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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

ENHANCED RESIN FOR METAL INSERT MOLDING APPLICATIONS
Nicolas J. Sunderland , William F. Thorne , XY Li, May 2010

OEMs that manufacture cellular phones and portable music players require thin, stiff, structural parts. Until now, the main approach has been the use of die casting and glass-filled plastic. The use of metal insert molding (where plastic is injected around a thin metal insert) enables manufacturers to have ultra thin designs, reduce dependence on costly metal and die-cast parts, improve yield and tool life, and provide a superior surface finish for decoration. However, metal insert molding can lead to high molded-in stresses due to differential shrinkage of the plastic resin, which in turn can lead to stress cracking in the surrounding plastic, especially when exposed to various chemical environments and heat/humidity aging. Bayer MaterialScience has formulated a new Makroblend?? PC/PBT resin (UT5205) to successfully be used in the encapsulation of a sheet metal insert for cell phone and music player applications.

EFFECT OF ENVIRONMENTAL EXPOSURE ON MATERIALS BASED ON BLENDS OF PLASTICIZED STARCH AND POLYPROPYLENE
Michael J. Forbes , James T. Goetz , Brian A. Young, May 2010

Due to the recent demand for environmentally friendly polymers and the duty to take advantage of renewable natural resources when possible biopolymers have become an important alternative to synthetic polymers. Starch when using glycerol as a plasticizer has proven to be a processable “green” polymer additive when compounded with maleated polypropylene. In this study material was characterized based on its ability to perform over five months of exposure to natural conditions. The effects on modulus and elongation with the addition of plasticized starch in a polypropylene matrix were evaluated and are presented.

EFFECT OF ENVIRONMENTAL EXPOSURE ON MATERIALS BASED ON BLENDS OF PLASTICIZED STARCH AND POLYPROPYLENE
Michael J. Forbes , James T. Goetz , Brian A. Young, May 2010

Due to the recent demand for environmentally friendly polymers and the duty to take advantage of renewable natural resources when possible, biopolymers have become an important alternative to synthetic polymers. Starch when using glycerol as a plasticizer has proven to be a processable ƒ??greenƒ? polymer additive when compounded with maleated polypropylene. In this study, material was characterized based on its ability to perform over five months of exposure to natural conditions. The effects on modulus and elongation with the addition of plasticized starch, in a polypropylene matrix, were evaluated and are presented.

COCONTINUOUS BLENDS: CONNECTING RHEOLOGY TO MORPHOLOGY VIA 3D IMAGING.
Masanori Okano, Masaharu Nishiura, Makoto Sarata, Hidekazu Nakano, Akiko Odawara, Yuya Hidekuma, Tohru Morii, Asami Nakai, Hiroyuki Hamada, May 2010

The time evolution of the interfacial area (Q) and the elastic modulus (Gƒ??) in a 50/50 PS/SAN cocontinuous blends was analyzed during annealing. Two regimes of coarsening marked by different rates of growing of the characteristic length (1/Q) and by different power laws describing the decrease of Gƒ?? were identified. A simplification to Doi-Ohta rheological model for small deformations was proposed and its predictions were compared to experimental results. Good agreement was observed only for blends with relatively low interfacial tension.

FATIGUE PROPERTIES OF JUTE FABRIC REINFORCED SHEET MOLDING COMPOUND (SMC) MOLDING
Masanori Okano , Masaharu Nishiura , Makoto Sarata , Hidekazu Nakano , Akiko Odawara , Yuya Hidekuma , Tohru Morii , Asami Nakai , Hiroyuki Hamada, May 2010

Recent earth environmental concern requires easy recycle material system and the use of biodegradable polymer and natural fiber is noticed in composite materials. To apply the natural fiber for the structural parts the use as reinforcement of Sheet Molding Compound (SMC) is desirable because it is expected that SMC can be used in various fields in terms of high productivity and dimensional stability. Considering that fiber reinforced composite is used for structural part the design of the strength is very difficult because the failure mechanism is complicated considerably. In this study SMC that reinforcement was jute cloth was prepared. The low-cycle bending fatigue test and the cross sectional observation of fracture part were performed. As a result the brittle crack propagation in the interface around the fiber bundle was seen in the specimen of warp and weft direction and the phenomenon such as brittle crack propagation was not confirmed in the specimen of 45-degree direction.

