Expancel Applications in Composites FEIPUR Sao Paulo, Brazil

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Expancel Applications in CompositesFEIPUR Sao
Paulo, Brazil

• Maf Ahmad PhD Technical Business Manager
  Expancel Americas
• November 11, 2008

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OBJECTIVE

• Overview of Plastic (Expancel) Microspheres
  Applications in Composites and Related Materials

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Composite Materials

• Engineered Materials
• Having two or more constituent materials with
  significantly different physical or chemical
  properties and which remain separate and distinct
  within the finished structure.

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Composite Materials

• Composites
• Materials that contain a reinforcement in form
  of
• Fibers or Particles, supported or glued by a
  binder.
• Example of Reinforcement Particle Spheres,
  rods, flakes.
• Laminates Bonding two or more layers of same
  or different
• materials for example plastic and fiber glass
  sheets, fabric etc.

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Binders in Composites

• Typical Binders for composites and laminates
• Polyester / Styrene
• Epoxies
• Poly olefins (Wood Plastics)
• Polyurethanes

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EXPANCEL MICROSPHERES

• Expancel Microspheres Very low density spherical
  particles
• Provide Light weight ness as well as
  reinforcement in composites
• Pre Expanded (DET) for Thermosets or where no in
  process heat applied
• Unexpanded (DU) where in process heat used eg
  baking and molding

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Expancel Microspheres
Heat

40 µm
10 µm
75 200 C
Diameter
Diameter
4 X Diameter Increase

• 1100 Kg/M³ 20 Kg/M³
• Density Change
  55 X Decrease

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SEM Unexpanded to Expanded Microspsheres
HEAT
Expancel DU (Unexpanded )
Expancel DET (Expanded)
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SEM Expancel DET
Expancel DET 40 Micron Diameter
Expancel DET 80 Micron Diameter
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Polyester Styrene Binders

• FRP Fiber Reinforced Plastics
• Culture Marble
• Putties Automotive Marine
• Sheets/Panels

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General Composition

• Polyester Resin
• Styrene
• Fillers
• Expancel Microspheres
• Catalyst/initiators/Promotors
• Fibers
• Application Spa/Tubs

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Polyester FRP Sprayable Components

• Unsaturated Polyester/Styrene (7030) 46.2
• Oil/Plasticizer 5.8
• Filler (Calcium Carbonate) 46.2
• Expancel DET 0.5
• De-Foamer/Wetting Agent 0.17
• Pigment (TiO2) 0.12
• Cobalt Promoter DMA (5050)
  0.01
• Peroxide Cadox M50A (AKzoNObel)
  1.0
• Glass Fiber Resin Ratio 4060

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Polyester Spray Up Application

• Spray up Process Mechanical Spraying Fiber
  Chopping Equipment for depositing resin glass
  reinforcement on
• Mold surface
• Or on Gel Coat over Mold Surface

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Spray Gun With Glass Chopper
Chopped Fiber
Resin Mix Spray
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SEM Cross Section Polyester Matrix With
Expancel Microspheres
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Polyester Spray - FRP

• Examples
• Showers and Tubs
• Boats
• Helmets
• Storage tanks

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Other Polyester Based Application

• Cast Sheet Panels (Transportation RV )
• Cultured or Synthetic Marble
• Putties (Boats Auto Motives)

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Synthetic Marble

• Filled Resins NO Fiber Reinforcement
• Look of natural marble
• Also called cultured marble
• Made by Casting
• Bath Room Sinks, Vanity Tops
• Bath tubs

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Cast Polyester
Cultured Marble PE Resin
100 Fillers (Ground Marble)
300 MEK
0.4 0.8 Pigments as needed Expancel (DET)
Microspheres 0.2 0.4 Plastic Microspheres
Provide durability, shock and crack resistance.
Reichold Polylite 32109
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Putties (Car Body Fillers)

• Formulation Composition
• Polyester Resin/Styrene , Carbonate Modifier
  additives
• Peroxide cured system
• Addition of 0.3 0.5 Expancel 461 DE 40 or
  Expancel 920 DE40
• Reduce Density, Shrinkage, and sand ability
  Improve Formulation cost.
• Expancel Technical Bulletin No. 2 for details.

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Epoxies

• Epoxies can be One Component or Two Component
  Systems
• Used in Composites and Laminates
• Applications Structural /Aircraft/Radar
  Detection Devices/Automotive
• Patching compounds and
  Putties
• Plastics Microspheres Addition (0.2 0.8)
  Enhance Sound damping, Thermal Insulation .
  And durability.

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SEM Cross Section Epoxy Matrix with Expancel DET
Microspheres
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Wood Plastic Composite (WPC)
Polypropylene
36 Wood Pellet
51 LLD PE

6 Coupling Agents
2 (Maleic Anhydride-PP or
Silanes) Lubricants (Calcium Stearate)
1 Plastic Microspheres
4
Expancel 950 MB 120
Processing through single or twin screw extruders
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WPC Flex Properties
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Mechanical Properties Elongation at Break
Courtesy of McMaster University, Hamilton, ON
Canada
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Mechanical Properties Stiffness Modulus
Courtesy of McMaster University, Hamilton, ON
Canada
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Polyurethanes

• PU is the most versatile family of polymers there
  is.
• Endless line of products with diverse range of
  properties through formulation.
• Widely used Flexible and Rigid Foams
• Durable Elastomers
• High Performance
  Adhesives and Sealants
• Coatings
• Gels

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Polyurethanes Typical Applications

• Sealants ( 1 Component)
• Roof Coatings (1 Component)
• Solid Tires (2 Component)
• Modeling Blocks (Europe, USA, Brazil)
• Leather Coatings (Europe, China, LA)
• Pipe Insulation (Europe)
• Shoe Soles ( LA, Europe, China)

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Modeling Compounds
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For Example roof-column supports in
refrigerated warehouse structures.
A high-density rigid cellular PU material support
heavy structural (steel) loads while insulating a
building interior from the supporting ground.
supplied to contractors in pre-cut, pre-drilled
blocks, ready for installation at the jobsite.
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PVC Synthetic Leather

• Applications
• Upholstery Garment
• Hand Bag /Luggage Material
• Automobile/Fabric
• Shoes
• ---- Upper
• ---- Linings

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Synthetic Leather Base Formulation (Plastisol)

• PHR
• PVC Resin (K Value 70 - 80) 100
• Plasticizer ( DINP or DOP) 60 - 100
• Stabilizer (Ca/Zn) 2
• Ethoxylated Soybean Oil 3
• Pigments (if desired)
• Expancel DU 3
  10

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Coatings - Synthetic Leather

• Plastisol/Expancel Paste applied as coating
• 150 300 um
• On Release Paper
• Laminated Textile, Non woven
• 0.5 to 2 mm thickness

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Synthetic Leather Preparation
SL Fabric Laminate
Fabric or Non Woven Web Or Release Paper

• Plastisol/ Expancel
• Coating

Oven 160 -180 C
SL Film
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Conclusions

• High strength high stiffness material fail
  because of the propagation of flaws through the
  matrix.
• Inclusion of fiber and/or particle light
  weight Plastic Microspheres Provide Reinforcement
  that
• Reduce or eliminate stress and strain
• Prevent related propagation of flaws and
  mechanical failures
• Provide tremendous potential advantage in
  strength to-weight or
• stiffness to weight ratios over conventional
  materials.

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• THANK YOU !

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