CASE HISTORY

Supplier Dow Corning Corporation Location Midland, MI Application Thermoplastics molding and extrusion Problem Manufacturers of automotive interior trim, appliances, luggage and other items are using increasing amounts of polypropylene (PP) and other thermoplastic olefins (TPOs) in their products, but mar and scratch resistance are a problem in some applications. Standard PP formulations generally offer scratch resistance up to about 5 Newtons of force, while OEMs are seeking material formulations that can resist 10 Newtons of scratch force or more when using a 1 mm stylus. Product line developed Dow Corning MB50 Series of Siloxane Masterbatch Additives Results Testing of the ultra-high molecular weight siloxanes in pelletized form has shown significant improvements in durability and surface characteristics. In particular, Dow Corning MB50-011 Siloxane Masterbatch (which is dispersed in nylon) demonstrated greater surface hardness and scratch resistance. These improvements were attained without sacrificing other desirable properties, such as paintability.

Siloxane additives for molding polypropylene and thermoplastic olefins

Silicone plastic additives have been effectively employed for many years to improve lubricity and flow of thermoplastics. However, incorporating liquid silicone additives into thermoplastic melts without specialized equipment poses many processing difficulties. It has also been challenging to produce quality masterbatches with greater than 20% silicone content, due to processing difficulties and silicone bleeding problems. Dow Corning has designed its new series of additives as dry, solid pellets that can be blended at the press during molding or extrusion. Based on ultra high molecular weight siloxane (15-20 million cs), these materials form a uniform dispersion within the polymer melt, controlling the mobility of the siloxane and virtually eliminating problems experienced with liquid additives. Testing has shown that when added to PP or TPOs at levels between 0.1% and 1.0%, the UHMW siloxane improves processing and flow by providing better mold fill, reduced extruder torque, internal lubrication, more efficient mold release, faster throughput and less warpage. At higher levels (1-4% siloxane), improved surface properties include better lubricity and slip from the reduced coefficient of friction, as well as greater mar and abrasion resistance. The research has demonstrated that scratch resistance improvements can be attained at loading levels of 15 Newtons and higher using the Ford five-finger scratch test.

15N 10N 7N 4.5N 2N Figure 1 Control TPO TPO + 4% MB50-321

These additives have been shown to be of particular value in improving mold fill of thin-walled parts, reducing mold cycle times and helping to relieve internal stresses which can cause part warping and other quality problems. In addition, the additives have been found to reduce screw slippage over conventional additives and improve mold release. The specially-formulated additives also help avoid the printing and paintability issues associated with some additive products.

A significant benefit over liquid siloxane additives is the ability to process Dow Corning MB50 Series Masterbatches in the same way as the thermoplastic to which they are added. Customer testing should be conducted to determine the effective level of siloxane masterbatch needed to obtain the desired benefits in the final product. The siloxane pellets can be added in a single screw extruder or added at the feed hopper during injection molding or extrusion processing.
Figure 2: Dow Corning Masterbatch Additives

Dow Corning Masterbatch additives have also been used to improve processing of highly filled polymers, where fillers are used to attain greater flame resistance. Heavy filler loadings (sometimes as high as 60-70%) can cause significant processing problems, and the very high viscosity of the melt can give the extruded part a poor finish. Using Dow Corning Masterbatch Additives reduces the melt viscosity and improves the flow of the polymer, helping to avoid the high torque and subsequent problems associated with extruding highly filled materials.

For More Information

For product information or a Material Safety Data Sheet (MSDS), contact your Multibase representative or visit www.dowcorning.com.

LIMITED WARRANTY INFORMATION - PLEASE READ CAREFULLY The information contained herein is offered in good faith and is believed to be accurate. However, because conditions and methods of use of our products are beyond our control, this information should not be used in substitution for customers tests to ensure that Multibases products are safe, effective, and fully satisfactory for the intended end use. Suggestions of use shall not be taken as inducements to infringe on any patent. Multibases sole warranty is that the product will meet the Multibase sales specifications in effect at the time of shipment. The exclusive remedy for breach of such warranty is limited to refund of purchase price or replacement of any product shown to be other than as warranted. MULTIBASE SPECIFICALLY DISCLAIMS ANY OTHER EXPRESS OR IMPLIED WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE OR MERCHANTABILITY. MULTIBASE DISCLAIMS LIABILITY FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES. Dow Corning is a registered trademark of Dow Corning Corporation. 2002 Multibase A Dow Corning Company. All rights reserved. Printed in USA FPH31805-1 Form no. 26-069B-01

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