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CH2--Si O Si O - Si
|
CH2- Si O Si O
Branched silicon resin.
Depending type of monomer, they may be homopolymer (made up of same monomer) or
Co-polymer (made up of different monomers)
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Ex. CH2 CH2 - n
H2N (CH2)6 NH C (CH2)4 C NH Homopolymer
Nylon 6,6
Polyethylene
(Co-polymer)
POLYMERISATION: It may be defined as the process of linking or joining together small
molecules like monomers to make large molecules.
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exact multiple of basic monomeric molecules. This monomeric molecule contains one
or more double bonds. By intermolecular rearrangement of these double bonds makes
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the molecule bifunctional. In this polymerization process light, heat and pressure or
catalyst is used to breakdown the double covalent bonds of monomers.
2R
(Free radicals)
(1)
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The second part of initiation under the addition of this radical to the just moment molecule (M)
to produce the chain initiating species M1.
R
Free radical
M1
.(2)
monomer molecule
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The two different modes of terminations can be represented in general terms by:
M*n + M*m M*n+m (Coupling)
M*n + Mm* Mn + Mm (Disproportionation)
What is Plastic?
Plastics are the materials that show the property of plasticity and can be
moulded into any desired shape and dimensions by the application of heat and pressure.
Plastics having variety of properties are in use in present applications. The properties are low
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thermal and electrical conductivities, easy to fabricate, low specific gravity etc. The plastics
can be fabricated for large number of colours and can be used for decorative purpose. Plastics
can be used to produce complicated shapes and accurate dimensions very cheaply by moulding
process. Plastics are generally used for making automobile parts, goggle, telephones, electrical
instruments, optical instruments, household appliances etc. plastics having high wear resistance
properties can be used for making gears, bearings etc.
Merits of Plastics
1.
2.
3.
4.
5.
6.
7.
Plastics can be made according to the order like hard, soft, rigid, tough, brittle,
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malleable etc.
8.
9.
10.
11.
12.
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Demerits of Plastics
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Thermoplastics
These are processed
by
Thermoset plastics
addition 1. These are proceed by condensation
polymerization.
2.
Polymerization.
Softens on heating and retaining the same 2. These are infusible and insoluble
chain on cooling.
3.
They are along chain linear polymers 3. They are branched or cross-linked
without any branched or cross linked
Polymer.
chain.
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4.
On repeated heating and cooling, there is 4. Some sort of chemical changes occur
On heating.
no change in chemical nature.
5.
These plastics undergo purely physical 5.These Plastics undergo physical as well
As chemical process.
process.
6.
7.
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compounding of plastics:
materials like plasticizers, fillers of extenders, lubricants, dies and pigments to the
thermoplastic and thermosetting plastics to increase their useful properties like strength,
toughness, etc. Resins have plasticity or binding property, but need other ingredients to be
mixed with them for fabrication into useful shapes.
Compounding of plastics:
Many plastics are virtually useless along but are converted into highly
serviceable products by combining them with a variety of additives, stabilizers etc., by the
compounding process. The exact formulation will depend upon the specific application
requirement. The different additives impart different physical properties which are used to
improve the performance of the plastic materials. Additives are widely used for thermoplastics,
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thermo sets and elastomers like phenolics or amino resins are useless alone but by the addition
of fillers, resins etc., they give a reversible products. Some of the compounding materials are
stabilizers, plasticizers, fillers, colorants or pigments, lubricants and accelerators.
reduce the cracking on the surface. Plasticizers are added to the plastics to increase flexibility
and toughness. Plasticizers also increase the flow property of the plastics.
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Example
Dibutytyle oxalate, Castor oil and Tricresyl phosphate
ii).
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fillers or Extenders
Fillers are generally added to thermosetting plastics to increase elasticity and crack
resistance. Fillers improve thermal stability, strength, non combustibility, water resistance,
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wood flour, Asbestos, Mica, Cotton, Carbon black, Graphite, Barium sulphate etc.
iii)
These are added to impart the desired colour to the plastics and give decorative effect.
iv
Lubricants
These are added to prevent the plastics from sticking to the moulds.
Example
Oils, Waxes, Soaps etc.
Thus the objective of compounding is to improve the properties of the basic resin, such
that the fabrication is made easy.
Fabrication of plastics:
Many methods of fabricating plastics into desired shaped articles are employed. This
production of plastics is known as fabrication of plastics. The methods, usually depends upon
the types of resins used i.e., whether thermosetting or thermoplastic. Different fabrication
techniques are described below.
