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
BREAKTHROUGH MATERIAL FOR LOW GLOSS AND ABRASION RESISTANCE WITH MOLDED-IN-COLOR AUTOMOTIVE INTERIOR COMPONENTS
The luxury impression of a vehicleƒ??s interior is strongly determined by the surface quality of the plastic interior trim parts. In higher level vehicles, this is achieved by covering the plastic surfaces with Polyvinyl Chloride (PVC) or Thermoplastic Olefin (TPO) skins, fabrics, or paint. However, in the majority of cases, cost constraints dictate the use of unpainted, molded-in-color plastic parts.The critical factors that determine the quality of unpainted interior part surfaces are low gloss appearance along with good scratch and abrasion resistance. The typical materials currently in use for molded-in-color parts are Polypropylene, talc-filled Polypropylene (TF-PP), talcfilled Thermoplastic Olefin (TF-TPO), Acrylonitrile Butadiene Styrene (ABS), Polyamide/ABS (PA/ABS), and Polycarbonate/ABS (PC/ABS). Through extensive development efforts over the past several years, the performance of these materials has significantly improved with respect to scratch resistance and low gloss aesthetic appearance. However, a significant gap in surface quality and robustness in comparison to the painted solution is still present. A development project aiming to reduce these specific deficiencies resulted in new innovative material formulations, which provide breakthrough improvements in low gloss appearance with excellent scratch and mar resistance. The resulting new material family makes use of the latest advancements in elastomer technologies from Dow Automotive. Velvexƒ?›, an Advanced Reinforced Elastomer, will enable the automotive OEM to realize significant cost savings through the elimination of paint in higher segment vehicle interiors, or with aesthetically more demanding applications.
PROCESSING OF PET NANOCOMPOSITES WITH DIFFERENT PERCENTAGE OF
SURFACTANTS USING TWIN SCREW EXTRUSION TECHNOLOGY
In this study a light guide plate was designed using different micro features on a three-sided surface.Simulation software was applied to analyze the luminance of brightness and uniformity under various micro pattern designs so that a fair optical performance can be achieved.Then a micro-patterned mold was made for molding. The effect of replication accuracy on the brightness and the luminance uniformity resulting from molding was investigated. It was found the replication accuracy is increased with increasing mold temperature and melt temperature. When the replication accuracies of the Vgroove at three-side surface were improved the resulting luminance was also increased by 17.96 %.
PROCESSING OF PET NANOCOMPOSITES WITH DIFFERENT PERCENTAGE OF
SURFACTANTS USING TWIN SCREW EXTRUSION TECHNOLOGY
Poly(ethylene terephthalate) (PET) nanocomposites and two organoclays with different content of the same surfactant were blended in a twin screw extruder. The effect of the amount of surfactant on the microstructure and isothermal crystallization kinetics of the filled and unfilled systems was studied. The isothermal data from differential scanning calorimetry was analyzed using the Avrami equation. The spherulitic structure was observed using scanning electron microscope. It was found that the amount of the surfactant significantly affected the crystallization and microstructure of PET/organoclay nanocomposite.
EFFECTS OF THE MECHANICAL PROPERTIES ON THE SCRATCH BEHAVIOR OF ABS COPOLYMER
The effects of the mechanical properties on the scratch resistance are investigated by using Ball-type Scratch Profile (BSP) test developed by Cheil Industries Inc. BSP test method is designed for evaluating the scratch resistance by quantifying the amounts of created scratch to scratch width depth range and area. To investigate the relation between scratch behavior and mechanical property the measured scratch width is compared with the mechanical properties such as tensile strength tensile elongation flexural strength and flexural modules. The Rockwell hardness and pencil hardness results are also compared with the measured scratch width and their relations are studies.
INVESTIGATION OF FIBER ORIENTATION IN FILLING AND PACKING PHASES
Fiber-reinforced engineering materials are widely used for their superior mechanical properties in lots of plastic parts. And it is truly believed that in the injection molding process the fiber orientation and anisotropy shrinkage are very complex 3D phenomena which may influence the product properties deeply. In this research the fiber orientation is considered both in filling and packing process numerically. The result of fiber orientation shows a good agreement with experimental data. Moreover the investigation illustrates the strength of fiber orientation in filling and packing phases.
ANOMALOUS MECHANICAL ANISOTROPY OF BETA-FORM POLYPROPYLENE
OBTAINED BY T-DIE PROCESSING
Structure and mechanical properties are
studied for extruded sheets of isotactic
polypropylene (PP) containing a small amount of
N N’-dicyclohexyl-2 6-naphthalenedicarboxamide
as a ?-form nucleating agent. It is found that the ?
trigonal crystals are predominantly formed in the
extruded samples containing the nucleating agent.
Since the ?-form crystals are responsible for the
marked mechanical toughness the impact strength
of the sheet sample containing the nucleating
agent is higher than that of the pure PP. Further
PP molecules in the extruded sheet are found to
orient perpendicular to the applied flow direction.
As a result the sheet shows anomalous
mechanical anisotropy.
