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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

A NEW BLOWN FILM DIE FOR CONTROLLABLY FORMING AND EXTRUDING MICRO-LAYERS POLYMER BLENDS AND COMPOSITES
Mike L. Zumbrunnen , David A. Zumbrunnen, May 2008

The variety and quality of blown film products can be greatly increased if two or more polymer components can be arranged into structures other than a few or several layers or if much thinner and more numerous layers are formed. This paper describes a new blown film smart die in which polymer melts are stretched and folded recursively by chaotic advection. Melts become arranged into multi-layers of prescribed thickness and number. Films can have many dozens hundreds and even thousands of layers. Moreover the layers can transform if desired to give particular derivative blend morphologies such as microscopic sponge-like structures interconnected layers platelets or droplets. Solid particles can also be arranged into networks or oriented within discrete layers.

A NEW BLOWN FILM DIE FOR CONTROLLABLY FORMING AND EXTRUDING MICRO-LAYERS, POLYMER BLENDS AND COMPOSITES
Mike L. Zumbrunnen , David A. Zumbrunnen, May 2008

The variety and quality of blown film products can be greatly increased if two or more polymer components can be arranged into structures other than a few or several layers or if much thinner and more numerous layers are formed. This paper describes a new blown film smart die in which polymer melts are stretched and folded recursively by chaotic advection. Melts become arranged into multi-layers of prescribed thickness and number.Films can have many dozens, hundreds, and even thousands of layers. Moreover, the layers can transform if desired to give particular derivative blend morphologies such as microscopic sponge-like structures, interconnected layers, platelets, or droplets. Solid particles can also be arranged into networks or oriented within discrete layers.

INFLUENCE OF POLYPYRROLE ON ELECTRICAL CONDUCTIVITY OF INJECTION-THERMOPLASTIC-COMPOSITE BIPOLAR PLATES
Rungsima Yeetsorn , Michael Fowler , Costas Tzoganakis, May 2008

Thermoplastic composites are thought to be one of the most promising candidate materials to substitute for conventional materials in bipolar plates for PEM Fuel Cells but it is difficult to meet desirable conductivities when using thermoplastic composite plates while maintaining processability. In this regard introducing small amounts of polypyrrole to the composites enhances electrical conductivity of the composites. Experiments involved both ex-situ tests of bipolar plate materials and in-situ fuel cell tests. From results the conductivity of the material and fuel cell performance increased more than 5% by adding 1.8% of polypyrrole.

INFLUENCE OF POLYPYRROLE ON ELECTRICAL CONDUCTIVITY OF INJECTION-THERMOPLASTIC-COMPOSITE BIPOLAR PLATES
Rungsima Yeetsorn , Michael Fowler , Costas Tzoganakis, May 2008

Thermoplastic composites are thought to be one of the most promising candidate materials to substitute for conventional materials in bipolar plates for PEM Fuel Cells, but it is difficult to meet desirable conductivities when using thermoplastic composite plates while maintaining processability. In this regard, introducing small amounts of polypyrrole to the composites enhances electrical conductivity of the composites. Experiments involved both ex-situ tests of bipolar plate materials and in-situ fuel cell tests. From results, the conductivity of the material and fuel cell performance increased more than 5% by adding 1.8% of polypyrrole.

NEW DEVELOPMENTS IN HIGH-GLOSS MOLDED-IN-COLOR ENGINEERED POLYOLEFIN ALLOYS
Mitesh Shah , Kevin Cai , Marta Drewniak , Sudhir Bafna, May 2008

High-gloss molded-in-color (MIC) engineered polyolefin materials have been rapidly gaining acceptance in the automotive industry as an alternative to painted plastic. This is evidenced by the recent commercialization of INDURE® X-76 for exterior trim on the Ford F-250 platform. INDURE® X-76 offers excellent surface durability weatherability processability and part appearance while reducing total system costs. This paper reviews the performance attributes and applicability of this class of high-gloss engineered polymers focusing on new developments that extend the property and performance envelope. High-gloss molded-in-color (MIC) engineeredpolyolefin materials have been rapidly gaining acceptance in the automotive industry as an alternative to painted plastic. This is evidenced by the recent commercialization of INDURE ?? X-76 for exterior trim on the Ford F-250?ÿ platform. INDURE ?? X-76 offers excellent surface ?ÿ ?ÿdurability weatherability processability and part appearance while reducing total system costs. This paper reviews the performance attributes and applicability of this class of high-gloss engineered polymers focusing on new developments that extend the property and performance envelope.

