Photostability of HDPE Filaments Stabilized with UV Absorbers (UVA) and Light Stabilizers (HALS) Bhupendra Singh Butola, Ph.D., Mangala Joshi, Ph.D. Department of Textile Technology, IIT Delhi, New Delhi INDIA Correspondence to: Bhupendra Singh Butola email: bsbutola@textile.iitd.ernet.in ABSTRACT HDPE monofilaments were photostabilized with hindered a min e ligh t stabilizers (HALS) and UV absorbers at varying stabilizer concentrations. The filaments were assessed for UV resistance by exposure to simulated outdoor weathering conditions in artificial weathering apparatus and testing the exposed samples at regular intervals for retained tensile properties. Films of HDPE of varying thickness and containing different concentrations of photostbilizers were also prepared. The UV protective ability of the films was assessed by measuring Ultra Violet Protection Factor (UPF). The results indicate that UV absorbers improve the stability of the filaments significantly. However, the best performance was displayed by filaments containing HALS. Various approaches have been used to tackle this problem. For protection of human skin, use of textiles capable of blocking harmful UV radiation during outdoor activity is finding increasing use. The other approach is to use flexible woven/knitted structures as sunscreen shelters made from UV stabilized polymers for outdoor activities. The UV stabilizers used in such applications have to perform twin tasks: The polymer should have a good UV resistance for a reasonably long service life and at the same time should be able to block/absorb the harmful UVR to protect the life and materials under the shelter. The science and technology of UV stabilizers have evolved over the years and today a wide range of UV stabilizers are available commercially. However, the Hindered Amine Light Stabilizer (HALS) class of photostabilizers based on antioxidants, which were developed over thirty years ago, offer excellent performance and have replaced many photostabilization systems [3-6]. Another class of stabilizers, known as UV absorbers, acts by absorbing UVR preferentially to polymers. The compounds belonging to this class are generally used in sunscreen lotions and UV protective textile clothing. Keywords: Ultra Violet Protection Factor (UPF), U V Absorber (UVA), Hindered Amine Light Stabilizer (HALS), weathering, Ultra Violet radiation, photostabilizer. INTRODUCTION The high energy of the solar radiation (200-400 nm), generally known as Ultra Violet radiation (UVR) can cause some undesirable effects in living creatures and may also reduce service life of materials due to its high energy. Almost a l l th e radiation of wavelength below 290 nm is filtered out by the ozone layer in earth’s atmosphere. The large doses, especially in the short UVB range (280-315 nm) may cause sunburns, skin cancer, photokeratitis, photodermatosis etc [1,2]. In addition to its deleterious effects on human beings, it also deteriorates the material properties of apparel, upholstery, draperies, carpets, furniture, paints, electronic parts, building construction materials - wood, plastic panels etc. and other articles of outdoor use and limits their durability and life span. With the alarming increase in the rate of ozone layer depletion in the earth’s atmosphere, the risks involved due to prolonged exposure to solar UV radiation are increasing day by day. Hence it becomes imperative to protect the human skin and other materials from harmful effects of solar UV radiation. Journal of Engineered Fibers and Fabrics Volume 8, Issue 1 – 2013 It is observed that most of the reported literature on development of UV resistant fibers and sunscreens is in patent [7-9] form and not much research/scientific studies on this development and analysis is available. Hence in this study an attempt has been made to develop UV stable HDPE monofilaments capable of providing UV protection, by use of best available photostabilizers and UV absorbers as additives. The aim is to use mixture of these additives at different ratios and to evaluate the performance of photo stabilized HDPE filaments in terms of their durability to UV radiation and their capability to provide UV protection. HDPE was chosen for the study as it is a commodity polymer, easily available at economical price and easy to process. Although pure PE should not absorb 61 http://www.jeffjournal.org (Relene E 52009) was supplied by Reliance Industries Limited with MFI of 50 and 0.9, respectively. Carbon black (Superfine, 30% loading in LLDPE) was provided by SCJ plastics, New Delhi. above 180 nm and hence should not degrade in sunlight [10] (solar radiation does not have light lower than 290 nm) the presence of chromophoric impurities in commercial PE make it susceptible to sunlight. Due to the presence of these moieties which may be introduced during polymerization or processing as carbonyl