ANOMALOUS MECHANICAL ANISOTROPY OF BETA-FORM POLYPROPYLENE OBTAINED BY T-DIE PROCESSING
Structure and mechanical properties are studied for extruded sheets of isotactic polypropylene (PP) containing a small amount of N,Nƒ??-dicyclohexyl-2,6-naphthalenedicarboxamide, as a ?ý-form nucleating agent. It is found that the ?ý trigonal crystals are predominantly formed in the extruded samples containing the nucleating agent.Since the ?ý-form crystals are responsible for the marked mechanical toughness, the impact strength of the sheet sample containing the nucleating agent is higher than that of the pure PP. Further, PP molecules in the extruded sheet are found to orient perpendicular to the applied flow direction.As a result, the sheet shows anomalous mechanical anisotropy.
LEARNING EFFICIENCY OF USING VIRTUAL MANUFACTURING IN E-LEARNING FOR THE OPERATION TECHNOLOGY OF INJECTION MOLDING MACHINE
E-Learning is now a popular learning method and it is a certain relation between e-Learning and Virtual Manufacturing‹¬?VM‹¬?. In the context it designed two experiments to prove the learning efficiency of using the VM technology in e-Learning. Two experiments were carried out including the learning efficiency test (LET) and the reliability test (RT). LET aims to prove whether the learning system provides learning efficiency; and RT aims to test the stability of the operating system. The results of experiments evidence that operation system provides the learner with learning efficiency 30% and reliability value( for operating time) is 0.835 . This hence concludes the usability of this way.
COST EFFECTIVE TiO2 EXTENSION IN WHITE COLOR CONCENTRATES USING ANHYDROUS
CALCIUM SULFATE
Anhydrous calcium sulfate is manufactured from high
purity naturally occurring gypsum deposits in Oklahoma
USA. The final product is a white fine grind powder
which is suitable to extend and replace TiO2 in white color
concentrate master batches. The material is heat stable in
the realm of plastics processing temperatures and it is
compatible with the various resins typically used in this
application. Due to its low Mohs hardness calcium
sulfate is easily processed while providing opacity by
acting as an efficient and cost effective TiO2 spacer in the
concentrate.
ADVANCED ON-LINE GAUGING SOLUTIONS FOR CONTINUOUS PROCESS MONITORING AND CONTROL
On-line gauging Systems with advanced Full Spectrum
InfraRed sensor technologies and control strategies
improve quality of multilayer high barrier films and
coatings increase productivity of the manufacturing
process and provide timely and valuable insights into the
Biax Film and Extrusion Coating manufacturing
processes with Process Analytical tools and Process
Diagnostics Visualization tools. Diagnostic tools such as
FFT Contourview Die mapping Process variables
trending etc. pinpoint the process problems in a timely
manner. The resultant Process Optimization contributes
significantly to improved product quality increased
productivity scrap reduction and high material yield.
ADVANCED ON-LINE GAUGING SOLUTIONS FOR CONTINUOUS PROCESS MONITORING AND
CONTROL
On-line gauging Systems with advanced Full Spectrum InfraRed sensor technologies and control strategies improve quality of multilayer high barrier films and coatings, increase productivity of the manufacturing process, and provide timely and valuable insights into the Biax Film and Extrusion Coating manufacturing processes with Process Analytical tools and Process Diagnostics Visualization tools. Diagnostic tools such as FFT, Contourview, Die mapping, Process variables trending etc. pinpoint the process problems in a timely manner. The resultant Process Optimization contributes significantly to improved product quality, increased productivity, scrap reduction and high material yield.
FUNCTIONALIZED POLYOLEFINS THAT DELIVER ROOM TEMPERATURE
ADHESION TO POLYURETHANES
Maleic anhydride (MAH) modified polymers and
ethylene acrylic acid (EAA) copolymers are known to
adhere well to polar materials in high temperature
processes such as in multi-layer film and sheet extrusion.
However these materials have been found to exhibit
unacceptable adhesion to polar materials such as
polyurethane foams adhesives and coatings in room
temperature applications. Three new developmental
products are now available for sampling which can be coextruded
with either low density polyethylene (LDPE)
propylene-ethylene elastomers or ethylene-?-olefin
elastomers and provide a high functionality surface layer
that enables adhesion to urethanes at room temperature.
Each product exhibits 100% cohesive failure from a
polyurethane foam applied at room temperature. Examples
of applications where these type of films and sheets would
be useful are: transportation (head rests consoles seating
headliners flooring); building and construction; consumer
durables packaging and the like. This paper describes
typical process conditions film and sheet properties and
adhesion performance of the functionalized polyolefins
that can adhere to polyurethane at room temperature.
FUNCTIONALIZED POLYOLEFINS THAT DELIVER ROOM TEMPERATURE ADHESION TO POLYURETHANES
Maleic anhydride (MAH) modified polymers and ethylene acrylic acid (EAA) copolymers are known to adhere well to polar materials in high temperature processes such as in multi-layer film and sheet extrusion. However, these materials have been found to exhibit unacceptable adhesion to polar materials such as polyurethane foams, adhesives, and coatings in room temperature applications. Three new developmental products are now available for sampling which can be coextruded with either low density polyethylene (LDPE), propylene-ethylene elastomers, or ethylene-?ñ-olefin elastomers and provide a high functionality surface layer that enables adhesion to urethanes at room temperature. Each product exhibits 100% cohesive failure from a polyurethane foam applied at room temperature. Examples of applications where these type of films and sheets would be useful are: transportation (head rests, consoles, seating, headliners, flooring); building and construction; consumer durables, packaging and the like. This paper describes typical process conditions, film and sheet properties, and adhesion performance of the functionalized polyolefins that can adhere to polyurethane at room temperature.
