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3 Additives

Practically all thermoplastic resins contain essen- by measuring changes upon exposure to elevated
tial stabilizers that are added during or immediately temperatures in heat aging ovens below the melting
after polymerization to prevent their degradation point of the polymer. Accelerated aging tests at
during monomer recovery, drying, and compounding, temperatures much higher than service temperatures
and in some cases even during storage. The types and yield rapid results, but these are generally not very
amounts vary depending on the type of the polymer. significant in actual practice. Ideally, oven-aging
Other additives may be added during different stages tests should be carried out as close to the use
of the processing and provide specific characteristics temperature as practical [5].
of the material during processing and/or application. In general, antioxidants inhibit the oxidation reac-
The following sections will briefly describe the tion by combining with free radicals or by reacting
most common additives used in the majority of with hydroperoxides. Primary antioxidants, such as
thermoplastics. The actual number of such additives hindered phenolics and secondary aromatic amines,
is very large, and more detailed coverage of this are radical scavengers. The most common simple
subject can be found in several publications [1e3]. hindered phenolic antioxidant is butylated hydroxy-
toluene (BHT) or 2,6-di-t-butyl-4-methylphenol [6].
Higher-molecular-weight-hindered phenolic antioxi-
dants are less volatile and are used when high pro-
3.1 Antioxidants
cessing temperatures are necessary or for high
Many organic materials, including polymers, temperature applications. The advantage of hindered
undergo reactions with oxygen. When polymers phenolic antioxidants is that they do not discolor
oxidize, they lose mechanical properties, such as easily. Moreover, certain high-molecular-weight
tensile strength, may become rough or cracked on the phenolic antioxidants are FDA approved [7].
surface, or discolor. These typical manifestations of Secondary aromatic amines are superior to phenolics
oxidation are referred to as aging and the effects of for high-temperature applications, but they discolor
oxidation on the chemical structure of the polymers easily and are therefore used only in combination with
as degradation [4]. Aging and degradation can be pigments or carbon blacks. In such combination the
inhibited or retarded by chemical substances called discoloration is masked. These antioxidants are not
antioxidants. approved for food-contact use [7].
Most antioxidants are used in polyolefins and Secondary antioxidants, also called peroxide
styrenics and impact-modified styrenics, and to decomposers [7], inhibit the oxidation of polymers
a somewhat lesser degree in polycarbonates, poly- by decomposing hydroperoxides. Phosphites and
esters, polyamides, and polyacetals. The type and thioesters are the most common secondary antioxi-
amount of antioxidant used depends on the type of dant. Phosphites are the most widely used secondary
resin and application; typical levels range 0.05e1% antioxidants. They are nondiscoloring and FDA
by weight on the weight of the polymer [4]. approved for many indirect food applications [7].
The effectiveness of antioxidants under process- Secondary antioxidants are usually combined with
ing conditions has to be assessed on the polymeric primary antioxidants for a synergistic effect.
melt. The usual procedure consists of multiple
extrusions or prolonged residence times in a hot
cylinder or in the injection molding machine. The 3.2 Light Stabilizers
properties evaluated are changes in melt flow index
and possibly yellowing. The assessment of the In general, polymers deteriorate in the presence of
effectiveness under conditions of actual use is done sunlight; the result is cracking, embrittlement,

Handbook of Thermoplastic Elastomers. http://dx.doi.org/10.1016/B978-0-323-22136-8.00003-X


Copyright 2014 Elsevier Inc. All rights reserved. 17
18 H ANDBOOK OF T HERMOPLASTIC E LASTOMERS

chalking, discoloration, and loss of mechanical scavengers, although they may also work as
properties, such as tensile strength, elongation, and quenchers and peroxide decomposers.
impact strength. Photodegradation occurs as a result HALS are available in a wide variety of molecular
of exposure to ultraviolet light at wavelengths weights. They display a low volatility and good
290e400 nm. Different wavelengths may produce stability at high temperatures. They can provide
different types of degradation, depending on the surface protection and be used alone or in combina-
polymer [8]. Specialty chemicals, called light stabi- tion with UV absorbers or quenchers. Use levels
lizers or UV stabilizers, are used to interfere with the depend on the substrate thickness, pigmentation, and
physical and chemical processes of light-induced application requirements; levels generally range from
polymer degradation. Stabilization of the polymer 0.1% to 1.5% [12e14].
can occur by the use of additives that absorb UV
radiation, preventing its absorption by the molecules
of the polymers, by free radical scavengers, by the
3.2.4 Evaluation of UV Stability
additives that decompose peroxides, or by quenchers The most accurate test of UV stability is the use of
that accept energy from the chromophore and convert the material in its intended end-use environment over
it to heat [9]. a period of time. Because outdoor testing takes a very
long time, accelerated testing using artificial light
3.2.1 UV Absorbers sources (xenon arc lamp, sunshine carbon lamp,
mercury arc lamp) is common. Filtered xenon most
UV absorbers act as optical filters; they absorb accurately reproduces the spectral energy distribution
ultraviolet light and release the excess energy as heat. of sunlight, while light sources with significant
The most widely used UV absorbers are 2-hydroxy- emission below 290 nm can produce different results
benzophenones, 2-hydroxyphenylbenzotriazoles, than those obtained in long-term outdoor weathering.
organic nickel compounds, and sterically hindered Accelerated tests may underestimate the effective-
amine light stabilizers (HALS). Other additives, such ness of HALS due to very high levels of UV radiation
as carbon blacks and certain pigments (e.g., titanium produced [14]. New types of artificial weathering
dioxide, zinc oxide), may be used as UV absorbers in devices have been developed in the past few decades,
certain applications where the color or loss of including those combining high UV intensity from
transparency does not matter [10]. fluorescent lamps with water condensation on the test
samples (such as QUV, UVCON) [15].
3.2.2 Quenchers
Quenchers are molecules that accept the energy
from an excited-state chromophore. The chromo- 3.3 Nucleating Agents
phore, after transferring its energy, reverts to its
ground state, a stable energy state. The quencher Polymers crystallize from a melt under the
dissipates the energy as heat, fluorescence, or phos- following conditions [16]:
phorescence, i.e., methods that do not result in the
degradation of the polymer. Most widely used  The molecular structure of the polymer must be
quenchers are organic nickel complexes, such as 2,20 - regular enough to allow crystalline ordering.
thiobis(4-octylphenolato)-n-butylamine nickel (II),  The crystallization temperature must be below
nickel salts of thiocarbamate, and nickel complexes the melting temperature, but not close to the
with alkylated phenol phosphonates [11]. Quenchers glass transition temperature of the polymer.
are often used in combination with UV absorbers.  Nucleation must occur prior to crystallization.
 The crystallization rate has to be sufficiently
3.2.3 Free Radical Scavengers high.
Free radical scavengers are similar to the
secondary antioxidants used to inhibit the thermal Because of chain connectivity, polymers crystal-
oxidation. They react with free radicals in the plastic lize in such a way that only a limited crystallinity is
material, reducing them to stable, unreactive prod- obtained. Polymers are, therefore, often referred to as
ucts. HALS function mainly as free radical semicrystalline materials. This chain connectivity is
3: A DDITIVES 19

