Polymer Processing

Module - 5
 Polymer materials
• Primary Bond - Covalent
H
Bonding
• Secondary Bonds – C

– van der Waals H

– Dipole Bonds
PE - mer
– Hydrogen Bonds
 Polymer Properties
• Tg
– Glass Transition Temperature
• MW
– Molecular Weight
• The combination of these
two properties will be a
great starting point for
identifying any polymer
material
  Increases tensile strength.
Increases flexural modulus.
 Reinforcing  Boron, carbon, fibrous Increases heat-deflection temperature
fibers minerals, glass, Kevlar (HDT).
Resists shrinkage and warpage.

 Improves electrical and thermal

 Conductive  Aluminum powders, carbon
conductivity.
fillers fiber, graphite

 Improves interface bonding between

 Coupling
 Silanes, titanates polymer matrix and the fibers.
agents

 Reduces the occurrence and spread of

 Flame  Chlorine, bromine,
combustion.
retardants phosphorous, metallic salts

 Extender  Calcium carbonate, silica,  Reduces material cost.

fillers clay
 Improves melt flow properties.
 Monomeric liquids, low-
 Plasticizers Enhances flexibility.
molecular-weight materials

 Provides colorfastness.
 Colorants
 Metal oxides, chromates, Protects from thermal and UV
(pigments
carbon blacks degradation (with carbon blacks).
and dyes)

 Blowing  Gas, azo compounds,  Generates a cellular form to obtain a

agents hydrazine derivatives low-density material.
 Major Processes

• Extrusion
• Injection Molding
• Blow Molding
• Thermoforming
• Rotomolding
Polymer Processes
Extrusion
Extrusion Product Examples
 Extrusion
• The extrusion machine forms the basis of
nearly all other polymer processes.
• Basically involves melting polymer pellets and
extruding them out through a two
dimensional die.
• Produces long, thin products
– Coating for electrical wire
– Fishing Line
– Tubes, etc.
Injection Molding
Injection Molding Product Examples

Nylon
sheaves
Injection Molding Machine Basics
Injection Molding Machine Operating
Sequence
 Mold closes and screw
begins moving forward
for injection

 The cavity fills as the

screw moves forward
as a plunger

 The cavity is packed as

the screw continues to
move forward as part
solidifies
 Injection Molding Machine Operating
Sequence, ctd
• The cavity cools as the gate
freezes off and the screw
begins to retract to
plasticize material for the
next shot

• The mold opens for part

ejection

• The mold closes and the

next cycle begins
 Injection Molding Process Control

• Very similar to die casting

• Must control heat transfer
and fluid flow
• Do that by controlling
temperature and pressure
 Co-injection Molding

1. 2.a.
Inject Inject
Skin Core

2.b.
Continue 3. Inject
injecting Skin
core until again to
cavity is purge
filled sprue.
Injecting hollow parts with complex
interior geometry
Gas Assist Injection Molding – Hollow
parts without interior control
 Injection – Compression Molding

 Very similar to
squeeze casting
 Injection Molding of Thermosets
• Thermoplastics “set” when they cool
– Mold temperature will be set to allow full cavity fill, while
increasing production rate
• Thermosets undergo a chemical crosslinking that
produces the solid structure
– Mold temperature will be hotter usually – set to allow full
cavity fill, while accelerating the chemical reaction to cure.
– Often called “Reaction Injection Molding” (RIM)
Blow Molding
 Blow Molding

Extrusion Blow Molding Injection Blow Molding

Stretch (Parasin) Blow Molding

 Blow Molding Cost Analysis
500 ml bottle – Cost per bottle 500 ml bottle – Cost per bottle
using a preform direct form mfg

Preform $0.040 Bottle $0.12

Shipping $0.006 Shipping (50,000 $0.06

(500,000 per per container @
container @ $3000 per 40’)
$3000 per 40')
Labor ($12 per $0.004
hour)
Waste (5%) $0.002

Electricity ($0.20 $0.004

per Kwh)
TOTAL $0.056 TOTAL $0.18
Thermoforming
Thermoforming Products
Thermoforming
Thermoforming Video
Rotomolding
 Rotomolding
• Used for relatively
dimensionally inaccurate items,
usually with a hollow interior
– Can be very large
– Garbage Cans
– Kayaks
– Interior dimensions can not be
critical
– Relatively primitive and therefore
inexpensive process
 Polymer Recycling
• 1998 – Approximately 20% of plastic waste is
recycled (optimistic estimate)
• 1998 – Polymers account for approximately
18% by volume of material to landfills
 Needs vs Challenges
• Needs for a viable program: • Challenges
– Stable supply of materials – 10-12 main polymer types
with reliable collection and
sorting – Thousands of blends
– Economical, proven and – Additives
environmentally sound – Impurities in supply (labels,
recycling process glass, dirt, etc)
– End use applications for the
recycled material
 Recycling of Polymers
• PET (polyethylene
terphthalate) beverage
containers, boil-in food pouches,
processed meat packages
• HDPE (high density
polyethylene) milk bottles,
detergent bottles, oil bottles,
toys, plastic bags
• PVC (polyvinyl chloride) food
wrap, vegetable oil bottles,
blister packaging
• LDPE (low density
polyethylene) shrink-wrap, plastic
bags, garment bags
• PP (polypropylene)
margarine and yogurt
containers, caps for
containers, wrapping to
replace cellophane
• PS (polystyrene) egg
cartons, fast food trays,
disposable plastic silverware
• Other multi-resin containers
 Basic recycling steps
• Sorting
• Size Reduction
• Densification
• Pulverization
• Melt Filtration
 Sorting
• Manual – very common
• Density based sorter
– Centrifugal
– Float/Sink methods
• Optical – same as peas,
potato chips, etc
• Spectroscopy – Infrared –
automation possible
 Size Reduction

• Shredders
• Rotary Knife
 Densification

• Basic purpose is to reduce to volume taken up by

bulk material
– Reduce from only 20 kg/m3 to almost 400 kg/m3
• Agglomeration – heat it up and compact it
 Pulverization
• Convert clean plastic
waste into powder
• After this process, some
of the product can
actually be used if low
purity requirements
– Recycled plastic lumber
for example
 Melt Filtration
• Improve purity of pulverized
polymer
– Needed for extrusion,
injection or blow molding
processes
• Basic process concept:
– Melt it
– Shove it through a screen
• Additional chemical
processing may be needed
if additional purity
requirement