groups in the polymer (which absorb weakly in 250 – 350 nm region), it starts to absorb UV light and gradually degrades by autoxidation [11-13]. The degradation of polyethylene (HDPE, LDPE and LLDPE) upon exposure to UV radiation has been shown to manifest in alteration of mechanical and physical properties and large chemical changes [14]. The exposure results in progressive cross linking and chain scission [15] of the polymer. Initially, cross linking may dominate which in some cases leads to slight increase in stress at break; chain scission [16] becomes dominant at later stages. Chemical changes result in formation of vinyl groups and several oxygenated functions like carbonyl, carboxyl and ester groups [14, 17]. Generally most of the researchers have focused on monitoring of carbonyl content for assessment of polymer degradation, as it has been shown to be directly related to mechanical and physical property changes. In general, carbonyl content has been shown to increase progressively with exposure level [16, 18, 19]. The exposure to UV radiation results in loss in mechanical properties like stress [20-21] and strain at break; however the strain at break has been a preferred parameter of study for many researchers. A gradual deterioration in strain at break [21-23] initially and sharp drop thereafter has been reported. While the elastic modulus has been shown to increase progressively [16, 20, 23] with exposure, development of surface cracks [18, 24] has also been reported. In thicker samples, the degradation has been shown to be dependent on the thickness of the film/slab [25]. The degradation occurs mostly on outer skin which is supported by gradual decrease in carbonyl content [16, 21] as one moves to the center of slab. The inner layers also have higher stress at break [16] as compared to outer layers. Again, the energy of UV radiation has an influence on the degree of deterioration. Higher energy UV radiation (lower wavelength) causes more degradation than lower energy radiation [26]. FIGURE 1. The structures and the code names of HALS and UVAs used in the study. Masterbatch Preparation Master batches containing 5 wt % photostabilizer in LLDPE were prepared on an SDL-Atlas F255A-D laboratory mixing extruder from SDL International (England). The extruder had automatic rotor and temperature control with a variable speed of 5–260 rpm and a water-cooled hopper. The rotor and die zone temperatures were kept at 160oC and the rotor speed was fixed at 45 rpm. The extrudate was quenched in water and cut to give masterbatch granules. HDPE Monofilament Preparation UV stabilized HDPE monofilaments were prepared by melt mixing and extrusion of HDPE and UV stabilizer masterbatches in Laboratory Extruder (Betol, England). MATERIAL AND METHODS Material Three HALS and four UV Absorbers used in this study were supplied by CIBA Specialty Chemicals, Mumbai. The structures and the code names used in the study are shown in Figure 1. LLDPE (Reclair M 26500) and tape and monofilament grade HDPE Journal of Engineered Fibers and Fabrics Volume 8, Issue 1 – 2013 The composition of stabilized prepared is given in Table I. monofilaments The letter at I position and numeral at II position– identify first additive. 62 http://www.jeffjournal.org one minute residence time at 4-ton pressure and two minute time at 7-ton pressure. After the 5-minute cycle, the sheets were taken out from the press and quickly quenched in running water to allow solidification of the molten film. After cooling, the films were removed from the press and tested for UPF. Numeral at III position – denotes concentration of the first additive. Similarly next three positions identify second additive and its concentration. The letter at VII position identifies 1% carbon black. Films of varying thickness were also prepared to study the effect of film thickness on UPF. The as spun monofilaments were drawn in two stages as per the optimized drawing conditions given in Table II. Artificial Weathering Exposure of the filaments was carried out in an accelerated weathering chamber. The test standard ASTM D 4355 – 84, Standard Test Method for Deterioration of Geotextiles from Exposure to Ultraviolet Light and Water (Xenon-Arc Type Apparatus) was followed for accelerated weathering in accelerated weathering equipment Xenotest Alpha. The test parameters used are given in Table III. TABLE I. The composition of stabilized HDPE monofilaments. TABLE III. Test parameters for accelerated testing. UPF Measurement The UPF of the films was measured in M284 UV Penetration Measurement System (SDL international Ltd, UK). The measurements were done as per Test Method AS/NZS 4399: 1996. TABLE II. Optimized drawing conditions for drawing of as spun monofilaments. Tensile Testing The tensile testing of the exposed and unexposed samples was carried out on INSTRON universal tensile