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Moulding of Plastics
Moulding of plastics comprises of forming an article to the desired shape by application
of heat and pressure to the moulding compounds in a suitable mould and hardening the
material in the mould. The method of moulding depends upon the type of resins used.
i) Compression moulding:
This method is applied to both thermoplastic and thermosetting resins. The predetermined
quantity of plastic ingredients in proper properties are filled between the two half pieces of
mould which are capable of being moved relative to each other heat and pressure are than
applied according to specifications. The containers filled with fluidized plastic. Two halves are
closed very slowly. Finally curing is done either by heating or cooling. After curing the
moulded article is taken out by opening the mould parts.
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When the materials have been cured sufficiently, half of the mould is opened to allow the
injection of the finished article without any deformation, etc. Heating is done by oil or
electricity.
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In this method, the principle is like injection moulding. The moulding powder is heated in a
chamber to become plastic. Later it is injected into a mould by plunger working at high
pressure through orifice. Due to this heat is developed and the plastic melts, takes the shape of
the mould.
d) Extrusion moulding:
This process is useful in the preparation of continuous wires with uniform cross section. The
heated plastic is pushed into the die with the help of screw conveyor. In the die, the plastic gets
cooled due to the exposure to atmosphere and by artificial air jets.
Extrusion moulding is used mainly for continuous moulding of thermoplastic materials into
articles of uniform cross section like tubes, rods, strips, insulated electric cables. The
thermoplastic ingredients are heated to plastic condition and then pushed by means of a screw
conveyor into a die, having the required outer shape of the article to the manufactured. Here
the plastic mass gets cooled, due to the atmospheric exposure (or artificially by air jets). A long
conveyor carries away continuously the cooled product.
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Differences
between
compression
techniques:
Compression Moulding
1. The plastic ingredient in proper
and
injection
moulding
Injection moulding
1. In this, the heated plastic is injected
is
applicable
thermoplastic
to
both
2. It is applicable to thermoplastic
and thermosetting
resins.
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plastic resins
4. It is less expensive.
4. It is expensive
of articles to be moulded.
8. High moulding cost.
articles to be moulded.
8. Less moulding cost.
Polyethylene:
This can be obtained by the polymerization of ethylene at 1500 atm and a temperature 150
250 0C in presence of traces of oxygen.
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Properties:
Depending upon the density, they may be LDPE and HDPE. If we use free radical initiator,
LDPE is the product while use of ionic catalysts results in the formation of HDPE.
It is a rigid, waxy white solid. Translucent. It is permeable to many organic solvents. It
crystallizes easily.
LDPE has a density 0.91 to 0.925 g/cm3
HDPE has a density 0.941 to 0.965 g/cm3
HDPE is linear and has better chemical resistance.
Uses: These are useful in the preparation of insulator parts, bottle caps, flexible bottles, pipes
etc.
LDPE is used in making film and sheeting. Pipes made of LDPE are used for both agricultural,
irrigation and domestic water line connections.
HDPE is used in manufacture of toys and other household articles.
PVC :
Poly Vinyl Chloride is obtained by heating a water emulsion of vinyl chloride in presence of a
small amount of benzoyl peroxide or hydrogen peroxide in an auto clave under pressure.
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CH = CH + HCl CH2 = CH Cl
Acetylene
Vinyl chloride
Properties: It occurs as a colourless rigid material.
It is having high density and low softening point.
It is resistant to light, atmospheric oxygen, inorganic acids and alkalis.
It is most widely used synthetic plastic.
Uses: It is mainly used as cable insulation, leather cloth, packing and toys.
It is used for manufacturing of film, sheet and floor covering.
PVC pipes are used for carrying corrosive chemicals in petrochemical factories.
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Nylon-6,6:
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It is prepared by Hexamethylene diamine and Adipic acid are polymerized in 1:1 ratio.
Properties: This is linear polymer not resistant to alkali and mineral acids.
Oxidising agents like hydrogen peroxide, potassium permanganate etc. are able to degrade the
fibres.
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Applications: Nylon-6,6 is mainly used for moulding purposes for gear bearings and making
car tyres, used for fibres etc.
This is mainly used in manufacture of tyre cord. Other uses include manufacture of carpets,
rope, fibre cloth etc.
POLYESTER
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Terylene is a polyester fibre made from ethylene glycol and terephthalicacid. Terephtalic acid
required for the manufacture of Terylene is produced by the catalytic atmospheric oxidation of
p-xylene.
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Properties: This occurs as a colourless rigid substance. This is highly resistant to mineral and
organic acids but is less resistant to alkalis. This is hydrophobic in nature. This has high
melting point due to presence of aromatic ring.