FLAME RETARDANCY OF POLYCARBONATE-PDMS COPOLYMER COMPOSITIONS
Inherent Flame Retardancy (FR) of copolymer
compositions of Polycarbonate–Polydimethylsiloxane is
presented in this paper. Properties such as limiting oxygen
Index char yield surface enrichment characteristics along
with UL94 performance are analyzed. Comparison is
made with neat polycarbonate. Superior inherent FR
coupled with good low temperature impact heat hydroaging
characteristics and transparency distinguishes
copolymer compositions from neat polycarbonate thereby
making these compositions excellent candidates for
engineering thermoplastic applications including medical
and food contact applications.
FLAME RETARDANCY OF POLYCARBONATE-PDMS COPOLYMER COMPOSITIONS
Inherent Flame Retardancy (FR) of copolymer compositions of Polycarbonateƒ??Polydimethylsiloxane is presented in this paper. Properties such as limiting oxygen Index, char yield, surface enrichment characteristics along with UL94 performance are analyzed. Comparison is made with neat polycarbonate. Superior inherent FR coupled with good low temperature impact, heat, hydroaging characteristics, and transparency distinguishes copolymer compositions from neat polycarbonate, thereby making these compositions excellent candidates for engineering thermoplastic applications including medical and food contact applications.
ADVANCED PROCESS DESIGN IN HIGH VOLUME KNEADER REACTORS USING MULTIPLE FEED PORTS TO AVOID CRUST FORMING FOAMING AND LOW HEAT TRANSFER
Kneaders reactors are used for combined unitary processing in the polymer industry for devolatilization compounding or polymerization. Multiple feed ports are used in screw type reactors to allow adding multiple substrates into one product whereas one unitary operation has to get to a certain degree of completion before the next substrate can be added. We have found that even for identical substrates multiple feed ports can be advantageous to avoid specific working points where the product behavior is disadvantageous for efficient processing. Such processes require advanced design simulation tools to predict process behavior. We compare simulation results on pilot and the scale up.
ADVANCED PROCESS DESIGN IN HIGH VOLUME KNEADER REACTORS USING
MULTIPLE FEED PORTS TO AVOID CRUST FORMING, FOAMING AND LOW
HEAT TRANSFER
Kneaders reactors are used for combined unitary
processing in the polymer industry for devolatilization,
compounding or polymerization. Multiple feed ports
are used in screw type reactors to allow adding
multiple substrates into one product whereas one
unitary operation has to get to a certain degree of
completion before the next substrate can be added. We
have found that even for identical substrates multiple
feed ports can be advantageous to avoid specific
working points, where the product behavior is
disadvantageous for efficient processing. Such
processes require advanced design simulation tools to
predict process behavior. We compare simulation
results on pilot and the scale up.
HOW CAN POLYMER RHEOLOGY BE USEFUL TO GUIDE PROCESSING
This presentation discusses the latest developments in
the field of nonlinear rheology of entangled polymeric
liquids resulting from nearly two dozens of publications
from the Polymer Dynamics Interface and Rheology
Group at Akron. The essential findings are that a)
entangled liquids respond to sudden startup flow
elastically and undergo cohesive failure or yielding before
subsequent flow is possible b) the flow field beyond the
yield point is dictated by the characteristics of the yielding
process that can be strongly inhomogeneous c) entangled
liquids possess finite cohesion that can be overcome after
flow cessation by internal elastic restoring forces.
HOW CAN POLYMER RHEOLOGY BE USEFUL TO GUIDE PROCESSING
This presentation discusses the latest developments in the field of nonlinear rheology of entangled polymeric liquids, resulting from nearly two dozens of publications from the Polymer Dynamics, Interface and Rheology Group at Akron. The essential findings are that a) entangled liquids respond to sudden startup flow elastically and undergo cohesive failure or yielding before subsequent flow is possible, b) the flow field beyond the yield point is dictated by the characteristics of the yielding process that can be strongly inhomogeneous, c) entangled liquids possess finite cohesion that can be overcome after flow cessation by internal elastic restoring forces.
THE EFFECT OF POST DIE PROCESSING TIME ON ADHESION
IN COEXTRUSION BLOWN AND CAST FILM
Peel strength between layers in coextruded cast film is
found to increase with increasing post die process time.
The results suggest that adhesion is limited by the time and
temperature available for bonding after new interfacial area
is created during drawing. This contrasts with previous
work in blown film where increases in peel strength with
process time were attributed primarily to stress effects.
The results from both processes however were found to
collapse onto a single master curve by multiplying the peel
strength by the modulus of the tie resin and dividing the
process time by the relaxation time of the tie resin.
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