POLYMER ADDITIVE: ENHANCING PERFORMANCE AND FUNCTIONALITY

BY

ERHIERORE EDESIRI HAPPINESS

A SEMINAR PAPER PRESENTED TO THE

IN PARTIAL FULFILMENT OF THE REQUIREMENTS FOR THE AWARD OF

SUPERVISED
BY
ENGR. M.D AYO

FEBRUARY, 2024

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 OUTLINE

Abstract

Introduction

Polymer Additive

Types of Polymer Additives

Commercial-based Polymer Additives:

Biobased Polymer Additives:

Enhancing Performance and Functionality of Polymer Additive

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 Abstract

The role of additives in commodity and specialty polymeric artifacts is of key importance since
pure polymers often show poor resistance to external factors (such as weathering, mechanical
stress, etc.) during their processing or end-use application. This chapter provides a technical
overview of the most important classes of polymer additives that can ensure protection against
weathering agents (UV radiation, oxygen), resistance to heat or flames, and improvement of
physical and mechanical properties, particularly plasticization and impact resistance.
Compatibilization of polymer blends is also discussed due to its importance in recycling of
plastic materials. Since esthetic appearance of finished products is of great concern, different
coloring technologies are also reported herein, ranging from standard to “special effect”
formulations.

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Introduction

Besides already established technical polymers, the plastics industry is continuously developing

new polymeric materials. Most of these products have to fulfill strict requirements during their

service life depending on the individual applications. However, indispensable properties of

plastic materials can only be achieved by optimal adjustment of the additives package to the

specific requirements. Therefore, the development of tailor-made recipes and also the

introduction of novel polymer additives and additive combinations contribute to strengthened

and continuously improved plastic articles.

As a consequence, it becomes mandatory to assess quickly the efficiency of additives with

respect to technical and environmental conditions to which they are likely to be subjected. Since

examination of changes of polymer materials at ambient conditions often requires long time

periods, several methods have been developed which allow an accelerated degradation.

Nevertheless, it has to be ensured that accelerated aging processes correlate with degradation

steps observed under normal service conditions. Regarding thermal and UV light-induced

degradation, various accelerated test methods are established studying the influence of additives

on polymer performance.58

Additives play a very important role both in the processability of plastic materials and in their

applications (Gatcher and Muller, 2016). The incorporation of additives makes polymer

materials suitable for multiple applications in the plastic market: automotive, design, packaging,

constructions, electronics, telecommunication (Prithchard, 2018). Additivation of molecules or

particles to the virgin polymer can improve the properties of the bulk product as well as its

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surface. For example, polypropylene (and polyolefins in general), would not be one of the most

widely employed commodity polymer without additives. It would, in fact, degrade in weeks,

because of its poor thermal oxidative stability (Bockhorn et al, 2019). According to the European

Community an additive is “a substance which is incorporated into plastics to achieve a technical

effect in the finished product, and is intended to be an essential part of the finished article”. This

chapter wants to give an insight on the most common additives used in plastic in the last few

decades; in particular we will focus on the following additives: antioxidants, light stabilizers, UV

absorbers, flame retardants, heat stabilizers, impact modifiers, plasticisers, compatibilizers,

coupling agents, colorants, pigments, whiteners.

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Polymer Additive

Plastics manufacturing has evolved significantly over time. Plastics were originally produced

using a few natural materials but now there are thousands of plastics formulated from a wide

range of natural and synthetic materials. One of the big changes over time in plastic formulations

is the use of polymer additives.

Additives are chemicals added to the base polymer to improve processability, prolong the life

span, and/or achieve the desired physical or chemical properties in the final product. While the

content of additives is typically only a few percent, their impact on polymer performance and

stability is significant. Once the additives are added, the polymer blend is referred to as a

masterbatch and is processed accordingly (Pritchard, 2018).

Types of Polymer Additives

There are countless options when it comes to additives and each one offers a specific

improvement to the polymer’s functionality or stability. Selecting the right additives for your

polymer may seem like a daunting task. Below are common categories of polymer additives.

Even within a specific category, such as flame retardants, there are numerous additive options

available; the additive that is best for a given plastic depends heavily on the base polymer (to

ensure compatibility) and the application of the final product (Malinconico, et al., 2014).

