Cellular Nanocomposites: a new type of light weight...

Cellular Nanocomposites: a new type of light weight advanced materials with improved properties

Dr. Miguel Ángel Rodríguez Pérez

OUTLINE

o BACKGROUND ON CELLULAR MATERIALS

o CELLMAT TECHNOLOGIES

o CELLULAR NANOCOMPOSITES: THE CONCEPT

o PRODUCTS DEVELOPED UNDER THIS CONCEPT

o IMPROVED STRUCTURAL FOAMS: ANICELL TECHNOLOGY.o IMPROVED THERMAL INSULATORS

o SUMMARY AND CONCLUSIONS

o CONTACT

Cellular Materials (also known as FOAMS) are two phases materials in which a continuous gas phase has been dispersed in a solid phase.

CELLULAR MATERIALS: DEFINITION

Open cell cellular materials

Closed cell cellular materials

Natural Cellular Materials

Cellular structures in nauture: a) bone b) wood

Natural cellular materials:(a) cork (b) balsa(c) sponge (d) trabecular bone(e) coral (f) cuttlefish bone(g) iris leaf (h) plant stalk

CELLULAR MATERIALS ARE PRESENT IN NATURE

CELLULAR MATERIALS: ADVANTAGES

ADVANTAGES OF POLYMERIC CELLULAR MATERIALS (also known as POLYMER FOAMS)

• WEIGHT AND COST REDUCTIONS• REDUCTION OF RAW MATERIAL CONSUMPTION WITH THE SUBSEQUENT

ENVIROMENTAL BENEFITS• POSSIBILITY OF PRODUCING LIGHTWEIGHT MATERIALS WITH HIGH STRENGTH AND

STIFFNESS• EXCELLENT THERMAL INSULATION• EXCELLENT IMPACT ENERY ABSORPTION• POSIBILITY OF PRODUCING MATERIALS WITH ACOUSTIC ABSORPTION CAPABILITIES

CELLULAR POLYMERS: THE MARKET

Material Tons in 2011 Average annual gorwth rate

Polyurethane 1,50E+07 3,6Polystyrene 6,45E+06 1,2

PVC 4,18E+06 2,6Polyolefins 1,15E+06 3,8

Otther 3,24E+05 2,3

10 % of the plastic resins used nowadays are used for the production of cellular polymers (27 millions of Tons in 2011). This is around 40000 millions of Euros

Assuming an average density of 50 kg/m3 and 10 mm thick samples the surface of the material produced in one year is 54 000 km2. (1/10 THE SURFACE OF SPAIN)

OUTLINE







o CONTACT

CELLMAT TECHNOLOGIES

CELLULAR MATERIALS LABORATORY: UNIVERSITY OF VALLADOLID; SPAIN

International recognized laboratory established in 1999 in the are of cellular materials and bioplastics:

•125 scientific papers

•10 patents and several novel technologies

•12 Ph D thesis

•More than 50 research projects

•Strong collaborations with companies around the world

www.cellmat.es

Specific and novel know-how and technologies on

advanced cellular materials

•Spin-off company of the University of Valladolid. Established in October 2012:

•Transferring knowledge and technology on cellular materials and bioplastics to industrial partners.

•Advising to plastics producers in manufacturing better and cheaper materials using specific know-how.

•Producing advanced foams and/or formulations for foaming applications

Lincensestranferagreements


CellMat Technologies offers to its customers several products related with the OPTIMIZATION AND IMPLEMENTATION OF NOVEL PROCESSES AND MATERIALS.

CELLMAT PRODUCTS

o IMPLEMENTATION OF FOAMING PROCESSESo OPTIMIZATION OF CELLULAR MATERIALS: PROCESS & PRODUCTo SUBSTITUTION OF OIL-DERIVED PRODUCTS BY BIOPLASTICS o TECHNICAL CONSULTANCY IN HALOGEN FREE FLAME RETARDANCYo SPECIFIC TRAINING COURSES

o Specialized know-howo Specific working methodologyo Quikness and no intereference with

production process. o Achievable results in short term periods. o Low cost industrial trials. o Scaling up at customer’s facilities. o Specific training for the involved staff. o High degree of commitment with our

customers.

