CHAPTER 12 : PLASTIC

(Plastik)


MATERIALS TECHNOLOGY 1
J3022
PREPARED BY : LIM YEE KAI
DEPARTMENT of MECHANICAL ENGINEERING
12.0 Introduction
Monomer : A molecule that can combine with others to form a polymer
Polymers : are a large class of materials consisting of many small molecules
(called monomer) ) that can be linked together to form long chains
(polymerization), thus they are known as macromolecules . Polymer are a
group of organic, semiorganic or inorganic.
Plastic : Polymer that have been or can be readily formed or molded into a
useful shape.
Monomer
Resin
Plastic
Polyme
r
12.2 Classification Of Polymer
Polymers
Thermoplastics
Crystalline
Amorphous
Thermosets Elastomers
12.3 Polymer Structure
Polymers are large molecules with strong intermolecular forces
and tangled chains
Crystalline and semi-crystalline have an arrangement of their
chains that comes from packing
Crystal region strengthen the polymer
The percentage of the polymer that is crystalline is called the
percent crystallinity, has an important influence on the
properties of the polymer.
Degree of crystallinity depends on the density.


12.5 Polymerization (Proses Pempolimeran)
POLYMERIZATION: Forming large molecules from small
molecules OR the process by which polymers are formed.
Types: Additional & Condensation Polymerization

12.5.1 Additional Polymerization
(Polyaddition or chain growth polymerization)
Definition:
*A polymerization technique where monomer
molecules add on to a growing polymer chain
one at a time.

The monomers quickly combine by an addition
reaction without losing any atoms, so that the polymer
has the same basic formula as the monomer.
nM ----> -(-M-)n-
(monomer) (polymer)


12.5.1 Additional Polymerization (Continued)
Vinyl polymers are addition polymers, which have the same atoms as
the monomer in their repeat units.
12.5.2 Condensation Polymerization
(step-reaction polymerization)
Definition:
*Covalent bonds are rearranged in such a way
that two monomers are connected and water is
"condensed" out.

12.5.2 Condensation Polymerization (Continued)
A few types of condensation polymers are listed below.
In the table, R and R' stand for organic groups.

12.6 Types of Polymer
Thermoplastic
Polystyrene (PS)
Polyethylene (PE)
Polyamides (PA)
Polycarbonate (PC)
Polyvinyl chloride (PVC)
Polyester (PET)
Thermosets
Epoxy
Urea formaldehyde
Melamine
Phenolics (Bakelite)
Polyurethane (PU)
Silicone
Thermoplastics Thermoset plastics
1. Addition polymerization.
2. Softens on heating and retaining the same
chain on cooling.
3. They are along chain linear polymers
without any branched or cross linked chain.
4. On repeated heating and cooling, there is no
change in chemical nature.
5. These plastics undergo purely physical
process.
6. By heating the plastics, they can be proceed.
7. Waste thermoplastics can be recovered.
1. Condensation polymerization.
2.Heat resistance.(infusible and insoluble
mass on heating )
3. They are branched or cross-linked
Polymer.
4. Some sort of chemical changes occur
On heating.
5.These Plastics undergo physical as well
as chemical process.
6. These plastics cannot be proceed by heating.
7. Waste thermosetting cannot be recovered.
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12.6.1 Thermoplastic (cont)
Polyethylene (PE)
Clear to whitish translucent thermoplastic.

LD: low glass transition temperature, Tg (very
attractive), used for plastic bags, coatings, and
squeeze bottles.

HD: more crystalline linear polymer with
improved strength, stiffness, and chemical
inertness.


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12.6.1 Thermoplastic (cont)
Polyethylene (PE)
Types
Low density (LDPE)

High Density (HDPE)

Linear low density (LLDPE)
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12.6.1 Thermoplastic (cont)
Polyethylene (PE)
Applications: containers,
insulation,
chemical tubing, bottles,
water pond liners etc
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12.6.1 Thermoplastic (cont)
Polyvinyl Chloride (PVC)
PVC is amorphous, does not recrystallize.
PVC homopolymer has high strength (7.5 to 9
ksi) and is brittle.
Compounding of PVC: Modifies and improves
properties.
Application: Clothing, Electric wires, Pipes,
Portable electronic accessories, Signs, Joining,
Ceiling tiles, Unplasticized polyvinyl chloride
(uPVC)

Products of PVC

PVC pipes, fittings, flexible hoses and gaskets
PVC Cement
PVC Ceiling Tiles
Credit card
PVC Products

PVC footwear PVC costume PVC car sticker & decal
PVC sign
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12.6.1 Thermoplastic (cont)
Polypropylene (PP)

Isotactic form is crystalline and has the most applications
Higher strength and stiffness than PE.
High melting (165-177
0
C)and heat deflection
temperature.
Low density, good chemical resistance, moisture
resistance , heat resistance, good surface hardness and
dimensional stability.
Applications: Useful in many application involving boiling
water or steam, house wares, appliances, packaging,
laboratory ware, bottles, etc.

