An engineering plastics manufacturer developed a novel acrylic copolymer for an engineering plastic composite. However, the developed composite did not achieve the targeted Shore D hardness.
The goal of the project was to enhance this critical mechanical property and implement modifications to attain the required hardness levels.
Objective
To enhance the Shore D hardness of a plastic composite manufactured using a novel acrylic copolymer.
Methodology
The following formulation adjustments were recommended:
- Incorporate High-Tg Monomers: Introducing monomers with higher glass transition temperatures can increase the rigidity and hardness of the copolymer.
- Adjust Monomer Ratios: Modifying the ratios of existing monomers can influence mechanical properties. Increasing the proportion of harder monomers relative to softer ones can lead to a copolymer with enhanced hardness.
- Incorporation of Suitable Fillers: Integrating surface-modified nano-silica composites into the acrylic matrix has to enhance hardness and solvent resistance. The optimal incorporation of nano-silica can lead to a significant increase in the composite's hardness.
We did a few iterations to understand the composite's product specification. After experimenting, we recommended a modified raw material ratio to increase the proportion of the harder monomer in the copolymer and the concentration of nano-silica composited in a suitable surfactant.
Testing and Results
Shore D hardness before = 76
Target Shore D hardness = 80
Shore D hardness after = 81
Conclusion
The successful strategic modifications in the monomer composition and the use of appropriate fillers helped tailor the copolymer's shore hardness. A careful selection and optimization of pre-formulation components is essential to achieve the desired mechanical properties of a product. This can be achieved without compromising the other attributes of the composite when done with the right plan and testing.
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Technical Formulation
New Molecular Entity Innovation
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