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Conference Proceedings

FRACTURE TOUGHNESS AND SCRATCH BEHAVIOR OF POLYMERIC THIN FILMS
Chinfu Lee, Brian Hare, H. J. Sue, May 2012

Two recent efforts on mechanical characterization of ductile polymeric thin films are presented. One is on fracture toughness determination of polyolefin thin films and the other is on scratch deformation study of laminated films for food packaging applications. Characterization of fracture toughness of ductile polymer thin films is nontrivial. It requires extreme care in sample preparation to avoid premature film damage, in fixture design to minimize out of plane film rotation, and in meaningful analysis to establish structure-property relationship. The essential work of fracture approach has been chosen for quantifying fracture toughness of ductile polyolefin films. Issues related to sample preparation, data generation and interpretation are discussed. Possible correlation between the fracture toughness and other industrial practices is also made. In the case of scratch test, it is found that the scratch performance correlates well with the field performance of the films. The usefulness of the scratch test for evaluating film structural integrity, adhesive strength between film layers, and laminate structural design optimization is discussed.

STRATEGIES FOR ACHIEVING HIGH EXPANSION FOAMS OF CROSSLINKED ETHYLENE-VINYL ACETATE (EVA) USING A CHEMICAL BLOWING AGENT
Nan Chen, Chul B. Park, May 2012

This paper investigates the foaming behaviour of crosslinked Ethyl-vinyl acetate (EVA) using a chemical blowing agent (CBA). In this study, foaming experiments were conducted using the chemically crosslinked polyolefin foamed BUN process, with the help of a compression molding machine. It was found that an optimum degree of crosslinking was needed to produce high quality EVA foams with high expansion ratios. A mountain-shape curve can be used to describe the relationship between the expansion ratio of the EVA foams and the crosslinking content. Furthermore, with more blowing agent used in the foaming process, the value of the optimum crosslinking content at the expansion ratio peak increases.

MECHANICAL PROPERTIES AND INTERACTION OF INDIVIDUAL NANOTUBES AND NANOPLATELETS IN EPOXY
Kevin L. White, Hung-Jue Sue, May 2012

We have investigated epoxy/MWCNT nanocomposites and propose that the primary role of the nanoparticles is to reduce stress concentrations at internal defect sites. This leads to improvement in ductility and tensile strength without affecting modulus. The shielding of internal defects may also allow synergistic interaction with secondary particles. This behavior is reported to promote improved fracture toughness in the presence of pre-formed thermoplastic particles, and substantially enhanced modulus and strength when coupled with exfoliated nanoplatelets.

THERMAL AND THERMOMECHANICAL BEHAVIOUR OF INJECTION MOLDED SOLID AND MICROCELLULAR POLYLACTIC ACID (PLA)/POLYHYDROXYBUTYRATE-VALERATE (PHBV) BLENDS
Haibin Zhao, Zhixiang Cu, Xiaofei Sun, Lih-Sheng Turng, Xiangfang Peng ,, May 2012

This paper investigated the thermal and dynamic mechanical properties of solid and microcellular injection molded PLA/ PHBV blends of different weight ratios. The properties were characterized by DSC and DMA. The results showed that when the content of PHBV exceeded 45% it could significantly affect the crystallinity of the PHBV and improve the G' for both solid and microcellular components. It was also found the Tg of the PLA phase decreased with increasing PHBV content.

ESTER FUNCTIONALIZATION AND STRUCTURAL MODIFICATION OF POLYPROPYLENE VIA SOLID-STATE SHEAR PULVERIZATION
J. Mirian Diop, John M. Torkelson, May 2012

Using solid-state shear pulverization, we have identified the potential to functionalize polypropylene by taking advantage of near ambient temperature reactions. Polypropylene was pulverized in the presence of benzoyl peroxide; under these temperature conditions the decomposition of benzoyl peroxide results in the formation of benzoyloxy radicals that react with the polypropylene chain, introducing ester functional groups onto the chain. Fourier transform infrared spectroscopy indicates that such functionality cannot be obtained using conventional high temperature processing methods.

