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Conference Proceedings

MECHANICAL PROPERTIES OF SULFONATED BLOCK COPOLYMERS
J. M. Sloan, E Napadensky, D Suleiman, May 2012

Dynamic mechanical analysis (DMA), and FT-IR was used to examine a series of highly sulfonated poly(styrene- isobutylene-styrene) (SIBS) block copolymers. Sulfonation levels of 53%, 64% and 97% were studied. These block copolymers were subsequently neutralized with three inorganic counter-ions, Mg2+, Ca2+ and Ba2+. The substitution of inorganic counter-ions maintained the glass transition temperature of the membrane at -60°C regardless of cation exchanged and increased the modulus of the rubbery plateau indicative of a crosslinking complex formation. New relaxations were observed above Tg for the highly sulfonated counter-ion substituted samples attributed to the Tg of the functionalized styrene segments. FT-IR results show a shifting of the IR bands attributed to the sulfonate groups when counter-ions are added, indicating the formation chemical crosslinks.

RHEOLOGICAL PROPERTIES AND FOAMING BEHAVIOR OF COAGENT-MODIFIED POLYPROPYLENE
Ying Zhang, Marianna Kontopoulou, J.Scott Parent, Savvas G. Hatzikiriakos, Chul B. Park, May 2012

Reactive modification of linear PP by radical mediated grafting in the melt state is investigated as a means of increasing its melt strength, thus resulting in improved foam processing characteristics. A tri-functional coagent, triallyl trimesate (TAM) is used to introduce long chain branching to the linear PP homopolymer. Rheological characterization is conducted to relate the rheological properties to the modified PP chain architecture. The foaming behaviour of the linear and branched PPs is investigated using a batch foaming apparatus with N2 as a blowing agent.

NUMERICAL VERIFICATION OF RHEOLOGICAL CHARACTERIZATION OF POLYSTYRENE DURING MICROCELLULAR INJECTION MOLDING
Shia-Chung Chen, Kuan-Hua Lee, Yu-Wan Lin, Tai-Yi Shiu, Chuan-Wei Chang, Jimmy C. Chien, May 2012

The purpose of this study is to investigate the rheological behavior of Polystyrene melt with dissolved SCF of nitrogen during Microcellular Injection Molding process applied with Gas Counter Pressure (GCP) technology; also, rheological behavior is compared with independent theoretical simulation using moldex3D. A slit cavity is designed to measure the pressure drop of polystyrene mixed with 0.4wt% supercritical nitrogen fluid under different mould temperatures (185°C, 195°C, and 205°C), injection speeds (5, 10, and 15 mm/s) as well as counter pressures (0, 150, 300 bars). It was found that the melt viscosity is reduced by up to 30% when GCP is increased from 50 to 150 bar as compared to conventional injection molding. The simulation results of pressure history well agrees with the experiments and provide a theoretical point of view on process design.

MEASUREMENT AND MODELING OF PLANAR AND UNIAXIAL EXTENSIONAL VISCOSITIES FOR LDPE POLYMER MELT
Martin Zatlouka, May 2012

In this work, novel patent pending rectangle and circular orifice dies have been used in order to determine planar and uniaxial extensional viscosities for extrusion coating LDPE through entrance pressure drop determination on conventional twin bore capillary rheometr. It has been revealed that the uniaxial extensional viscosity/uniaxial extensional strain hardening is higher in comparison with the planar extensional viscosity and recently proposed non-Newtonian fluid model can described the measured rheological data reasonably well.

ANTIMONY TRIOXIDE-FREE FLAME RETARDANT SYSTEMS FOR POLYMERIC MATERIALS
Subramaniam Narayan, Marshall Moore, May 2012

Flame retardants in polymers play a significant role in protecting lives and reducing damage in the event of a fire. Typically brominated flame retardants (BFR) require a synergist such as antimony trioxide (ATO) that enables lower loadings of the BFR in polymer formulations. However for compliance to certain voluntary environmental standards, it is desirable to replace ATO partially or completely in polymer formulations. This work describes the replacement of ATO in formulations containing a newly developed flame retardant, Emerald 1000 (FR1). In high impact polystyrene (HIPS), FR1 is shown to exhibit good flame retardancy when combined with a char forming polymer like polyphenylene ether (PPE). Similarly in polycarbonate (PC)/acrylonitrile butadiene styrene (ABS) systems, FR1 shows good flame retardancy, without the need for ATO synergist. More importantly FR1 does not negatively impact the mechanical properties of the system.

