Abstract Process Economics Program Report 51D POLYMER NANOCOMPOSITES (September 2010)

Transcription

1 Abstract Process Economics Program Report 51D POLYMER NANOCOMPOSITES (September 2010) This report is an update of our earlier PEP report (PEP Report 51C) on polymer nanocomposites which was published in Development in polymer nanocomposites was at a relatively early stage with only a few commercial products by Most of the efforts were focused on clay-based nanoparticles. Since then the field of polymer nanocomposites has grown greatly. The progress in polymer nanocomposites has been wide and encompassed many different industries. New types of nanoparticles or nanofillers have been developed. Applications range from automotive, biological implants, packaging, aircraft components, etc. However, commercialization of many applications has taken longer than anticipated. There are still technological challenges to be overcome before there is widespread commercialization of polymer nanocomposites. The main barriers to overcome include cost and dispersion of the nanoparticles with the polymer matrix. In this report, we will review the current state of polymer nanocomposites in terms of patent literature, other scientific literature and commercialization activities. Nanofillers and polymer nanocomposites encompass a wide subject area. The report will focus on nanoparticles and polymer nanocomposites that are already commercialized or have a commercialization potential. The commercial status, potential markets, and producers of polymer nanocomposites are discussed. Technological developments in nanoparticles and polymer nanocomposites production will be reviewed. Nanoparticles or nanofillers reviewed in this report include claybased nanoparticles such as montmorillonite and halloysite, carbon-based nanoparticles such as carbon nanotubes and graphene sheets, and other nanofillers such as nanosilica, metal oxide nanoparticles, polymeric nanoparticles and cellulose nanofibers. SRI Consulting PEP Report 51D

2 A private report by the Process Economics Program Report No. 51D POLYMER NANOCOMPOSITES by Susan Bell September 2010 Menlo Park, California 94025

3 SRIC agrees to assign professionally qualified personnel to the preparation of the Process Economics Program s reports and will perform the work in conformance with generally accepted professional standards. No other warranties expressed or implied are made. Because the reports are of an advisory nature, neither SRIC nor its employees will assume any liability for the special or consequential damages arising from the Client s use of the results contained in the reports. The Client agrees to indemnify, defend, and hold SRIC, its officers, and employees harmless from any liability to any third party resulting directly or indirectly from the Client s use of the reports or other deliverables produced by SRIC pursuant to this agreement. For detailed marketing data and information, the reader is referred to one of the SRI Consulting programs specializing in marketing research. THE CHEMICAL ECONOMICS HANDBOOK Program covers most major chemicals and chemical products produced in the United States and the WORLD PETROCHEMICALS PROGRAM covers major hydrocarbons and their derivatives on a worldwide basis. In addition the SRIC DIRECTORY OF CHEMICAL PRODUCERS services provide detailed lists of chemical producers by company, product, and plant for the United States, Western Europe, Canada, and East Asia, South America and Mexico.

4 CONTENTS GLOSSARY... xiii 1 INTRODUCTION SUMMARY INTRODUCTION COMMERCIALIZATION OF POLYMER NANOCOMPOSITES TECHNOLOGICAL ASPECTS Nanoparticles Polymer Nanocomposites Polymer/Clay-Based Nanocomposites Polymer/Carbon-Based Nanocomposites Polymer/Other Nanocomposites STATUS OF POLYMER NANOCOMPOSITES INTRODUCTION PATENT ACTIVITIES NANOPARTICLE SUPPLIERS Clay-Based Nanoparticles Applied Minerals Inc Nanocor Inc Southern Clay Products Elementis Specialties Laviosa Chimica Mineraria NaturalNano Research, Inc NanoClay and Technologies, Inc Carbon-Based Nanoparticles Asbury Carbon Bayer MaterialScience AG Cheap Tubes, Inc SRI Consulting iii PEP Report 51D

5 CONTENTS (Continued) CNano GrafTech International Hyperion Catalysis International Materials & Electrochemical Research (MER) Nano Carbon Technologies (NCT) Nanocyl Pyrograf Products, Inc. (PPI) Showa Denko K.K. (SDK) Vorbeck Materials Unidym Inc XG Sciences Other Nanoparticles Aspen Aerogel Bayer MaterialScience AG Cabot Corporation Hybrid Plastics Lanxess AG Minerals Technologies Inc Nanophase Nanotek Prices COMMERCIAL POLYMER NANOCOMPOSITE APPLICATIONS Polymer/Clay Nanocomposites Polymer/Oxides Nanocomposites Polymer/POSS Nanocomposites Polymer/Polymer Nanocomposites Polymer/Aerogel Nanocomposites Polymer/CNT Nanocomposites SAFETY, HEALTH AND ENVIRONMENTAL ASPECTS OF POLYMER NANOCOMPOSITES SRI Consulting iv PEP Report 51D

