Professional Documents
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PLASTICS
Fillers and Additives
Additives are added to Polymers to Improve
– Processibility Requirements
– Strength and Performance of part,
– Appearance,
– Life and Durability,
– Cost Savings
Types of Additives
• Anti Counterfeiting • Fillers/ Extenders
• Antioxidants • Fragrances
Manufacturers will employ technologies and methods to ensure customers are protected and un-
effected by counterfeit products.
Mechanisms will be in-place to identify/ segregate genuine products
STATIC ELECTRICITY
A stationary electric charge, typically produced by friction, which causes
sparks or crackling or the attraction of dust or hair
1. Primary Thermal-
Ignition Source heats the bulk plastic and leads to raise in Temperature of
Bulk Plastic
2. Primary Chemical
The Heated plastic starts to degrade. Due to supply of High Energy,
degradation releases Gases and Chemical Radicals to surrounding
3. Polymer Decomposition
Plastic Starts decomposes into Mix of Molecules of Lower Molecular
Weights like Gases, Liquids, Charred Solids and Smoke
Combustion of Plastics
4. Ignition-
The combustible Gases start to burn in the presence of Ignition. Liquids
and Gases start burning, but bulk plastic does not burn
5. Combustion:
Burning happens near the bulk plastic and process can be self sustaining
if the energy released is sufficient
6. Flame Propagation:
based on type of plastic, combustion produces Flames which can
propagate to layers of charred materials and releases smoke and toxic
gases
Mechanism of Flame Retardants
Masterbatch (MB) is a solid or liquid additive for plastic used for coloring
plastics.
They can also be used for imparting other properties to plastics (Additive
Master batches)
Specific Carrier Material are used in master batch, to match the type of
polymers.
It can slightly alter the processing behavior of the plastic, customer needs to
clarify his requirements while finalising the master batch.
Colors can be
• Custom Colors- Customer has the option of selecting the specific color or
finish required
• Standard Colors- Customer will select from the group of colors listed by
OEMs of resin
Pigments and Master-batches
Mechanism of UV Effects
• Carbon bonds of some polymers, are the centres of attack
• Ultraviolet rays interact with these bonds to form free radicals,
which then react further with oxygen in the atmosphere,
producing carbonyl groups in the main chain.
• The exposed surfaces of products may then discolour and crack,
and in extreme cases, complete product disintegration can occur.
• Different places have different extent of UV exposure ratings for
the part. Different Plastics have different levels of sensitivity to
UV of different wavelengths. (Degrading UV is within 280-315nM
of Wavelength)
UV/ Light Stabilisers
Types of UV stabilisers
– UV Absorbers-
• Absorb UV Light and dissipate as Heat to surroundings.
• cheap UV stabilisers but for short term use.
• Not suitable for thin walled products (<100 Microns)
– Eg-Carbon Black, Hydroxy Phenyl Benzo Triazole & Etc
– Benxo Quenchers-Help is cooling UV -agitated links of polymers to reduce carbonyl
formation. Eg: Nickel Quenchers-Gives Tan or Green Tinge to the product
Function:
Used to reinforce or improve tensile strength, flexural strength and
stiffness of the material. Often fibre-based .
• Glass Fibers
• Carbon Fibres,
• Aramid Fibres,
• Mica
• Calcium Silicates
• Graphene (new Generation Material-Graphite in nano size)
Fillers and Reinforcements- Glass Fibres
• Glass, Aramid, and Carbon fibers are the only fibers of importance
for the reinforcement of plastics
• 90% of glass fibers is Aluminum Boron Silicate Glass
• R and S glass fibers for increased strength – 50% higher
• ECR glass for high acid resistance
• Zirconium oxide for high alkaline environment
• D-glass for improved dielectric properties
• C-glass to build up anticorrosion layer against aggressive media
Fillers and Reinforcements- Glass Fibres
I. Advantages
1. Increased Strength
2. Increased stiffness
3. Increased HDT
4. Reduced Shrinkage
5. Reduced coefficient of thermal expansion
6. Increased dimensional stability
7. Reduced cycle times
8. Reduced weight
J. Disadvantages
1. Reduced impact strength
2. Directional warping
3. Increased abrasion
4. Reduces surface appearance quality
Fillers and Reinforcements- Carbon Fibres
Carbon Fibers
A. Produced from either Polyacrylonitrile (PAN) or pitch
(mainly pitch)
B. Forms
1. Filament yarns (woven) – 320k filaments (1-12k used in plastics)
2. Short fibers – 3-6 mm long
C. Safety considerations
D.Advantages
1. Increased strength
2. Increased extension at break
3. Increased modulus (stiffness)
4. Electrical conductivity
5. Reduced coefficient of thermal expansion
6. Reduced weight
Fillers and Reinforcements- ARAMID Fibres
Aramid Fibers
1. Melt at 500ºC
1. Two forms
a. Unoriented – type A
b. Oriented – higher modulus
– type B
2. Types
a. Kevlar
b. Nomex
3. Will absorb moisture – properties will fail in a strongly
acidic or alkaline environment
Fillers and Reinforcements- ARAMID Fibres
F. Advantages
1. Increases strength
2. Increased modulus
3. Reduced coefficient of thermal expansion
4. Reduced weight
5. Greatly increased impact strength at elevates stress rates –
antiballistic
6. Lubricational effect when surfaces containing Aramid
fibers rub together
Fillers and Reinforcements- CHALK
Other fillers
1. Precipitated Calcium Carbonate – finer particle size, very
pure, more $$
2. Dolomite – more abrasive, less weather resistance than
CaCO3
3. Gypsum – Calcium Sulphate – increased acid resistance
4. Asbestos – greatly increases stiffness – health hazard
5. Carbon Black - conductivity
6. Graphite - lubricant
7. Metal Flake - conduction
8. Magnetic fillers
Fillers and Reinforcements- OTHERS
Additives/
Fillers/ Common materials Effects on polymer properties
Reinforcement
• EU Directive 2002/96/EC WEEE (Waste Electrical and Electronic Equipment) that establishes limits
for the content of a product that must be recyclable or reusable.
• EU Directive 2003/11/EC ROHS (Restriction Of the use of certain Hazardous Substances) restricting
the use of six toxins from most electronic and electrical equipment
• EU Directive 90/128/EC for monomers and additives for plastics intended for food contact
• EU Directive 2002/72/EC relating to plastic materials and articles intended to come in contact with
foodstuffs
• EU Directive 2002/61/EC Aryl Amine Breakdown Products in Azo Dyes ➢ EU Directive 67/548/EEC
Carcinogenic and Regulated Dyes
• FDA and The United States Code of Federal Regulations (CFR) – 21 CFR Parts 175-178 to regulate
adhesives, Components of coatings/ paper / paperboards, polymers and adjuvants and production
aids.
• United States Environmental Protection Agency (USEPA) – Methods 606, 506-1 and 8061 regulating
Phthalates and Adipates
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YOU
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