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
Mechanical and Thermal Characterization for Sterilized Medical Elastomers
Tahua Yang, Sherwin Shang, Lecon Woo, Craig Sandford, May 2004
We have applied thermal, mechanical, and rheological techniques in the product development for medical elastomers with success. In this presentation, examples of actual product application will be used to illustrate the utility of these techniques and to demonstrate the derived information that was used in developing successful elastomeric related medical products.
Epoxy + Montmorillonite Nanocomposite: Effects of Water, Ultrasound, and Stoichiometry on Aggregates
Peter Butzloff, Nandika Anne D'Souza, May 2004
The effect of controlled water addition to the development of random aggregates of alkonium ion substituted montmorillonite clay in epoxy was studied based on changes to the hardener mix ratio, clay composition, and ultrasonic treatment before cure. The effects on the glass transition temperature and microhardness were determined. The introduction of water before ultrasonic mixing altered the apparent size of the treated clay aggregates observed in these mixtures after cure. The clay aggregates also appeared to change the location and the distribution of water-induced microcracks in the cured nanocomposites. This information was used to develop a technique to remove aggregates without causing microcracks.
Development of a New Solution to Vary the Thickness of the Parison over its Circumference While It Is Extracted
Heinz G. Gross, May 2004
Complex blow molded parts afford not only a variation of the thickness of the parison in axial direction but also in circumference direction to end up in the desired optimal thickness distribution in the final part. Integrating a partial multi-walled Flex Ring into a blow molding die allows to alter the local flow channel geometry. While deforming the Flex Ring its geometry alters gradually, so no dead spots are created. As additionally the deformation of the Flex Ring keeps within its linear elastic range the deformation can be repeated for every cycle. The principle of the technology will be explained and potential solutions of the new technology will be discussed.
Preform Optimization Using Non-Linear Finite Element Simulations
Jerry Dees, May 2004
Non-linear finite element simulations of the blow molding and thermoforming processes have been used to provide accurate predictions of the material thinning. However, this powerful simulation tool has provided limited assistance to the design and optimization of the wall thickness distribution of preforms used in injection blow molding. Trial-and-error methods are often used in design. This paper presents a technique that converts finite element analysis of the injection blow molding process into a design/optimization tool. A systematic optimization technique for preform design that uses an iterative series of non-linear finite element simulations will be described. The series of simulations converges on a preform wall thickness distribution that will result in a specified thickness distribution in the blow molded product. This design technique is especially effective for non-circular or irregular shaped products.
The Influence of Blowing Time and Blowing Pressure on Bottle's Labeling
Sylvain Jeannin, May 2004
Extrusion Blow Molding process is one of the only ways to produce hollow parts. This process is particularly difficult to control due to the parison swelling in the air without mould, contrary to the Injection Blow Molding in which all the different steps of the process take place in mould.There are four stages in this process. First of all the plasticising, followed to the extrusion through the die head. The next stage consists of the parison’s forming, then the transfer in the mould. The third stage is the blowing of the hollow part and finally there is the deflashing so that to obtain the final product.The purpose of this study is to show the importance of the cooling on the final quality of the product. The study has particularly been concentrated on two parameters of the forming of the hollow part. These two parameters are the blowing time and the blowing pressure. We have studied the different shapes obtained with the adjustment of these parameters and we tried to find a correlation between shape and quality of the labeling.
How to Reduce the Costs of the Rheological Simulation in Blow Molding Industry?
Jean-Emmanuel Noreux, Sylvain Jeannin, May 2004
The aim of our study is to show that we can readily obtain a first estimate of the behavior of a tube in blow molding only using free software. From a numerical model of biaxial stretching and blowing of a parison with specific boundary conditions and thanks to a mathematical package freely available on internet : « Octave », we have studied some rheological laws of plastic materials in order to find the evolution of the radius and of the height of the tube during the blowing process. Finally, to prove that our method can be right, we check our analytical results against a complete Finite Elements simulation performed with « Polyflow ».