FATIGUE PROPERTIES OF JUTE FABRIC REINFORCED SHEET MOLDING COMPOUND (SMC) MOLDING
Masanori Okano , Masaharu Nishiura , Makoto Sarata , Hidekazu Nakano , Akiko Odawara , Yuya Hidekuma , Tohru Morii , Asami Nakai , Hiroyuki Hamada, May 2010

Recent earth environmental concern requires easy recycle material system, and the use of biodegradable polymer and natural fiber is noticed in composite materials. To apply the natural fiber for the structural parts, the use as reinforcement of Sheet Molding Compound (SMC) is desirable because it is expected that SMC can be used in various fields in terms of high productivity and dimensional stability.Considering that fiber reinforced composite is used for structural part, the design of the strength is very difficult because the failure mechanism is complicated considerably. In this study, SMC that reinforcement was jute cloth was prepared. The low-cycle bending fatigue test and the cross sectional observation of fracture part were performed. As a result, the brittle crack propagation in the interface around the fiber bundle was seen in the specimen of warp and weft direction, and the phenomenon such as brittle crack propagation was not confirmed in the specimen of 45-degree direction.

VISCOELASTICITY OF POLYMER/OLIGOMER ATHERMAL BLENDS
Zhigang Sun, Leszek A. Utracki, May 2010

The viscoelastic properties of poly(ñ-ethyl styrene), its hexamer, and their athermal blends at various concentrations are studied. Master curves for the dynamic shear responses, G' and G are successfully constructed for both the pure materials and the blends indicating the validity of the time-temperature superposition principle. The shift factors used to construct the master curves show weaker dependence in the blends. The segmental dynamics appear unchanged by concentration which is different from the calorimetric studies where mixtures show obviously broadened glass transitions and depressed enthalpy overshoots."

ULTRASONIC DIAGNOSIS OF THE VIBRATION BEHAVIOR OF SCREWS IN A SINGLE SCREW EXTRUDER
Zhigang Sun , Leszek A. Utracki, May 2010

Ultrasonic diagnostic method of screw behavior during extrusion has been designed developed and evaluated for a single screw extruder. It was found that under the same processing conditions and depending on the past history of the equipment usage the vibration behavior of screws in the inspected processing equipment could vary noticeably and the vibration pattern repeated itself at every two screw revolutions. Results suggest that the vibration behavior of the screw is dictated by how the screw is engaged in and the status of the gearbox.

MODELING THREE-DIMENSIONAL VISCOELASTIC FLOW AROUND A CLOSELY-SPACED LINEAR PERIODIC ARRAY OF CYLINDERS
David Adrian , Scott Phillips , Robert Armstrong, May 2010

A framework and code are being developed to simulate fiber and film processes; currently the code can handle three-dimensional, enclosed, isothermal, incompressible, creeping flow of a Giesekus fluid. The code is an extension of the parallel methods developed by Caola et al from two- to three-dimensional flows. The code has been tested on a benchmark problem that shows an elastically-driven flow transition from a twodimensional, steady flow to a three-dimensional, time periodic flow: flow around a closely-spaced linear periodic array of cylinders in a rectangular channel, a flow studied experimentally by Liu. Numerical simulations have been conducted in this geometry with the Oldroyd-B model, ?ý=0.67, wall separation distance 8-32 radii, and Deborah number from 0.1 to 1.1. The range of bounding wall edge effects on the flow field is shown to be 4 radii, and a small-magnitude overshoot in the primary velocity component near the wall can be observed, similar to the cat's ears observed by Poole et al in planar gradual-contraction expansion flow. The expected critical Weissenberg number of the flow transition has not yet been reached; the time integration to steady state diverges at moderate Weissenberg number. However, the velocity profile shows oscillatory behavior similar to what is reported at the flow transition.

RELIABILITY OF INKJET PRINTED AG TRACES SUBMITTED TO HIGH CURRENT DENSITY TEST
Joseph Dooley, Gary Oliver, Karen Xiao, May 2010

Printable electronics is a new emerging technology with capabilities of producing high volumes, low price and flexible electronics. However, a number of questions, mainly related reliability of such devices, are still pending. In this paper, metal nanoparticles based ink was printed on flexible polyimide substrates. Samples were submitted to high current density electrical test. Samples were tested until failure generating reliability curves. Printed traces presented low reliability probably due to the large amount of pores and grain boundaries in its microstructure and also because of the trace inhomogeneity. Thus, the application of this technology depends on process improvements.

