Ar cle

Control of the mat/gloss balance

SpecialChem / May 10, 2004

Introduction
What is the optical problem?
Ageing of gloss
Which ways to control gloss/mat balance?
The processing parameters
Effect of the roughness of the matching surface during shaping
Choose the right polymer
Effect of mineral pigments and fillers on gloss
Effect of plasticizer level and polymer grade on gloss
Specific additives to make a polymer mat
Specific additives to make a polymer glossy
Conclusion

Introduction

Why is a part attractive or repulsive? The first contact between a human and a thing is the first sight that is impressed by the shape, colour and gloss.

Impression inferred by gloss or mat aspect is partly objective and partly subjective depending on the reflected light, the individual, the purpose of the item, its shape and colour, the ta
a same car it is preferred to have a glossy body part and a mat interior trim.

Gloss can be physically and objectively measured by an optical method but from a marketing point of view it is necessary to test the part with a representative panel of consumers.

What is the optical problem?

As we can see on Figure 1:

An incident beam of light is reflected by a perfectly plane surface with nearly the same intensity and in a homogeneous direction. The angle of reflection is equal to the an
the optimal intensity of light and the surface is glossy.
If there is an unevenness of the surface, the part of the beam that irradiates the unevenness is reflected in other directions and the eye receives only a part of the beam
directions. The material is less glossy or mat if the entire surface is rough.

Figure 1: Principle of light reflection on smooth and rough surfaces

The intensity of the reflected beam varies with the incidence angle, the more so as the roughness increases. The tests (ISO 2813, ASTM D 523, DIN 67530) can be achieved at given

60° for medium gloss surfaces, suitable for gloss reading between 10 and 70 units
2° 0for high gloss surfaces (60° gloss reading superior to 70 units)
85° for mat surfaces (60° gloss reading inferior to 10 units).

To fix ideas:

A glossy ABS or paint for body car achieves a Gardner gloss value superior to 90 units.
A high-pressure laminate for the manufacture of chalkboards achieves a gloss value as low as 10 units.

Ageing of gloss

Like the mechanical properties, gloss evolves during weathering depending on the polymer and the recipe as shown in Figure 2 concerning two PVCs of very different properties.

Figure 2: Effect of weathering on gloss of PVC

Which ways to control gloss/mat balance?

Gloss/mat balance for a given raw material depends on:

The processing parameters

The surface roughness of the matching surface during shaping
The eventual post treatments.

Gloss/mat balance for a given processing depends on:

The choice of the basic polymer: certain polymer families as ABS for example are marketed in various gloss grades such as super, high, medium, low…gloss or mat.
The additives.

The processing parameters

Temperature is very important, notably the mould temperature during injection:

The hotter the mould surface is, the better the melt can reproduce the structure of the cavity.
Too hot a cavity delays cooling because the mould cannot be opened before the demoulding temperature has been reached, and the cycle times are prolonged.
Hot melt being periodically injected into a colder mould, the cavity temperature tends to increase during the moulding phase. On the other hand, the temperature tends to decrease d
phase. Uniform reproduction of the surface and homogeneity of gloss need a uniform temperature level into the mould and between successive moulding sequences.

For example, the same mirror housings made of Novodur show important differences of gloss according to the moulding temperatures, 30°C and 60°C.

Effect of the roughness of the matching surface during shaping

The surface finish of the mould is an important parameter to define the final aspect and all other conditions being identical:

A perfectly polished cavity leads to the glossiest aspect

A satin finish leads to a mat aspect.

Choose the right polymer

Producers market grades targeting defined levels of gloss for specific applications. According to the customers' requirements for the targeted applications, the aspect varies between
examples are listed below without claiming to be exhaustive:

Shine-E Rynite® RE8000 (DuPont) is a super-gloss thermoplastic polyester. In 60-degree- angle gloss testing, sample parts typically achieve scores superior to 90 units. T

Moulded-in colour appliance applications, such as oven door handles, oven components and motor housings.
On-line painted car parts, unpainted super-gloss components for many uses
Off-road vehicles such as ATVs, tractors or riding mowers, particularly for parts exposed to engine or exhaust heat.

Surlyn Reflection Series, alloys of ionomer and nylon, permit rugged moulded-in colours that facilitate paint-free manufacturing. The new Blast sports motorcycle, from Ha
body parts of this super-gloss alloy.
Avantra 525K (BASF) is a medium impact grade of polystyrene with exceptional gloss, developed primarily for extrusion and thermoforming applications. Avantra 525K is
glossy cap layer over HIPS sheet used in durable goods such as refrigerator liners and shower/tub surrounds. Gardner gloss (60° - ASTM D523) is 95.
Basell develops Lampro GRP Sheet, a range of surface finishes including Embossed, Standard Satin or Gloss and Gelcoated GRP combining High or Super Gloss with a
STYRON A-TECH 1110 resin is a high-gloss styrenic resin with Gardner gloss levels up to 95 based on Dow's patented new technology for polystyrene production.
suitable for use with in-housing colouring systems.
Formalloy HG™ (Spartech) is a new proprietary thermoformable polypropylene alloy with Gardner gloss tested on formed parts of 80 (60° Angle) and 55 (20° Angle). UV
applications in the marine, automotive, recreational vehicles, agricultural, lawn & garden, and medical markets.
Lexan SLX (GEP) film is laid on top of a thermoformed substrate. The Lexan SLX/substrate is designed to suppress painting. GE claims to have achieved Gardner gloss s
units for some car paints. The gloss is retained after a long period of time outdoors, remaining above 95 gloss units after three years of artificial weather testing.
Clear-Lay is a rigid PVC film /sheet for thermoforming, with claimed gloss value superior to 95 (Gardner 60- ASTM-D523). It is suitable for die cutting, welding, gluing and
K-mac Maclac Low Gloss ABS 170 Plastic Resin is an ABS with gloss value of 25 (Gardner - ASTM D523)
PANELYTE™ is a high-pressure laminate with gloss value of 10 units suitable for the manufacture of chalkboards.