also the main reason why polymers crystallize at The usual amounts of nucleating agents used in
significantly lower temperatures than they melt. thermoplastics are up to 0.5%; higher amounts
When polymers crystallize from the melt, the usually do not produce further enhancement. They
polymer crystals (lamellae) organize from a primary are incorporated as powder/powder mixtures, as
nucleus and form complex spherical macrostructures suspensions or solutions, or in the form of a master-
called spherulites. The spherulites contain lamellae batch. Regardless which method is used, a good
as well as amorphous regions between the lamellae. predispersion of the nucleating agent is necessary for
The spherulites continue to grow into the melt until an optimum effect [19].
their growth fronts impinge on the growth fronts of
neighboring spherulites.
The onset of phase transformation is indicated by 3.4 Flame Retardants
the appearance of very small particles of the new
phase. Eventually primary nucleation will occur and Many thermoplastics, particularly those with high
the crystal growth will follow [17]. The rate of carbon content, are inherently flammable due to their
nucleation is strongly dependent on temperature. petrochemical origin. Polyolefins ignite when in
The number and size of spherulites formed are contact with a flame and burn with a faintly luminous
determined by whether the nucleus formation is flame even after the ignition source is removed.
homogeneous or heterogeneous. The formation of Melting occurs due to the high temperature of the
nuclei is greatly enhanced by the addition of foreign flame, producing burning drips. Thermoplastics
substancesdthe nucleating agents. Since very many containing halogens tend not to burn easily; some of
more nuclei are formed in the presence of a nucle- them do not burn at all, the main factor being the
ating agent, under the same cooling conditions the content of the halogen.
resulting spherulites will be considerably smaller Additives used to retard or stop burning are
than in a material to which no nucleating agents have referred to as flame retardants. Flame retardants
been added. Nucleated polymers therefore have finer generally impart their properties to polymers in the
grain structure than unnucleated ones, and this is condensed or the gas phase. In the condensed phase,
reflected in their physical and mechanical properties; the additive can remove thermal energy from the
thus plastics with coarse spherulites are more brittle substrate by functioning as a heat sink or by
and less transparent or translucent than ones with the participating in char formation to form a barrier heat
same crystalline fraction but a fine-spherulitic and mass transfer. The additive can also provide
structure. flame retardancy by conduction, evaporation, or
Nucleation increases the crystallization tempera- mass dilution, or by participating in endothermic
ture and the rate of crystallization; as a result, parts reaction.
can be removed from the mold at higher tempera- Char forming systems, also called intumescent
tures, and molding cycle times are reduced. Nucle- systems, form a foamy porous protective barrier on
ated materials have higher tensile strength, stiffness, the polymeric material to shield it from further
flexural moduli, and heat deflection temperatures, pyrolysis and combustion. Most intumescent systems
but impact strength is generally lower. Clarity is require an acid source (catalyst), a char-forming
enhanced by increased cooling rate and reduced compound (carbonific), and a gas-evolving
spherulite size, which reduces the scattering of light compound (spumific). In a typical system, phos-
as it passes through the material [18]. phorus compound promotes the charring of
Nucleating agents can be roughly classified as a substrate (typically a carbon-oxygen compound or
follows [19]: oxygen-containing polymer) and this char is foamed
by gases released during the decomposition of
 Inorganic additives, such as talc, silica, and clay a nitrogen compound. The acid is typically a phos-
phoric acid or a suitable derivative, such as ammo-
 Organic compounds, such as salts of mono- or nium polyphosphate. Typical carbonifics include
polycarboxylic acids (e.g., sodium benzoate), pentaterythritol and other polyols. Common spu-
and certain pigments mifics include urea, melamine, and dicyandiamide.
 Polymers, such as ethylene/acrylic ester Commercial intumescent systems containing cata-
copolymers lyst, carbonific, and spumific are available [20].
20 H ANDBOOK OF T HERMOPLASTIC E LASTOMERS

