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

The Effect of Nucleation Specificity on Thermal Behaviour of Photodegraded Polypropylene

Jana Výchop?ová, Roman ?ermák, Martin Obadal, Vincent Verney, Sophie Commereuc, May 2007

This work focuses on thermal behaviour of UVirradiated polypropylenes (PP) containing ?- or ?- nucleating agents or their combination. After irradiation the samples were melted, then non-isothermally crystallized and subsequently melted again. It was found that ?-nucleated PP possessed the highest UV-stability. The photodegradation was also suppressed in materials containing ?-nucleating agent. The effect of UVirradiation led to a splitting of crystallization exotherms into two peaks. The strong efficiency of ?-nucleating agent used was reflected by predominant formation of ?- phase in non-irradiated material containing a combination of both ?- and ?-nucleating agents. However, after only 24 hrs of UV-irradiation this effect was reduced and a preferable formation into ?-phase in re-melted material was detected.

Hybrid Tooling Technologies and Standardization for the Manufacturing of Inserts for Micro Injection Molding

G. Tosello, B. Fillon, S. Azcarate, A. Schoth, L. Mattsson, C. Griffiths, L. Staemmler, P.J. Bolt, May 2007

This paper is based on the European Platform’s activities within the 4M Network of Excellence “Multi- Material Micro Manufacturing”. To overpass limitations of the current existing micro tooling capabilities, a new generation of micro hybrid tooling technologies for micro replication was developed. A metrological approach was applied to standardize the employed tooling processes (micro milling, ?EDM, laser micromachining, electrochemical ?-milling). The micro tools were then tested with different polymers (PP, PP + nano fillers, PC, COC). The paper provides a comparison of these technologies concerning obtainable feature sizes, surface finish, and aspect ratios of both micro tools and micro molded parts.

Evaluation of Oriented Polypropylene/Cast Polypropylene Film at the Heat-Sealing Part and the Edge

Yumi HASHIMOTO, Yasuo HASHIMOTO, Yew Wei LEONG, Kazushi YAMADA, Hiroyuki HAMADA, May 2007

Heat-sealing process is often employed in packaging applications of polymeric films, especially for plastic bags. Often, the failure of plastic bags would initiate from a pinhole, crack, and/or the edge near the heat-sealed part. In this study, effects of heat-sealing temperature on mechanical properties of heat-sealing part and the edge of Oriented Polypropylene/Cast Polypropylene films were investigated. Fracture toughness and tear tests were conducted with the heat-sealed Oriented Polypropylene/Cast Polypropylene films. The thermal properties of the heat-sealed parts obtained by differential scanning calorimetry (DSC) were also investigated.

Long-Term Thermal Insulation Performance of Polystyrene Foam Boards with Decay of Blowing Agents

Zhenjin Zhu, Jinho Zong, Chul B. Park, May 2007

This paper studied the long-term thermal insulation performance of polystyrene foam boards with the decay of blowing agents. A transient cell-to-cell diffusion model was developed to predict the decay of blowing agents. The Mie Theory was used to quantify the radiative conductivity. A cubic-parallel-series analogy of electric circuit was employed to acquire the thermal conductivity of gaseous phase and polymer matrix. Thus, the thermal insulation performance was estimated as the blowing agents decayed. The effects of foam morphology and blowing agent type on thermal insulation capacity were examined.

Understanding Melt Rheology & Foamability of PP-Based TPO Blends

F. Gunkel, A.N.J. Spörrer, G.T. Lim, D.S.B. Sampath, V. Altstädt, May 2007

Rubber-toughened PP is an important resin for many engineering applications. By structural foaming, material cost-saving and lightweight structures can be achieved. In this study, physical blends of PP and poly(ethylene/octene) with various compositions were characterized regarding their melt strength and shear viscosity. The high pressure MuCell® foaming process was used to obtain structural foams with average cell diameters of < 50 ?m and cell densities of ~ 8 × 106 cells/cm3. This study presents key correlations between material rheology and its suitability for structural foaming and elucidates how the foaming behavior is linked to blend composition and melt temperature for an optimum system.

A Shrinkage Prediction in Rubber Compression Moulding

Supasit Rodkwan, Watcharapong Chookaew, Nuchanat Na Ranong, Chana Raksiri, Kunnayut Eiamsa-ard, May 2007

One of the common problems found in rubber compression moulding is the shrinkage of rubber products leading to the loss of shape. In this research, an application of artificial neural network in prediction of the rubber product shrinkage in compression moulding is presented. A back propagation neural network was developed to determine the shrinkage based on the variables of the rubber compound, processing variables such as mould temperature and mould sizing. The neural network prediction for an inside diameter shrinkage and a cross section diameter shrinkage indicate that the architectures 5-11-21-1 and 5-11-16-1 provide a good prediction within 95.9% and 96.1% accuracy, respectively.