MICRO INJECTION MOLDING OF POLYMERS FOR BIOMIMICKRY OF ORGAN TISSUE
John W. Rodgers, Burak Bekisli, John P. Coulter, May 2012

Two types of polystyrene were injection molded into macroscale parts with microscale features. UV photolithography was utilized to create microchannels on the surface of silicon wafers. Higher mold temperatures facilitated filling of the microfeatures. In addition, an undercut microchannel feature promoted pillar elongation. HIPS exhibited greater heights at identical mold temperature conditions. Pillars with heights of 15 µm were molded with an aspect ratio of 9.3. Polymer surfaces could provide control of biological cell activity

KINETIC, THERMODYNAMIC AND STRUCTURAL FACTORS GOVERNING THE DISPERSION OF NANOCLAYS IN POLYMER MELTS
Mark D. Wetzel, May 2012

Polymer nanocomposites offer a potential solution to improve, while maintaining, multiple, incompatible properties, such as mechanical and optical performance. In order to demonstrate significant property enhancements, a well-controlled dispersion of a nano-scale filler into a polymer matrix is required. Melt processing represents the most economical and flexible route to producing thermoplastic nanocomposites. This paper describes a set of melt compounding experiments to help establish the kinetic and thermodynamic factors that govern the dispersion of layered silicates in ionomers. The results show that the stress imparted during the melt blending influences dispersion. However, the thermodynamic compatibility between the filler surface, organic modifier and matrix polymer plays a dominant role in the exfoliation process.

DETERMINATION OF KINETIC CURE PARAMETERS CONSIDERING SPECIFIC HEAT TEMPERATURE DEPENDENCE
Rogerio L. Pagano, Veronica M.A. Calado, Frederico W. Tavares, Evaristo C. Biscaia, May 2012

In this work, an algebraic-differential equations (EAD) system is applied to estimate parameters using both isothermal and non- isothermal data. Temperature dependence of the specific heat is considered inside the EAD as an algebraic restriction. The estimation procedure is based on the use of a mass and energy balance in DSC furnace. The approach found all kinetic parameters by using deterministic and heuristic algorithms. The results show that the use of an energy balance is a good methodology to estimate cure kinetic parameters of both isothermal and non-isothermal experiments.

ANALYSIS OF THE PROPERTIES AS CONTENT OF END-GROUP FOR POLYCARBONATE (PC)IN MELT POLYMERIZATION PROCES
Su Ran Lee, Sang-hyun Park, Byung Hoon Lim, Kwan Hwi Park, Byoung Ok Jang, May 2012

There are two processes to polymerize polycarbonate in the petrochemical industry: One is interfacial polymerization(interfacial PC) and the other is melt polymerization(melt PC). Recently, the latter is mostly used in that it is eco-friendly process. The most difference of product produced by two systems is the content of specific end-group. It is detected to a little bit value in interfacial polymerization, while it generally has more content in melt polymerization. It is supposed that the more content of the end-group is, the bigger change of the property induce as surrounding environment. In order to analyze an effect of the end-group, polycarbonate substituted to other end-group was made from melt PC using a suitable end-capping agent. And then, several properties were examined like melt index, viscosity and color. As the result, the end-capped PC showed less change of the properties than general melt PC, and it is similar to interfacial PC. It was verified that the properties of melt PC is adversely affected by the specific end-group.

DEVELOPMENT OF LIGNIN-BASED THERMOPLASTICS FOR COMPOSITE APPLICATIONS
Amit K Naskar, May 2012

Current trends in renewable resin systems for composite applications will be presented in this talk. Our recent efforts on synthesis of lignin-based bio-thermoplastics show significant promise. Various methods of establishing chemical synthetic routes for producing lignin-based thermoplastics that can increase the value of lignin by-products will be discussed. Compatibilization of blends of lignin with different polymeric matrices results good thermoplastic for certain lignin loadings. These routes would provide a low-cost alternative, recyclable resins for future composite applications.

POLYESTER DEVELOPMENT PROGRESS FOR EXTRUSION BLOW MOLDING APPLICATIONS
Mark A. Treece, Thomas J. Pecorini, May 2012

This work highlights three decades of polyester resin development for the extrusion blow molding (EBM) process. The optimal formulation for a clear EBM material must fulfill three main requirements: process efficiently on existing equipment, produce bottles with robust drop impact performance, and have an acceptable recyclability story. Balancing these criteria in a single formulation is challenging, since obtaining compatibility in the PET recycle stream inherently causes drawbacks to processing and bottle performance. Nevertheless, significant innovation has enabled Eastman to provide the market with a comprehensive portfolio of copolyester technology, suitable for a variety of needs.