Other flame retardants act in the condensed phase, and health risks of brominated diphenyl ethers, which
not by forming an intumescent layer but by depos- can, under some conditions, form brominated dioxins
iting a surface coating that insulates the polymer and furans.
from the heat source and retards the evolution of Recent research efforts in the field of nano-
additional fuel. Some silicone flame retardants are composites have yielded flame retardant additives
thought to deposit silicon dioxide (sand) on the that are effective and environmentally friendly.
polymer surface [21]. Intercalated polymer-clay nanocomposites have
The most widely used flame retardant, alumina been used in several polymers and were found to
trihydrate (ATH), functions in the condensed have lower peak heat-release rates than pure
phase, not as a char former or protective-layer polymers [24]. The advantage of such systems is
former but as a heat sink and a source of that only small loadings (3e6%) impart flame
a noncombustible gas (H2O) for fuel dilution. ATH retardancy without affecting physical properties of
starts to decompose at 230  C and eventually loses the resin used [25]. Another approach is the use of
34.5% of its mass as water vapor. Magnesium bishydroxydeoxybenzoin (BHDB) monomer that
hydroxide decomposes at 340  C and loses 31% yields polymers with char yield as high as 70%.
mass. Both ATH and magnesium hydroxide This monomer releases water vapor rather than
decompose endothermically and remove heat from hazardous gases [26].
the condensed phase, which decreases the rate of
polymer decomposition. Substantial quantities of
these additives are needed to impart flame retard-
3.4.1 Flammability Tests
ancy to a combustible polymer. For example, Flammability tests have been developed to
a resin formulation containing 40e60% by weight measure the burning parameters, such as burning
of ATH is typical. time, dripping, smoke emission, and flame spread, of
Flame retardants acting in the gas phase inter- a material under specific conditions, in order to
rupt the combustion chemistry of the fire. During predict its performance in an actual fire. Many
combustion, polymer fragments interact with applications require specific performance levels in
oxygen and other highly reactive species in a chain particular tests.
reaction to form oxygen radicals, hydroxyl radi- The most common test is the Underwriters Labo-
cals, and hydrogen radicals. Certain additives, ratory UL-94. In this test, the specimen is suspended
mainly those containing halogens or phosphorus, vertically over a Bunsen burner and surgical cotton.
can chemically interact with these radicals to form The specimen is ignited for 10 s with a defined gas
less energetic species and interrupt the chain flame from below. If the specimen extinguishes after
propagation necessary for fire initiation or contin- the removal of the ignition flame, it is ignited once
uation [22]. A typical example of such flame more for 10 s. The results are classified in the
retardant systems is antimony trioxide, which is following way:
effective in halogenated polymer systems. Some
phosphorus flame retardants can also be effective 3.4.1.1 V-0 Rating
in the gas phase. Zinc borate has been used as
a partial or complete replacement for antimony  Afterflame time <10 s
oxide mostly in olefins. Zinc borate is less  Sum of afterflames (10 flame applications)
expensive than antimony oxide and also functions 50 s
as a smoke suppressant, afterglow suppressant, and  No burning drips ignite the cotton
antiarcing agent [23].
 Specimens do not burn completely to the clamp
Organic compounds containing halogens (chlorine
or bromine) function in the gas phase of the  Afterglow after removal of ignition 30 s
combustion reaction by scavenging free radicals
formed during combustion. Antimony trioxide is 3.4.1.2 V-1 Rating
generally added to halogenated flame retardants for
synergistic effect [23].  Afterflame time <30 s
Brominated flame retardants are subjected to  Sum of afterflames (10 flame applications)
increasing restrictions due to possible environmental 250 s
3: A DDITIVES 21

 No burning drips ignite the cotton 3.5.1 Optical Properties


 Specimens do not burn completely to the of Colorants
clamp
Pigment and dyes produce color in a resin from
 Afterglow after removal of ignition 60 s selective absorption of visible light with wavelengths
ranging from w380 nm (violet) to 760 nm (red). The
perceived color is the color of the light transmitted
3.4.1.3 V-2 Rating through the colorant and not the light that was
absorbed. Complementary colors are red-green, blue-
 Afterflame time <30 s
orange, and violet-yellow. The human eye can detect
 Sum of afterflames (10 flame applications) color differences of about 1 nm in wavelength.
250 s Absorption of all wavelengths will produce a black
 Ignition of cotton by burning drips color; no absorption will appear colorless [29].
 Specimens do not burn completely to the clamp Because dyes are in solution, color is produced
only from light absorption, and the material is
 Afterglow after removal of ignition 60 s transparent. A dispersion of pigment particles in
a resin can also reflect or scatter light. If the refractive
Limiting oxygen index (LOI) test is based on index of the pigment particle is different from that of
determining the minimum concentration of oxygen spherulites in the polymer microstructure, light will
necessary for candle-like burning of 3 min. be reflected, and the particle dispersion will scatter
Numerical data are obtained, and the LOI is light in all directions. Light reflection and scattering
generally directly proportional to the concentration produces opacity in an originally transparent resin.
of the flame retardants. A higher LOI indicates that Resins can be colored and opaque if light is absorbed
more oxygen is needed to support combustion. only at particular wavelengths, or white and opaque
Air contains w21% oxygen, so a rating lower than if all light is reflected (no absorption). The color
this will usually support combustion under normal shade is affected by the particle size of the pigment.
atmospheric conditions [27]. The LOI method Ultramarine blue pigments are nonreflective due to
has been standardized by American Society for a refractive index similar to that of the plastic [30].
Testing Materials as ASTM D2863 and by Inter-
national Organization for Standardization as ISO
4589-2 [28].
In Europe, the German DIN 4102, the British BS 3.5.2 Characteristics of Colorants
476 Part 7, and the French NF P 92-501 are used to
Pigments must be adequately dispersed in the
test building materials and to assign flammability
polymer for optimum scattering; specks and uneven
ratings [28].
coloration can result from incomplete dispersion. If
agglomerates are present they may adversely affect
3.5 Colorants mechanical properties of the resulting product,
mainly tensile strength, impact strength, and flex
Colorants used in plastics are pigments or dyes. fatigue.
Dyes are organic compounds that are soluble in Pigments should be compatible with the polymer;
the plastic, forming a molecular solution. They poor compatibility may be a cause of part failure.
produce bright, intense colors and are transparent Some pigments may be partially soluble in the resin
and easy to disperse and process. Pigments are and may migrate through the polymer to the surface,
generally insoluble in the plastic; color results from where they rub off. Pigments must be also compatible
the dispersion of fine particles (w0.01e0.1 mm) with any other additives present in the formulation.
throughout the resin. They produce opacity or High temperature during processing can damage
translucence in the final product. Pigments can be or destroy the pigment, causing changes in shade or
inorganic or organic compounds, and they can be loss of color. Thermal sensitivity is related to both
available in a variety of forms, such as dry temperature and duration of exposuredlong cycles
powders, color concentrates, liquids, and precol- in injection molding and rotational molding can have
ored resins. a more adverse effect than high-speed extrusion.
22 H ANDBOOK OF T HERMOPLASTIC E LASTOMERS