6 CONTENTS (Continued) 4 NANOPARTICLES INTRODUCTION CLAY-BASED NANOPARTICLES Nanoclay Montmorillonite Layered Structure Sepiolite Fibrous Structure Halloysite Tubular Structure Kaolin Layered Structure Talc Layered Structure Layered Double Hydroxides (LDHs) Organoclay CARBON-BASED NANOPARTICLES Carbon Black Carbon Nanotubes Properties Carbon Nanotube Production Expandable Graphite Graphene Sheets or Nanoplatelets Properties Graphene Sheet Production OTHER NANOPARTICLES Calcium Carbonate Silicon Oxide Nanoparticles Metal Nanoparticles Metal Oxides Nanoparticles Polymeric Nanoparticles Aerogels Properties SRI Consulting v PEP Report 51D

7 CONTENTS (Continued) Aerogel Production Polyhedral Oligomeric Silsesquioxanes (POSS) Properties POSS Production Cellulose Nanofibers Properties Cellulose Nanofiber Production POLYMER/CLAY NANOCOMPOSITES INTRODUCTION EXFOLIATION OF ORGANOCLAY OR NANOCLAY TO FORM POLYMER NANOCOMPOSITES IN-SITU POLYMERIZATION PROCESS MELT INTERCALATION PROCESS SOLUTION INDUCED INTERCALATION PROCESS LATEX PROCESS PRODUCTION OF POLYAMIDE/CLAY NANOCOMPOSITES PRODUCTION OF POLYOLEFIN/CLAY NANOCOMPOSITES PRODUCTION OF EVA COPOLYMERS/CLAY NANOCOMPOSITES PRODUCTION OF POLYESTER/CLAY NANOCOMPOSITES PRODUCTION OF PVC/CLAY NANOCOMPOSITES PRODUCTION OF POLYSTYRENE/CLAY NANOCOMPOSITES PRODUCTION OF POLYCARBONATE/CLAY NANOCOMPOSITES PRODUCTION OF ELASTOMER/CLAY NANOCOMPOSITES Styrene-Butadiene-Rubber (SBR) Elastomers Halobutyl Elastomers Thermoplastic Elastomers PRODUCTION OF ACRYLIC LATEX POLYMER/CLAY NANOCOMPOSITES SRI Consulting vi PEP Report 51D

8 CONTENTS (Continued) PRODUCTION FLUOROPOLYMER/CLAY NANOCOMPOSITES POLYMER NANOCOMPOSITE PROPERTIES Mechanical Properties Barrier Properties Flame Retardancy Other Properties CASE STUDY: POLYMER/CLAY-BASED NANOCOMPOSITES FOR AUTOMOTIVE APPLICATIONS POLYMER NANOCOMPOSITES WITH CARBON-BASED NANOPARTICLES INTRODUCTION POLYMER/CARBON NANOTUBE NANOCOMPOSITES In-Situ Polymerization for Polymer/CNT Nanocomposite Production Solution Processing for Polymer/CNT Nanocomposite Production Melt Mixing for Polymer/CNT Nanocomposite Production Properties of Polymer/CNT Nanocomposites POLYMER/GRAPHENE NANOCOMPOSITES POLYMER NANOCOMPOSITES WITH OTHER NANOPARTICLES INTRODUCTION CALCIUM CARBONATE NANOPARTICLES SILICON OXIDE NANOPARTICLES METAL OXIDE NANOPARTICLES POLYMERIC NANOPARTICLES METAL NANOPARTICLES OR NANOMETAL AEROGELS POLYHEDRAL OLIGOMERIC SILSESQUIOXANES (POSS) CELLULOSE NANOFIBERS SRI Consulting vii PEP Report 51D

9 CONTENTS (Concluded) APPENDIX A PATENT SUMMARY TABLES... A-1 APPENDIX B DESIGN AND COST BASES... B-1 APPENDIX C CITED REFERENCES... C-1 APPENDIX D PATENT REFERENCES BY COMPANY...D-1 APPENDIX E PRODUCT INFORMATION... E-1 SRI Consulting viii PEP Report 51D