tester, INSTRON, USA. Following test parameters were used. Film Preparation Films of 200 µ thickness were prepared from as spun monofilament granules in a laboratory press (Carver, USA). The granules were spread uniformly between two chrome plated stainless steel sheets and required thickness was obtained by use of suitable spacers between the sheets. Lower and upper platen temperatures were set at 150oC each. After required temperature was attained, the granules were between stainless steel sheets and transferred to the press. A two-minute residence time without pressure was given for the granules to melt and flow. This was followed by Journal of Engineered Fibers and Fabrics Volume 8, Issue 1 – 2013 Gauge Length – 100 mm Traverse speed – 30 mm/min No of Tests per sample – 5 THEORY/CALCULATION UV Protection The UV protection provided by a material or structure is generally measured in terms of its transmissibility to UVR. This is then converted to Sun protection factor (SPF) or Ultra Violet protection factor (UPF) using the formula given below. The conversion of UV transmissibility makes it easier to relate to the UV protection provided by a material in objective terms. 63 http://www.jeffjournal.org Sun Protection Factor (SPF) or TABLE V. The UPF values of HDPE films stabilized with 0.2 % UV absorbers. = Ultra Violet Protection factor (UPF) Where E ‐ S T - Relative erythemal spectral effectiveness Solar spectral irradiance, w/m2 Wavelength step, nm Transmittance of the item, %, measured in steps of 5 nm. From the results it is clear that the relationship between thickness and UPF is not linear. The value of UPF increases sharply with film thickness and this relationship between the UPF and thickness is different for two different stabilizers. RESULTS AND DISCUSSION Criteria for Selection of UV Stabilizers The stabilizers were used alone as well as in combinations as they are known to show synergistic effect. The concentrations of the stabilizers (except Carbon Black) were varied in the range 0.1-0.3 wt % as they are quite effective even at such low levels. To reduce the number of compositions, the type and concentration of the UV absorber was optimized on the basis of its performance on HDPE sheets of 200µm in terms of UPF value. The concentration of the UV Absorbers was kept constant at 0.2% and the results are given in Table IV. TABLE IV. The U PF values of 0.2mm thick HDPE films stabilized with 0.2 % UV absorbers. FIGURE 2. Variation of UPF for various UV absorbers with thickness at 0.2 wt % content. Since the UPF imparted to the HDPE was the highest with UVA2, it was selected for use in combination with HALS for synergistic effect. Carbon black was also selected for the study and used alone at different concentrations as well as in combination with other stabilizers. The reason for its selection was its effectiveness and economic price and in applications where black color is not a constraint, it is a very useful stabilizer. Effect of Stabilizer Concentration on UPF of HDPE Films Similarly, the effect of the stabilizer concentration on UPF of the HDPE films was also studied by preparing the HDPE films of 0.2 mm thickness and increasing concentrations of UVA2. The value of UPF is plotted against concentration and shown in Figure 3. Again it is clear from the figure that UPF of films increases sharply with increase in stabilizer concentration. The relationship between UPF and stabilizer concentration in the film seems to be approximately linear. Effect of Film Thickness on UPF of HDPE Films Films of various thicknesses were prepared from HDPE with the stabilizer concentration maintained at 0.2%. The results are given in Table V and plotted in Figure 2. Journal of Engineered Fibers and Fabrics Volume 8, Issue 1 – 2013 64 http://www.jeffjournal.org the retained strength for different UV stabilizers varied from 35 to 55% only. In comparison, the HALS provided much better performance and the strength retained after the same exposure time was much higher, varying between 78 and 90%. FIGURE 3. Variation of UPF with concentration (for UVA-2) at 200 μ film thickness. Effect of Stabilizer Type and Concentration on the Mechanical Properties of HDPE Monofilaments All the monofilaments prepared by method described in monofilament preparation section described above and having compositions as per Table I were tested in an artificial weathering chamber. The test parameters are described in Table III. The samples were taken out at regular intervals and evaluated for tensile strength and elongation retained. The results are given in Table VI. FIGURE 4. Strength retention of monofilaments stabilized with various additives upon exposure to accelerated artificial weathering conditions. TABLE VI. Retention of strength and elongation of HDPE filaments stabilized with various stabilizer systems after different exposure times. Another interesting