Functionally Graded Polymer Nanocomposites (FGPNCs) Filled with Nano Sized Filler

Sandeep S. Ahankari, K.K. Kar, May 2007

A novel FGPNCs has been developed using polymer matrix (polyisoprene) and nanomaterials (amorphous carbon). Its performance is evaluated for structural application through storage modulus, loss tangent, tensile strength, modulus, hardness, hysteresis loss, tear strength, SEM, etc. The functionally graded nanocomposites show better properties i.e., modulus, tear strength, hysteresis loss and strain energy density compared to homogeneous composite at the same percentage of nano filler loading. As for examples, 20, 35 and 40% improvement in modulli at 50, 100 and 200% elongation with respect to homogeneous composites are observed where the average nanomaterial is 30% by weight.

Manufacture and Mechanical Characterization of a Composite Material Made of Wasted Tires and Recycled Polyethylenetherephtalate (PET)

R. Mis-Fernandez, J.A. Azamar-Barrios, J. Rodriguez-Laviada, C.R. Rios-oberanis, May 2007

Solid residue was obtained by two processes to reduce discarded tires: pyrolysis and thermal shock. Techniques such as X-ray, FTIR, TGA and SEM were used to characterize the samples. Two types of polyethylenetherephtalate, PET (virgin and recycled) were analysed physicochemical and mechanically to be used as matrix. A composite material was manufactured by employing a Brabender mixing chamber in order to use the granules as filler on PET at different concentrations. The mixed material was laminated and tension test were undertaken in samples to acquire the mechanical properties. Studies of fractography were performed to understand the failure mechanics.

An Optimization of Natural Rubber Injection Molding Process Using CAD/CAE: A Case Study on the Motorcycle Rubber Step

Supasit Rodkwan, Seksan Winyangkul, Kittinan Unnanon, Chana Raksiri, Kunnayut Eiamsa-ard, May 2007

This research aims to apply Computer Aided Design/Engineering (CAD/CAE) techniques for an optimized rubber injection molding condition using a case study of rubber steps used in motorcycles. The input parameters include both physical and mechanical material properties of natural rubber and operating conditions such as gating and runner positions. The simulated variables such as temperature, pressure and velocity profiles were founded and analyzed. The numerical results are correlated well with empirical data using the vertical injection molding machine. This research provides researchers the computational tool to obtain the optimized rubber injection molding.

Relationship between Surface Microstructure and Improved Scratch Whitening Resistance of Thermoplastic Polyolefins for Automotive Applications

Theresa Hermel-Davidock, James Seliskar, James Oelberg, May 2007

This paper will examine the scratch whitening resistance of PP rich, injection molded Thermoplastic Polyolefins (TPOs) for exterior automotive applications. Significant attention will be given to the influence of the molecular architecture of the polypropylene (PP) component on the surface morphology and resultant scratch whitening resistance of the injection molded part. Material parameters and surface crystallinity which contribute to enhanced scratch whitening resistance will be highlighted.

Shape Memory Polyurethane-Clay Nanocomposites

Feina Cao, Sadhan C. Jana, May 2007

In this paper, we present results on shape memory behavior of polyurethane (PU)/clay nanocomposites. These nanocomposites were prepared via bulk polymerization method and contained exfoliated clay particles as revealed by transmission electron microscopy and wide angle X-ray diffraction method. The PU matrix contained a crystalline soft segment, which was responsible for shape fixity. The presence of clay decreased the crystallinity of soft segments and consequently shape fixity, but the magnitude of shape recovery stress increased, e.g., by 20% with only 1 wt% clay. The mechanism of reinforcement was studied by monitoring stress relaxation and phase separation.

Injection Molding Process Optimization Using the Process Monitoring System

Joong-Keun Kang, Hyung Keun Chang, Young-Kee Cho, Byung-Ohk Rhee, May 2007

To make sure the stable state of resin in the process optimization test, the process monitoring system (PMS) was applied in a wide range in this study. For each critical step of the test, the way to utilize the PMS depended upon the phenomenon in the mold and the purpose of the test. The dependent variables such as switchover point and holding time were properly set with the aid of the PMS. Based on the relationship of the state of the resin with pressure and temperature, a new PMS index was proposed. The index showed the best correlation with the part weight among various indices through the correlation analysis.

Hybrid Nanocomposites of Carbon Nanotubes (CNTs) Grown on Carbon Fiber in Polyester Matrix with Improved Thermomechanical Properties

Prabhat Agnihotri, Kamal K Kar, May 2007

Carbon nanotubes (CNTs) were grown on the surface of carbon fiber using thermal chemical vapor deposition (CVD) technique. Ni is used as a catalyst. The coating of catalyst on the surface of carbon fiber was done by electroless dip coating technique. By performing structural characterization of CNT coated carbon fiber using scanning electron microscope (SEM) and transmission electron microscopy (TEM), the length and diameter of CNTs were measured and found to be ~9000 nm and ~40 nm respectively. Thermo gravimetric analysis (TGA) of as received and CNT coated carbon fiber samples in nitrogen atmosphere indicates that the CNT coated carbon fiber samples are thermally more stable. The improvement in storage modulus in CNT coated carbon fiber samples is observed in dynamic mechanical analysis (DMA).

