Cellular Nanocomposites: a new type of light weight advanced

materials with improved properties

Dr. Miguel ngel Rodrguez Prez

OUTLINE
o BACKGROUND ON CELLULAR MATERIALS
o CELLMAT TECHNOLOGIES
o CELLULAR NANOCOMPOSITES: THE CONCEPT
o PRODUCTS DEVELOPED UNDER THIS CONCEPT
o IMPROVED STRUCTURAL FOAMS: ANICELL TECHNOLOGY.
o IMPROVED THERMAL INSULATORS
o SUMMARY AND CONCLUSIONS
o CONTACT

CELLULAR MATERIALS: DEFINITION

Cellular Materials (also known as FOAMS) are two phases materials in which
a continuous gas phase has been dispersed in a solid phase.

Open cell cellular materials

Closed cell cellular materials

CELLULAR MATERIALS ARE PRESENT IN NATURE

Natural Cellular Materials

Cellular structures in nauture: a) bone b) wood

Natural cellular materials:

(a) cork (b) balsa
(c) sponge (d) trabecular bone
(e) coral (f) cuttlefish bone
(g) iris leaf (h) plant stalk

CELLULAR MATERIALS: ADVANTAGES

ADVANTAGES OF POLYMERIC CELLULAR MATERIALS (also known as POLYMER
FOAMS)
WEIGHT AND COST REDUCTIONS
REDUCTION OF RAW MATERIAL CONSUMPTION WITH THE SUBSEQUENT
ENVIROMENTAL BENEFITS
POSSIBILITY OF PRODUCING LIGHTWEIGHT MATERIALS WITH HIGH STRENGTH AND
STIFFNESS
EXCELLENT THERMAL INSULATION
EXCELLENT IMPACT ENERY ABSORPTION
POSIBILITY OF PRODUCING MATERIALS WITH ACOUSTIC ABSORPTION CAPABILITIES

CELLULAR POLYMERS: THE MARKET

10 % of the plastic resins used nowadays are used for the production of cellular polymers
(27 millions of Tons in 2011). This is around 40000 millions of Euros
Material
Polyurethane
Polystyrene
PVC
Polyolefins
Otther

Tons in 2011
1,50E+07
6,45E+06
4,18E+06
1,15E+06
3,24E+05

Average annual gorwth rate

3,6
1,2
2,6
3,8
2,3

Assuming an average density of 50 kg/m3 and 10 mm thick samples the surface of the material produced in
one year is 54 000 km2. (1/10 THE SURFACE OF SPAIN)

OUTLINE
o BACKGROUND ON CELLULAR MATERIALS
o CELLMAT TECHNOLOGIES
o CELLULAR NANOCOMPOSITES: THE CONCEPT
o PRODUCTS DEVELOPED UNDER THIS CONCEPT
o IMPROVED STRUCTURAL FOAMS: ANICELL TECHNOLOGY.
o IMPROVED THERMAL INSULATORS
o SUMMARY AND CONCLUSIONS
o CONTACT

CELLMAT TECHNOLOGIES
CELLULAR MATERIALS LABORATORY:
UNIVERSITY OF VALLADOLID; SPAIN

Spin-off company of the University

of Valladolid. Established in October
2012:

International recognized laboratory established

in 1999 in the are of cellular materials and
bioplastics:
125 scientific papers
10 patents and several novel technologies
12 Ph D thesis
More than 50 research projects
Strong collaborations with companies around
the world
www.cellmat.es

Specific and novel

know-how and
technologies on
advanced cellular
materials

Lincenses
tranfer
agreements

Transferring knowledge and

technology on cellular materials and
bioplastics to industrial partners.
Advising to plastics producers in
manufacturing better and cheaper
materials using specific know-how.
Producing advanced foams and/or
formulations for foaming applications

CELLMAT TECHNOLOGIES
CellMat Technologies offers to its customers several products related with the OPTIMIZATION AND IMPLEMENTATION
OF NOVEL PROCESSES AND MATERIALS.

