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The SPE Library contains thousands of papers, presentations, journal briefs and recorded webinars from the best minds in the Plastics Industry. Spanning almost two decades, this collection of published research and development work in polymer science and plastics technology is a wealth of knowledge and information for anyone involved in plastics.

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Conference Proceedings

FLAME RETARDANT PC/ABS BLENDS FOR NOVEL LOW GLOSS MEDICAL APPLICATIONS
Amit S. Kulkarni , Srinivas Siripurapu , Todd M. Loehr , Parminder Agarwal , B. Parthipan , Pooja M.K., May 2010

Flame retardant (FR) PC/ABS blends find applications in the medical housings market owing to their superior processability and a fine balance between the primary requirements of flammability performance, mechanical properties and chemical resistance to hospital cleaners. In recent times, low part-surface gloss is emerging as an important requirement for such applications. This manuscript showcases a new chlorine-bromine free FR PC/ABS blend which meets these demanding requirements for extrusion and thermoforming applications.

AN INLINE MEASUREMENT SYSTEM FOR MICRO-FEATURES AND STRUCTURED SURFACES
B.R. Whiteside , R. Spares , P.D. Coates, May 2010

A system offering two different measurement methods for 3-dimensional evaluation of micromoulded surface features within a moulding process has been designed, manufactured and tested. The system adopts two methods for height measurement and subsequent 3D surface reconstruction. The first method, for feature sizes in the region 10?¬m to 2mm and non-optical surfaces, uses a local contrast technique to calculate when regions of the component come into focus and calculates surface heights accordingly. The second method, for the measurement of optically smooth, featureless surfaces, uses White Light Interferometry techniques to measure surface data. Both methods are seamlessly integrated into the system and require nothing more than a lens change to switch between the two.

HIGH SPEED THERMAL IMAGING OF MICROMOULDING
R. Spares , B.R. Whiteside , P.D. Coates, May 2010

Micromoulding is a thermally dominated process. Due to manufactured parts having high surface area to volume ratios extremely high cooling rates are achieved. Thermal measurements using surface mounted thermocouples at comparable rates are impractical due to their relatively high response times. To address this issue an AGA 782 SW thermal imaging camera has been modified such that it runs in a linescan mode and data are collected using a high speed digitiser to allow capture rates of 2500 lines per second. The rapid cooling of a range of components and materials have been recorded and the superheating of air traps within the component have been observed. Due to manufactured parts having high surface area to volume ratios extremely high cooling rates are achieved. Thermal measurements using surface mounted thermocouples at comparable rates are impractical due to their relatively high response times. To address this issue an AGA 782 SW thermal imaging camera has been modified such that it runs in a linescan mode and data are collected using a high speed digitiser to allow capture rates of 2500 lines per second. The rapid cooling of a range of components and materials have been recorded and the superheating of air traps within the component have been observed.

HIGH SPEED THERMAL IMAGING OF MICROMOULDING
R. Spares , B.R. Whiteside , P.D. Coates, May 2010

Micromoulding is a thermally dominated process.Due to manufactured parts having high surface area to volume ratios extremely high cooling rates are achieved.Thermal measurements using surface mounted thermocouples at comparable rates are impractical due to their relatively high response times. To address this issue an AGA 782 SW thermal imaging camera has been modified, such that it runs in a linescan mode and data are collected using a high speed digitiser to allow capture rates of 2500 lines per second. The rapid cooling of a range of components and materials have been recorded, and the superheating of air traps within the component have been observed

FEASIBILITY OF USING BIO-DEGRADABLE PLASTIC FOR AUTOMOTIVE APPLICATIONS IN TYPICAL AUSTRALIAN WEATHER
Martin N. Bureau, Marion Maire, Gerardo Diaz-Quijada, Lucie Robitaille, Abdellah Ajji, Yahye Merhi, May 2010

End of Life Vehicles (ELVs) are becoming a growing concern because of their impact on the environment. The automotive industries are facing worldwide pressure to help find environmentally friendly ways of disposing end of life vehicles. Though most of the metal parts from the ELVs are recycled however, plastic components from the shredder residue are complex to separate and they are being mostly dumped into the landfill. The main purpose of this paper is to present an alternate solution to this environmental issue by using bio-degradable plastic in the automotives. Experimental works have been done to check the change in mechanical properties of bio-degradable plastic for accelerated weathering test. The results resemble the impact of weather on bio-degradable plastic while using for automotives in typical Australian environment.

