SPE Library
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
EFFECTS OF NYLON6 NANOCOMPOSITES WITH NANOCLAY QUANTITY ON PART MOLDABILITY OF IN MOLD DECORATION MOLDING
S.H. Masood, M. Nikzad, Vishal Patel, May 2010
Nylon6 nanocomposites (with2.0 wt% and 4.0 wt% nanoclay-montmorillonite) and two kinds of PC film with thickness of 0.125 mm and 0.175 mm combined varied ink formulas were used to investigate the effect of nanoclay quantity on ink washout of in mold decoration molding (square plate specimen with thickness of 2.0mm). It was found that Nylon6 nanocomposites with nanoclay quantity of 4.0wt% would increase 30% washout area than of 2.0wt% addition quantity. In addition, higher injection speed would increase shear stress leading to large ink washout area whereas higher melt temperature would decrease ink washout area.
MELT FLOW ANALYSIS OF ABS IN FUSED DEPOSITION MODELLING PROCESS
S.H. Masood , M. Nikzad , Vishal Patel, May 2010
This paper presents a numerical study of melt flow behaviour of ABS plastic through the melt flow tube of the liquefier head of the Fused Deposition Modelling (FDM) rapid prototyping process using the finite element analysis. Main flow parameters including temperature, velocity and pressure drop have been investigated. Liquefier head of FDM machine has been modelled parametrically and the effects of physical modifications including nozzle angle variation on the melt flow parameters have been investigated accordingly. Results provide promising information on flow behaviour of new ABS based composites for processing in the FDM system to fabricate new products.
POLYSTYRENE MONTMORILLONITE NANOCOMPOSITE MICROCELLULAR FOAM USING SUPERCRITICAL CARBON DIOXIDE AS BLOWING AGENT
Babu Padmanabhan, Chetan Chincholi Jayanth, May 2010
Exfoliated organoclay in the polystyrene-block-poly(2-vinyl pyridine) was used the as a model material for investigating the heterogeneous nucleation effect of nanoclay in polymer foams. Using strictly controlled foaming process, the experimental results indicate that exfoliated clay in polymer matrix is able to decrease the cell size and increase the cell density. The cell size can be reduced to about 1.4 ?¬m and the cell density increase to 8.4*1010 cells/cm3 when 20 wt.% of organoclay was added. On the contrary, aggregated nanoclay has no effect on the cell size and cell density.
SPECIAL INTAKE ELEMENTS TO OVERCOME FEED LIMITATION IN COROTATING TWIN-SCREW EXTRUDERS -DESIGN FEATURES AND EXPERIMENTAL RESULTS
Babu Padmanabhan , Chetan Chincholi Jayanth, May 2010
Forced and starve feeding are well known feeding methods to input material into a co-rotating twin screw extruder. Polymers in powder form and materials such as talc and mica are a challenge to introduce into the extruder. The geometry of the intake zone screw elements and the side-feed zone screw elements decide the conveying ability and the intake capacity of the extruder. The problem of lower intake capacity is solved by the use of Single Flight Shovel (SFV) Triple Flight Shovel (TFV) and Regular Flight Shovel (RFV) classified as 'FV' type elements (Patent Pending). The screw flights are designed to plough through the material similar to the working of a snowplough. Increase in intake capacity compared to Erdmenger-type and Schubkanten-type screw elements is discussed.
SPECIAL INTAKE ELEMENTS TO OVERCOME FEED LIMITATION IN COROTATING TWIN-SCREW EXTRUDERS -DESIGN FEATURES AND EXPERIMENTAL RESULTS
Babu Padmanabhan , Chetan Chincholi Jayanth, May 2010
Forced and starve feeding are well known feeding methods to input material into a co-rotating twin screw extruder. Polymers in powder form and materials such as talc and mica are a challenge to introduce into the extruder. The geometry of the intake zone screw elements and the side-feed zone screw elements decide the conveying ability and the intake capacity of the extruder. The problem of lower intake capacity is solved by the use of Single Flight Shovel (SFV), Triple Flight Shovel (TFV) and Regular Flight Shovel (RFV) classified as 'FV' type elements (Patent Pending). The screw flights are designed to plough through the material similar to the working of a snowplough. Increase in intake capacity compared to Erdmenger-type and Schubkanten-type screw elements is discussed.