COST SAVINGS
BETTER PERFORMANCE
IMPROVED PRODUCTIVITY
ADAPTATION TO THE MARKET

CELLMAT PRODUCTS
o
o
o
o
o

o
o
o
o
o
o
o
o

Specialized know-how
Specific working methodology
Quikness and no intereference with
production process.
Achievable results in short term periods.
Low cost industrial trials.
Scaling up at customers facilities.
Specific training for the involved staff.
High degree of commitment with our
customers.

CELLMAT TECHNOLOGIES

IMPLEMENTATION OF FOAMING PROCESSES

OPTIMIZATION OF CELLULAR MATERIALS: PROCESS & PRODUCT
SUBSTITUTION OF OIL-DERIVED PRODUCTS BY BIOPLASTICS
TECHNICAL CONSULTANCY IN HALOGEN FREE FLAME RETARDANCY
SPECIFIC TRAINING COURSES

o
o
o

STAGES MOULDING
OPENCELLMAT
ANICELL

Based on the use of nanoparticles

OUTLINE
o BACKGROUND ON CELLULAR MATERIALS
o CELLMAT TECHNOLOGIES
o CELLULAR NANOCOMPOSITES: THE CONCEPT
o PRODUCTS DEVELOPED UNDER THIS CONCEPT
o IMPROVED STRUCTURAL FOAMS: ANICELL TECHNOLOGY.
o IMPROVED THERMAL INSULATORS
o SUMMARY AND CONCLUSIONS
o CONTACT

CELLULAR NANOCOMPOSITES
CELLULAR NANOCOMPOSITES
Polymer containing nanofillers

Cellular structure

Weight reduction
Saving of raw materials and costs
High stiffness and specific strength
Thermal insulation and acoustic
absorption
Tailor-made properties

CELLULAR NANOCOMPOSITES
MULTIFUNTIONAL ROLE OF NANOPARTICLES IN CELLULAR MATERIALS
EFFECTS IN THE SOLID MATRIX

Modifying

Improving

Improving

Improving

polymer

Thermal

Mechanical

Flame

morphology

stability

performance

retardancy

EFFECTS IN THE FOAMING BEHAVIOR

Nucleating

Modification

Improving

agents for the

of Polymer

Barrier

cells

rheology

properties

CELLULAR NANOCOMPOSITES
Cellular material properties

Cellular structure

Properties of the material in the

cell walls

Act as nucleating
agents for the
cells
Modification

Improving

of Polymer

Barrier

rheology

properties

Modifying

Improving

Improving

polymer

Thermal

Mechanical

morphology

stability

performance

Improving
Flame
retardancy

SINERGETICS EFFECTS SHOULD BE EXPECTED

BETTER IMPROVEMENTS IN THE PROPERTIES OF FOAMS THAN IN SOLIDS OF THE SAME
COMPOSITION
BETTER PROPERTIES THAN CONVENTIONAL CELLULAR POLYMERS

OUTLINE
o BACKGROUND ON CELLULAR MATERIALS
o CELLMAT TECHNOLOGIES
o CELLULAR NANOCOMPOSITES: THE CONCEPT
o PRODUCTS DEVELOPED UNDER THIS CONCEPT
o IMPROVED STRUCTURAL FOAMS: ANICELL TECHNOLOGY.
o IMPROVED THERMAL INSULATORS
o SUMMARY AND CONCLUSIONS
o CONTACT

IMPROVED STRUCTURAL FOAMS: ANICELL TECHNOLOGY

Sandwich panes are currently used in several
sectors to produce light weigh composites
P

CELLULAR
CORE

SKINS

SKINS

CORE

IMPROVED STRUCTURAL FOAMS: ANICELL TECHNOLOGY

Balsa Wood

PVC foams

LM Glassfiber
Azimut Benneti

Low world availability

High prices

Lack of homogeneity

Why Polypropylene (PP)?

Low Price.
Wide Availability.
High stiffness and strenght.
Easy processability.
However
Poor foaming capability.

