Thermoplastic elastomers costs

Because of increased production and the lower cost of raw material, thermoplastic elastomeric materials are a significant and growing part of the total polymers market. World consumption in 1995 is estimated to approach 1,000,000 metric tons (3). However, because the melt to soHd transition is reversible, some properties of thermoplastic elastomers, eg, compression set, solvent resistance, and resistance to deformation at high temperatures, are usually not as good as those of the conventional vulcanized mbbers. AppHcations of thermoplastic elastomers are, therefore, in areas where these properties are less important, eg, footwear, wine insulation, adhesives, polymer blending, and not in areas such as automobile tires. 

For over a century plastics have successfully competed with other materials in old and new applications providing cost-performance advantages, etc. In fact within the plastic industry there is extensive competition where one plastic competes with another plastic. Examples include many such as thermoplastic elastomers vs. thermoset... 

There are two approaches to the combining of scrap rubber and plastics. The initial interest was to use the cmmb in minor proportions to toughen the plastics improving impact strength and reduce the overall cost. A more recent interest is to develop a type of thermoplastic elastomer (TPE) wherein the mbber is the major component bonded together by thermoplastics, which can be processed and recovered as thermoplastics. 

The hydrogenation of the centre block of SBS copolymer produced oxidation stable thermoplastic elastomer. This product was commercialized by the Shell Development Company under the trade name of Kraton G. The field of thermoplastic elastomers based on styrene, 1-3-butadiene or isoprene has expanded so much in the last 10 years that the synthetic rubber chemist produced more of these polymers than the market could handle. However, the anionically prepared thermoplastic system is still the leader in this field, since it produced the best TPR s with the best physical properties. These TPR s can accommodate more filler, which reduces the cost. For example, the SBS Kraton type copolymer varies the monomer of the middle block to produce polyisoprene at various combinations, then, followed... 

The following TPs are the main thermoforming materials processed high-impact and high-heat PS, HDPE, PP, PVC, ABS, CPET, PET, and PMMA. Other plastics of lesser usage are transparent styrene-butadiene block copolymers, acrylics, polycarbonates, cellulosics, thermoplastic elastomers (TPE), and ethylene-propylene thermoplastic vulcanizates. Coextruded structures of up to seven layers include barriers of EVAL, Saran, or nylon, with polyolefins, and/or styreneics for functional properties and decorative aesthetics at reasonable costs.239-241... 

High molecular weight PTHF has excellent elastomeric properties but its price is four to five times higher than that of usual rubbers. However, low molecular weight glycols, which are easily prepared from THF and are very useful for the preparation of polyurethanes and polyester thermoplastic elastomers, has been commercially developed inspite of these high costs. 

Hybrid versions of silicone-thermoplastic semi-IPNs have been developed (19). A hybrid interpenetrating network is one in which the cross-linked network is formed by the reaction of two polymers with structurally distinct backbones. Hydride-functionalized siloxanes can be reacted with organic polymers with pendant unsaturated groups such as polybutadienes (5) in the presence of platinum catalysts. Compared with the polysiloxane semi-IPNs discussed earlier, the hydride IPNs tend to maintain mechanical and morphologically derived properties, whereas properties associated with siloxanes are diminished. The probable importance of this technology is in cost-effective ways to induce thermoset characteristics in thermoplastic elastomers. 

Block copolymers are an important class of polymers used in many applications from thermoplastic elastomers to polymer-blend stabilizers. Their synthesis is most often done by ionic polymerization, which is both costly and sometimes difficult to control. However, block copolymer properties strongly depend, for example, on the exact chemical composition, block molar mass, and block yield. These parameters can be evaluated in a single experiment using copolymer GPC with multiple detection. 

Because of low cost, high heat deflection temperature (HDT (104°C)), notched impact resistance, improved low temperature impact and flexibility, weather resistance, flame retardancy, and impact resistance, the PP/EPDM blend has got a widespread applications. These unique characteristics of this thermoplastic elastomer blend make it an attractive alternative to conventional elastomer in a variety of markets such as automobile industries, wire, cable insulator, automobile bumpers and fascia, hose, gaskets, seals, weather stripping, among others. 

The market of PP/EPDM blends has grown dramatically because of its recycling abihty and processability by conventional thermoplastic processing equipment. The unique characteristics of thermoplastic elastomer made it an attractive alternative to conventional elastomers in a variety of markets. Liu et al. showed from the experimental blends (53) that materials cost reduction of between 30% to 50% is possible in comparison to commercial products if one applies the PP/EPDM blends to the construction of a basketball court, a tennis court, and a roller hockey rink, which were estimated around 7000, 14,000, and 40,000, respectively. The cost comparison took into account the percentage of rubber or PP used in experimental blend, the exponential factor for a scale-up process and the overall surface area of the specific applications. Among many possible application of this blend two readily feasible applications are roofing and flooring. 

Thermoplastic elastomeric materials have many important applications including cable and wire especially in mineral, electronic equipment, and automobile industries. The most commonly used method of obtaining thermoplastic elastomer in materials is to toughen plastics by blending rubbers and plastics. Among the most versatile polymer matrices, polyolefins such as PP are the most widely used thermoplastics because of their well-balanced physical and mechanical properties and their easy processability at a relatively low cost, which makes them a versatile material. PP has the disadvantage of... 

Other hot melts are based on low molecular weight polyethylene, combined with tackifying agents. These tend to be lower in cost and performance than the EVA-based hot melts, and they are used primarily with paper packaging, such as cartons and multi-wall bags. Atactic PP can also be used as the base for hot melt adhesives. Pressure-sensitive hot melt adhesives for tapes and labels often employ thermoplastic elastomers, consisting of block copolymers of styrene and butadiene or isoprene. 

The lower cost of thermoplastic processing is the motivation for the development of thermoplastic elastomers. However, failure in the achievement of truly... 

Resistance to hydrocarbon oils/solvents and maximum use temperature are key performance parameters for TPEs that dictate in which applications they can be used. As expected, higher performance thermoplastic elastomers are more expensive (Kear, 2003). A qualitative comparison of cost vs. performance is shown for various classes of thermoplastic elastomers in Figure 13.22. Styrenic block copolymers such as SBS and SEES are less costly than TPVs but have reduced oil resistance and lower maximum use temperatures. The advantage of SEES over SES with regard to temperature resistance is not... 

As stated previously, styrene-diene triblock copolymers are the most important category of thermoplastic elastomers. Unlike most other TPEs, they can be blended with large quantities of additives without a drastic effect on properties. In almost all applications, the actual triblock copolymer content is less than 50%. Oils are used as a processing aid and do not result in a significant loss of properties if the polystyrene domains are not plasticized. For this reason, naphthalenic oils are preferred. The use of inert fillers such as clays or chalks reduces the cost of the final material. Unlike conventional rubbers, inert fillers do not have a substantial effect on the mechanical properties of TPEs. Thermoplastics such as polyethylene or polypropylene are also used to improve the solvent resistance and can increase the upper service temperature. Polystyrene homopolymer is used as a processing aid, which also increases the hard phase weight fraction and causes the material to stiffen. 

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