Some pigments can act as nucleating agents, 3.5.4 Organic Pigments


altering the mechanical properties and improving the
clarity of the resin [31]. Organic pigments are usually brighter, stronger,
and more transparent than inorganic pigments but are
not as light resistant. They may be partially soluble in
many thermoplastics, with a much greater tendency
3.5.3 Inorganic Pigments to migrate.
The most common inorganic pigments include Azo pigments are the largest group of organic
oxides, sulfides, hydroxides, chromates, and other pigments; they contain one or more azo (eN]Ne)
complexes based on metals such as cadmium, zinc, chromophoric groups and form yellow, orange, and
titanium, lead, and molybdenum. They are generally red pigments. Monoazo pigments, i.e., with only one
more thermally stable than organic pigments and are chromophore, exhibit low thermal and light stability
more opaque and resistant to migration, chemicals, and have a tendency to bleed; they are not usually
and fading. They can cause wear on processing used in plastics. Polyazo fillers, with more than one
equipment, such as extrusion machine screws and chromophore, do not tend to bleed, and have better
barrels. The use of compounds of heavy metals (e.g., thermal stability and excellent chemical stability.
cadmium) has been restricted due to toxicity issues. Nonazo pigments have varied structures, usually
White pigments: titanium oxide (rutile) is the most polycyclic and sometimes complexed with metals.
widely used white pigment. It is used either alone or Phthalocyanine blues and greens, most of which are
in combination with other colorants to control complexed with copper, are highly stable to light,
opacity and produce pastel shades. Other white heat, and chemicals, and form highly transparent,
pigments are zinc oxide, zinc sulfide, and lead intense colors with high tinting strength. Other
carbonate (lead white). organic pigments are quinacridones (red, violet,
Black pigments: carbon black, which is essentially orange), dioxazines (violet), isoindolines (yellow,
pure carbon, is by far the most widely used black orange, red), and perylenes, flavanthrones, and
pigment. When combined with white pigments, it anthraquinones [32].
produces different shades of gray, depending on the
particle size and tinting strength of the carbon black 3.5.5 Special Effect Pigments
grade. Iron oxide, Fe3O4, is another black pigment,
Some colorants produce special effects in plastics,
which has lower thermal stability and tinting
such as pearlescence or phosphorescence. The
strength.
pigment must be well dispersed in the resin and must
Other colored pigments: a variety of inorganic
be carefully handled during processing. Pearlescent
compounds are used for coloring thermoplastics.
pigments produce pearly lusters and iridescencedthe
Following are the most common ones:
resin has a soft, silky, and/or multicolor appearance.
Luster is produced by reflection of light by thin
 Yellow pigments: Chrome yellow; nickel-,
(<1 mm) platelets oriented in parallel layers. Pearl-
chrome-titanium yellow; iron oxides; lead
escent pigments include titanium dioxide-coated
chromates
mica (muscovite), ferric oxide-coated mica, and
 Orange pigments: Molybdate orange and bismuth oxychloride.
cadmium orange Metallic flakes are used to produce silvery lusters
 Brown pigments: Iron oxide or combination of or gold bronze effects. Aluminum, copper, and alloys
chrome/iron oxides of copper and zinc (bronze) are commonly used.
 Red pigments: Iron oxide; cadmium sulfide/ Aluminum can be processed up to 310e340  C
selenide (600e650  F) with loadings in the range 0.5e4%.
Copper is susceptible to oxidation starting at
 Blue pigments: Ultramarine (aluminosilicate w120  C (250  F) and can tarnish, depending on
with sodium ion and ionic sulfur groups); mixed temperature and duration of exposure. Slow discol-
metal oxides, based primarily on cobalt oration occurs in outdoor applications [33,34].
aluminate Fluorescent pigments appear to glow in daylight;
 Green pigment: Chrome oxide; cobalt-based they absorb visible and ultraviolet light, and then
mixed oxides emit the light in longer wavelengths. A glow appears
3: A DDITIVES 23

when this light combines with the reflected color of Table 3.1 Classification of Surface Resistivity
the plastic. Phosphorescent pigments also emit light
at longer wavelengths than when it was absorbed, but Surface Resistivity
(ohms/sq) Classification
the yellow-green glow appears only in darkness.
Phosphorescence is produced by the addition of 10 5
Conductive
doped zinc sulfide [35]. >10 to 10
5 9
Static dissipative
>10 to 10
9 14
Antistatic
3.5.6 Colorant Forms
>10 14
Insulative
Colorant forms include dry color, color or pellet Ref. [35].
concentrates, liquid color, and precolored resins.
A precolored resin contains the colorant already
dispersed in the polymer; all other forms require that can produce shocks or fires, and damage to
dispersion by the resin processor. electronic components.
Dry colorants are powders composed of one or Static electricity or an electrostatic charge is
more pigments or dyes. They are supplied in pre- a deficiency or excess of electrons, which occurs on
weighed packets and must be compounded and ungrounded or insulated surfaces. It is produced by
dispersed into the resin. Dry colorants are the most triboelectric charges, that is, charges generated by
economical form, provide the largest selection of friction between two surfaces, such as movement of
colors, and use a minimum of warehousing space. paper through a copier or printer. The ability of
Their disadvantage is their tendency to dust and to material to discharge static electricity is classified
cross-contaminate. according to its surface resistivity, the ratio of direct
Color concentrates are colorants dispersed in current (DC) voltage to current passing across
a resin carrier that is formulated for use in a particular a square unit of area, in ohms/sq (see Table 3.1).
polymer family. Color concentrates can contain Surface resistivity is independent of the size of the
10e80% colorant, depending on the application square or its units.
requirements, the pigment used, and the compound- A material with useful antistatic properties has
ing equipment. Color concentrates are the most a surface resistivity between 109 and 1012 ohms/sq.
common form of in-house coloring. They are most Static decay rate of insulating polymers measures the
frequently supplied in pellets for easy flowing and ability of grounded material to dissipate a charge
metering. induced on its surface. The decay rate of an insulated
Liquid colorants are composed of a pigment in material is much slower than that of a material treated
a nonvolatile liquid carrier. Liquid carriers include by dissipative materials.
mineral oils and complex fatty acid derivatives and
can contain surfactants for improved dispersion and 3.6.1 Types of Antistatic Agents
cleanup. The viscosities range from maple syrup to
gel-like consistencies, and good dispersion can Antistatic agents, commonly called antistats, can
frequently be obtained with high pigment loading be ionic or nonionic. Ionic antistats include cationic
(10e80%). The carrier can affect polymer properties compounds, such as quaternary ammonium, phos-
and its processing behavior. phonium, or sulfonium salts, and anionic compounds,
See Refs [1e3] for a comprehensive treatment of usually sodium salts of sulfonates, phosphates, and
the subject of coloring additives, their types, their carboxylic acids. Nonionic antistatic agents include
chemistry, and technology. esters, such as glycerol esters of fatty acids, and
ethoxylated tertiary amines. Antistats are used
usually at levels from 0.5% to <1%; loading levels
3.6 Antistatic Agents depend mainly on the resin processing temperatures,
the presence of other additives, and application
In general, thermoplastics are good insulators; requirements, such as clarity, printability, and FDA
because of that, they do not conduct electricity, and compliance [36].
an electric charge can build up on the surface of In general terms, antistatic agents can be divided
a part, leading to problems with dust accumulation, according to the method of application into internal
static cling in films and fabrics, electric discharge and external agents [37].
24 H ANDBOOK OF T HERMOPLASTIC E LASTOMERS

