DDSP Polymers: Course Assignment

DDSP Introduction – Course Assignment

Diploma in Design and Specification of Plastics
Auckland: Semester 1 2019
Due 4:00pm, Monday 18th April 2019

A Certificate of Completion for this course will be issued on successful completion of this assignment.

Return to: DDSP Polymers, Plastics New Zealand, P.O. Box 76 378, Manukau City 2241
or email to: ddsp@plastics.org.nz

Name: …………EDUARDO EXPOSITO ESPINOSA

Company: …… FISHER & PAYKEL HEALTHCARE…………………………………….

Telephone contact: ……0211676317………………………………………

Email: …………edu.exposito87@gmail.com…………

Instructions:
 Please ensure all assignments are typed
 Please answer each question with a short paragraph of 3-4 sentences. Images may also be
used.
 Please ensure that this assignment is your own work. Individual assignments only – no group
work or less.

1. Why is polyethylene a high melting solid, whilst paraffin oil is a liquid?

Polyethylene has high molecular weight, high melting Point and low melt index flow and the number of
carbons in polyethylene is greater than 10,000.
Paraffin oil has a low molecular weight. Because of this and other differences, paraffin has a much lower
melt point and is softer than polyethylene.

2. Why does ‘semicrystalline’ polymer have both a crystalline and an amorphous phase,
and how are the phases identified (what techniques can be used)?
Semi-crystalline polymers have both crystalline and amorphous regions because they combine the
strength of crystalline polymers with the flexibility of amorphous. Semi-crystalline polymers can be tough
with an ability to bend without breaking, the crystals are small and connected to the amorphous regions
by polymer chains so there may be no sharp well-defined boundaries between the two types of regions.
- Differential Scanning Calorimetry (DSC) can be used to determine amount of crystallinity in a
polymer.
- Dynamic Mechanical Thermal Analysis (DMTA) studies the response of the amorphous phase of
a polymer to an applied stress.

3. Why doesn’t an ‘amorphous’ polymer have a crystalline phase?

100% amorphous polymer does not have crystal, and by definition the melting temperature is the
temperature where the crystalline order is destroyed. Amorphous polymer has a low order structure;
polymer chains solidify in a random way (not forming crystal structure).

4. What happens to a Semicrystalline and an Amorphous moulded part when it is exposed

to a temperature above its glass transition temperature in an end use situation?
Amorphous resins lose their strength quickly above their glass transition temperature (Tg).
Semi-crystalline retain useful levels of strength and stiffness well beyond their glass transition
temperature (Tg).

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5. Why are amorphous polymers transparent, and how can you make an opaque
semicrystalline polymer transparent.
Amorphous polymers do not have crystalline phase and appear transparent.
In semicrystalline polymers the distance between the folded chains in the crystalline phase I approximate
the wavelength of light. Incident light is reflected and scattered within the crystalline phase creating
opacity.

If the distance between the folded chains in the crystalline phase is increased through mechanical
orientation the structure can become transparent.

6. Define ‘Glass Transition Temperature’ and ‘Melting Point’ in terms of polymer

morphology
Glass transition Temperature is the gradual and reversible transition in amorphous materials (or in
amorphous regions within semicrystalline materials), from a hard and relatively brittle glassy state into a
viscous or rubbery state as the temperature is increased.

The Tm when applied to polymers suggests not a solid-liquid phase transition, but a transition from a
crystalline phase to a solid amorphous phase.

7. How has the polymer producer created the high mechanical strength and high glass
transition temperatures of amorphous ‘engineering polymers’, such as polycarbonate?

Modifying the polymer through glass fibre reinforcement. Glass fibres may be added in various amounts
(10%, 20%, 30% and 40%) to increase tensile strength and Tg.

8. Use morphology terminology to explain how and why high impact polystyrene and ABS
polymers are more impact resistant (tougher) than general purpose polystyrene
This form of PS typically is produced by adding around 5-10% rubber or butadiene copolymer.

9. Name and explain the ‘special’ attractive force which supplements inter-chain attraction
in the polyamide polymer family.
Hydrogen bonding result of increasing the even number of methylene groups or inserting an odd number
of the same group

10. Give at least two reasons why a thermoplastic elastomer differs from a thermoset
elastomer?
- Liquid silicone rubber forms a permanent shape and you cannot remould it, unlike TPE
- Thermosets has the utmost resistance to high temperatures without altering its shape. Over a range of
extreme temperatures — whether hot or cold — the material remains stable.

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11. How does the Melt Flow Index (MFI) test relate to the way polymers actually process?
Melt Flow Index (MFI) is a measure of how many grams of a polymer flow through the die in ten minutes.
MFI test conducted during the process study to differentiate to the actual processing temperature.

12. How and why do semicrystalline thermoplastics shrink more than amorphous
thermoplastics during the cooling phase of the injection moulding process?
When crystalline materials are cooled below their melting point, the molecules in the crystalline phase
begin to arrange themselves in a more orderly way, meaning that they take up less volume than they
would if they were amorphous. The shrinkage rate of crystalline polymers is therefore greater than those
of amorphous ones

13. Why is it important to (and how can you) translate technical data sheet properties to your
actual application?
Because each property value relates to a well understood, repeatable, reliable test related to
international standards. Therefore, this makes comparison with other grades of similar plastics from a
range of suppliers much easier. It is also important to understand the difference between design
properties and inherent properties of materials.

14. Provide 4 reasons (with short explanations) why it is vital to select a material before
tooling and part design are commenced

To avoid problems downstream plastic selection is an important and complex task that involves many
considerations, such as:

- Temperature: Thermal stress that may occur during normal and extreme use conditions, as well
as during assembly, finishing and shipping.

- Chemical resistance: The effects that occur when any solid, liquid or gas come in contact with the
part.

- Finish: The material’s ability to produce the desired finish such as gloss, smoothness and other
appearance values as it comes from the mould.

- Cost: Resin pricing as well as the cost calculations for manufacturing, maintenance, assembly
and disassembly to reduce labour, tooling, finishing and other costs.

- Availability: The resin’s availability in regard to amount needed for production.

15. Provide 3 potential risks and 3 potential advantages (each with reasoning) of sourcing a
material from a compounder

RISKS:
- Potential variations in performance and lot-to-lot consistency
- Formulation may change as they buy raw material in open market
- By the time material from a compounder is received at a customer, it may have been at
processing temperature at least 3 times already.
ADVANTAGES:
- Generally cheaper than majors suppliers
- Provide an important service in customizing performance
- Seamless supply chain between the polymer producer and end user

16. Where should responsibility lie for the cost of a new part and why?
The cost of a new part is closely linked to part design and process design. The part designer is
responsible for the outcomes of the tool design. The part cost is related to material mass, materials cost,
cycle time, and possibly machine capability.

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