–> Plasticizers: base polymers are often rigid and do not have the necessary flexibility and

rheology, or flow, properties that are needed for plastics processing. Plasticizers are added to

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improve rheology as well as elasticity. Plasticizers are one of the most common polymer

additives and an example is phthalate esters used in PVC products.

–> Anti-aging stabilizers: nearly every plastic is prone to degradation when exposed to UV

light, such as from sunlight, and oxygen including ozone. The degradation causes brittleness,

discoloration, and loss of some physical properties. Additives, referred to as anti-oxidants,

stabilizers, or anti-ozonants, are added to combat the deterioration of the plastic and to

significantly extend the life span of the final product. Examples of antioxidants include phenols,

aryl amines, and phosphates, and examples of UV stabilizers include benzophenones and

benzotriazoles. Additionally, black is an excellent UV absorber so paints, dyes, or elemental

carbon black are often added to protect products against UV light.

–> Blowing agents: these additives are added to the base polymer and when a specific

temperature is reached during processing they decompose, releasing gas that forms a cellular

structure within the plastic. This structure reduces density and improves insulation properties.

There are many different blowing agents available from salts to complex nitrogen-releasing

chemicals.

–> Flame retardants: flame retardants prevent, delay, or slow down combustion. These

additives are common in electrical products to avoid the ignition and burning of plastics. Flame

retardants can be mixed with the base polymer, or added during the plastic processing step, or

even as a surface layer finish on the final product. Halogens such as bromines as well as

phosphorus and nitrogen chemistries are common flame retardants.

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–> Nucleating agents: these additives improve mechanical properties and transparency. They

also speed up the plastic crystallization rate, reducing overall cycle time.

–> Processing: these additives are combined with the polymer to improve the processability and

processing characteristics of the material. Examples of processing additives include lubricants,

and more specifically, fatty acids, hydrocarbon waxes, and some types of polyethylene.

–> Anti-static: these additives are used to minimize the potential for static electricity build up on

the surface of the plastic, and in some cases even prevent it entirely. Examples of anti-static

additives include amines, ammonium compounds, and polyethylene glycol esters.

–> Colorants: the purpose of these agents is to change the color of the final product. These

additives are often pigments or dyes. The specific dye or pigment selected is largely based on

which base polymer is being used as the two materials have to be compatible.

–> Odor: there are also additives to modify the odor of the final product. An example of an odor

agent is when a chemical is added to paints to produce a more pleasing smell.

–> Anti-microbial: given the increasing trend in implantable medical devices and other

technologies, anti-microbial additives are becoming more popular. These agents protect against

deterioration of the plastic and reduce the potential for a microbiological attack.

Polymer additive can also be categorized into commercial and biobased additive. Commercial-

based and biobased polymer additives offer different advantages and considerations, depending

on various factors such as environmental impact, performance, cost, and regulatory compliance.

Here's a comparison between the two:

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Commercial-based Polymer Additives:

1. Availability and Diversity: Commercial-based polymer additives are widely available

and offer a diverse range of options to suit different applications and performance

requirements. They have been extensively researched and developed, resulting in a broad

array of additives with well-understood properties and performance characteristics.

2. Performance and Consistency: Commercial-based additives often provide consistent

and predictable performance due to their well-established manufacturing processes and

formulations. Manufacturers can rely on these additives to deliver specific enhancements

to polymer properties such as mechanical strength, durability, and processability.

3. Cost-effectiveness: In many cases, commercial-based polymer additives may be more

cost-effective compared to biobased alternatives due to economies of scale, established

supply chains, and production efficiencies. This can make them more accessible for

manufacturers seeking cost-effective solutions.

4. Regulatory Compliance: Commercial-based additives are typically well-regulated and

have established safety data, making it easier for manufacturers to ensure compliance

with relevant regulations and standards regarding health, safety, and environmental

impact.

Biobased Polymer Additives:

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1. Renewable and Sustainable: Biobased polymer additives are derived from renewable

biomass sources such as plants, algae, or bacteria, offering a more sustainable alternative

to petroleum-based additives. They can help reduce dependence on fossil fuels and

mitigate environmental concerns associated with traditional additives.