Internal antistats are incorporated into the poly- static electricity. They can be applied internally or
mer mass as surfactant additives, either before or externally. When incorporated internally, they must
during processing (e.g., molding). They have limited be partially incompatible with the polymer so that
compatibility with the polymer and continuously they can exude to the surface. Antiblocking agents
migrate to the part surface. An antistat must exhibit include natural and manufacturing waxes, metallic
the proper amount of compatibility with the given salts of fatty acids, silica compounds, or polymers,
polymer for a controlled migration to the surface. such as polyvinyl alcohol, polyamides, polyethylene,
External antistats are applied directly to the polysiloxanes, and fluoroplastics [38].
surface of the finished article from an aqueous and/or
alcohol solution (concentration typically 1e2%) as
a spray or a dip. Internal and external antistatic 3.9 Processing Aids
agents can function as lubricants and mold-release
Processing aids is a general term that refers to
agents [37,38].
several different classes of materials used to
improve the processability and handling of high-
3.6.2 Electrically Conductive molecular-weight polymers. The benefits are real-
Materials ized mainly in the melt stage of the host polymer
Static electricity can be dissipated by addition of [40]. Two main groups of processing aids are
conductive fillers, such as special conductive grades lubricants and fluoropolymer-based additives. Each
of carbon black or graphite. In such a case, electrons has a distinct effect on the polymer melt, and they
are then conducted through the polymer, and resis- are used in different ways.
tivity values less than 108 ohms/sq [39] and often as Lubricants are used in polymer processing to
low as 102e103 ohms/sq [38] are obtained with high lower melt viscosity or to prevent polymers from
loadings of conductive carbon black or graphite. sticking to metal surfaces. Internal lubricants act
Other conductive materials used less frequently are intermolecularly, making it easier for polymer
various metals (silver, copper, aluminum, iron, brass, chains to slip past one another. Lowering viscosity
steel fibers), and metal-coated particles (mica, glass improves polymer flow. Materials used for lubri-
flakes, glass beads). cants include metal soaps, hydrocarbon waxes,
polyethylenes, amide waxes, fatty acids, fatty
alcohols, and esters [38].
3.7 Slip Agents Fluoropolymer-based processing aids are mostly
copolymers of vinylidene fluoride and hexa-
Slip agents are used in plastic films and sheets to fluoropropylene. This material is commonly referred
provide surface lubrication during and immediately to as fluoroelastomer, even though it is not cross-
after processing. They have limited compatibility linked when used as a processing aid and thus has no
with the polymer and exude to the surface, providing elastomeric properties [41]. The most pronounced
a coating that reduces the coefficient of friction. Slip effect of fluoropolymer processing aids is the elimi-
agents reduce sticking of the plastic to itself by nation of the melt fracture during polymer extrusion.
minimizing tack and facilitate processing on high-
speed packaging equipment. They also can improve
antistatic properties, lower plasticity, and act as mold 3.10 Fillers and Reinforcements
release agents [38].
Slip agents are usually modified fatty acid esters, Fillers are relatively inexpensive, solid substances
used in concentrations of one to three parts per that are added in fairly large volumes to polymers to
hundred parts of polymer (phr) of fatty acid amines, adjust volume, weight, cost, surface, color, process-
especially erucamide and oleamide [38]. ing behavior (rheology), shrinkage, expansion coef-
ficient, conductivity, permeability, and mechanical
properties. They can be roughly divided into inactive
3.8 Antiblocking Agents or extender fillers and active or functional or rein-
forcing fillers.
Antiblocking agents prevent plastics films from Inactive fillers are used mainly to reduce costs,
sticking together due to cold flow or a buildup of while active fillers bring about a special change in
3: A DDITIVES 25