observation that can be made from the figure is that among the four UV absorbers tested, UVA 3 provides the best strength retention (55%) after the exposure for 1890 hrs. The remaining UVAs (UVA1, UVA2 and UVA3) were almost identical in terms of % strength retention. Although there was significant difference in the UPF values obtained using these additives, it does not reflect in the stabilization provided to the HDPE filaments. Hence it can be inferred that there is probably no correlation between the ability of an additive to provide protection from UV light (UPF value) and stabilization (% retained strength). As among the four UVAs the best stabilization was provided by UVA3, it was selected for mixing with various HALS in order to obtain possible synergistic effect for stabilization of HDPE filaments. The concentration of HALS was reduced to 0.2%. It is evident that there is practically no loss of strength in all cases at the end of 1890 hrs of exposure. This was to be expected as the stabilization provided with only HALS was quite high. This leaves little scope for differentiation between the three types of HALS or analysis of any kind of synergism between the two types of stabilizers. A longer exposure time would have brought out the differences between various HALS. The results shown in Table VI are selectively plotted in Figure 4. Figure 4 depicts the strength retention of HDPE monofilaments stabilized with UV Absorbers and HAL Stabilizers. It is clear from the figure that unstabilized HDPE filaments lose strength rapidly upon exposure to artificial radiation and practically all the strength is lost much before the 1000 h exposure time. In comparison, UV Absorbers provide good short term stability. However, at the end of 1890 hrs of exposure, Journal of Engineered Fibers and Fabrics Volume 8, Issue 1 – 2013 65 http://www.jeffjournal.org The data indicates that at 0.3 % concentration level, the UV absorbers used in the study provide a service life of approximately 1400 hrs to HDPE filaments. Since the UV absorbers act as photostabilizers primarily by absorbing the UV radiation (which also results in high UPF values of HDPE films, especially with UVA2 and UVA3), it is logical to conclude that loss in their effectiveness after long exposure hours will also result in lower UPF values of stabilized films. This means that polymers stabilized only with UV absorbers not only lose mechanical properties but also their ability to provide the UV protection with time and this aspect is a cause for concern because at some point of time such polymers would cease to provide adequate protection without material actually failing in terms of mechanical properties.. However, UV absorbers are very effective stabilizers in thick sections since decrease in the transmittance of light absorbed increases exponentially with thickness (Lambert’s Law) [27]. The inner middle layers remain unaffected as most of the radiation is absorbed by outer layers. However since the filaments used in the study have a diameter in the range 0.16-0.18 mm, UV absorbers were not very effective when used alone. Table VI also shows the effect of carbon black concentration on the stabilization of HDPE filaments in terms of strength retained. Again it is clear that there is no loss in the strength of filaments after an exposure of 1890 hrs. Again, either a longer exposure time or lower carbon black concentration would have been required to reach a more definitive conclusion. From the data in Table VI the following observations can be made: 1. Pure HDPE filaments lose more than one third of its strength after 325 hrs of exposure. By 797 hrs it has lost practically all strength and becomes brittle in the exposure rack itself. 2. All the stabilized filaments provide good stability till 797 hrs of exposure (retention of almost 90% strength) except the one stabilized only with UVA4. 3. By 1347 hrs, filaments stabilized only with UV absorbers record a drop of approximately 30-50% in strength and extension. At same exposure level, filaments stabilized only with HALS show a drop of only 10-20% only in strength. 4. After 1890 hrs of exposure UV absorber stabilized filaments show further drop in strength (4565%) and Elongation (35-60%). The drop at same exposure level is only 10-20% for HALS. 5. Filaments stabilized only with carbon black and combinations of different stabilizers continue to show very good stabilization against weathering even after 1890 hrs of exposure. The maximum drop in strength or elongation is around 10% only. Hindered amine Light Stabilizers (HALS) being the best UV stabilizers developed till date, provides a much higher stabilization level to HDPE filaments as compared to UV absorbers at the same (0.3%) concentration level. More exposure is required to find out the service life in case of HALS. Carbon Black provides exceptional stability even