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from liquid to gas occurs) to form
The use of plastics has been an
important part in the history of
engineering and product design in the
twentieth century. They have given us
the ability to develop a range of products
in a very wide number of areas, from
lightweight unbreakable containers, safe
hygienic toys and inexpensive
household objects to artificial limbs and
life saving medical equipment.
Slide 1:
Polymers are long chain of molecules
made up of repeating units of smaller
molecules called monomers. (Monomers
– small molecular fragments) It’s like
making a necklace from many small
beads. Almost all of the things we use in
our everyday lives are all synthesized
polymers.
Synthetic polymers are polymers which
are man-made using chemical
processes. They were made by copying
the structures of natural polymers to
produce synthetic polymers. Almost all
of the raw materials for synthetic
polymers are obtained from petroleum
by refining and cracking processes.
One type and the most common
synthetic polymer of all is polyethylene.
Slide 2:
Naphtha is a flammable liquid made
from distilling petroleum. It looks like
gasoline.Naphtha is used to dilute
heavy oil to help move it through
pipelines, to make high-octane gas, to
make lighter fluid, and even to clean
metal.
Plastics are made from oil. ...
Most plastics use naphtha as main raw
material.Naphtha is further decomposed
thermally and separated utilizing the
difference in the boiling point
(temperature at which the phase change
ethylene and propylene, which are the
raw materials for plastics.
Slide 3:
Blow molding (BrE moulding) is a
specific manufacturing process by which
hollow plastic parts are formed and can
be joined together. It is also used for
forming glass bottles or other hollow
shapes.
In general, there are three main types of
blow molding:
extrusion blow molding, injection blow
molding, and injection stretch blow
molding.
The blow molding process begins with
melting down the plastic and forming it
into a parison or, in the case of injection
and injection stretch blow molding (ISB),
a preform. The parison is a tube-like
piece of plastic with a hole in one end
through which compressed air can pass.
The parison is then clamped into
a mold and air is blown into it. The air
pressure then pushes the plastic out to
match the mold. Once the plastic has
cooled and hardened the mold opens up
and the part is ejected. The cost of blow
molded parts is higher than that of
injection-molded parts but lower than
rotational molded parts.
Slide 4:
Extrusion is a process that can be
compared to squeezing toothpaste out
of a tube.
Extrusion is a continuous process of
converting a solid plastic mass, pellet or
powder into a melted form where it is
pushed through a die into a shape. This
shape is then moved through various
secondary operations where it is cooled
then cut, coiled or experiences a variety
of other possible operations.
The extrusion is cooled by water or air
as it leaves the die and is finally cut to
the required length. The shape of the die
can be varied from a simple hole with a
centrally supported core to produce
tubes such as pipes, to very complex
sections for curtain tracks or hollow
window frames.
Slide 5:
This process is one of the most common
of all plastics manufacturing processes.
The polymer, in granule form, is heated
until fused and forced into a closed
mould. Because of the viscous (thick,
syrupy) nature of the fused polymer,
very high pressures are needed to make
it flow, which means that the machine
and mould have to be very strong to
withstand the forces involved.
Because of the ability of the plastic to
show even the smallest of marks very
fine detail can be cut into the surface of
the mould, for example in the form of
trade marks, lettering or textures.
It is a fast process and is used to
produce large numbers of identical items
from high precision engineering
components to disposable consumer
goods.
Pressures from 70-200 MPa (10-30
Kpsi)
Slide 6:
Structural foam is a composite material
produced when a polymer, usually
thermoset (but can be thermoplastic), is
combined with either an inert physical
gas, such as nitrogen, or a chemical
blowing agent during the molding
process. The result is not a solid
material but a low-density, microcellular
“core” combined with a high density
outer “skin”. The core decreases the
overall weight of the material while the
solid skin allows it to remain strong and
impact resistant.
The texture of the core has been
frequently described as resembling a
“sponge” or a “honeycomb”. Because of
its unique core texture, structural foam is
typically anywhere from 20% to 40%
lighter than solid polymers, aluminum,
steel, sheet molding compound or other
commonly used materials.
Commonly used thermoplastics include
but are not limited to: polyurethane,
polycarbonate, polyphenylene oxide
(Noryl), polybutylene terephthalate
(Valox), and acrylonitrile butadiene
styrene.
Process:
The process of molding parts from
structural foam is very similar to the
traditional method of reaction injection
molding. Two components, for example
polyol and isocyanate (which are
combined in order to create
polyurethane) are stored in liquid form in
separate containers. They are mixed
together to form a resin which is injected
into a pre-prepared mold and cures via
the means of a chemical reaction.