properties so that the compound meets the require-  Electrical and magnetic properties
ments demanded of it; however, in reality, there is no  Acid solubility
filler that is fully inactive and reduces costs only [42].
Some reinforcing fillers function by forming  Loss on ignition
chemical bonds with the polymer. Others produce  pH
enhancements in mechanical properties by taking up  Moisture content
volume; they bind to nearby polymer chains,
decreasing polymer chain mobility and increasing The reinforcing properties of fillers can be
polymer orientation at the filler surface. The enhanced by coupling agents. Coupling agents,
increased orientation results in increased stiffness, usually silanes and titanates, improve the interfacial
lower deformability, and increased strength. Reduced bond between the filler and resin. They are bifunc-
mobility results in higher glass transition temperature tional molecules, in which one end reacts with polar,
[43]. Another effect some fillers can have is on inorganic materials while the other end reacts with
crystallinity by promoting nucleation [44]. organic, nonpolar substrates. They function as
Particle size and shape, as well as derived prop- molecular bridges between filler and resin. Commer-
erties like specific surface and particle packing, are cially available coupling agents have different func-
the most significant factors affecting the mechanical tional groups appropriate for the particular resin. The
characteristics of a compound. In addition, porosity final effect is an improved adhesion between the filler
and tendency to agglomeration (weak bonding) and the polymer, which results in enhanced mechan-
and/or aggregation can have important effects both on ical properties, such as tensile strength, flexural
processing behavior and mechanical properties [45]. modulus, impact strength, and heat deflection
The true density of a filler depends on the chemical temperature.
composition and morphology. Lightweight fillers,
such as hollow glass spheres, reduce the density of
a compound, whereas heavy fillers increase it and
may be used, for example, for sound deadening 3.10.1 Fillers Commonly Used
applications. Most of the commercial fillers have in Thermoplastic Polymers
densities between 1.5 and 4.5 g/cm3. Because most
fillers are used in powder form, the bulk, or loose 3.10.1.1 Cubic and Spheroidal Fillers
density significantly affects handling and feeding Natural calcium carbonate depending on raw
during processing. Fine fillers can have bulk densities material source is available in the form of chalk,
below 0.2 g/cm3 because of air entrapment and limestone, or marble. Natural calcium carbonate
electrostatic charges, thus limiting their use on reduces cost of a compound without dramatic change
conventional processing equipment. These problems in properties.
can be partially solved by split feeding, improved Precipitated calcium carbonate is most commonly
degassing, and surface treatment and/or compacting prepared from calcined limestone (CaO) and carbon
of the filler [46]. dioxide. Precipitated calcium carbonate is very pure
Specific surface area is defined as the total surface and fine but more expensive than the natural product,
area per unit weight of the filler. The most widely which limits its use. It is often offered surface treated
used method of determining specific surface is by the with fatty acids. Because of its high specific surface
nitrogen absorption (BET) method. A simple method (20e40 m2/g) it has a major effect on rheological
to get figures related to the specific surface area is to properties and adsorption properties (stabilizers,
determine the oil absorption. The result is given as plasticizers) [48].
the quantity of the fluid in mL per gram of filler and Barium sulfate is available both as natural mineral
provides a rough estimate of the minimum quantity (barite) and synthetic product (blanc fixe). It has the
of polymer needed to disperse the filler [47]. highest specific gravity among the commercial
Other properties of fillers and reinforcement fillers, is inert, very bright, and easy to disperse.
affecting the specific properties of a compound are: Barium sulfate is most widely used for sound dead-
ening applications (foams, piping), in carpet backing,
 Optical properties floor tiles, sporting goods, brake and clutch linings,
 Hardness and abrasiveness radiation shielding, and as white pigment.
26 H ANDBOOK OF T HERMOPLASTIC E LASTOMERS

Glass and ceramic beads are widely used in resin properties, including heat deflection temperature
systems. They are often treated by silanes to enhance (HDT), creep resistance, shrinkage, and coefficient of
the bonding between resin and particles or coated by linear thermal expansion (CLTE). Talc has adverse
metals (Ag, Cu) and used as conductive fillers. effects on toughness, elongation at break, weld line
Spherical fillers impart tear and compressive strength, long-term thermal aging, and UV resistance
strength, dimensional stability, scratch resistance, [51].
and stiffness to compounds. Hollow glass beads Mica, like talc, is a sheet silicate with an excellent
reduce specific gravity of the compound and are used platelet structure. The most important grades of mica
in foams, syntactic foams, and in automotive parts. are muscovite and phlogopite. Both these grades have
Solid spheres are used in bumper formulations, TV aspect ratios of 20e40 and are used in thermoplastics
and computer housings, connectors, etc. to improve rigidity, dimensional stability, and HDT.
Synthetic silica is essentially amorphous silicone Mica also exhibits good electrical properties and is
dioxide with primary particles with diameters acid resistant [52]. Muscovite appears white to
ranging from 10 to 100 nm and forming aggregates virtually colorless, while phlogopite has a golden
(secondary particles) 1e10 mm in size. Silica prod- brown inherent color. Mica is relatively difficult to
ucts are named after their production process: fumed, disperse; therefore, its surface is treated by amino-
fused, and precipitated [45] and their surface area; silanes, waxes, or aminoacetates. Another disadvan-
depending on the process used they may vary from 50 tage of mica is poor weld line strength.
to 800 m2/g [49]. Synthetic silicas are used as semi- Kaolin and clay, a variety of hydratized
reinforcing fillers in thermoplastics, elastomers, as aluminum silicate that comes in varying degrees of
antiblocking additives for films, as viscosity regula- purity. The mineral has a hexagonal, sheet-like
tors, and as matting agents. To enhance their rein- crystal structure with an aspect ratio of 10
forcing properties, synthetic silicas are treated by maximum, is pale in color, and possesses excellent
silane coupling agents. In summary, silicas perform chemical resistance and good electrical properties.
the following functions in thermoplastics [50]: The average particle size of commercial products
ranges between 1 and 10 mm, and the surface areas
 Reduction of shrinkage and crack formation range from 10 to 40 m2/g [53].
 Reinforcement The main application for kaolin is as filler in the
rubber industry, where distinction is made between
 Prevention of film blocking hard and soft clay (according to its reinforcing
 Improvement of dimensional stability under effect). Kaolin is often used in calcined form and
heat with special surface treatments (e.g., with silanes). In
 Reduction of the coefficient of linear expansion thermoplastics, it contributes to the improvement of
chemical resistance, of electrical properties, and to
 Improvement of electrical properties
the reduction of water absorption. It lowers the crack
 Increase of hardness tendency in finish articles, and improves shock
 Reduction of die swell resistance and surface quality. The lamellar structure
results in improvement in the surface hardness of the
 Affecting rheological behavior
finished products [54].
Carbon black is predominantly used as reinforce-
ment in elastomers. Its use in thermoplastics is limited 3.10.1.3 Fibrous Fillers
to pigmentation, UV protection, and conductivity.
Glass fibers (chopped strand) are frequently used
Specific uses in thermoplastic elastomers are dis-
as reinforcement in thermoplastics. They are cost-
cussed in sections covering individual types of TPEs.
effective, and a broad range of physical properties
can be achieved for a large number of applications.
3.10.1.2 Platy Fillers Glass fiber reinforcements are strands of filaments
Talc, the softest of all minerals with a Mohs hard- drawn to different diameters between 3.8 and 18 mm.
ness of 1, is chemically magnesium silicate hydrate. The number of filaments per strand, the configuration
Most talc goes into polypropylene compounds for the of the strand, and the fiber length-to-weight ratio can
automotive industry. Talc positively affects many be varied, depending on the desired properties [55].
3: A DDITIVES 27