EXTRUSION FOAMING OF HIGH-MELT-STRENGTH PP WITH SUPERCRITICAL CARBON DIOXIDE I: CELL NUCLEATION BEHAVIORS
Taher Azdast , Eung Kee Lee , Kyung-Min. Lee , Chul B. Park , Hani E. Naguib , Amir H. Behravesh , Elke Pachner , Andreas Praller, May 2008

This paper investigates the cell nucleation behaviors ofnon-crosslinked high-melt-strength (HMS) polypropylene (PP)foams blown with supercritical Carbon Dioxide (CO?ÿ2). Varying?ÿ?ÿ2. It was also observed that the effect of CO2on the cell density was more pronounced when low talc contentwas used?ÿ. Regardless of the amount of nucleating and blowing?ÿ?ÿ. It also appeared that?ÿthe die pressure did not affect the cell density significantly.agent the cell density was significantly improved by using a diewith a high pressure-drop-rate geometrythe talc and CO2 content changed the cell density. The effect ofdie pressure and pressure drop rate on cell nucleation behaviorsof HMS PP was also observed by using different die geometries.Three dies were deliberately designed to have either differentpressure drop rates while having the same die pressure or withdifferent die pressures while having same pressure drop rate.Experimental results indicated that regardless of the die theeffect of talc on the cell density was more significant at a lowconcentration of CO

RHEOLOGICAL PROPERTIES OF LONG CHAIN BRANCHED POLYETHYLENE MELTS AT HIGH SHEAR RATE
Jaejwan Kim , Dong Hak Kim , Younggon Son, May 2008

Capillary extrusion experiments involving a number of polyethylenes with emphasis on assessing the effect of long chain branching are performed. None of the metallocene catalyzed linear low density polyethylenes (mLLDPE) produced by Dow Chemicals which are believed to have some level of long chain branching show temperature dependence on the viscosity at the gross melt fracture regime. Furthermore these materials do not show spurt or stick-slip flow in contrast with most linear polyethylenes. LDPE and blends of LDPE with linear polyethylenes also show the absence of stick-slip flow but temperature dependence on the viscosity. From these observations we conclude that the stick-slip flow is very sensitive to the existence of long chain branching and the behavior of the stick-slip flow can be used as an indicator of LCB.

RHEOLOGICAL PROPERTIES OF LONG CHAIN BRANCHED POLYETHYLENE MELTS AT HIGH SHEAR
Jaejwan Kim , Dong Hak Kim , Younggon Son, May 2008

Capillary extrusion experiments involving a number of polyethylenes with emphasis on assessing the effect of long chain branching are performed. None of the metallocene catalyzed linear low density polyethylenes (mLLDPE) produced by Dow Chemicals, which are believed to have some level of long chain branching, show temperature dependence on the viscosity at the gross melt fracture regime. Furthermore, these materials do not show spurt or stick-slip flow, in contrast with most linear polyethylenes. LDPE and blends of LDPE with linear polyethylenes also show the absence of stick-slip flow, but temperature dependence on the viscosity. From these observations, we conclude that the stick-slip flow is very sensitive to the existence of long chain branching, and the behavior of the stick-slip flow can be used as an indicator of LCB.

