Introduction to Polymers

Defination
A substance which has a molecular structure built up
chiefly or completely from a large number of similar
units bonded together, e.g. many synthetic organic
materials used as plastics and resins.
Polymer Processing
Various additives are added in order to ease processing
(Reduction in Melt viscosity)
Plasticizers and Softeners
Lubricants and flow Promoters
Anti-Aging Additives (To avoid discoloration and
structural degradation)
Blowing agents (Products which involves blowing of
parison)
Antioxidants
Extrusion
Pipe Extrusion
Sheet Extrusion
Blow Molding
Film Blowing
Injection Molding
Coating
Calendaring
Extrusion
Polymer is propelled continuously along a screw
through regions of high temperature and pressure.
Polymer is melted and compacted.
Forced through a die to give die shaped product.
Cooled by air or immersed in water.
Method is used to make
Rods
Tubing and hoses
Sheets (>0.254mm thick)
Films (<0.254mm thick)
Film Extrusion
The extrusion can be carried out by
Sheet Extrusion
Blown Film Process
In Blown film process tubular die is used.
Hallow tube of product is extruded upward.
Air is used as a medium to inflate the tube to avoid
collapse.
Film Extrusion
A- Film Die
(Contd.)
B- Die Inlet from Extruder
C- Air Inlet
D- Plastic Tube
E- Air Ring for cooling
F- Guide rolls
G- Collapsing Frame
H- Pull Rolls
I- Windup roll
Blow Molding

Extruder or reciprocating-screw injection machine can be used.

Molten polymer tubing (Parison) is extruded in open mold.
By means of compressed air or steam the parison is blown into the configuration of mold.
Used for making bottles and similar products.
Injection Molding

Polymer is preheated in the chamber to a flow temperature.

Melt is forced into a relatively cold, closed mold by high
pressure applied by reciprocating screw.
Cycle time is 10-30 seconds and multi-cavity molds allow
the production of many parts per cycle.
Calendering Used for the
manufacturing of sheets
or films.
Granular resin or thick
sheet is passed between
pairs of highly polished
heated rolls under high
pressure.
For thin films a series of
rolls are used with a
gradual reduction in nip.
Casting
Liquid plastic which is generally thermoset except for
acrylics is poured into a mold without presssure,
cured, and taken from the mold. Cast thermoplastic
films are produced via building up the material (either
in solution or hot-melt form) against a highly polished
supporting surface. Low mold cost, capability to form
large parts with thick cross sections, good surface
finish, and convenient for low- volume production.
Compression molding
Principally polymerized thermoset compound,
usually preformed, is positioned in a heated mold
cavity; the mold is closed (heat and pressure are
applied) and the material flows and fills the mold
cavity. Heat completes polymerization and the part is
ejected.
Pultrusion
This process is similar to profile extrusion, but it does
not provide flexibility and uniformity of product
control, and automation. Used for continuous
production of simple shapes (rods, tubes, and angles)
principally incorporating fiberglass or other
reinforcement. High output possible.
Rotational molding
A predetermined amount of powdered or liquid
thermoplastic or thermoset material is poured into
mold; mold is closed, heated, and rotated in the axis of
two planes until contents have fused to inner walls of
mold; mold is then opened and part is removed. Low
mold cost, large hollow parts in one piece can be
produced, and molded parts are essentially isotropic in
nature.
Slush molding
Powdered or liquid thermoplastic material is poured
into a mold to capacity; mold is closed and heated for
a predetermined time in order to achieve as pecified
buildup of partially cured material on mold walls;
mold is opened and unpolymerized material is poured
out; and semifused part is removed from mold and
fully polymerized in oven. Low mold costs and
economical for small production runs.
Thermoforming
Heat-softened thermoplastic sheet is positioned over
male or female mold; air is evacuated from between
sheet and mold, forcing sheet to conform to contour of
mold.
Transfer molding
Related to compression and injection molding
processes. Thermoset molding compound is fed from
hopper into a transfer chamber where it is then heated
to plasticity; it is then fed by a plunger through sprues,
runners, and gates into a closed mold where it cures;
mold is opened and part ejected. Good dimensional
accuracy, rapid production rate, and very intricate
parts can be produced.