at 1% concentration (recommended loading is 2-3%) with almost 100% retention in strength and elongation after 1890 hrs exposure. The only problem with carbon black seems to be the black color imparted to HDPE filaments, which may be a deterrent in some applications. Some useful insight about the effectiveness of the stabilizer systems can be obtained from the analysis of the data given in the table. It would be helpful if some criteria can be formulated to define the useful service life of the filaments. Since in this study the effect of weathering on filaments is being evaluated in terms of strength and elongation, the useful service life of the filaments can be defined as the exposure level in terms of radiation dose/exposure time at which the filaments lose 50% tensile strength. The logic in arriving at such a value lies in the fact that most of the filaments had tenacity values higher than 6. After 50% loss in strength the filaments would have a tenacity value higher than 3, a safe level. This can then be converted into years by comparing the radiation dose thus obtained with average annual total solar radiation dose recorded at any of the reference climatic locations. Journal of Engineered Fibers and Fabrics Volume 8, Issue 1 – 2013 The combinations of UVA2 at 0.3% concentration with different HALS at 0.2, 0.3 and 0.4% concentration levels also provides excellent stabilization to HDPE filaments. Again the retention in strength is almost 100% after 1890 hrs exposure. Although higher exposure level is required to arrive at more definitive conclusion, it can certainly be argued that HALS and UV absorbers exhibit synergistic property. Polymer degradation in U V radiation occurs by formation of polymer peroxides and polymer free radicals due to oxygen absorption[13]. These result in chain scission. While UV absorbers 66 http://www.jeffjournal.org absorb most of UV radiation, there is less generation of polymer peroxide and polymers radicals. HALS then can deal more efficiently with these intermediates. [3] It can also be said that combination of HALS with UV absorbers not only improves the life of filaments, it also imparts UV protective property (UPF) to polymers. The combination of UVA2, HALS and carbon black also provides almost total stabilization till 1890 hrs of exposure, which is obvious since carbon black alone is very effective. [4] [5] CONCLUSION A range of HDPE monofilaments photostabilized with different concentrations of UV Absorbers, HALS, carbon black and their combinations in various ratios were prepared and evaluated for photostability to simulated solar radiation in an accelerated weathering chamber. The concentration of the UVAs and HALS varied in the range of 0.2-0.4 wt % and that of carbon black from 1 to 3 wt%. It was observed that while neat HDPE filaments lost almost all tensile strength at around 800 hours of exposure, all photostabilized filaments retained upwards of 90% strength at the same exposure time. Filaments stabilized only with UV Absorbers show a further drop of 30-50 and 45-65% in strength at 1347 and 1890 h exposure respectively whereas the drop is 10-20% only at similar exposure levels for filaments stabilized with HALS. Hence it can be concluded that while UV Absorber stabilized filaments lose strength progressively with exposure to UV light, filaments stabilized with HALS remain stable to UV radiation at up to 800 h exposure time. However filaments stabilized with neat carbon black (1-3 wt %), combination of UVA, HALS and combination of HALS, UVA and carbon black don’t show and drop in strength even after 1890 h exposure. [6] [7] [8] [9] [10] [11] [12] [13] [14] One of the UV Absorbers (UVA-2) improved the UPF value of HDPE film of 200 μ thickness to 135. Hence, there is additional advantage of better UV protection in terms of higher UPF in filaments where UV Absorbers are also used along with HALS. [15] REFERENCES [1] Bajaj P. Kothari V K, Ghosh S B. Some innovations in UV protective clothing. Indian J. Fibre Text. Res 2000; 25; 315-329. [2] Bohringer B, Schindling G, Schon U, Hanke D, Hoffman K, Altmeyer R, Klotz M L. UV Protection by Textiles. Melliand International 1997; 3; 165-167. 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Alterations of molecular characteristics of polyethylene under the influence of UV-radiation, Polymer 2000; 41; 5787–5791. Gijsman P, Jan Hennekens J, Koen J.Comparison of UV degradation chemistry in accelerated (xenon) aging tests and outdoor tests (II). Polymer Degradation and Stability1994; 46; 63-74. Lambert J H. Photometria sive de mensura et gradibus luminis, colorum et umbrae, Augsburg, Germany: Eberhardt Klett, 1760, 391-392. Journal of Engineered Fibers and Fabrics Volume 8, Issue 1 – 2013 AUTHORS’ ADDRESSES Bhupendra Singh Butola, Ph.D. Mangala Joshi, Ph.D. IIT Delhi Hauz Khas New Delhi 110016 INDIA 68 http://www.jeffjournal.org