BREAKTHROUGH INVENTIONS AND INNOVATIONS IN DIE DESIGN FOR POLYMER PROCESSING
Joseph Dooley , Gary Oliver , Karen Xiao, May 2010

After a polymer has been converted from a solid to a molten state it must be processed into a final shape to have value to a customer. This final shape may be a pellet a film a sheet a profile or many other final geometries. This paper will discuss some of the breakthrough inventions and innovations in die design that are used to produce this vast array of final polymer product shapes. ?ÿ ?ÿ The objective of this work was to develop an impactmodifier to improve the impact strength of poly(L-lactide)(PLLA). Graft copolymers of PLLA and polyethylene(PE) were synthesized via the ring-openingpolymerization of L-lactide initiated by PE modified withhydroxyl groups (macroPE). The macroPE was preparedvia the metallocene catalyzed copolymerization ofethylene and 5-hexen-1-ol. DSC and DMA on thecopolymers and PLLA blends indicated a two-phasepolymer system. The blends exhibited significantlyincreased loss moduli and maximum tan ƒ?? s whencompared to virgin PLLA indicating a high probability ofincreased impact toughness while the storage moduli ofthe blends remained approximately constant.

SHAPING THE EXPERTS OF TOMORROW: PREPARING THE WORKFORCE OF THE FUTURE
Michael Jaffe, George Collins, Anthony J. East, Willis Hammond, Zohar Ophir, Xianhong Feng, Paul Friedhoff, May 2010

With the retiring baby-boomers, educational challenges, poor public perception of manufacturing, and difficult economic climate, we are on the cusp of entering one of the most challenging times in American manufacturing. American manufacturers within all industries will be faced with tremendous difficulty in finding the skilled workforce they need to be competitive in todayƒ??s market. We need to identify the problem and layout a feasible first step in addressing it if we hope to minimize the impact.

CORN (SUGARS) BASED CHEMISTRIES FOR THE POLYMER INDUSTRY
Michael Jaffe , George Collins , Anthony J. East , Willis Hammond , Zohar Ophir , Xianhong Feng , Paul Friedhoff, May 2010

Corn (sugars) may be viewed as a chemical feedstock to produce new monomers polymers and additives for a broad range of chemical intensive industries. Corn based chemicals are attractive because they as generally regarded as safe (GRAS) are a renewable resource and can be made readily available at competitive pricing. Interest is focused on isosorbide which offers molecular geometry and chemical functionality compatible with many existing commercial chemistries. Applications ranging from the creation of new polymer backbones for use as thermoplastics or thermosets to the identification of low molar mass compounds that can act as plasticizers stabilizers or compatiblizers are under investigation. Of special interest is the impact of asymmetric reactivity chirality and controlled stereochemistry in the design and performance of new cost-effective structures with commercial potential. As petroleum becomes more expensive and the assurance of long range cost-effective supply questionable creation of alternative chemistries from renewable resources such a corn (glucose) becomes more attractive.

CORN (SUGARS) BASED POLYMER CHEMISTRIES FOR THE POLYMER AND COSMETICS INDUSTRIES
Michael Jaffe , George Collins , Anthony J. East , Willis Hammond , Zohar Ophir , Xianhong Feng , Paul Friedhoff, May 2010

Corn (sugars) may be viewed as a chemical feedstock to produce new monomers, polymers and additives for a broad range of chemical intensive industries. Corn based chemicals are attractive because they as generally regarded as safe (GRAS), are a renewable resource and can be made readily available at competitive pricing. Interest is focused on isosorbide which offers molecular geometry and chemical functionality compatible with many existing commercial chemistries. Applications ranging from the creation of new polymer backbones for use as thermoplastics or thermosets to the identification of low molar mass compounds that can act as plasticizers, stabilizers or compatiblizers are under investigation. Of special interest is the impact of asymmetric reactivity, chirality and controlled stereochemistry in the design and performance of new, cost-effective structures with commercial potential. As petroleum becomes more expensive and the assurance of long range, cost-effective supply questionable, creation of alternative chemistries from renewable resources such a corn (glucose) becomes more attractive.

KINETICS OF MICROEMULSION COPOLYMERIZATION FOLLOWED BY RAMAN SPECTROSCOPY
Miguel A. Corona-Rivera , Jorge Flores , Jorge E. Puig , Eduardo Mendizábal, May 2010

In this work the kinetics of microemulsioncopolymerization of styrene-methyl methacrylate usingdodecyltrimethylammonium bromide (DTAB) wasfollowed on line by low-resolution Raman spectroscopy.Reactions were carried out in a three-mouth reactor at 60oC. Raman spectra were taken every 30 seconds. Becausethe spectrophotometer has low resolution the C=C peakoverlaps with the aromatic ring stretch vibration and curve deconvolution was necessary. Overall conversion obtained by Raman spectroscopy agrees with that obtained by gravimetry. Because the overlap of the C=C peaks ofstyrene and methyl methacrylate it was not possible tofollow the individual monomer conversion by thistechnique.