SHEAR UNIFORMITY IN CO-ROTATING TWIN SCREW EXTRUDER - A GEOMETRICAL STUDY OF SHEAR RATES IN A FULLY FILLED ZONE
Babu Padmanabhan , Chetan Chincholi Jayanth, May 2010
Increase in screw speed results in increased localized shear rates in co-rotating twin-screw extruders due to higher radial and meta-radial shear. This results in shear non-uniformity which in-turn results in degradation of shear sensitive material. Shear rates induced by kneading elements with different geometries are studied in the axial (longitudinal) radial and meta-radial shear planes. Elements with fractional lobed geometry having unequal tip angles show greater shear uniformity minimizing excessive shear in small regions. A careful study of the geometries of kneading elements and their shear distribution is provided for practical use in compounding application.
SHEAR UNIFORMITY IN CO-ROTATING TWIN SCREW EXTRUDER - A GEOMETRICAL STUDY OF SHEAR RATES IN A FULLY FILLED ZONE
Babu Padmanabhan , Chetan Chincholi Jayanth, May 2010
Increase in screw speed results in increased localized shear rates in co-rotating twin-screw extruders due to higher radial and meta-radial shear. This results in shear non-uniformity which in-turn results in degradation of shear sensitive material. Shear rates induced by kneading elements with different geometries are studied in the axial (longitudinal), radial and meta-radial shear planes. Elements with fractional lobed geometry having unequal tip angles show greater shear uniformity minimizing excessive shear in small regions. A careful study of the geometries of kneading elements and their shear distribution is provided for practical use in compounding application.
TWIN SCREW EXTRUSION OF THERMOPLASTIC POTATO STARCH
D. Lawton, G. Wang, Q. Liu, M.R. Thompson, May 2010
Among starch species, potato tends to have a much narrower processing window in extrusion machinery for the preparation of thermoplastic starch compared to other common starch sources from corn or wheat. The present study demonstrates through a series of screw design refinements, a working approach to setting up a reasonable processing window of this starch type and discusses the issues involved. Finally the paper demonstrates through a series of trials with one of the optimal screw configuration, the influence of shear and formulation on final properties for the thermoplastic product.
IN-SITU ULTRASONIC COMPATIBILIZATION OF PEN/LCP BLENDS
T. Kuboki, Y.H. Lee, J.W.S. Lee, W. Zhu, C.B. Park, M. Sain, May 2010
In-situ compatibilization of immiscible blends of PEN and thermotropic LCP was achieved by the ultrasonically-aided extrusion process. Ultrasonically treated PEN underwent degradation. In PEN/LCP blends, LCP acted as a nucleating agent. Ultrasonically induced copolymer formation was detected by MALDI-TOF mass spectrometry in the blends. Ultrasonic treatment of 90/10 PEN/LCP blends improved interfacial adhesion in fibers spun at intermediate draw down ratios (DDR), improving their ductility. The lack of improvement in the mechanical properties of fibers spun at high DDR after ultrasonic treatment was attributed to the disturbance of interfacial copolymer by high elongational stresses.
EFFECTS OF CLAY ON MECHANICAL PROPERTIES OF INJECTION MOLDED HIGH-DENSITY POLYETHYLENE/CLAY NANOCOMPOSITE FOAMS
T. Kuboki , Y.H. Lee , J.W.S. Lee , W. Zhu , C.B. Park , M. Sain, May 2010
This paper investigates the effects of clay on the mechanical properties of injection molded high-density polyethylene (HDPE)/clay nanocomposite foams that contained a very small amount of clay in the range of 0.1 to 1 wt%. Nanocomposite compounds were prepared by a melt blending masterbatch process and injection molded by using an advanced structural foam molding machine inwhich N2 was used for foams as a physical blowing agent.The results suggest that the addition of clay increased the flexural strength and modulus of both solid and foam nanocomposites as its contents were increased. The results also indicate that the foam nanocomposites always exhibited lower flexural properties but higher notched Izod impact strength than solid nanocomposites at each given clay amount.