HIGH-SHEAR-RATE RHEOLOGY OF POLYSTYRENE MELTS
Wei Sheng Guan, Han Xiong Huang, May 2012

This work presents a systematic analysis on the capillary rheology of polystyrene melts under high shear rates ranging from 103 to 106 s-1. The precise Bagley correction was achieved by means of the enhanced exit pressure technique. The end pressure drop was found to predominate over the Bagley-corrected capillary pressure drop in the high shear rate range. Furthermore, the dissipation heating, pressure dependence, and compressibility effects were quantitatively evaluated. Results implied that the apparent nonlinearity of the Bagley-corrected capillary pressure drop versus apparent shear rate profile, which occurred at the shear rates of above 105 s-1, mainly resulted from the dissipation heating. In the shear rate ranges investigated, the corrected rheological behavior could be adequately described by the power law.

PREPERATION AND CHARACTERIZATION OF PP-PET SEA-ISLANDS TYPE BICOMPONENT AS-SPUN FIBERS BY HIGH-SPEED MELT SPINNING
Joo-Hawn Yoo, Wan-Gyu Hamn, May 2012

In this study, to investigate characteristic fiber deformation behaviors in high-speed melt spinning process of sea-islands type bicomponent fiber, high-speed melt spinning for PP-PET sea-islands type bicomponent fiber was conducted upto 7 km/min. Overall diameter profiles from nozzle to winder for single- and bi-component fibers could be obtained through on-line measurement of diameter. Structure evolution of obtained as-spun fibers was systematically investigated by using 2D WAXD, DSC, birefringence, and tensile test etc.

MONITORING OF THERMAL HOMOGENEITY IN SINGLE SCREW EXTRUSION USING INFRARED TEMPERATURE SENSORS
Javier Vera Sorroche, Elaine Brown, Adrian Kelly, Phil Coates, May 2012

The ability of infrared temperature sensors to provide information relating to the thermal homogeneity and melting performance of single screw extruders has been investigated. Infrared sensors were located in the barrel of a single screw extruder close to the end of the screw and in an instrumented die adaptor. Results were compared to those obtained from a thermocouple grid sensor located at the entrance to the extruder die. Two grades of high density polyethylene were used in experiments with three extruder screw geometries at a range of screw speeds. When located in the die adaptor, the infrared sensor detected temperature fluctuations related to melting instabilities but these were smaller in magnitude than the actual fluctuations detected by the thermocouple grid sensor due to the limited penetration depth of the infrared sensor. When located in the extruder barrel the infrared sensor provided a bulk measurement of melt temperature across the depth of the screw channel in the metering section which correlated more closely with that measured using the thermocouple grid.

COMPUTER SIMULATION OF FLOW BALANCE IN THE DIE OF SLOT COATER: PART 1: LAND GEOMETRY
Hyun Kim, Yohan Park, Jinsoo Hong, M.Y. Lyu, S.K. Shin, J.K. Seo, May 2012

Coating operations such as spin coating, curtain coating, role coating, slide coating, slot coating, and etc. are dated from long time ago and still considered very important processing. Slot coating is considered very important specially for the manufacturing of liquid crystal display parts. Photo resistant is coated on the glass and is sent to next process to make TFT board. Coating quality such as uniformity of coating thickness can be divided into two categories, which are machine direction quality and transverse direction quality. Machine direction quality is related to die lip design and operation conditions whereas the transverse direction quality is related to flow uniformity inside of the die. The flow uniformity is governed by flow balance in the die. The most important design factors for the inside die geometry are manifold and land. Through this study the flow balance according to the land design has been examined by computer simulation. The parameters for land design are length and shape. Exit velocity at the outlet of die is different from land designs. The best land design has been investigated in this study.

SUPERCRITICAL FLUID DOSAGE CONTROL USING ARTIFICIAL NEURAL NETWORK (ANN) FOR MICROCELLULAR INJECTION MOLDING
Xiaofei Sun, Lih-Sheng Turng, Patrick J. Gorton, Eugene P. Dougherty Jr, May 2012

Supercritical fluid (SCF) dosage is one of the most important parameters for microcellular injection molding. Highly accurate and repeatable SCF dosage is required to ensure high part quality and consistency. In this study, an artificial neural network (ANN) based SCF dosage control strategy was proposed to predict and compensate for the possible variations in the coming SCF dosing stage to achieve a more repeatable SCF dosage. The result shows that this control strategy can be successfully implemented, and that it leads to significant improvements in dosage consistency and part quality.