WELDABILITY OF BIOPLASTICS
S.B. Tan, P.R. Hornsby, M. McAfee, M.P. Kearns, M. McCourt, P.R. Hanna, May 2010

The cooling process in conventional rotational moulding has a relatively long cycle time. It is normally accomplished by external forced air convection and external water spray cooling. In some instances, an evaporative cooler is employed to create atomised fog external to the mould during the cooling cycle. Internal water spray cooling is an attractive approach to reduce the cycle time and enhance the product properties in rotational moulding. It is shown that water spray cooling of polymers is affected by water droplet size and water droplet velocity. This paper outlines an introduction to the characterisation of water droplets. The effects of these parameters on water spray cooling of polymers are also presented, using a purpose built experimental test rig. With the growing demand for environmentally friendly biorenewable resources, there has been a parallel growth in the development of bioplastics. These include commercially available starch-derived plastics and plastics derived from renewable oil and proteins. As with any plastic, these new materials must often be joined to produce final products. This paper reviews impulse and ultrasonic welding of PLA as well as friction welding of plant protein-based plastics. It was found that each of these plastics can be welded with weld strengths matching the parent material strengths.

THE EFFECTS OF WATER DROPLET SIZE AND VELOCITY ON SPRAY COOLING OF POLYMERS DURING ROTATIONAL MOULDING
S.B. Tan , P.R. Hornsby , M. McAfee , M.P. Kearns , M. McCourt , P.R. Hanna, May 2010

The cooling process in conventional rotational moulding has a relatively long cycle time. It is normally accomplished by external forced air convection and external water spray cooling. In some instances, an evaporative cooler is employed to create atomised fog external to the mould during the cooling cycle. Internal water spray cooling is an attractive approach to reduce the cycle time and enhance the product properties in rotational moulding. It is shown that water spray cooling of polymers is affected by water droplet size and water droplet velocity. This paper outlines an introduction to the characterisation of water droplets. The effects of these parameters on water spray cooling of polymers are also presented, using a purpose built experimental test rig.

MEASUREMENT AND MANAGEMENT OF PERFORMANCE OF COMPANIES USING BENCHMARKING TOOLS
Wantinee Viratyaporn, Richard L. Lehman, May 2010

The paper deals with methods of measurement of company performance and identification of key factors that influence it. It is based on the results from a research involving managers of selected companies, which took place within the scope of cooperation of the university with a cluster of plastic processing companies. Further in the contribution is presented the possibility of increasing performance of companies using benchmarking tools for the identification of strengths and weaknesses, which affect the company performance. This is shown on a practical example of a cluster activity.

HYDROXYAPATITE- POLYLACTIDE COMPOSITE FOR BONE REPAIR
Shih-Po Sun , Montgomery T. Shaw , Mei Wei , James Olson, May 2010

The aim of this study was to investigate the interealtions between the design processing and properties of hydroxyapatite-poly(lactide) composites intended?ÿ as biodegradable bone grafts for joining fractured bone tissues.?ÿ Poly(lactide) fibers were employed to increase the axial strength and toughess of the composite.?ÿ The hydroxyapatite nano rods are also aligned in the axial direction during the pultrusion process to increase the low-strain modulus of the composite.?ÿ The resulting composite with a composition of HA: PCL:?ÿ PLA= 3: 34: 63 (vol%) had a tensile modulus of 6.6 GPa.

EFFECT OF NANO FILLERS IN HYBRID BIO DEGRADABLE THERMOPLASTIC CORNSTARCH MATERIALS
Spencer Seung Kim , Bok Hee Kim , Joshua Knies, May 2010

There is a global interest in replacing petroleum based synthetic composites with biodegradable hybrid materials in order to use renewable resources and to reduce the amount of persistent non-biodegradable plastics waste. Fillers (or reinforcements) play an important role to improve various characteristics in biodegradable hybrid composites. Various types of inorganic fillers are used to modify the properties of biodegradable composites in industrial applications. This paper attempts to investigate the effects of inorganic fillers (such as halloysite nano clay and calcium carbonate (CaCO3)) on the mechanical properties (tensile testing) and microstructures of hybrid thermoplastic cornstarch (TPS) material systems.







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