10 FIGURES 1.1 Polymer Nanocomposite Patent Activity Polymer Nanocomposite Patent Activity Polymer Nanocomposite Patent Activity Based on Nanoparticles Polymer Nanocomposite Patents Issued by Country or Region Graphene Nanoplatelet Production Aerogel Production POSS Structure Cellulose Nanowhisker Production from Wheat Straw Schematic of Shear Mixing and Extensional Flow Predicted Young s Modulus of a Polymer Composite Based on the Halpin-Tsai Model Flexural Impact at Low Temperatures for TPO/Clay Nanocomposites SRI Consulting ix PEP Report 51D

11 TABLES 2.1 Different Clay-Based Nanoparticles Different Carbon-Based Nanoparticles Other Nanoparticles Properties of Nanoparticles for Mechanical Enhancement Methods to Produce Polymer Nanocomposites Polymer Nanocomposite Patent Activities (Year ): Companies Polymer Nanocomposite Patent Activities (Year ): Research Institutes and Universities Commercial Nanoclay and Organoclay Suppliers Commercial Carbon-Based Nanoparticle Suppliers Commercial Suppliers: Other Nanoparticles Nanoparticle Prices Commercial Applications of Polymer Nanocomposites Organic Compounds Used for Organoclay Typical Mechanical Properties of Carbon Nanotubes Typical Properties of Cabot Nanogel Silica Aerogels Mechanical Properties of Different Clay-Based PA-6 Nanocomposites Mechanical Properties of Different Clay-Based PP Nanocomposites Mechanical Properties of SBR/Clay Polymer Nanocomposites Formed by a Latex Process Mechanical Properties of Nylon Nanocomposites with Halloysite Clay Nanotubes Mechanical Properties of Polypropylene Nanocomposite with Halloysite Clay Nanotubes Multi-Layer PET Bottle Containing MXD6 Nylon/Clay Nanocomposites Oxygen Barrier Properties Enhancement Using Nanocomposite Barrier Coatings Polyethylene Nanocomposite Pipes Barrier Properties of HDPE/Clay Nanocomposites SRI Consulting x PEP Report 51D

12 TABLES (Continued) 5.10 Flame Retardancy of Clay-Based Polymer Nanoclay/Conventional FR Systems for Polypropylene Cost of Polypropylene Composites Typical Class A SMC Formulation Tough Low-Mass Class A SMC Formulation Comparison of Weight and Estimated Costs of Tough Low-Mass SMC and Conventional Materials Comparison of Electrical Conductivity of PC/ABS Resins with Different Additives Comparison of Ductility of PC/ABS Resins with Different Additives Comparison of Properties of Polymer/FGS and Polymer/Clay Nanocomposites Potential Coating Property Improvement with Metal Oxide Nanoparticles Effect of Microgels on Rubber Composite Properties Properties of TPE Containing Microgels Effect of Bridgestone s Polymeric Nanoparticles on Rubber Composite Properties Yield Strength of Various Nickel Particles Properties of Polypropylene/POSS Composites Mechanical Properties Polyimide/POSS Composites Permeability of Nylon 6 with POSS Mechanical Properties of Neat PLA and PLC/Cellulose Nanofibers Composites A.1 Nanoparticles Patent Summary... A-3 A.2 Polymer/Clay Nanocomposites Patent Summary...A-17 A.3 Polymer Nanocomposites with Carbon-Based Nanoparticles Patent Summary...A-45 A.4 Polymers Nanocomposites with Other Nanoparticles Patent Summary...A-56 E.1 Nanocor Clay Nanomer Fillers for Nylon Nanocomposites... E-3 SRI Consulting xi PEP Report 51D

13 TABLES (Concluded) E.2 Nanocor Imperm Nanocomposites... E-3 E.3 Nanocor Clay Nanomer Fillers...E-4 E.4 Nanocor Clay Nanomer Fillers for Epoxy Resins... E-4 E.5 Laviosa Chimica Mineraria Dellite Grades... E-5 E.6 Southern Clay Cloisite and Nanofil Fillers... E-5 E.7 Hyperion Catalysis Fibril Nanotube-Based Masterbatches... E-6 E.8 Hyperion Catalysis Fibril Nanotube-Based Ready-to-Mold Compounds... E-7 E.9 XG Sciences xgnp Graphene Nanoplatelets... E-8 E.10 Lanxess Nanoprene Nanoadditive... E-8 SRI Consulting xii PEP Report 51D