Polymer Processing

Polymer materials
 Primary Bond -
Covalent Bonding H

 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  Reduces material cost.

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

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

 Blowing  Gas, azo compounds, hydrazine  Generates a cellular form to obtain a low-
agents derivatives 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. Inject 2.a. Inject

Skin Core

2.b.
Continue 3. Inject
injecting Skin again
core until to purge
cavity is sprue.
filled
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 (500,000 $0.006 Shipping (50,000 $0.06

per container @ per container @
$3000 per 40') $3000 per 40’)

Labor ($12 per $0.004

hour)
Waste (5%) $0.002

Electricity ($0.20 per $0.004

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  Challenges
program:  10-12 main polymer types
 Stable supply of materials
 Thousands of blends
with reliable collection and
sorting  Additives
 Economical, proven and  Impurities in supply
environmentally sound (labels, glass, dirt, etc)
recycling process
 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