Product of PP

Document Boxes & PP Folders
PP knife handle
PP rope
OPP Tape
PP Chair
Toys
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12.6.1 THERMOPLASTIC (cont)
Polystyrene (PS)
Transparent, brittle and chemically inert
By heating polystyrene with a foaming agent,
expanded polystyrene can be made. Expanded
beads create excellent thermal insulation properties
(Styrofoam).
Styrofoam is extremely light, white solid foam. It
mainly used to make light-weight ceiling tiles in
buildings, and food boxes and shock absorbers
for packaging.

Polystyrene (PS) continue..
Poor weatherability and easily attacked by chemicals.

Low processing cost and good dimensional stability.

Applications: Automobile interior parts, dials and knobs of
appliances and housewares

1939: Wood TV Cabinet
1948: Phenolic TV Cabinet
1970: HIPS TV Cabinet
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12.6.1 Thermoplastic (cont)
Polymethyl Methacrylate (PMMA)/
Acrylic
Rigid and relatively strong.
Completely amorphous and very
transparent.
Good outdoor weatherability and is
more impact-resistant than glass.
An acrylic commonly known as
Plexiglas.
Applications: Glazing of aircraft,
boats, skylights, advertising signs etc.

Automotive lamps
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12.6.1 Thermoplastic (cont)
Polyamides (PA)
High strength due to hydrogen bonding between molecular
chain
Flexibility of carbon chain contributes to molecular flexibility,
low melt viscosity and high lubricity.



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12.6.1 THERMOPLASTIC (cont)
Tough, opaque solids with moderate melting points.
Outstanding characteristic is the ability to draw into fibers,
becoming tough, transparent materials of relatively high
strength.
High strength, toughness and dimensional stability.
Very high impact strength.
High heat deflection temperature.
Engineering applications:
Widely used in the textile industry: Armor, personal protection,
sport equipment.
Audio equipment, drumheads woodwind reeds.
Others used: rope, cable, sheath, electricity generation, building
construction, brakes, expansion joints and hoses, composite
material.

Products of Polyamides (PA)

Kevlar Ballistic vests
Inner lining of tubeless tyres
Reinforcing composite
materials (combination
with carbon fiber, glass
fiber) used in body of
gitar, cricket bats, boat.
Nylon Stocking
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12.6.1 THERMOPLASTIC
Thermoplastic Polyesters
Primarily used as fibers and films with the most important
being polyethylene terephthalate (PET)
Phenylene ring provides rigidity




Good insulator: independent of temperature and
humidity.
Applications: Switches, relays, TV tuner components,
circuit boards, impellers, housing and handles



Products of Polyester

Photographic film
polyester cellophane tape
Polyester backpack
Polyester tie
Mens polo
T-shirt
Polyester sarees
100% Polyester
Coral Short Robes
Polyester
pants
Recycle Polyester

recycled polyester fiber
On July 20, 1969 the human race accomplished its greatest technological
achievement of all time when Neil Armstrong set foot on the moon. This
feat would not have been possible without many materials science
developments. Plastics played an important roll. For example, the Apollo
A7L space suits were a multi-layer plastic structure comprised of nylon
fabric, neoprene coated nylon fabric, Dacron (PET) fabric, aluminized
Mylar (PET) film, Kapton (PI) film, and Teflon (PTFE) coated fabric.
The fish bowl helmet was produced from transparent polycarbonate.
The space suits of today make even more extensive use of plastics.
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12.6.2 Thermosets (cont)
Epoxy Resins
Good adhesion, chemical resistance and
mechanical properties

High molecular mobility, low shrinkage during
hardening

Applications: Protective and decorative coating,
drum lining, high voltage insulators and
laminates

Commercial/Industrial Epoxy Floor Coating

(a) (b) (c)
Products of Epoxy

Epoxy printed circuit board (PCB)
Double-Sided Printed Circuit Boards (PCBs)
Epoxy Surfboards
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12.6.2 Thermosets (cont)
Phenolics
Low cost, good insulating and mechanical properties.
Produced by polymerization of phenol and
formaldehyde.
General purpose compounds: Usually wood flour filled to
increase impact resistance.
High impact strength compounds: Filled with cellulose
and glass fibers.
High electrical insulating compounds: Mineral (Mica)
filled.
Heat resistant compounds: Mineral filled.
Applications: Wiring devices, auto transmission parts,
plywood lamination, adhesives, shell molding.

Products of Phenolics

Bakelite
letter opener
Bakelite radio Bakelite pool ball
Phenolic Plywood
1948: Phenolic TV Cabinet
Cookware with phenolic
handle
Melamine
Application: Molded dinnerware, buttons, control
buttons, & knobs

Melamine dinnerware Melamine Faced MDF / Chipboard
Melamine Milk

Staff members of the local quality supervision bureau empty
melamine tainted milk powder packets at a garbage dump site in
Shenzhen
Which companies are affected?

