally Benign & Safe | Processing and Performance Additives
[Link] Curing Agents they also act as ODSs and their use would be temporary.27
On 1 January 2005 the US Environmental Protection
Whereas thermoplastic resins usually are fully polymerized
Administration (EPA) issued a ‘Use Ban’ regulation on
when submitted to processing, thermosetting resins are pre
HCFC-141b blowing agent. With the phaseout of HCFC, manu
pared for processing in an uncured state, and they are
facturers diverged down one of two paths – hydrofluorocarbons
irreversibly cured during the processing stage. The cure (or
(HFCs) or hydrocarbons. Those concerned about the flammabil
‘cross-linking’) may be done through heat (generally above
ity of hydrocarbons selected one of several HFC options, such as
200 °C), through irradiation, or through a chemical reaction.
hydrofluoroolefins. However, the high global warming potential
Curing initiates a change in the molecular structure or even
(GWP) of the HFCs has continued to raise questions about their
creates a new polymer (curing of a polyol with a polyisocyanate
long-term future as blowing agents, and international agreements
yielding a polyurethane (PUR)). Substances that promote or
on ODSs are the driving force for the conversion to zero
control the cross-linking reaction are called curing agents. An
ozone-depleting hydrocarbon blowing agents such as n-pentane,
agent that does not enter into the reaction is called a catalyst.
isopentane, or cyclopentane.28 Additionally, polymer foams cre
Curing agents react with molecules and are coupled directly
ated using supercritical carbon dioxide (scCO2) as a processing
into the cured system as a structural moiety of the polymer.
solvent have garnered much interest in recent years.29
Epoxy resins by curing form a three-dimensional and infu
Chemical blowing agents are solid organic or inorganic
sible network. The choice of the epoxy curing agent (ECA)
compounds that release a propellant gas, usually N2 and/or
depends on the processing method, curing conditions, physical
CO2, at a specific processing temperature. The following pro
and chemical properties desired, and toxicological and envir
duct classes are of particular importance:30
onmental limitations. The main chemistries on which ECAs are
based are polyamides and aliphatic amines (Chapter 10.28). Azo compounds
However, a variety of other curing agents containing active • Azodicarbonamide (ADC)
hydrogen atom, such as melamine-formaldehyde, urea- Hydrazine derivatives
formaldehyde, polysulfides, or mercaptans,25 have been used. • p-Toluenesulfonyl hydrazide (TSH)
Polyester resins and UP resins are usually cured by addition
• 4,4′-Oxybis(benzenesulfonyl hydrazide) (OBSH)
of peroxides, which generate free radicals and cause
Semicarbazides
cross-linking. For ambient temperature, cure reducing agents
• p-Toluenesulfonyl semicarbazide (TSSC)
such as tertiary aromatic amines or heavy metal salts of Co, Va,
or Fe are often employed as accelerators. Agents that speed up Tetrazoles
the oxidative drying process of natural drying oils in coating • 5-Phenyltetrazole (5-PT)
technology (Chapter 10.03) are called dryers or siccatives. They Nitroso compounds
are chemically identical to the accelerators for UP resins. • N,N′-Dinitrosopentamethylenetetramine (DNPT)
Carbonates
• Sodium bicarbonate.