IMPROVEMENT OF PLASTIC PROPERTIES USING SQUARE SHAPE CONFORMAL COOLING CHANNELS
Mark A. Sanner, Robert R. Gallucci, Andy May, May 2010
Effective cooling channel design in the mould is important because it not only affects cycle time but also quality of the injection moulded plastic part. A good cooling system design can reduce cycle time and achieve dimensional stability of the part which will consequently produce better quality part. This paper describes a new square sectioned conformal cooling channel system for injection moulding. Both simulation and experimental verification have been done with these new cooling channels system. Comparative analysis has been done for an industrial part, a plastic bowl, with conventional cooling channels using the Moldflow simulation software. Experimental verification has been done for a test plastic part with mini injection moulding machine. Comparative results are presented based on temperature distribution on mould surface, cooling time or freezing time of the plastic part and hardness number of the plastic part. Results provide a uniform temperature distribution and hardness number with reduced freezing time of the plastic part.
INJECTION MOLDING OF TRANSPARENT HIGH IMPACT POLYETHERIMIDE-POLYESTER CARBONATE BLENDS
Mark A. Sanner , Robert R. Gallucci, May 2010
Injection moldable thermoplastic polyetherimidepolyester carbonate miscible blends with Tgƒ??s rangingfrom 142ƒ??218oC were developed for applicationsrequiring practical impact and melt flow property capabilities greater than those currently achieved with Polyetherimide. The resin blends demonstrate significant improvement in room temperature ductility and high speed impact resistance with total energy required for sample fracture increased as high as 98% depending on blend ratio. The addition of polyester carbonate in the resin blend increased the melt flow rate 10x as compared to unblended polyetherimide therefore resulting in meltprocessing temperatures to 290-370 oC and moldtemperatures of 80-150 oC with actual processingconditions dependent on blend composition. The injection molding processability of the resins and their material properties are presented and compared to polyetherimide.
MECHANICAL PROPERTIES OF HEAT SEALED RECYCLED POLY(ETHYLENE TEREPHTHALATE) SHRINK FILM
Rei-ichi Konishi, Kazushi Yamada, Yasuo Hashimoto, Yew Wei Leong, Tetsuya Tsujii, Hiroyuki Hamada, May 2010
In recent years, the development of recycling methods for waste PET bottles has generated much interest due to environmental and waste management concerns. Therefore, in this study, recycled PET (RPET) was considered instead of PS or PVC to prepare shrink films for labeling purposes. However, the labels would still have to be removed from the bottles prior to recycling due to color incompatibility. For this reason, the tear properties of the RPET labels, especially at the heat sealed regions, are elucidated and correlated to film crystallinity and molecular orientation.
MECHANICAL PROPERTIES OF HEAT SEALED RECYCLED POLY(ETHYLENE TEREPHTHALATE) SHRINK FILM
Rei-ichi Konishi , Kazushi Yamada , Yasuo Hashimoto , Yew Wei Leong, May 2010
In recent years, the development of recycling methods for waste PET bottles has generated much interest due to environmental and waste management concerns. Therefore, in this study, recycled PET (RPET) was considered instead of PS or PVC to prepare shrink films for labeling purposes. However, the labels would still have to be removed from the bottles prior to recycling due to color incompatibility. For this reason, the tear properties of the RPET labels, especially at the heat sealed regions, are elucidated and correlated to film crystallinity and molecular orientation.
CHARACTERIZATION OF WPC PRODUCED USING COMPRESSION MOLDING WITH DIRECTIONAL FIBER ALIGNMENT
M. R. Islam, H. Semeralul, G.M. Rizvi, E. Haghverdian, May 2010
Wood Plastic Composites (WPC) require improvements in properties such as strength, which will help WPC find applications in areas where it is now deemed unsuitable. Compression molding provides a quick method for preparing test specimen. During extrusion a substantial amount of wood fibers get aligned in the direction of flow, whereas, in compression molding these are generally randomly oriented in two dimensions. A properly designed mold ensures greater uni-directional alignment of fibers so that test specimens have greater similarity of fiber orientation with extruded profiles. In this paper, a compression molding system, designed to provide greater one dimension extensional flow is discussed.