Chopped and continuous strands are used in injection applications are packaging films and rigid containers,
molding, at loadings 5e30%. Mats can be made from automotive and industrial components [59].
chopped or continuous strands. Glass fiber reinforced
resins have high tensile strength, high stiffness and
flexural modulus, high creep resistance, impact 3.11 Plasticizers
resistance, and high heat deflection temperatures. In
addition, they exhibit excellent dimensional stability 3.11.1 Types of Plasticizers
and low CLTE. The reinforcing efficiency of glass Plasticizers are defined as substances added to
fibers can be further enhanced by the use of coupling polymeric materials to improve their flexibility,
agents (e.g., silanes). Because glass fibers orient in extensibility, and processability. It is characteristic of
the flow directions during injection molding, plasticizers that they lower the melting temperature,
shrinkage is greatly reduced in the direction of flow; melt viscosity, glass transition temperature, and
in the transverse direction, the shrinkage reduction is elastic modulus of polymers without altering their
not so great. Disadvantages of glass fibers are chemical nature [60]. Technologically, they fulfill
warpage, low weld line strength, and low surface several functions. They act as processing aids, enter
quality. Because of their abrasiveness, they can into physical interaction with the polymer, and
damage machinery and tooling, but hardened coat- enable materials to be tailor-made, or very nearly
ings on barrels, screws, and tooling can minimize so, to specific property requirements.
abrasion [56]. Commercial plasticizers are normally supplied in
Carbon fibers and aramid fibers have exceptional the form of low to high viscosity liquids and more
reinforcing properties, but because of their high rarely as solid products. Since many thermoplastics
cost they are used only in specialized applications require high processing temperatures, plasticizers
such as aerospace, marine, military, and medical used for such materials have to have sufficient heat
applications. resistance to prevent discoloration, decomposition, or
excessive evaporation rates during processing. Low
volatility is also required for application, where the
3.10.1.4 Nanofillers polymeric material is used at elevated temperatures
Nanofillers are defined as fillers with particle for extended periods of times. Typical plasticizers
sizes in the 1e100 nm range [57]. Such fillers, e.g., meeting the requirement of low volatility are, for
carbon blacks, synthetic silicas, and precipitated example, phthalates and adipates prepared from C10
calcium carbonate, have been around for a long to C13 aliphatic alcohols and esters of trimellitic acid
time; however, their primary particles form bigger, [61]. For articles exposed to complex effects of
stable secondary particles through agglomeration, weathering, not only volatility but also resistance to
so ultimately they cannot be classified as light, water extraction, and fungal attack are
nanofillers. required. It is not always easy to find a plasticizer or
Recently, different nanofillers, such as nanoclays a combination of plasticizers, and often some kind of
(montmorrilonite, smectite) and needle-shaped compromise has to be made.
nanowhiskers, have become commercially available Migration problems can occur under unfavorable
[58]. Nanoclays are exfoliated (separated into indi- circumstances in multiplayer articles, such as artifi-
vidual layers), and reinforcing primary particles with cial leathers and films causing degradation or
extremely high aspect ratios (greater than 200) are excessive tackiness of the layer that originally did not
formed [58]. Exfoliation is enhanced by the surface contain plasticizer. In such cases a polymeric plasti-
treatment, so-called intercalation by compounds cizer could be the correct choice.
containing ammonium or phosphonium functional Flammability might be another issue in many
groups. This converts the surface from hydrophilic to applications. In such cases phosphoric esters (e.g.,
organophilic [59]. The advantage of such fillers is tricresyl phosphate or trichloroethyl phosphate) and
that they produce very good mechanical properties at chlorinated paraffins with high chlorine content are
low loadings, scratch resistance, superior barrier used. Both these groups of plasticizers are irritants
properties, enhanced fire resistant properties, and and may cause health problems when ingested or
improved heat distortion performance when absorbed through skin. Therefore, adequate protec-
compared to neat polymers. Major current tion must be used when handling them.
28 H ANDBOOK OF T HERMOPLASTIC E LASTOMERS