Why Nanocomposites?
NANCORE

Nanoscale enhance mechanical

properties
Synergetic effects
However

POLYPROPILENE BASED
LackFOAMS
of knowledge about the physics of foaming.
NANOCOMPOSITE

IMPROVED STRUCTURAL FOAMS: ANICELL TECHNOLOGY

1- A novel production process
called
Improved Compression Moulding

2- Formulations based on non crosslinked polymer

matrix:

One-step production method.

Common industrial equipment: Presses
Pressures between 5 and 80 bars.
Temperatures around 200C.
Short cycle times.

Thermoplastic polymers suitables for foaming.(HMS

PP, PET etc.)
Blowing Agents.
Nanofillers.
Fire retardants.

IMPROVED STRUCTURAL FOAMS: ANICELL TECHNOLOGY

PP without nanopartciles
PP with nanoparticle s
(less stable foam)
(more stable foam)
Possibility of reducing the density and improving the cellular structure by using nanofillers

IMPROVED STRUCTURAL FOAMS: ANICELL TECHNOLOGY

FILLED POLYPROPYLENE

Anisotropy Ratios: 2.3-2.5

IMPROVEMENT OF THE MECHANICAL

PROPERTIES BY THE FILLERS
ADDITION

IMPROVED STRUCTURAL FOAMS: ANICELL TECHNOLOGY

o AniCell CC exhibits similar or even higher mechanical performance than crosslinked PVC and rigid PU foams.
o AniCell OC products presents superior mechanical properties (both in compression and shear than PU based
rigid foams). ICM technology possibilities combining high degree of cell interconnection and excellent
mechanical performance.

IMPROVED STRUCTURAL FOAMS: ANICELL TECHNOLOGY

From an economical point of

view, AniCell represents an
economically viable alternative
to products such as PVC or PU
foams

IMPROVED STRUCTURAL FOAMS: ANICELL TECHNOLOGY

AniCell cores can be used in strategic sectors such as:
o
o
o
o
o
o
o

BUILDING AND CONSTRUCTION

AUTOMOTIVE
RENEWABLE ENERGIES
AERONAUTICS
NAVAL INDUSTRY
TRAINS
ETC

o
o
o

Thermal insulation
Acoustic insulation
Fire protection

Core of sandwich structures

included in the hull of yachts

Core of sandwich panels for

aircraft interiors

Filling material for blades in

wind turbines

Core of sandwich panels for train

interiors, floors, doors, etc.

IMPROVED STRUCTURAL FOAMS: ANICELL TECHNOLOGY

LOW DENSITIES: 90-200 kg/m3
NON-CROSSLINKED PP BASED
HIGH MECHANICAL PROPERTIES
CLOSED AND OPEN CELL VERSIONS
COST SAVINGS

OUTLINE
o CELLMAT TECHNOLOGIES
o CELLULAR NANOCOMPOSITES: THE CONCEPT
o PRODUCTS DEVELOPED UNDER THIS CONCEPT
o IMPROVED STRUCTURAL FOAMS: ANICELL TECHNOLOGY.
o IMPROVED THERMAL INSULATORS
o SUMMARY AND CONCLUSIONS
o CONTACT

IMPROVED THERMAL INSULATORS

Thermal insulation
One of the main applications of cellular materials is the thermal insulation
(buildings, pipes, fridges...), with a high social, environmental and economic impact.

13.15%

13.15%
26.3%

14.7%
14.7%

Commercial buildings
Commercial buildings

27.9%
27.9%

31.1%
31.1%

Transport
Transport

Manuf acturing Industry

Manufacturing Industry

Households (Residential)-others
Households (Residential)

Households (Residential)-climatization

75% power consumption*

Optimal thermal insulation
75% CO2 emissions*
*Study from BASF. Dinamic simulation (Passiv Haus Institut)

IMPROVED THERMAL INSULATORS

XPS (extruded polystyrene) FOAMS ARE WIDELY USED AS THERMAL
INSULATORS IN BUILDING AND CONSTRUCTION
(SIX MILLIONS OF TONS IN 2011)

DUE TO RESTRICTIONS IN THE USES OF GASSES WITH GLOBAL WARNING POTENTIAL

THE MAIN STRATEGY FOR IMPROVEMENT IN THIS AREA IS REDUCING CELL SIZE OF
THE FINAL FOAM: THIS REDUCES THE THERMAL CONDUCTIVITY
SPECIFIC NANOPARTICLES COULD BE VERY HELFULL FROM THIS POINT OF VIEW.