NONWOVEN PET FIBER STRUCTURES FOR VASCULAR GRAFT APPLICATIONS
Martin N. Bureau , Marion Maire , Gerardo Diaz-Quijada , Lucie Robitaille , Abdellah Ajji , Yahye Merhi, May 2010

Synthetic grafts from woven polyethylene terephthalate fibers or expanded polytetrafluoroethylene have been used for decades to replace diseased arteries. However, their thrombogenicity and low compliance (vs.arteries) inevitably lead to their occlusion. A need exists for new synthetic grafts with an anti-thrombogenic surface and high compliance to improve long-term patency. Grafts from nonwoven PET fiber structures obtained from melt blowing are evaluated. Contrary tocommercial woven Dacron ', they allow for mechanical compliance adjustment through control of fiber diameter, porosity and graft structure configuration. Their low thrombogenicity, when properly surface-treated using polyethylene glycol functionalization, artery-matching compliance and promising burst pressure are reported.

INDUSTRIAL SCALE-UP FEASIBILITY OF EXTRUDED PVC FOAMS USING BLENDS OF VIRGIN AND SUB-CRITICAL CO2 GAS-SATURATED PELLETS
Dustin Miller , Vipin Kumar, May 2010

The use of gas-saturated pellets as a means to deliver a controlled amount of blowing agent for foam extrusion was investigated. Various PVC blend ratios of unsaturated virgin and CO2 pre-saturated pellets were created before placing into the hopper. It was found that PVC profiles with a uniform microstructure can be produced. The blend ratio is a critical process parameter as it governs the amount of gas delivered to the process. Due to the high solubility of CO2 at room temperature sub-critical pressures can be used to saturate the PVC pellets. The process was successfully carried out in an industrial R&D lab and appears to be adaptable for large scale production. Due to manufactured parts having high surface area to volume ratios extremely high cooling rates are achieved. Thermal measurements using surface mounted thermocouples at comparable rates are impractical due to their relatively high response times. To address this issue an AGA 782 SW thermal imaging camera has been modified such that it runs in a linescan mode and data are collected using a high speed digitiser to allow capture rates of 2500 lines per second. The rapid cooling of a range of components and materials have been recorded and the superheating of air traps within the component have been observed.

HYDROXYAPATITE-COATED CARBON FIBER/POLYAMIDE 12 COMPOSITE FOR HIP REPLACEMENT WITH IMPROVED OSSEOINTEGRATION
S. Dimitrievska , J. Whitfield , S. A. Hacking , M. N. Bureau, May 2010

Bone loss around femoral implants used for total hip arthroplasty is a persistent clinical concern. In some cases, it may be caused by stress shielding, which is generally attributed to a mismatch in stiffness between the femoral implant and host bone. In this regard, a fatigue resistant, carbon fiber (CF) polyamide 12 (PA12) composite hip stem coated with hydroxyapatite (HA) for hip replacement has been developed to match bone stiffness and achievefixation by osseointegration. In vitro studies withosteoblast cells (MG63) showed no cytotoxicity of the composite components as seen by the cellular growth andcomposites interaction. In vivo studies comparing thecomposite and Ti-6Al-4V (Ti64) rods in the rabbit and rat femurs demonstrated significantly higher bone apposition to the composite than Ti64 rods. The results of this study indicate that the invasion of surrounding bone cells and thus osteointegration together with its bone-matching mechanical properties make the HA-coated CF/PA12 composite stem a promising hip replacement candidate.

NANOSCOPIC CHARACTERIZATION OF PLASTISOL GELATION AND FUSION PROCESS UTILIZING SCANNING ELECTRON MICROSCOPY AND ATOMIC FORCE MICROSCOPY
Jerome S. Jourdan , David P. Owen, May 2010

Understanding the physical properties associated with the gelation and fusion of a PVC plastisol will help to improve process efficiency. Plastisol gelation and fusion was characterized using both scanning electron microscopy (SEM) and atomic force microscopy (AFM) and compared to tensile properties developed at various temperatures. Both SEM and AFM show good agreement during the early stages of gelation. However AFM continues to show particle boundaries during latter stages of gelation and fusion that provide a more accurate comparison with resulting tensile properties.