For articles made from polar polymers (PVC, Antimicrobials are natural or synthetic, mostly
acrylonitrile, and their copolymers) that are exposed low-molecular-weight substances that kill or
to low temperatures (typically below 40  C or suppress the growth of viruses, bacteria, and/or fungi
40  F) special plasticizers, such as dibutyl phtha- (i.e., yeasts and molds). Antiviral activity is only of
late, dioctyl phthalate, and dioctyl adipate, are suit- minor interest to the polymer processing industry
able. The low temperature brittleness is reduced with with the exception of medical devices, such as
increasing amount of plasticizer. Depending on the catheters. Major interest is in antimicrobials agents
base polymer, the plasticizer content may be as high that control the growth of bacteria and fungi.
as 45% [62]. Depending on the target organisms, this activity is
There are many types of plasticizers, each having described as bacteriostatic (inhibiting the growth of
a compatibility with specific types of polymers. They bacteria) or fungistatic (inhibiting the growth of
can be grouped in the following manner [63]: fungi). In contrast, the activity killing the bacteria or
fungi is called bactericidal or fungicidal activity.
 Phthalic esters Each antimicrobial substance has a specific spectrum
 Phosphoric esters of activity with susceptible microbial species [64].
Manifestations of deterioration of a plastic mate-
 Adipic, azelaic, and sebacic esters rial due to a microbial attack are:
 Citric esters
 Staining
 Trimellitic esters
 Deterioration of electrical properties, particu-
 Halogenated hydrocarbons
larly of insulation power
 Hydrocarbons (aliphatic, naphthenic, and
 Deterioration of mechanical properties
aromatic)
 Enhanced dirt uptake
 Benzoic esters
 Odor
 Fatty acid esters (oleates, stearates, ricino-
leates), pentaerithrol
Detailed coverage of this subject and a compre-
 Fatty esters, epoxidized hensive list of commercial antimicrobial agents are in
 Polyesters (polymeric plasticizers) Ref. [64].
 Polymers, polycondensates Fluorescent whitening agents have the main effect
to either improve or mask the initial color of plastics,
which is often slightly yellowish. Moreover, they can
3.11.2 Methods of Incorporation produce a brilliant white color of certain articles
Plasticized polyvinyl chloride compounds, plasti- or increase the brilliancy of colored and black-
sols, require relatively large amounts of plasticizers. pigmented articles.
They are prepared in planetary mixers, internal Many thermoplastics absorb the light in the blue
mixers, and dissolvers. Practically all thermoplastics spectral range of natural daylight, which is referred to
and elastomers can be mixed with plasticizers and as blue defect, causing a more or less pronounced
other compounding ingredients in batch and contin- yellow appearance. There are essentially three basic
uous mixers. Specialty or sensitive compounds principles to compensate for it, namely bleaching,
prepared in small batches are usually mixed on roll compensation for the blue deficit, and increase in
mills. Plasticizers can be added in liquid form or as reflection [65].
a dispersion (dry blend) on a carrier. Only a few of the known classes of fluorescent
whitening agents have the properties required for
mass whitening of plastics and fibers, namely bis-
3.12 Other Additives benzoxales, phenylcoumarins, and bis-(styryl)
biphenyls [65].
Other specialized additives have different func- The low thermal stability of PVC is well known.
tions in certain polymers and applications and Despite this fact, processing of PVC and its blends at
include antimicrobials, fluorescent whitening agents, elevated temperatures is possible by adding specific
and PVC stabilizers. heat stabilizers to stop the damage. When PVC is
3: A DDITIVES 29

processed at high temperatures, it is degraded by The form (liquid, powder, paste, pellets) and the
dehydrochlorination, which is a chain scission and microstructure of the additives are important because
cross-linking of macromolecules. Free hydrogen this may strongly affect the mixing process, partic-
chloride (HCl) evolves, and discoloration of the resin ularly the sequence in which the individual ingredi-
occurs along with important changes in physical and ents are added to the mix.
chemical properties. This degradation can be The aspects of health, hygiene, and impact on
controlled by the addition of stabilizers. A heat environment are extremely important in the selection
stabilizer must prevent the dehydrochlorination and use of any ingredient (see Section 3.14
reaction, which is the primary process in degradation. following).
Currently, the following commercially available
classes of heat stabilizers for PVC are:
3.14 Health, Hygiene, and Safety
 Alkyltin stabilizers
 Mixed-metal stabilizers (K, Ca, Ba, Cd) Health risks must be considered in all cases where
human beings are in contact with chemicals. This, of
 Organic phosphites
course, also applies to additives for any polymeric
 b-Diketone stabilizers material. Within the lifetime of an additive, the
 Epoxidized fatty acid ester stabilizers following phases are important [1]:
 Organotin mercaptides and organotin sulfides
 Production
 Lead stabilizers
 Incorporation of the additive and processing of
 Metal-free stabilizers the polymeric material into its end use
 Use of the finished article
Detailed discussion of this subject is in Ref. [66].
 Disposal of used articles

3.13 Selection of Additives The phases mainly applicable to this chapter are
the selection, handling, and incorporation of addi-
In the selection of additives by their function, it is tives into the compound; however, the way the indi-
important to consider not only the desirable proper- vidual additives affect the health, hygiene, and
ties it will confer on the compound but also the side environment during the use and disposal of the
effects it may have on other properties and its effect finished article also has to be considered.
on overall processability of the whole compound. The manufacturers of the additives are obliged to
Additives for thermoplastics are supplied in many assess among other things the health and environ-
varieties with frequent overlaps in properties [3]. mental impacts of their products during storage,
Mineral fillers are increasingly offered with surface handling, and fabrication by issuing specific docu-
treatments to improve their bonding with the polymer mentation, such as material safety data sheets
matrix and give improved mechanical properties to (MSDS), which has to be provided with the mate-
the final products and, at the same time, improved rials, including samples for laboratory work.
incorporation during mixing. Some pigments (e.g., Because of the large number of additives with
titanium dioxide, carbon black, or zinc oxide) can different molecular structures, their individual bio-
provide shielding against the effects of UV radiation. logical activity may rank from inactive to highly
Lubricants may plasticize the compound but can also active, or nontoxic to toxic. Specific regulations
act as mold release agents and in some instances exist for contact with food, for pharmaceutical
add antistatic properties to the product during its devices and packaging, for toys, pipes for drinking
lifetime [3]. water supply, etc. It is beyond the scope of this
The current trend is to use multifunctional addi- chapter to discuss details; only basic principles are
tives, or hybrid systems, or exploit synergistic effects addressed.
between two or more additives. This development is Product handling in production facilities
evident in the development of technology for UV requires particular attention with the emphasis to
light stabilization and flame retardancy [3]. avoid possible contamination harmful to humans.
30 H ANDBOOK OF T HERMOPLASTIC E LASTOMERS

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where drums or other packages are opened and editors. Plastics additive handbook. 2nd ed.
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When handling solid additives, the safest way is to [6] Maier C, Calafut T. Polypropylene: the definitive
store them in silos and use single-component dosing users guide and handbook. Norwich (NY):
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lighting, explosion-proof switches in areas where Publishing; 1998. p. 33.
explosive solvents are used, and use of warning signs, [13] Light stabilizers for polyolefins, Technical
floor, and wall markings reduce or entirely eliminate Report A-349B7M92, Ciba Geigy Corporation,
many hazards. Emergency showers and showers for 1992.
flushing eyes are other important devices for safety [14] Maier C, Calafut T. Polypropylene: the definitive
and good hygiene. users guide and handbook. Norwich (NY):
More detailed coverage of this subject is in Plastics Design Library/William Andrew
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