2. Lower Environmental Impact: Biobased additives generally have a lower

environmental footprint compared to their commercial counterparts, as they often require

fewer non-renewable resources and produce fewer greenhouse gas emissions during

production.

3. Biodegradability and Eco-toxicity: Some biobased additives may offer improved

biodegradability and lower eco-toxicity compared to commercial-based additives,

particularly in applications where end-of-life disposal is a concern, such as single-use

plastics and packaging materials.

4. Performance and Compatibility: While biobased additives have made significant

advancements in recent years, they may still face challenges related to performance and

compatibility with existing polymer formulations. Manufacturers may need to carefully

evaluate and optimize biobased additives to ensure they meet performance requirements

without compromising other properties.

5. Market Acceptance and Adoption: Biobased polymer additives are gaining traction in

the market as environmental concerns and sustainability become more prominent.

However, widespread adoption may still be hindered by factors such as cost

competitiveness, performance limitations, and the availability of suitable biomass

feedstocks.

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Enhancing Performance and Functionality of Polymer Additive

Polymer additives play a crucial role in enhancing the performance and functionality of polymers

in various ways:

 Mechanical Properties Enhancement: Additives like fillers, reinforcements, and impact

modifiers can significantly improve the mechanical properties of polymers, such as

strength, stiffness, toughness, and impact resistance. This enhancement makes polymers

more suitable for demanding applications in industries like automotive, construction, and

aerospace.

 Flexibility and Durability Improvement: Plasticizers are additives that increase the

flexibility and durability of polymers by reducing their glass transition temperature. This

allows for the production of flexible and resilient materials, particularly in applications

like vinyl flooring, wire and cable insulation, and flexible PVC products.

 Heat and Light Stability: Stabilizers, including antioxidants and UV stabilizers, help

protect polymers from degradation caused by exposure to heat, light, or oxygen. By

incorporating these additives, manufacturers can extend the lifespan of polymer products

and maintain their properties even under harsh environmental conditions.

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 Flame Resistance: Flame retardant additives reduce the flammability of polymers,

delaying or inhibiting the spread of fire. This is critical in applications where fire safety is

paramount, such as electronics, building materials, and transportation.

 Processability Enhancement: Processing aids improve the processability of polymers

during manufacturing by reducing melt viscosity, improving flow properties, and

enhancing mold release characteristics. This leads to more efficient production processes

and higher-quality end products.

 Aesthetic Appeal: Colorants are additives used to impart color to polymers for aesthetic

purposes or to provide UV protection. By adding colorants, manufacturers can produce

polymer products in a wide range of colors and finishes, enhancing their visual appeal

and marketability.

 Biocidal Properties: Antimicrobial agents inhibit the growth of bacteria, fungi, and other

microorganisms on polymer surfaces, reducing the risk of degradation and contamination.

This is particularly important in applications like food packaging, healthcare products,

and water treatment systems.

 Polymer additives enable manufacturers to tailor the properties of polymers to meet

specific performance requirements for a wide range of applications. By selecting the

appropriate additives and incorporating them into polymer formulations, manufacturers

can enhance the performance, durability, and functionality of polymer products to better

meet the needs of end-users.

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Conclusion

In all areas in polymer technology, health standards must be applied to regulate the use of

additives. Most sensitive problems involve the use of halogen-containing flame retardants, heavy

metals (as used in pigments and PVC stabilizer systems), and plasticizers. Nowadays the main

concerns of society regarding polymer industry is focused on plastic recycling. So far, most

exploited technology is incineration of plastics in order to produce consisting amounts of energy.

Additivation of any particulate can affect the safety of the incineration process, releasing

dangerous combustion by-products in the atmosphere. Fortunately, toxicity and safety issues lead

research and development teams to study more sustainable alternatives with applications in even

wider areas than those originally envisaged.

Therefore, biobased, biodegradable polymer formulations are increasingly studied, and a large

number of biodegradable polymers is already commercially available (Malinconico et al, 2014).

In this regard, substitution of oil-based, synthetic additives with natural compounds acting as

processing aids (Ambrogi et al, 2011), plasticizers (Battegazzore et al, 2014), stabilizers

(Bridson et al, 2015) or antibacterials (Arrieta et al, 2014) is also attracting interest aiming at

manufacturing bio-based and biodegradable polymer formulations.

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