8/12/2014 40
12.6.2 Thermosets (cont)
Polyurethanes (PU)
Primarly used as faoms
Depending on cross-linking, urethanes may behave as
thermosets, thermoplastic, or elastomers
Application include
Fibers
Coatings
Foams for furniture
Mattresses
Insulation
Packing or shipping material

Products of Polyurethanes (PU)
PU foams

In-line skate wheels
PU foodbed
and midsole
Products of Polyurethanes (PU)

PU condom
Cool room PU panel
PU panel
PU Foam
Plastic Moulding
Extrusion Moulding
Injection Moulding
Blow Moulding
Transfer/Compression
Moulding
Extrusion Blow Moulding
Injection Blow Moulding
Stretch Blow Moulding
Pengacuanan Penyemperitan
Pengacuanan Penyuntikan
Pengacuanan Pindah/Mampatan
Pembentukan Bahan Plastik
Stretch Blow Moulding
Pengacuanan Peniupan
Extrusion Moulding (Pengacuanan Penyemperitan)
- Feed section- stock comes in from hopper and preheated,
- Compression section- resin transformed into liquid form,
entrapped air forced out via compression
- Metering section- homogen melt, sufficient pressure to
pump through the die.
Injection Moulding (Pengacuanan Penyuntikan)
This schematic illustrates the basics of plastic injection molding
system.
A hot, molten polymer is injected into a cold mold.
A screw apparatus can be used to inject the polymer into the
mold.
After the part is solidifies, the mold is opened and part is ejected.

Cycle Time of Injection Moulding Machine
Injection Moulding is a CYCLIC process:
Injection: polymer is injected into the mold cavity
Hold on time: once the cavity is filled, a holding pressure is maintained to
compensate for material shrinkage
Cooling: the molding cools and solidifies.
Screw Back: at the same time, the screw retracts and turns, feeding the next shot
in towards the front.
Mold Opening: once part is sufficiently cool, the mold opens and the part is
ejected
The mold closes and clamps in preparation for another cycle.
Test Your Understanding




Plastic model
Products of Injection Moulding
Compression Moulding
Compression molding is an old and widely used molding process for
thermosetting plastics.
Its applications also include thermoplastic phonograph records,
rubber tires, and various polymer matrix composite parts.
Materials for compression molding include phenolics, melamine,
urea-formaldehyde, epoxies, urethanes, and elastomers. Typical TS
plastic moldings include electric plugs, sockets, and housings; pot
handles, and dinnerware plates.

The process, consists of:
(1) loading a precise amount of molding compound, called the charge,
into the bottom half of a heated mold.
(2) bringing the mold halves together to compress the charge, forcing it
to flow and conform to the shape of the cavity
(3) heating the charge by means of the hot mold to polymerize and cure
the material into a solidified part.
(4) opening the mold halves and removing the part from the cavity.

Compression Moulding
Advantages
molds that are simpler, less expensive, and
require low maintenance
less scrap
low residual stresses in the molded parts (thus
favoring this process for flat thin parts such as
phonograph records).

Disadvantages
longer cycle times and therefore lower
production rates than injection molding.
Injection Blow Moulding Process
2 different process.
Parison formed from injection blow moulding system is called a preform.
It is not a finished part but subjected to subsequent steps that forms the
final shape.
Proven to be economical.
Extrusion Blow Moulding
In Extrusion Blow Molding
(EBM), plastic is melted and
extruded into a hollow tube (a
parison).

This parison is then captured by
closing it into a cooled metal
mold.

Air is then blown into the
parison, inflating it into the
shape of the hollow bottle,
container or part.

After the plastic has cooled
sufficiently, the mold is opened
and the part is ejected.
Stretch Blow Molding
Plastic is first molded into a "preform" using the Injection Molded Process.
These preforms are later fed (after cooling) into an EBM blow molding machine.
In the SBM process, the preforms are heated (typically using infrared heaters)
above their glass transition temperature, then blown using high pressure air into
bottles using metal blow molds.
Usually the preform is stretched with a core rod as part of the process.
The stretching of some polymers, such as PET (PolyEthylene Terepthalate)
results in strain hardening of the resin, allowing the bottles to resist deforming
under the pressures formed by carbonated beverages, which typically approach
60 psi.
Blown Film Extrusion
Plastic pellets are fed and melt in the extruder.
Resin enters annular die and forced inside a mandrel where it is shaped into
sleeves, extruded into a die opening in form of thick walled tube.
Using pressure of internal air introduced from center of mandrel, molten tube
will expend into bubble of desired diameter and lower the film thickness.
Air is maintained at constant pressure.
Nip rollers are used to collapse the bubble, stretch the film and serve as take-
off device for the line.
Blown Film Extrusion

REFERENCES
William D.Callister, Jr, Materials Science and
Engineering an Introduction, 2003, 5
th
edition,John
Wiley & sons,Inc.
Smith W.F & Hashemi J. (2004) Foundation of
material science and engineering third edition.
NY:McGraw-Hill Company, inc.
Serope Kalpakjian and Steven R. Schmid,
Manufacturing Engineering and Technology, 2001,
4
th
edition, Prentice Hall,Inc.