[Link] Blowing Agents
Blowing agents are additives used in the manufacture of foamed
plastics, which have the advantage of lightness, contribute to
material and cost savings, and are distinguished by the fact that 10.21.5 Additives for Polymer Properties
they are thermally insulating. Blowing agents usually create fine and Performance
and regular cellular structures during polymer processing. Foam
[Link] Plasticizers
blowing agents encompass a wide variety of applications, includ
ing refrigerators, building insulation, automobiles, furniture, and As defined by ASTM D 883 and DIN EN 971-1, a plasticizer is
packaging. The applications encompass materials such as rigid an inert liquid or solid organic substance, predominantly an
PUR and polyisocyanurate foams and, to a lesser extent, extruded ester with low volatility incorporated into a plastic or elastomer
PS board foam and phenolic foam. Blowing agents can be divided to increase its flexibility, workability, or distensibility.31 A plas
into chemical blowing agents that liberate the blowing gas by a ticizer, among other contributions, will reduce the melt
chemical reaction or physical blowing agents, that is, a blowing viscosity, lower the temperature of a second-order glass transi
gas that is liberated by vaporization or by release of pressure. tion, or lower the elastic modulus of a polymer. This is achieved
Common practice has been to use nonflammable fully by physical interaction with the polymer loosening the strength
halogenated ‘first-generation’ chlorofluorocarbons (CFCs) such of intermolecular forces between macromolecules and result
as CFC-11, CFC-12, and CFC-113 (Class I substances26) to propel ing in a higher flexibility of the macromolecules or segments of
liquid plastic resin and function as an insulating component of the macromolecules (Figure 5). As the plasticizer molecules are
the foam. The fully halogenated CFCs, however, have been iden not chemically bound to the macromolecules, they are free to
tified as ozone-depleting substances (ODSs) and as a self-associate and associate with the polymer molecules. As
consequence the Montreal Protocol and its subsequent amend these interactions are weak, there is a dynamic exchange pro
ments to the Vienna Convention for the Protection of the Ozone cess, whereby as one plasticizer molecule becomes attached at a
Layer have led to the efficient phaseout of these CFCs and their site or center of the macromolecule, it is readily dislodged and
replacement by ‘second-generation’ blowing agents (Class II sub replaced by another. At low plasticizer level, the polymer–
stances26) such as hydrochlorofluorocarbon (HCFC)-141b that plasticizer interactions are the dominant interactions, while at
can operate within existing equipment and applications. high plasticizer concentration, plasticizer–plasticizer interac
However, because HCFCs themselves contain chlorine atoms, tion can become more significant. This can also explain the
Polymer Processing: Environmentally Benign & Safe | Processing and Performance Additives 375
O o
O C O C(O)
o o
O C(O) O C(O)
o o
O C O C(O)
O
Epoxidized soybean oil Epoxidized linseed oil
particularly of plasticizers because of their widespread propa used with PC and PBT, especially for low-temperature
gation in many articles of daily use including toys has created a impact modification.
need for all manufactures to provide products with reduced ‘ABS’ graft copolymers provide better clarity and transpar
environmental impacts, and to especially consider the carbon ency than normally available from MBS-type modifiers. Such
load on the atmosphere.1d Accordingly, ‘safer plasticizers’ with ABS impact modifiers may be prepared by graft polymerizing
better biodegradability and less biochemical effects, which styrene and acrylonitrile (SAN) as grafting monomers by emul
additionally do not contribute to greenhouse gas emissions sion polymerization in the presence of a butadiene-based or
during production or degradation are desirable. styrene/butadiene-based rubber substrate.41
Some such plasticizers are as follows: ‘AIMs’ are eventually the most broadly used class of impact
modifiers as they overcome the limitations of MBS and ABS
• Acetylated monoglycerides; these can also be used as food with regard to weather resistance, particularly in the case of
additives rigid PVC in building applications. AIMs are also used in engi
• Alkyl citrates, used in food packagings, children toys, and neering thermoplastics such as PC, PBT, and PET. AIMs are
medical products such as PVC blood containers32 typically methacrylate/butyl acrylate/styrene core-shell graft
• 1,2-Cyclohexanedicarboxylic acid diisononyl ester terpolymers. They are generally made by first preparing a rub
(i.e., hydrogenated DINP), used in food packaging, medical bery phase based on cross-linked n-butyl acrylate or n-butyl
devices, toys, and child-care articles. It is compatible with a acrylate/butadiene. The hard shell is commonly methyl metha
wide range of polymers including PVC33 crylate polymerized onto the rubbery core.42
‘EVA’ copolymer impact modifiers for PVC in practice are
• Mono- and diesters of biologically derived succinic acid34
EVA/VC graft polymers. They are prepared by suspension poly
• Isosorbide esters.35
merization of a solution of EVA in vinyl chloride monomer.
‘CPE’ impact modifiers are prepared by chlorination of
HDPE. These have commonly been used in PVC extrusion
and injection molding applications including siding and win
[Link] Impact Modifiers dow profiles.43
In general terms, impact modifiers are polymeric additives,
usually composed of a rubber or a polymer containing a rub
bery phase, built into a polymer matrix to absorb mechanical [Link] Antiblocking Agents
energy and to improve the impact resistance of finished arti The self-adhesion or sticking together of plastic films when, for
cles.36 More particularly, vinyl chloride and styrene example, opening fresh plastic garbage bags is called ‘blocking’.
homopolymers are typical examples of materials that show a Blocking is especially severe with polyolefin, polyester, and
certain propensity for brittle fracture at low temperatures or polyamide film after production and/or during prolonged sto
high deformation rates and need an impact modifier to rage. Therefore, antiblocking additives are used to minimize
improve toughness. Also wood plastic composites37 and engi the adhesion and reduce the blocking force between film layers.