Influence of Part Thickness, Glass Fibre Content and Line Energy on Laser Transmission Welding of Polyamide mXD6

P.J. Bates, M-E Druart, M. Chen, G. Zak, J. Billiet, May 2007

Laser transmission welding is a process used to join two thermoplastic materials based on their abilities to transmit and absorb laser energy. The influence of part thickness, glass fibre content, and line energy on the laser welding of a semi-aromatic polyamide was examined. Plaques of polyamide mXD6 were moulded at three different thicknesses (0.5 mm 1 mm, and 2 mm), a range of glass fibre contents (0, 30, 50 and 60%) in both natural and black. Lap welds were made using a Rofin Sinar diode laser in a contour welding mode over a range of line energies. The assemblies were tested in shear and the fracture surfaces examined using scanning electron microscopy.

Shrinkage and Cooling Simulation of Injection Molded Parts in Melt Solidification Processes

Shiu-Wu Chau, Yin-Jie Juang, May 2007

The numerical prediction of three-dimensional warpage simulation during cooling process for injection molded parts before demolding is conducted in this paper. Similar to other warpage calculations, the energy equation for injection molded parts is solved together a thermal elastic models to investigate the shape deformation inside mold. Different from previous studies assuming melt cooling from solid state, the injection molded parts are cooled from fluidic state using a solidification model. Additionally, the influence of mold constrain is also taken into account.

Modeling the Rheology and Orientation Distribution of Short Glass Fibers Suspended in Polymeric Fluids: Simple Shear Flow

Aaron P.R. Eberle, Donald G. Baird, Peter Wapperom, May 2007

In this paper we present a constitutive relation for predicting the rheology of short glass fibers suspended in a polymeric matrix. The performance of the model is assessed through its ability to predict the steady-state and transient shear rheology as well as qualitatively predict the fiber orientation distribution of a short glass fiber (0.5 mm, L/D < 30) filled polypropylene. In this approach the total extra stress is equal to the sum of the contributions from the fibers (a special form of the Doi theory), the polymer and the rod-polymer interaction (multi-mode viscoelastic constitutive relation).

Ultrasound Assisted Single Screw Extrusion Process for Dispersion of Carbon Nanofibers in Polymers

Avraam I. Isayev, Changdo Jung, Kaan Gunes, May 2007

A novel method for the continuous dispersion of carbon nanofibers (CNFs) in a polymer matrix for manufacturing high performance nanocomposites was developed using an ultrasonically assisted single screw extrusion process. The effect of ultrasound on die pressure, electrical conductivity, rheological, morphological and mechanical properties of polyetherimide (PEI) filled with 1-20 wt% CNFs was studied. A reduction in the die pressure, percolation threshold and an increase in the viscosity, Young's modulus and electrical conductivity along with better CNF dispersion in nanocomposites was achieved through ultrasonic treatment.

Studies on the Thermomechanical Properties of Nickelphosphorous Coated Carbon Fiber Fabric/Polyester Laminates

Niranjan Patra, Kamal K Kar, May 2007

A systematic study was carried out to investigate the effects of nanoscaled electroless nickel-phosphorous alloy coating on the thermomechanical properties of woven carbon fiber fabric reinforced polyester matrix composites. The electroless nickel-phosphorous coated carbon fiber fabrics with different coating time interval (0, 5, 10, 15, 20, 25, 30mins) were prepared. The polyester matrix was then used to manufacture weave carbon fabric/polyester nanocomposites using wet lay-up process. Dynamic mechanical analysis (DMA) studies were carried out in bending and tensile mode. Experimental results showed Maximum improvements in modulus for 30mins coating time reinforced composites. Dynamic mechanical analysis showed enhancement in thermomechanical properties. The nickel-phosphorous coated carbon fiber fabric composites showed a considerable improvement in the glass transition temperature (Tg).

Microstructural Characteristics of Micro-Injection Molded Thermoplastics

Jingsong Chu, Andy Hrymak, Musa R. Kamal, May 2007

A micro-injection molding machine was used to obtain micro-moldings of polyethylene, in order to study the effects of processing conditions on some microstructural characteristics of the moldings. The processing variables were estimated, based on experimental data and on simulation results. Polarized light microscopy was used to evaluate morphology. Three-dimensional distribution of shrinkage was measured. Micro-mechanical properties (modulus and hardness) were measured with a nanoindenter. The microstructure and properties will be explained in light of the thermo-mechanical history.

The Effect of Implementing Hybrid Mold Temperature Dependant Heat Characteristics on the Accuracy of 3D Injection Molding Simulation

Ludwig Cardon, Cristoph Hinse, May 2007

When analyzing the thermal behavior of hybrid molds, normally fixed values for thermal characteristics are implemented. This paper will discuss the underestimated effect of temperature dependant heat characteristics of hybrid mold materials on the accuracy of 3D injection molding simulation via obtained results of a former PhD work and implementation of this knowledge into Moldex3D (M3D).A hybrid mold of a technical part was designed to analyze this problem. It also resulted in a better understanding of the mold design strategy and 3D simulation advantages for multiple material molds related to filling, warpage, cooling and final part quality.