Processing of Polymers

Increasing use of polymers

Light, tough, corrosion resistant and cheap Price: Raw material + Processing

Processing of Solid Polymers:

Polymer heated to the melt state, shaped under high pressure and cooled down to room temperature (below Tg or Tm) to preserve its shape. Shaping involves shear, bulk and elongational deformations of the polymer melt, which have different viscoelastic characteristics. From: Principles of Polymer Engineering (McCrum et al. 1995)

Processing of Polymers
Extrusion
Films and sheets Fibers and filaments Pipes, tubing and profiles Wire coating

Injection Molding Thermoforming Blow Molding Compression and Transfer Molding

Extrusion
Most common polymer processing (60% of world production). Manufactures an endless product of constant cross-section that is cut, sawed, chopped, rolled or reduced to specific length. Two-part process including plastication and shaping
Extruder converts a solid feedstock into a homogeneous melt and pumps it through a die at a uniform rate. Following the die, a train of equipment ensures the extrudate cools to the right shape with the required molecular orientation.

Extrusion: Extruder: Plastication

Cold polymer granules fed into a hopper and supplied to the screw by gravity Granules advance between the flights of the screw and the hot walls of the barrel As the polymer advances along the extruder, it becomes liquid (by melting or by passing through the glass transition) The polymer becomes pressurized at it moves along the extruder, so it can easily exit the extruder through a die.

Extrusion:

Screw Parameters: 1) Zones (number, lengths, types) 2) Helix angle () 3) Flight width (W) A.) Conventional; B.) For fragile polymers; C.) PVC-type; D.) Nylon-type 4) Channel depth (H) 5) Screw Length to Diameter ratio

Extrusion:

Shaping: Die shape dictates the nature of the polymer product.

Circular die: Melt spinning of fibers Slit die: Sheet casting Annular die:
Film blowing Pipes ( > 12 mm) and tubing ( > 12 mm) Wire coating

Extrusion:
The Die-swell Issue: A polymer extrusion problem
Phenomenon: Swelling of the extrudate occurs at the die exit. Explanation: Polymer liquid is stressed as the cross section decreases Swelling is due to unrelaxed stresses (rubber elasticity). Swell ratio (DS/DC) depends on residence time in constrained region (die). Parameters which affect the swell ratio: LC, , MW, T DB DC DS

Extrusion:

Film Blowing

Extrusion: Pipes and Tubing

Extrusion:
Wire Coating

Extrusion: Die-swell Issue

Solution : 1) Keep die swelling phenomenon. Why? 2) Design die profile to account for die swelling. 2) Use pull rolls to draw down extrudate.

Injection Molding:
Injection + Molding

Reciprocating-screw injection molding machines are the most common (thermoplastics and thermosets). Do we need to apply pressure during molding ? Why ?

Injection Molding:
Injection + Multiple Moldings

Cycle time: several seconds to several minutes.

Injection Molding:
Gate Designs: Cause work to be done to make the liquid flow through a small constriction, so T increases ( decreases).
Important for homogenization Important for control of orientation Important for control of surfaces

Injection Molding:
Pressure, Temperature and Velocity Controls:

Thermoforming
Application for large formings, thin wall packaging, short-run or prototype products. Much lower initial investment than injection molding.

With matched molds

Pressure-bubble vacuum-snapback technique

Blow Molding
Blow molding is widely used for producing hollow containers in vast numbers and cheaply. Three major variants:
Extrusion-blow molding Injection-blow molding Stretch-blow molding

Common features
Formation of a precursor (hollow tube called a parison). One end of parison is closed, so it can be inflated in the heated, softened state. Inflation continues until parison touches the walls of the cooled mold. Mold is opened and bottle released.

Extrusion-Blow Molding

Four-step Process
A) B) C) D) Extrusion of parison in open mold Mold closes and parison is inflated When parison reaches the walls of the mold, it is cooled The mold is open and the bottle released

Injection-Blow Molding

Three-steps at three stations

A) Parison is injection molded on to a steel rod. B) Parison is inflated by air and take the shape of the mold. C) The mold opens and the bottle is released.

Compression and Transfer Molding

Compression Molding
Historically, the first technique for mass production Used currently only for cross-linked polymers Partially cross-linked polymer between two-halves of mold Upper part of mold is lowered and polymer is compressed Cross-linking reaction is completed under controlled P&T Mold is open and product released Advantages: Flow over shorter distances, thus less frozen-in stresses Cheaper and easier mold design Cheaper mold maintenance

Compression and Transfer Molding

Transfer Molding
Measured charge of partially cross-linked polymer is heated in a pot, from which it is rammed into a heated mold. Forcing polymer through a gate leads to homogenization and pressure increase and heating. Cross-linking is completed and solidified sample released. Use for the production of precision shapes (electronic industry).