IMPROVED THERMAL INSULATORS

In PS FOAMS nucleating agents are used during production
Talc: Conventional nucleating agent in foamed extruded sheets
(3 microns in size)

Potential nucleation density: 1010 cells/m3

Alternative: Nanoclays with a much lower size.

Potential Nucleation density: 1013 cells/cm3

COMPARING THE STRUCTURE AND PROPERTIES OF PS FOAMS

PRODUCED USING TALC AND SPECIFIC TYPE OF NANOCLAYS

IMPROVED THERMAL INSULATORS

Talc 1%

1 wt.% clays

0.25 wt.% Clays

3 wt.% clays

0.5 wt.% clays

5 wt.% clays

IMPROVED THERMAL INSULATORS

Main characteristics of samples containing different contents
of clays.
Sample

Cell size
(m)

Standard
deviation (m)

Cell density
(cells/cm3)

Talc 1%

73.01

27.2

1.75108

clays 0.25 %

29.18

13.4

1.36109

clays 0.5 %

30.35

17.3

1.30 109

clays 1 %

30.56

14.4

1.35109

clays 3%

18.37

6.6

1.101010

Clays 5%

11.46

3.9

2.561010

Significant reduction of cell size versus talc

IMPROVED THERMAL INSULATORS

Clays content (%)

Clays content (%)

SIGNIFICANT REDUCTION OF THERMAL CONDUCTIVITY AND

STRONG INCREASE OF THE MECHANICAL PROPERTIES.
BETTER PERFORMANCE AND POSSIBILITY OF DENSITY
REDUCTION (COST REDUCTION)

OUTLINE
o CELLMAT TECHNOLOGIES
o CELLULAR NANOCOMPOSITES: THE CONCEPT
o PRODUCTS DEVELOPED UNDER THIS CONCEPT
o IMPROVED STRUCTURAL FOAMS: ANICELL TECHNOLOGY.
o IMPROVED THERMAL INSULATORS
o SUMMARY AND CONCLUSIONS
o CONTACT

SUMMARY AND CONCLUSIONS

o Cellular polymers or polymer foams are important materials in
man made world. They are materials with increasing importance in
all industries. They have the ability to reduce weight, and costs,
improve the mechanical performance at low weight and contribute
to thermal and acoustic management.
o Nanoparticles can improve significantly the properties of cellular
polymers. SINERGY BETWEEN FOAMING AND NANOPARTICLES.
This novel materials are very close to commercial success in several
market sectors.
o Participating in European projects is challenging but an active
participation can improve in a very significant extend the
knowledge and skills of any company and/or research group.

OUTLINE
o CELLMAT TECHNOLOGIES
o CELLULAR NANOCOMPOSITES: THE CONCEPT
o PRODUCTS DEVELOPED UNDER THIS CONCEPT
o IMPROVED STRUCTURAL FOAMS: ANICELL TECHNOLOGY.
o IMPROVED THERMAL INSULATORS
o SUMMARY AND CONCLUSIONS
o CONTACT

THANK YOU VERY MUCH

FOR YOUR ATTENTION.

CONTACT
CELLMAT TECHNOLOGIES S.L.
CENTRO DE TRANSFERENCIAS Y
TECNOLOGAS APLICADAS (CTTA)
PASEO DE BELN 9A OFICINA 105
47011, VALLADOLID
TELFONO:+34 983 189 197
info@cellmattechnologies.com
www.cellmattechnologies.com