neering plastics such as polycarbonate (PC), polybutylene It is anticipated that this is done by creating a microrough
terephthalate (PBT), or PC/PBT alloy primarily applied in surface, thereby reducing the contact area and self-adhesion
shaped articles for automobiles and outdoor sports equipment between film layers. Antiblocking agents are suitable inorganic
may need impact modifiers. For effective use, the impact modi filler materials such as natural silica, synthetic silica gel, talc,
fier rubber particles must be larger than a critical size for each of zeolites, or limestone as well as special organic compounds
the matrix polymers. A critical volume fraction of the rubber such as cross-linked polymethylmethacrylates.44
phase is also required in order to achieve significant improve
ments in toughness relative to that of the matrix polymer, and
adhesion between the rubber phase and the brittle matrix is [Link] Slip Additives
required. Grafting of the rubber phase with the matrix mono
mers typically leads to the required adhesion between the Slip additives are used to reduce friction between films and
rubber particles and the matrix.36,38 between film and converting equipment, which improves
Impact modifiers include39 movement through extrusion lines and downstream packaging
operations and enhances processing or end applications. Fatty
• methacrylate butadiene styrene (MBS) polymers acid amides, including primary and secondary amides, are the
• ABS copolymers most commonly used slip additives. Similar to external lubri
• all acrylic impact modifiers (AIMs) cants, they migrate or bloom to the surface where they form a
• EVA copolymers microcrystalline structure that decreases friction. Primary, unsa
• chlorinated polyethylene (CPE). turated fatty acid amides such as erucamide (Figure 7) and
oleamide migrate quickly and are the most efficient slip agents
Typically, ‘MBS’ polymers are prepared in two or more for polyolefins. Secondary amides, for example, oleyl palmita
stages where the core is about 90–50 parts of polybutadiene mide, are less volatile at the higher process temperatures with
or butadiene copolymers and the shell is about 10–50 parts very slow migration rates. They may be used in multilayer films
of a lower alkyl methacrylate, especially methyl methacry and in engineering plastics.45
late. Besides MBS, AIM and ABS impact modifiers are also Manufacture of fatty acid amide slip agents is carried out by
grafted rubber thermoplastics with core-shell structure.40 reacting a fatty acid or a fatty acid methyl ester and ammonia at
MBS impact modifiers find application in PVC and are high temperature and pressure (e.g., 240 °C and 136 atm).46
Polymer Processing: Environmentally Benign & Safe | Processing and Performance Additives 377
radical chain reaction can be initiated. UV radiation also facil Figure 8 Hindered amine light stabilizer Tinuvin® 770 (introduced 1976
itates weathering, i.e., the degradation of a polymer surface by by Ciba-Geigy).
378 Polymer Processing: Environmentally Benign & Safe | Processing and Performance Additives
Brx Bry
[Link].1 Inorganic additive flame retardants
x + y = 1–10 Br Br
‘Aluminum trihydrate’ (ATH) is often used as the sole flame
retardant. At high loading as a flame retardant and smoke (1) (2)
suppressing filler/extender; it can act synergistically with Br Br
Sb2O3, zinc borate, or phosphorus-containing flame retardants CH3
phosphate-containing composition. High efficiency of phos (b) Lindner, R. A.; Worschech, K. In Encyclopedia of PVC, 2nd ed.; Nass, L. I.;
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Perspektiven nachwachsender Rohstoffe in der Chemie; Eierdanz, H., Ed.; VCH:
be the result of stable char formation. The char affects the
Weinheim, 1996; pp 91–106.
flammability in the following three ways: reduction of flam 15. [Link]
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Biographical Sketch
Rainer Höfer graduated in Inorganic Chemistry with Professor Oskar Glemser at the Georg-August-Universität Göttingen in
1973 with work on sulfur-nitrogen-fluorine chemistry. He spent 3 years at the Technical University of Oran (ENSEP),
Algeria, as Maître de Conférences and Directeur de l’Institut de Chimie before joining Henkel in Düsseldorf. With Henkel
KGaA and then as vice president Research & Technology with Cognis GmbH in Monheim, he has assumed global research
and development, application technology, technical sales service, strategic business development, and technology scouting
responsibilities in oleochemistry, polymer chemistry, and surfactant chemistry for the polymerization, coatings, graphic
arts, adhesives, engineering plastics, agrochemical, synthetic lubricants, mining, and pulp and paper markets.
He is founder of Editorial Ecosiris with consultancy and publishing activities in the domains of green chemistry,
renewable resources, sustainable development, and interculturation.