PULL AND FOAM - INJECTION MOULDING METHOD: FOAMED RIBS FOR STIFFENING PLANE COMPONENTS
Hans-Peter Heim, Mike Tromm, Stefan Jarka, Joachim Schnieders, Stefan Gövert, May 2012

The pull and foam method is a foam injection moulding method which introduces the possibility to partially foam a component. In this way, thin-walled, hardly foamed components with foamed ribs can be made in one processing step, thus also components with graded properties. One the one hand this components possess a high stiffness, one the other hand a high surface quality. The method introduces the advantages of foam injection moulding procedure to new application fields.

COMPATIBLIZED POLYPHENYLENE SULFIDE/LIQUID CRYSTAL POLYMER ALLOY FOR ELECTRICAL&ELECTRONIC APPLICATIONS
Rong Luo, Xinyu F. Zhao, May 2012

The combination of polyphenylene sulfide (PPS) and liquid crystal polymer (LCP) in polymer blend is a potential way of creating new polymer properties. However, the two polymers are incompatible, and typical physical blends do not realize synergistic performance. Herein we report a compatiblized PPS/LCP alloy. Morphology and thermal analysis confirm the improved compatibility of PPS and LCP. As a result, mechanical properties of the compatiblized PPS/LCP alloy are improved. In particular, the notched Izod impact improves by 45% and weld line strength improves by 37% compared to PPS/LCP physical blend. The surface quality as measured by surface gloss of the compatiblized alloy is also improved significantly. In addition, the compatiblized PPS/LCP alloy is halogen free according to IEC 61249-2-21 standard and meets V-0 flammability of the UL-94 standard. Such compatiblized PPS/LCP alloy is an ideal material for electronics applications such as connectors and printer parts.

ULTRA-HIGH THERMALLY TREATED LLDPE NANOCOMPOSITES: TRANSPORT PROPERTIES AND ELECTROMAGNETIC SHIELDING
Byron Villacorta, Amod A. Ogale, Todd Hubing, May 2012

The electromagnetic shielding effectiveness (EM SE) and the electrical properties of ultra-high thermally treated carbon nanotubes/nanofibers in LLDPE matrix were evaluated. EM SE displayed dependence on electrical resistivity and electrical permittivity. Nanocomposites at 60wt% nanomodifier content showed EM SE values as high as 67 dB at 1.5GHz. The primary shielding mechanism in these nanocomposites was absorption. Therefore, such nanomaterials have potential use in electromagnetic compatibility applications.

PROGRESS ON SIMULATING LONG-GLASS FIBER ORIENTATION IN COMPLEX MOLDING GEOMETRIES
Kevin J. Meyer, Donald G. Baird, May 2012

The mechanical properties of fiber reinforced materials are highly dependent on fiber orientation generated within the composite during molding operations. Rheologically obtained parameters for fiber suspensions are applied to current models to predict fiber orientation in complex geometries independent of experimental considerations. This method provides an a priori pathway to determine fiber orientation based solely on rheological testing of the suspension and independent of the mold geometry. Furthermore, predictions for fiber orientation are carried out using the traditional rigid fiber Folgar-Tucker model as well as the semi-flexible Bead-Rod model which allows for the inclusion of fiber bending to be taken into account often witnessed in long-glass fiber (LGF) systems. Computations for fiber orientation are performed for center-gated disks and predictions with the two above models are compared to experimental data.

HIGH PERFORMANCE METALLOCENE POLYETHYLENE BASED ON SK INNOVATION’S NEXLENE™ TECHNOLOGY
Sewon Oh, Seungbum Kwon, Hyeongtack Ham, Sungseok Cha, May 2012

SK innovation has developed a new polyethylene technology, Nexlene™, capable of producing from mPOE to mHDPE based on SK’s novel metallocene catalyst. The process technology is based on a solution process and therefore is capable of producing octene-1 copolymers. Additionally, the bimodal process allows for product tailoring via adjusting the molecular weight distribution and co-monomer distribution. So we can obtain high performance Nexlene™ products with superior general physical properties, transparency, processibility, and organoleptic properties.