COST SAVINGS

IMPROVED PRODUCTIVITY

BETTER PERFORMANCE

ADAPTATION TO THE MARKET


o STAGES MOULDINGo OPENCELLMATo ANICELL

Based on the use of nanoparticles

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o CONTACT

CELLULAR NANOCOMPOSITES

“CELLULAR NANOCOMPOSITES”

Polymer containing nanofillers Cellular structure

� Weight reduction

� Saving of raw materials and costs

� High stiffness and specific strength

� Thermal insulation and acousticabsorption

� Tailor-made properties

MULTIFUNTIONAL ROLE OF NANOPARTICLES IN CELLULAR MATERIALS

Improving

Mechanical

performance

Improving

Thermal

stability

Improving

Flame

retardancy

Modifying

polymer

morphology

EFFECTS IN THE SOLID MATRIX

Improving

Barrier

properties

Nucleating

agents for the

cells

Modification

of Polymer

rheology

EFFECTS IN THE FOAMING BEHAVIOR


Cellular material properties

Cellular structure Properties of the material in the

cell wallsAct as nucleating

agents for the

cells

Modification

of Polymer

rheology

Modifying

polymer

morphology

Improving

Thermal

stability

Improving

Mechanical

performanceImproving

Barrier

propertiesImproving

Flame

retardancy

SINERGETICS EFFECTS SHOULD BE EXPECTED

BETTER IMPROVEMENTS IN THE PROPERTIES OF FOAMS THAN IN SOLIDS OF THE SAME COMPOSITION

BETTER PROPERTIES THAN CONVENTIONAL CELLULAR POLYMERS


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o CONTACT

Sandwich panes are currently used in several sectors to produce light weigh composites

CELLULAR CORE

SKINS

P

δ

SKINS CORE

IMPROVED STRUCTURAL FOAMS: ANICELL TECHNOLOGY

NANCORE

POLYPROPILENE BASED NANOCOMPOSITE FOAMS

Lack of homogeneity

Balsa Wood PVC foams

Low world availabilityHigh prices

Why Polypropylene (PP)?

Low Price.Wide Availability.

High stiffness and strenght.Easy processability.

However…

Poor foaming capability.

Why Nanocomposites?

Nanoscale enhance mechanical properties

Synergetic effects

However…

Lack of knowledge about the physics of foaming.


LM GlassfiberAzimut Benneti

1- A novel production processcalled““““Improved Compression Moulding””””

•One-step production method.•Common industrial equipment: Presses•Pressures between 5 and 80 bars.•Temperatures around 200ºC.•Short cycle times.

2- Formulations based on non crosslinked polymermatrix:

• Thermoplastic polymers suitables for foaming.(HMS PP, PET etc.)

• Blowing Agents. • Nanofillers.• Fire retardants.


PP without nanopartciles(less stable foam)

PP with nanoparticle s (more stable foam)


Possibility of reducing the density and improving the cellular structure by using nanofillers

Anisotropy Ratios: 2.3-2.5

IMPROVEMENT OF THE MECHANICAL PROPERTIES BY THE FILLERS

ADDITION

FILLED POLYPROPYLENE


o AniCell CC exhibits similar or even higher mechanical performance than crosslinked PVC and rigid PU foams. o AniCell OC products presents superior mechanical properties (both in compression and shear than PU based

rigid foams). ICM technology possibilities combining high degree of cell interconnection and excellent mechanical performance.


From an economical point of view, AniCell represents an

economically viable alternative to products such as PVC or PU

foams


o BUILDING AND CONSTRUCTIONo AUTOMOTIVEo RENEWABLE ENERGIESo AERONAUTICSo NAVAL INDUSTRYo TRAINSo ETC…

AniCell cores can be used in strategic sectors such as:

o Thermal insulationo Acoustic insulationo Fire protection

Filling material for blades in wind turbines

Core of sandwich structures included in the hull of yachts

Core of sandwich panels for aircraft interiors

Core of sandwich panels for train interiors, floors, doors, etc.