DIBENZOATE PLASTICIZER PLATFORM DEVELOPMENT FOR PVC APPLICATIONS
William D. Arendt, Emily L. McBride, Rebecca Brewer, May 2012

Dibenzoates plasticizers are well established and are used in PVC applications. Chemically these plasticizers are non-phthalates and dibenzoates function well as high solvating type plasticizers. In the past, new benzoates, dibenzoate blends and grades were developed to keep pace with formulators’ needs. A new generation dibenzoate triblend platform has been developed to offer formulators an improved high solvator to complement general purpose plasticizer performance. A basic plastisol evaluation protocol was utilized to help determine how to formulate with these new blends. In addition to the basic data developed, examples of performance in starting plastisols will be shown.

EXPERIMENTAL INVESTIGATIONS ON VANE EXTRUDER FOR POLYMER SHORT THERMO-MECHANICAL HISTORY PROCESSING
Jinping Qu, Guizhen Zhang, Jia-Jia Chen, Xiao-chun Yin, He-zhi He, May 2012

The screw extruder is one of the mostly used equipment for polymer processing and its conveying mechanism is based on the shear flow. This leads to the materials experiencing a long thermo-mechanical history. Vane extruder is an innovative equipment which totally alters the shear conveying mechanism of screw extruder. The solid compacting and conveying section, the establishment of pressure section and the melting section simultaneously occur in the vane extruder which is different from the screw extruder. This results in the short thermo-mechanical history in the vane extruder. And the crushing of solid-bed and the elongational flow are generated in the vane extruder. Therefore, it does not decrease the plasticating and mixing effects even though it has shorter thermo-mechanical history than the screw extruder. The plasticating and mixing effects are found better in the vane extruder compared to the screw extruder through the experimental investigations.

STUDY OF THE INTERFACIAL PROPERTIES OF FIQUE FIBER REINFORCED POLYETHYLENE ALUMINIUM
Miguel Ángel Hidalgo, Mario Fernando, MuñozJosé Mina, Tim A. Osswald, May 2012

By using a pull-out test the mechanical bonding at the interface fique fiber-Low Density Polyethylene- Aluminum (LDPE- Al) matrix was measured. Experimental results of the shear stress at the interface point out that a critical length of 21 mm optimally transfers the stresses from the matrix to the fiber. In addition, a volume of 50% fique fiber showed better mechanical strength when compared to volumes of 10 and 30%. Optimization of the critical length and volume ratio (fique fiber/matrix) allowed the manufacturing of boards using a hot plate machine.

DEECOM®: A SUSTAINABLE PROCESS USED IN VARIOUS RECLAMATION PROCESSES
Sue Reynolds, May 2012

Polymer manufacturing utilizes metal parts which are reclaimed for reuse. Traditional reclamation methods utilize solvents and other chemicals which have high energy demand and involve expensive disposal methods. The DEECOM® technology, solvent-free relatively low temperature reclamation technology, is based on pressure swing techniques designed to physically disrupt and remove polymer from parts. The process mechanism results in filter reclamation procedures that have high degree of sustainability and provide opportunity to recycle the removed polymer.

POLYHEDRAL OLIGOMERIC SILSESQUIOXANE SURFACE MODIFICATION AND NANODISPERSION
Sarah E. Morgan, May 2012

The dispersion of nanoscale reinforcements in polymer matrices remains a significant challenge in achieving desired properties in nanocomposite materials. Polyhedral oligomeric silsesquioxane (POSS) nanostructured chemicals, consisting of an inorganic cage structure with an organic corona, provide a unique opportunity to control nanoscale dispersion by tuning the organic substituents to allow interaction with specific substrates. The structure can also be tailored to provide preferential surface segregation in a polymer melt to achieve desired modification of surface properties. The estimation of POSS solubility in polymer matrices through calculated solubility parameters and molecular dynamic simulations will be discussed in relation to experimental results. The dispersion of POSS and POSS-modified nanoparticles in selected systems will be reviewed.