Uses: It is mostly used for making synthetic fibres. It can be blended with wool, cotton for
better use and wrinkle resistance. Other application of polyethylene terephthalate film is in
electrical insulation.
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Properties: Due to the presence of highly electronegative fluorine atoms and the reqular
configuration of the polytetrafluoro ethylene molecule results in very strong attractive forces
between the different chains.
These strong attractive forces give the material extreame toughness, high softening point,
exceptionally high chemical-resistance towards all chemicals, high density, waxy touch, and
very low coefficient of friction, extremely good electrical and mechanical properties: It can be
machined, punched and drilled. The material, however, has the disadvantage that it cannot be
dissolved and cannot exist in a true molten state. Around 3500c, it sinters to form very viscous,
opaque mass, which can be moulded into certain forms by applying high pressures.
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Uses: as insulating material for motors, transformers, cables, wires, fittings, etc, and for
making gaskets, packing, pump parts, tank linings, chemical-carrying pipes, tubings and tanks,
etc,; for coating and impregnating glass fibres, asbestos fibres and cloths; in non-lubricating
bearings and non-sticking stop-cocks etc.
POLY URETHANES:
Poly urethanes are obtained, commercially, by treating diisocyanate and diol. For example,
Perlon-U (a crystalline polymer) is obtained by the reaction of 1,4-butane diol with 1,6-hexane
diisocyanate.
Properties: 1. polyurethanes are less stable than polyamides at elevated temperature.
2.
They are characterized by excellent resistance to abrasion and solvents.
Uses: Polyurethanes are used as coatings, films, foams, adhesives and elastomers. Resilient
polyurethane fibres (spandex) are used for foundation garments and swim-suits. They also find
use as a leather substitute (corfoam). They are used to cast to produce gaskets and seals.
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Bakelite:
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Applications: It is used for making electric insulator parts like switches, plugs, switch boards
etc. For making moulded articles like telephone parts cabinet of radio and television.
Silicone resins:
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Silicone resins contain alternate silicone-oxygen structure, which has organic radicals attached
to silicon atoms. Thus, their structure is:
Where R= alkyl or phenyl radical
Preparation: reacting silicon with alkyl halide or silicon halide with Grignard reagent.
The reaction product is fractionally distilled to get different organo-silicon chlorides, which are
then polymerized by carefully controlled hydrolysis.
1. Dimethyl-silicon dichloride is bifunctional and can yield very long chain polymers,
E.g.
2. Trimethyl silicon chloride is monofunctional and hence, a chain-stopper. This is,
therefore, used in proportions to limit the chain-length.
3. Monomethyl silicon chlorides is trifunctional and goes cross-linking to the final
polymer. Its proportion used in polymerization, determines the amount of cross-linking
that can be obtained.
Characteristics of silicones:
1. Depending on the proportion of various alkyl silicon halides used during their
preparation, silicones may be liquids, viscous liquids, semi-solid, rubber-like and
solids.
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Natural Rubber:
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Vulcanization:
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Buna-S rubber is probably the most important type of synthetic rubber, which is produced by
copolymerization of butadiene (about 75% by weight) and styrene (25% by weight).
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1,3-Butadiene
Acrylonitrile
Poly butadiene co-acrylonitrile
Compounding and vulcanization methods are similar to those of natural rubber.
Properties:
i.
Due to the presence of cyano group, nitrile rubber is less resistance to alkalis than
natural rubber;
ii.
Excellent resistance to oils, chemicals, aging (sun light). As the acrylonitrate
percentage is increased in nitrile rubber, its resistance to acids, salts, oils, solvents
etc. increases. But the low temperature resilience suffers.
iii.
Compared to natural rubber, nitrile rubber (vulcanized) has more heat resistance and
it may be exposed to high temperatures.
iv.
It has good abrasion resistance, even after immersion in gasoline or oils.
USES:
For making Conveyor belts, Lining of tanks, Gaskets
i.
Printing rollers , Oil-resistance foams
ii.
Automobile parts and high altitude air-craft components
iii.
Hoses and adhesives.
Thiokol :
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This also called as polysulphide rubber (or Gr-P). It can be prepared by the
condensation polymerization of sodium polysulphide (Na2Sx) and ethylene dichloride.
Cl CH2 - CH2 Cl
Ethylene dichloride
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S S
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Na S S Na + Cl CH2 - CH2- Cl
Sodium polysulphide Ethylene dichloride
S S
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-CH2 CH2 S S CH2 CH2Thiokol
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Uses: For surface coatings and manufacture of foams and spandex fibres.
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