A PLASTICS MANUFACTURING SYSTEMS EDUCATION
EC Brown, BR Whiteside, R Spares, PD Coates, May 2010

Plastics manufacturing is an interdisciplinary endeavor crossing chemical, mechanical, and electrical engineering as well as other fields. In this paper, a systems approach is described for the decomposition and development of a plastics manufacturing system. The case study involves the design, implementation, and validation of a thermal imprint lithography machine used in an undergraduate process control course. Its development motivated systems thinking about open and closed loop control, variances between theory and practice, performance measurement, and process optimization.

ULTRASONIC MONITORING OF MICROMOULDING
EC Brown , BR Whiteside , R Spares , PD Coates, May 2010

An ultrasonic measurement system has been developed and operated in conjunction with a suite of process monitoring transducers on a Battenfeld Microsystem 50. Measurements are non-invasive; piezoelectric sol-gel sensors can be integrated with the mould and their low-profile nature is ideally suited to the constraints of the micromoulding environment allowing measurement of flow front position cooling dynamics shrinkage morphology changes during solidification and cycle repeatability. Ultrasonic measurements of mould filling and cooling dynamics have been validated using flow visualization techniques on the same machine.

ULTRASONIC MONITORING OF MICROMOULDING
EC Brown , BR Whiteside , R Spares , PD Coates, May 2010

An ultrasonic measurement system has been developed and operated in conjunction with a suite of process monitoring transducers on a Battenfeld Microsystem 50. Measurements are non-invasive; piezoelectric sol-gel sensors can be integrated with the mould and their low-profile nature is ideally suited to the constraints of the micromoulding environment, allowing measurement of flow front position, cooling dynamics, shrinkage, morphology changes during solidification and cycle repeatability. Ultrasonic measurements of mould filling and cooling dynamics have been validated using flow visualization techniques on the same machine.

MATERIAL SELECTIONS ROLE IN CHEMICAL RELATED FAILURES
Melissa L. Kurtz, May 2010

Failure of plastic products is the result of the materialƒ??s behavior in the application but is also influenced by human factors such as material selection design processing and use. Material selection is critical to the success of a product. One of the greatest challenges relates to understanding chemical exposure in the application and the materialƒ??s corresponding resistance.Unsuitable chemical resistance of a material accounts for a majority of failures with a significant number involving exposure to secondary fluids. This paper will explore case studies that focus on chemical related failures as the result of improper material selection and understanding of secondary exposure conditions.

HIGH STRAIN RATE RHEOMETRY OF POLYMER MELTS RELEVANT TO MICROMOLDING AND THIN-WALLED INJECTION MOLDING
A L Kelly , B R Whiteside , T Gough , P D Coates, May 2010

The rheology of polymer melts has been measured at strain rates up to 107 s-1, relevant to micromolding and thin walled molding processes, using an instrumented high speed injection moulding machine. Deviations from shear thinning behavior were observed for commercial grades of polyethylene, polypropylene, polystyrene and PMMA, and shear thickening behavior occurred for some of the polymers examined. Off line parallel plate rheometry and twin bore capillary rheometry were used to provide rheological data at low and medium shear strain rates respectively. Measured shear viscosity was found to follow Newtonian behavior at low rates and shear thinning power law behavior at intermediate strain rates. At shear strain rates approaching or above 106 s-1, shear viscosity reached a rate-independent plateau, and in some cases shear thickened with further increase in strain rate. A relationship between the measured high strain rate rheological behavior and molecular structure was found, with polymers containing larger side groups reaching the rate independent plateau at lower strain rates than those with simpler structures. These results have implications for micromolding of particular polymer architectures.

AN INVESTIGATION ON ANTIBACTERIAL PROPERTIES OF MEDICAL-GRADE PVC MODIFIED THROUGH A MULTISTEP PHYSICOCHEMICAL APPROACH
Tim Gough, Ben R. Whiteside, Phil D. Coates, May 2010

Medical-grade polyvinyl chloride (PVC) was modified through a multistep physicochemical approach to yield a novel anti-adherent surface against potentially pathogenic bacteria. This was fulfilled via surface activation by coplanar surface dielectric plasma, followed by radical graft copolymerization of a spacer to render a well-defined polymer brush finally coated by biologically active species. Various surface probes together with in vitro biological assay were performed. Up to 85 % and 50% reduction in adherence degrees of gram-negative and positive strains were attained, respectively. Along with bacteria structural characteristics, wettability and surface topography of substrate were established to be principal parameters in adhesion.