INTEGRATED ANALYSIS OF CAD AND CAE FOR HOT-RUNNER DESIGN
Wen-Ren Jong, Ping-Huei Lee, Yu-Cheng Chang, Tai-Chih Li, Yu-Hung Ting, Jerry Hsu, May 2010
To maintain the constant temperature for the plastic inside the hot-runner manifold is an important quality control in mass-production injection-molding process with hot-runner design. Without the constant and uniform temperature distribution, the molded parts wonƒ??t have good yield percentage. As such, this work takes CAD model and the temperature of heater to simulate the temperature distribution of hot-runner manifold. The results show very good agreement with the experimental verification and can be utilized to improve the heater design and efficiency, as such the temperature distribution of manifold can be further optimized.
INTEGRATED ANALYSIS OF CAD AND CAE FOR HOT-RUNNER DESIGN
Wen-Ren Jong , Ping-Huei Lee , Yu-Cheng Chang , Tai-Chih Li , Yu-Hung Ting , Jerry Hsu, May 2010
To maintain the constant temperature for the plastic inside the hot-runner manifold is an important quality control in mass-production injection-molding process with hot-runner design. Without the constant and uniform temperature distribution, the molded parts won’t have good yield percentage. As such, this work takes CAD model and the temperature of heater to simulate the temperature distribution of hot-runner manifold. The results show very good agreement with the experimental verification and can be utilized to improve the heater design and efficiency, as such the temperature distribution of manifold can be further optimized.
EFFICIENCY EVALUATION OF GAS-ASSISTED HEATING AND ITS APPLICATION TO DYNAMIC MOLD TEMPERATURE CONTROL TO IMPROVE MICRO-FEATURED MOLDING
Shia-Chung Chen , Yaw-Jen Chang , Sung-Wei Huang , Jen-An Chang , Je-Wei Yang, May 2010
In the study a gas-assisted heating system was established and its efficiency evaluated. Relevant parameters including the variable geometry for gas entrance (Circular and Divergent channel) gas temperature and gas flow rate as well as the mold surface coating of ZrO2 were varied for heating efficiency consideration. The results show that the maximum heating rate and temperature reached 33oC/s and 245.3oC when air temperature was 500oC at a flow rate of 400 L/min. It was also found that the divergent entrance channel obtains better temperature uniformity. Finally a case study of molding biochips with a micro channel showed replication accuracy increases of up to 22%.
EFFICIENCY EVALUATION OF GAS-ASSISTED HEATING AND ITS APPLICATION TO DYNAMIC MOLD TEMPERATURE CONTROL TO IMPROVE MICRO-FEATURED MOLDING
Shia-Chung Chen , Yaw-Jen Chang , Sung-Wei Huang , Jen-An Chang , Je-Wei Yang, May 2010
In the study, a gas-assisted heating system was established and its efficiency evaluated. Relevant parameters, including the variable geometry for gas entrance (Circular and Divergent channel), gas temperature, and gas flow rate, as well as the mold surface coating of ZrO2, were varied for heating efficiency consideration. The results show that the maximum heating rate and temperature reached 33oC/s and 245.3oC when air temperature was 500oC at a flow rate of 400 L/min. It was also found that the divergent entrance channel obtains better temperature uniformity. Finally, a case study of molding biochips with a micro channel showed replication accuracy increases of up to 22%.
EFFECT OF PROCESSING CONDITIONS ON MECHANICAL PROPERTIES OF ULTRA HIGH SPEED INJECTION MOLDED ABS PARTS
Hsin-Shu Peng , Shia-Chung Chen , Hsien-Hsun Tseng , Peming Hsu , Yu-Tseng Lin, May 2010
It is known that the ultra high speed injection molding is a proper solution for molding thin-wall parts.This study investigates the effect of processing conditions including melt temperature, mold temperature, injection speed on mechanical strength of molded ABS parts. Both single gate and double gates tensile test specimens were molded with and without weldlines. It was found that higher melt temperature and mold temperature as well as faster injection speed would increase tensile strength.Faster injection speed will also influence part mechanical properties, particularly in Young's modulus will increase of 15%, due to flow-induced molecular orientation along melt flow direction.
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