BULK RESIN DENSITY AND PLASTICITY FOR PET AND LDPE
Stephen J. Derezinski, May 2008

The compression of the solid resin feed in the extrusion process increases its density to form the solid feed plug. Laboratory measurements were made of the density of the resin feed as a function of stress for PET and LDPE resins. Also the densities upon release of the stress were recorded and they showed that PET resin remains significantly more compressed than does the LDPE resin. The LDPE resin is more elastic and this difference is postulated to be a factor in the mechanics of the solid plug melting and flow stability. Supportive extruder stability data are cited shown and analyzed.

SIMULATION OF SCREWS FOR INJECTION MOLDING
Dr. Jiri Vlcek , Luke Miller , CT Huang, May 2008

This paper deals with the simulation of the plastification unit (extruder) for the injection molding process. It shows the theory and how the method of simulation of an extruder for the extrusion process is modified to cover the effects in injection molding mainly the facts that the screw stops rotating for a certain time and it moves backward while rotating and melting the polymer. To see the quality of the prediction of such a modified program a set of experiments was performed. A comparison of the results of these experiments with the program prediction will be shown. The presentation will also cover the most important variables to be checked for achieving good melt delivery performance in the injection molding process.

SIMULATION OF SCREWS FOR INJECTION MOLDING
Dr. Jiri Vlcek , Luke Miller , CT Huang, May 2008

This paper deals with the simulation of the plastification unit (extruder) for the injection molding process. It shows the theory and how the method of simulation of an extruder for the extrusion process is modified to cover the effects in injection molding, mainly the facts that the screw stops rotating for a certain time and it moves backward while rotating and melting the polymer. To see the quality of the prediction of such a modified program, a set of experiments was performed. A comparison of the results of these experiments with the program prediction will be shown. The presentation will also cover the most important variables to be checked for achieving good melt delivery performance in the injection molding process.

AN ESTIMATE OF LONG SERVICE TERM FOR GRP PRODUCTS
Valery G. Makarov , Rakhil M. Sinelnikova, May 2008

The long service term of GRP products such as technological pipes ducts scrubbers etc. is determined by the chemically resistant layer of multilayered fiberglass which is in direct contact with the technological environment. The diffusion of technological medium into the structure of the GRP leads to a change in the dielectric properties of the material. These changes can be used to predict the long service term of GRP products under the influence of technological environment. The ability to predict the residual life period of GRP products and results of the pipe operation with the partially damage of the chemical resistant layer under conditions of the sulfuric acid production are considered.

AN ESTIMATE OF LONG SERVICE TERM FOR GRP PRODUCTS
Valery G. Makarov , Rakhil M. Sinelnikova, May 2008

The long service term of GRP products such as technological pipes, ducts, scrubbers, etc. is determined by the chemically resistant layer of multilayered fiberglass, which is in direct contact with the technological environment. The diffusion of technological medium into the structure of the GRP leads to a change in the dielectric properties of the material. These changes can be used to predict the long service term of GRP products under the influence of technological environment. The ability to predict the residual life period of GRP products and results of the pipe operation with the partially damage of the chemical resistant layer under conditions of the sulfuric acid production are considered.

BENEFITS OF AN ENERGY USAGE INDICATOR FOR INJECTION MOLDING SIMULATION
Paul Brincat , Russell Speight, May 2008

With growing concern regarding our environmental impact greater focus has been placed on ways we can reduce our impact by improving our decisions designs and processes. The use of injection molding simulation has been shown to reduce material consumption reduce production scrap assist in recycling existing materials create better quality products that have a prolonged life and reduce energy consumption required during the manufacturing process. This paper will present the benefits of an additional measure called an Energy Usage Indicator that can assist part designers using injection molding simulation to easily identify the processing requirements of a polymer material.

BENEFITS OF AN ENERGY USAGE INDICATOR FOR INJECTION MOLDING SIMULATION
Paul Brincat , Russell Speight, May 2008

With growing concern regarding our environmental impact, greater focus has been placed on ways we can reduce our impact by improving our decisions, designs and processes. The use of injection molding simulation has been shown to reduce material consumption, reduce production scrap, assist in recycling existing materials, create better quality products that have a prolonged life and reduce energy consumption required during the manufacturing process. This paper will present the benefits of an additional measure, called an Energy Usage Indicator, that can assist part designers using injection molding simulation to easily identify the processing requirements of a polymer material.