Effect of mineral pigments and fillers on gloss

Figure 3 compares in a same PVC recipe:

A rutile titanium dioxide

A photostable rutile titanium dioxide
A barium sulphate.

Figure 3: Effect of pigment on gloss of PVC during weathering

The effects of pigment nature and treatment of rutile are very significant.

Talc's lamellar platelets enhance matting.

Mica can promote glossy effects.

Effect of plasticizer level and polymer grade on gloss

Figure 4 compares the gloss of a same basic PVC recipe, differing by the:

Polymer grades.
Plasticizer level, 30 to 50 phr of the same plasticizer.

Figure 4: Effect of plasticizer level on gloss of three PVC recipes

differing by the polymer grade

Specific additives to make a polymer mat

The principle for matting the surface is to create a roughness by adding:

 Special mineral fillers.
Another secondary polymer more or less miscible with the main polymer.
Proprietary additives.

Special mineral fillers

Special silicas such as Acemat® products based on precipitated silicas, Ketjensil, Nanogel hydrophobic silica aerogels are marketed for their matting properties.

Alloys: example of TPOs

By the variation of the type and the level of EPDM in a TPO, it is possible to obtain gloss values (Figure 5) in a range of 44 to 74 (60° angle). Unfortunately, the other properties are als

Figure 5: Effects of EPDM types and levels on gloss of three TPOs

Proprietary matting agents

Acemat® OP 278 is a copolymer made from the monomer building blocks methylmethacrylate (MMA), styrene (S) and butylacrylate (BA). The matting particles (BA, S) a
significantly reduces the residual gloss of calendered film or blow film. It is suitable for soft and rigid PVC, polystyrene, ABS, SAN or PUR.
STRUKTOL® V-MAT G, a mixture of additives and light coloured aliphatic resins with a molecular weight below 2000, is highly effective for matting and texturing of rigid PV
'Tospearl', a unique solid particulate silicone resin produced by TOSIL (GE Silicone affiliate) can be used as matting agent without otherwise affecting release properties.
Orgasol®, ultra fine polyamide powders with a porous structure and a narrow particle size distribution are marketed by Atofina as non-thixotrope matting agents.
Vinnolit C 100 V, P 90, C 65 V and C 66 W are high-molecular weight PVCs that act as matting agents when blended with a paste-making PVC.
Acryperl® 100 (Atofina) consisting of very fine pearls of crosslinked copolymer containing acrylic monomers is a matting agent for PVC.

Specific additives to make a polymer glossy

The principle to obtain more glossy polymers is to reduce roughness or to add a new surface on the part. Let us quote some examples:

Polishing: plastics as well as metals can be polished to increase their gloss.

Post-moulding: sheets or plates can be post-moulded in perfectly polished moulds to obtain glossy sheets or plates.
Lay out of films, IMD (In Mould Decoration), FIM (Film Insert Moulding), IMC (In mould Coating), painting, gelcoating: the gloss of the film or the paint gives the final gloss

Conclusion

A convenient gloss/mat balance is important to retain the attention of prospects and customers. Unfortunately, polymers have very various optical properties and their aspect can be in
a deep mat and there are all the steps between both.

If the other properties allow it, the choice of plastics inherently adapted to the desired gloss/mat balance is advised.

If the specifications and customer's demands require a definite polymer it is possible to modify its gloss/mat balance by:

Optimisation of processing.
Use of convenient cavity surface.
Modifying the formulation and use proprietary additives.
Polishing the part.
Post-moulding in perfectly polished moulds.
Covering the polymer with a glossy film or a paint or a gelcoat.

References:

Technical books and guides, papers, websites: Akzo Nobel, Atofina, Basell, BASF, Byk, Cabot, Clariant, Degussa, DuPont, GEP, Hoechst, Mclac, Omya, PK Enterprises, PRW, Rainguard, Schulman, Solvay, Spartech, Struktol, Un

VASUDEO Y.B. AND ALL. (Antec 2001, p.2423)

DALPIAZ J. (SPE, Automotive TPO, 2000, p.333)
GESENHUES U. (Polymer Degradation and Stability, 68, 2000, p.185)
SAETHRE B. AND ALL. (Plastics, Rubber and Composites, 28, 4, 1999, p.170)
DHARIA A. (Antec'99, 1999, p.1703)