� LOW DENSITIES: 90-200 kg/m3

� NON-CROSSLINKED PP BASED� HIGH MECHANICAL PROPERTIES� CLOSED AND OPEN CELL VERSIONS� COST SAVINGS


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o CONTACT

Thermal insulation

*Study from BASF. Dinamic simulation (Passiv Haus Institut)

75% power consumption*

75% CO2 emissions*

One of the main applications of cellular materials is the thermal insulation (buildings, pipes, fridges...), with a high social, environmental and economic impact.

Optimal thermal insulation

Commercial buildings

Transport

Manufacturing Industry

Households (Residential)

14.7%

31.1%27.9%

26.3% Commercial buildings

Transport

Manufacturing Industry

Households (Residential)-others

Households (Residential)-climatization

14.7%

31.1%27.9%

13.15%13.15%

IMPROVED THERMAL INSULATORS

XPS (extruded polystyrene) FOAMS ARE WIDELY USED AS THERMAL INSULATORS IN BUILDING AND CONSTRUCTION

(SIX MILLIONS OF TONS IN 2011)


DUE TO RESTRICTIONS IN THE USES OF GASSES WITH GLOBAL WARNING POTENTIAL THE MAIN STRATEGY FOR IMPROVEMENT IN THIS AREA IS REDUCING CELL SIZE OF

THE FINAL FOAM: THIS REDUCES THE THERMAL CONDUCTIVITY

SPECIFIC NANOPARTICLES COULD BE VERY HELFULL FROM THIS POINT OF VIEW.


In PS FOAMS nucleating agents are used during production

Talc: Conventional nucleating agent in foamed extruded sheets

(3 microns in size)

Potential nucleation density: 1010 cells/m3

Alternative: Nanoclays with a much lower size.

Potential Nucleation density: 1013 cells/cm3

COMPARING THE STRUCTURE AND PROPERTIES OF PS FOAMS PRODUCED USING TALC AND SPECIFIC TYPE OF NANOCLAYS

Talc 1% 0.25 wt.% Clays 0.5 wt.% clays

1 wt.% clays 3 wt.% clays 5 wt.% clays


Main characteristics of samples containing different contents of clays.

Sample Cell size(µm)

Standard deviation (µm)

Cell density(cells/cm 3)

Talc 1% 73.01 27.2 1.75·108

clays 0.25 % 29.18 13.4 1.36·109

clays 0.5 % 30.35 17.3 1.30· 109

clays 1 % 30.56 14.4 1.35·109

clays 3% 18.37 6.6 1.10·1010

Clays 5% 11.46 3.9 2.56·1010


Significant reduction of cell size versus talc

△


SIGNIFICANT REDUCTION OF THERMAL CONDUCTIVITY AND STRONG INCREASE OF THE MECHANICAL PROPERTIES. BETTER PERFORMANCE AND POSSIBILITY OF DENSITY

REDUCTION (COST REDUCTION)

Clays content (%) Clays content (%)

OUTLINE






o CONTACT

SUMMARY AND CONCLUSIONS

o Cellular polymers or polymer foams are important materials in man made world. They are materials with increasing importance in all industries. They have the ability to reduce weight, and costs, improve the mechanical performance at low weight and contribute to thermal and acoustic management.

o Nanoparticles can improve significantly the properties of cellular polymers. SINERGY BETWEEN FOAMING AND NANOPARTICLES. This novel materials are very close to commercial success in several market sectors.

o Participating in European projects is challenging but an active participation can improve in a very significant extend the knowledge and skills of any company and/or research group.

OUTLINE






o CONTACT

THANK YOU VERY MUCH FOR YOUR ATTENTION.

CONTACT

CELLMAT TECHNOLOGIES S.L.CENTRO DE TRANSFERENCIAS Y

TECNOLOGÍAS APLICADAS (CTTA)PASEO DE BELÉN 9A OFICINA 105

47011, VALLADOLID

TELÉFONO:+34 983 189 [email protected]

Date post:	02-Aug-2020
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Cellular Nanocomposites: a new type of light weight...

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