DETAILED CHARACTERISATION OF MICROMOULDED PRODUCTS
Tim Gough , Ben R. Whiteside , Phil D. Coates, May 2010

The Microscale Polymer Processing: Applying the Tools (MUPP2) research programme aims to understand how molecular architecture influences processability of polymers, and the structures obtained through processing. Part of this programme involves micromoulding of a range of products, including those made from very highly controlled molecular architecture polymers (e.g. controlled MWD polystyrenes, PMMAs with nanocomposites), at a range of processing conditions. These products have been characterised using stress birefringence and polarised Raman spectroscopy to assess residual molecular orientation in conjunction with Small Angle Neutron Scattering (SANS) techniques. Experimental results indicate the variation in properties along small bar specimens. These results will be discussed, along with associated very small scale shear and extensional flow characterisations at lower strain rates

BIODEGRADABLE POLYURETHANE/SOY PROTEIN SHAPE-MEMORY POLYMER BLENDS PREPARED VIA ENVIRONMENTALLY-FRIENDLY AQUEOUS DISPERSIONS
Atakan Altinkaynak, Mahesh Gupta, Mark A. Spalding, Sam L. Crabtree, May 2010

Biodegradable and biocompatible shape-memory polymer blends of soy protein (SP) and polyurethane (PU) based on poly(?æ-caprolactone) (PCL) has been synthesized using environmentally-friendly aqueous dispersion technique. High-pressure supercritical carbon dioxide (scCO2) foaming technique was applied to the blends to generate three-dimensional interconnected porous structures or scaffolds with special enhanced benefits for potential biomedical applications such as soft tissue engineering and/or drug release. Blending PU dispersion (PUD) with SP significantly increased the biocompatibility and biodegradability properties of the materials and improved their shape-memory capability. The PCL soft segment was found to be miscible with SP over the entire range of concentration as confirmed by DSC measurements, where a single Tg located between the Tg of the pure SP and PCL soft segment was observed for all blend concentrations. The shape-memory behavior of the blends was investigated for different concentrations under free-stress condition. The rate of strain recovery was found to be SP concentration dependent. The stress recovery of the blend reached a maximum value at wSP = 0.1 weight fraction. This finding was attributed to the maximum increase in the degree of crystallinity of PCLsoft segment at wSP = 0.1 as conformed by X-ray analysis.

INFLUENCE OF THE COMPRESSION MOLDING PROCESS ON IMPACT BEHAVIOR
Alex G. Zestos, Cole L. Grinnell, Long J. Vinh, Robert D. Pike, William H. Starnes, Jr., May 2010

Self-reinforced polypropylene composites are particularly appropriate for process-induced property gradation during the compression molding process. They react especially sensitive to temperature and pressure and can therefore cover a large gradation spectrum. With the help of a newly developed, differentially tempered compression mold, area-dependent thermal gradation is possible. The locally varying material properties yielded by compression molding can be optimally verified by instrumentalized impact experiments. The equivalents for stiffness (modulus of resilience) and strength (maximal force) can be determined, alongside energetic characteristic values like dissipative and storage work.

SMOKE SUPPRESSION OF PVC BY METAL-EXCHANGED CLAY AND ZEOLITE ADDITIVES
Alex G. Zestos , Cole L. Grinnell , Long J. Vinh , Robert D. Pike , William H. Starnes Jr., May 2010

Cone calorimetry studies showed that various metalexchanged clays and zeolites containing only 3–4% of Cu(II) Cu(I) Zn(II) or Al(III) were effective smoke suppressants and fire retardants for plasticized PVC. Copper(II)-Zn(II) and Cu(II)-Al(III) synergism for smoke and heat reduction was observed with binary blends of the clays and the effectiveness of the additives was usually improved considerably by heating plasticizer-additive mixtures under very high shear before combining them with the polymer. Possible mechanisms of action of the additives are discussed.

SMOKE SUPPRESSION OF PVC BY METAL-EXCHANGED CLAY AND ZEOLITE ADDITIVES
Alex G. Zestos , Cole L. Grinnell , Long J. Vinh , Robert D. Pike , William H. Starnes Jr., May 2010

Cone calorimetry studies showed that various metalexchanged clays and zeolites containing only 3'4% of Cu(II), Cu(I), Zn(II), or Al(III) were effective smoke suppressants and fire retardants for plasticized PVC. Copper(II)-Zn(II) and Cu(II)-Al(III) synergism for smoke and heat reduction was observed with binary blends of the clays, and the effectiveness of the additives was usually improved considerably by heating plasticizer-additive mixtures under very high shear before combining them with the polymer. Possible mechanisms of action of the additives are discussed







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