RHEOLOGY AND STRUCTURE OF FILLED PROPYLENE/ETHYLENE COPOLYMERS
Paula Wood-Adams , Arkady Fatseyeu , Cheng Huang , Teresa Karjala , Patricia Ansems, May 2008

We have studied a new family of propylene/ethylene(P/E) copolymers produced by The Dow ChemicalCompany which allow high filler loadings whilemaintaining good processability. Our goal was to providea fundamental understanding of the unexpectedly lowviscosity exhibited by these materials when filled withparticulates. We propose that in these copolymers interfacial slip (between the particles and the polymermelt) is enhanced by the presence of a thin layer of lowviscosity polymer around the particles. The formation ofthis layer is surface tension driven and can occur insystems such as these copolymers which are homogeneousin the bulk. Such behaviour has been observed with blockcopolymersand blends; this study is the first time it hasbeen observed in an industrial copolymer of this type.

ITERATIVE LEARNING CONTROL OF MOLD-OPEN POSITION IN INJECTION MOLDING
S. Y. Mo , Y. Yang , F. Gao, May 2008

Mold-open position (MOP) is an important variable in the injection molding machine (IMM) control system. A precise control of mold open position can improve the process stability. This paper demonstrates that the variation of mold-open offset which is the key problem in moldopen positioning. Iterative learning estimator (ILE) is used in batch direction to estimate this offset. To guarantee the repeatability of this offset an Iterative Learning Control (ILC) scheme is applied to control the mold-open velocity to achieve a relatively low and stable value around the end of mold-open. The control result shows that the combined system of ILE and ILC can obtain precise MOP.

ITERATIVE LEARNING CONTROL OF MOLD-OPEN POSITION IN INJECTION MOLDING
S. Y. Mo , Y. Yang , F. Gao, May 2008

Mold-open position (MOP) is an important variable in the injection molding machine (IMM) control system. A precise control of mold open position can improve the process stability. This paper demonstrates that the variation of mold-open offset, which is the key problem in moldopen positioning. Iterative learning estimator (ILE) is used in batch direction to estimate this offset. To guarantee the repeatability of this offset, an Iterative Learning Control (ILC) scheme is applied to control the mold-open velocity to achieve a relatively low and stable value around the end of mold-open. The control result shows that the combined system of ILE and ILC can obtain precise MOP.

RESEARCH OF CONVEYING CHARACTERISTICS OF POLYMER VANE EXTRUDER
Qu Jinping , Yin Xiaochun , He Hezhi , Zhang Guizhen, May 2008

The working principles of vane extruder are entirely different from screw extruder. Materials were conveyed and plasticized by a group of vanes and the materials suffered mainly normal stress during processing. The heat history and mechanical history that the materials suffered were greatly decreased contrast to screw extruder. In this paper working principles of the vane extruder were introduced in detail. Experiments were carried out on the vane extruder to study the conveying characteristics and the experimental results were presented. Experimental results showed that the specific energy consumption is low and the change of material’s properties has little effect on throughput.

RESEARCH OF CONVEYING CHARACTERISTICS OF POLYMER VANE EXTRUDER
Qu Jinping , Yin Xiaochun , He Hezhi , Zhang Guizhen, May 2008

The working principles of vane extruder are entirely different from screw extruder. Materials were conveyed and plasticized by a group of vanes and the materials suffered mainly normal stress during processing. The heat history and mechanical history that the materials suffered were greatly decreased contrast to screw extruder. In this paper working principles of the vane extruder were introduced in detail. Experiments were carried out on the vane extruder to study the conveying characteristics and the experimental results were presented. Experimental results showed that the specific energy consumption is low and the change of materialƒ??s properties has little effect on throughput.










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