PRECISION CONTROL OF MORPHOLOGY,ORIENTATION AND FUNCTION WITH FIELD ASSISTED ALIGNMENT TECHNIQUES ON NOVEL ROLL TO ROLL MANUFACTURING PLATFORMS
Miko Cakmak, May 2012

There is a significant excitement brewing in the application of polymers for functional films for new applications such as transparent conductive flexible electrodes for flexible electronics, high throughput high selectivity separation membranes and ultrahigh density storage devices. These are enabled by the recent developments in roll to roll manufacturing that combines multiple functions in one machine to add desired properties. For example, at National Polymer Innovation Center at University of Akron, we developed a hybrid roll to roll manufacturing line that facilitate incorporation of continuous conductive nanofibers into polymer solutions/or photocurable monomers to produce flexible transparent conductive electrodes to enable flexible displays, photovoltaics and OLEDs. This was possible by integrating a large farm of nanofiber generators to single and multilayer casting system to produce pilot scale films that can be flexed many hundreds of time around sharp radius without loss of initial conductivities and transparencies. We will illustrate the utility of this R2R line in producing die sensitized flexible PV devices. In traditional polymer processes involving flow, the anisotropic phases inevitably oriented with details of the flow field and rarely if at all these phases/nanoparticles are oriented normal to the surfaces of the products in particular films. In order to achieve this “Z-orientation” or phases/and or particles normal to the film plane, we also developed a brand new 70ft long machine to orient and organize polymer phases, nanoparticles normal to the film plane. This is achieved by application one or more of following external force fields: electric, Magnetic and thermal gradient fields. These are incorporated in this pilot scale line. In this presentation, we will show illustrations of the use of this line in anisotropic nanoparticle alignment, block copolymer phase alignment in the Z-direction.

EFFECT OF TYPICAL MELT TEMPERATURE NON-UNIFORMITY ON FLOW DISTRIBUTION IN FLAT DIES
Olivier Catherine, May 2012

In this study, the influence of non-uniform incoming melt temperature profiles on the flow in a flat die is evaluated. Flat film die flow channels are typically designed to provide uniform flow distribution at the die exit assuming uniform incoming melt temperature profiles. However, in real extrusion conditions, it can be challenging to obtain an ideally uniform melt temperature delivery to the die. There are many reasons why the melt temperature non- uniformity is obtained. Two typical scenarios are evaluated; (i) the temperature profiles generated by an incorrect melt pipe design will be calculated and input in a die flow model as inlet boundary condition and (ii) the influence of a polymer subject to excessive viscous dissipation in the extruder. This work uses 3D computational fluid dynamics (CFD) models.

A SINGLE MACHINE SCHEDULING STRATEGY FOR ENERGY SAVING IN INJECTION MOLDING PROCESS
Guixia Gong, Ningyun Lu, Jianhua Lu, Yi Yang, May 2012

A single machine scheduling strategy is proposed for minimizing the global energy consumption of an injection molding machine with multiple products. The total energy consumption contains three parts: switchover energy, transitional energy and stable operation energy. The transitional energy consumption model is developed. The scheduling problem is formulated as a typical travelling salesman (TSP) problem, which will be solved by a GA-based lexicographic optimization framework. Experimental results show the feasibility and effectiveness of the proposed energy-saving-oriented single machine scheduling strategy.

EFFECT OF EPOXIDIZED SOYBEAN OIL ON MECHANICAL PROPERTIES OF POLYLACTIC ACID BLENDS
Yong Qing, Fu Zhao, Chen Quan, Huan Zheng, Gui Wu, Zhang Zhen, Qu Jin Ping, May 2012

Epoxidized soybean oil (ESO), as a plasticizer, was melt blended with polylactic acid (PLA) in an internal mixer. The effects of ESO on the mechanical properties of the PLA/ESO blends were studied by means of the tensile, flexural, and impact tests. The elongation at break for the PLA/ESO blends was obviously improved with an increase in ESO loading, and was 16.8 times than that for pure PLA when the ESO loading was 5 wt %. Compared with pure PLA, the blends appeared lower tensile strength, tensile modulus, flexural strength, and flexural modulus. However, ESO improved impact strength for PLA matrix. Impact strength for the blends increased at first and then decreased as the ESO loading increased, which arrived a maximum of 2.9 times than that for pure PLA when the ESO loading was 10 wt %.










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