A NOVEL METHOD TO PREPARE PET NANOCOMPOSITES BY WATER-ASSISTED MELT COMPOUNDING
Maryam Dini, Pierre J. Carreau, Tahereh Mousavand, Musa R. Kamal, Minh-Tan Ton - That, May 2012

Polyethylene terephthalate (PET) nanocomposites were prepared via melt compounding of PET using a twin screw extruder. Water was fed to the extruder to assist in intercalation/exfoliation. The ratio between the water and PET feed rates was varied and Cloisite Na+, Cloisite 30B and Nanomer I.238E were used. Wide angle x-ray diffraction (XRD), scanning electron microscopy (SEM), differential scanning calorimetry (DSC) and rheometry were used to characterize the PET nanocomposites.

VIRTUAL PROTOTYPING APPLIED TO A BLOW MOLDED CONTAINER
Philippe Klein, View Paper Frédéric Fradet, Hossam Metwally, Thierry Marchal, May 2012

This study shows how the parison of a large (1000 liters) blow molded water container can be optimized (programmed) to improve its mechanical performance as related to hydrostatic loading while keeping the weight of the part to a minimum. This case study is composed of two parts. The first (baseline) case is aimed at validating the computational model by comparing the material distribution predicted by the model with available experiments. As an input to the baseline simulation, the initial thickness variation along the parison was obtained from direct measurements from the field and used for the baseline case. The final material distribution obtained from the blow molding simulation is then compared to those of the real part. A structural analysis is next performed using static implicit FEA to predict the container's performance when it is completely filled with water and enclosed in a steel cage. The objectives are to compute the total deformation, and the total (von-Mises) stresses. The variable material distribution obtained from the blow molding step is used in the structural model. In the second part of the case study, the initial parison thickness used in the field was challenged and optimized. The objective of the optimization (programming) was to find out the minimum initial thickness of the parison that will increase the minimum final thickness to a desired value. The optimized container is lighter than the original design by 10% while at the same time being more rigid.

STRUCTURE AND PERFORMANCE OF MULTILAYER NANOCOMPOSITES FILMS
M. Fereydoon, F. Sadeghi, H. Tabatabaei A. Ajji, May 2012

In this study, we investigated the structure and properties of multilayer films with a nanocomposite core layer. The core layer materials considered were polypropylene (PP), polylactic acid (PLA) and polyamides (PA-6) and the side layers were polyethylenes (PE). The multilayer films were obtained from the extrusion cast or film blowing processes. The structure of the films was investigated using microscopy, X-ray diffraction and differential scanning calorimetry. The properties studied were the mechanical properties in terms of modulus, strength and elongation in addition to tear, haze and barrier properties of the films. The effect of nanoclay content in the range of 1 to 7.5 wt% was investigated. In terms of structure, it was found that the clay platelets aligned in the films plane. Exfoliation was observed for the PA nanocomposite systems, some intercalation was observed in the case of PLA-nanoclay and no change in the clay spacing was observed in the case of PP-nanoclay system. For the performances, it was generally found that the presence of clay enhanced the modulus, tear and barrier properties, but little change was observed in the other properties. The barrier properties correlated with the state of dispersion of the clay platelets. Multilayer films with PA nanocomposites showed the highest barrier to oxygen permeation.

FILM INSERT MOLDING BASED ON POLYOXYMETHYLENE AND POLY(LACTIC ACID): MORPHOLOGY AND MECHANISM OF INTERFACIAL ADHESION
Satoshi Nagai, Makiko Sakurazawa, Kunihiko Fujimoto, Masayuki Nagai, May 2012

Film insert moldings were fabricated by using PLA as film and POM copolymers with various oxyethylene repeating units. The interfacial adhesion properties between film and substrate were determined by micro-cutting analyses. POM containing high oxyethylene content shows superior adhesive strength than those with low oxyethylene content. The growth of the POM-PLA mix layer was explained by mechanism of “negative pressure” in POM phase attributed by POM crystallization and partial miscibility between POM and PLA.

A NEW STERILIZABLE HIGH TEMPERATURE POLYETHERIMIDE BLEND FOR HEALTHCARE APPLICATIONS
Mark A. Sanner, Robert Gallucci, Scott Davis, May 2012

A transparent, high temperature thermoplastic Polyetherimide (PEI) resin blend with improved impact resistance and enhanced hydrostability has been developed for healthcare applications. The two-phase resin blend can be sterilized using traditional methods such as high temperature autoclave, ethylene oxide, gamma radiation, as well as STERRAD® NX®, a low- temperature hydrogen peroxide plasma sterilization process. Injection molding of the new resin blend and mechanical property and color retention after sterilization is described and compared to polyphenylsulfone (PPSU).










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