Thermal Characterization for Radiation Treated Medical Products
Sherwin Shang, Tahua Yang, Lecon Woo, Craig Sandford, May 2004
A key feature for medical products is the need to sterilize products prior to release. However, the radiation dose, which disrupts DNA sequences in bioburdens, can also damage and alter polymer properties in substantial ways. Contrary to known degradations, there are also property enhancements through irradiation. In this presentation, both property degradation and enhancement will be illustrated with actual examples.
Aspects of Micromoulding Polymers for Medical Applications
M.T. Martyn, B. Whiteside, P.D. Coates, P.S. Allan, G. Greenway, P. Hornsby, May 2004
Micromoulding is maturing as a viable technology used in the manufacture of intricate, minute, 3d plastic components. There still remains a knowledge gap in understanding the effects of processing on product properties. Studies conducted within our laboratories reveal that polymer melts are exposed to extremely high shear and heat transfer rates in the process. These process conditions influence product morphology and properties.
Rapid Prototyping to Rapid Manufacturing
Anthony J. Sexton, May 2004
Since its inception, Rapid Prototyping (RP) has undergone many changes and enhancements in both materials and systems. One of these system enhancements is the Stereolithography (SLA) small beam laser, which was proposed to 3-D Systems Inc. in the summer of 1993.
Fabrication and Analysis of Plastic Hypodermic Needles
Hoyeon Kim, Jonathan S. Colton, May 2004
This paper presents the fabrication of plastic hypodermic needles using micro-injection molding and the analyses of their buckling behavior. As a needle cannula is a thin-walled column (here 0.7 mm outer diameter and 0.15 mm thick), it is vulnerable to buckling. The buckling behavior is characterized through numerical simulations and experiments.
Stretch Blow Molding of PET Bottle: Simulation of Blowing Process and Prediction of Bottle Propeties
Hern-Jin Park, Jong Ryang Kim, In Seon Yoon, May 2004
This paper presents a technique for describing more accurately mechanical behaviors of a PET stretch blow molded bottle by using distributions of modulus and thickness over the bottle surface. The values of modulus and thickness at each point of surface of the bottle were predicted from deformation histories of the material during the blowing process, which were obtained in numerical simulation of the blowing process. It also needed experimental measurements and estimation of mechanical properties of a stretched material up to stretch conditions in the blowing process in order to find out dependency of the properties on stretch conditions.
Evaluating the Use of Aluminum Inserts on SL Puzzle Molds for Injection Molding of Complex Parts: A Case Study
Valter Estevão Beal, Aurélio da Costa Sabino Netto, Carlos Henrique Ahrens, May 2004
Stereolithography is a rapid prototyping technique that is also capable to producing rapid molds with high accuracy in a short time. The mold's life expectancy is strongly dependent on the part geometry. This factor could induce weak regions in the mold that are more susceptible to collapse, like sharp corners and thin features. An alternative that could be used is to conceive the mold as a puzzle where slides are manually placed inside a main slot and drawn during the ejection. This work describes a comparison between two puzzle molds that had been made with and without aluminum inserts.
Determining, Understanding & Controlling the Morphology of Injection Moulded Parts Produced in Stereolithography Moulds
R.A. Harris, P.M. Dickens, May 2004
The direct use of moulds produced by stereolithography (SL) provides a rapid tooling technique, which allows low volume production by plastic injection moulding. The process’ greatest advantage is that it provides parts that are the same as those that would be produced by the conventional hard tooling in a fraction of the time and cost. However, work by the author demonstrates that the parts possess different characteristics to those produced by conventional tooling methods. These revelations defy the greatest advantages of the SL injection moulding tooling process - the moulded parts do not replicate parts that would be produced by conventional hard tooling. This work investigates the mechanisms in SL tooling that induce these different part properties and describes different approaches to modifying the process which allow the moulded parts to demonstrate characteristics closer to those produced by conventional means. The work also indicates control methods that may be unique to SL tooling.
Mold Conceptual Design Based on Fuzzy Logic
Wang Yu, Ruan Xue-yu, May 2004
Mold conceptual design is the most important phase of mold design. The decisions made during this phase are of high level and have a direct influence on performance of the mold and development costs. The main task for mold conceptual design is the in-principle determination of each mold element type (design scheme). Because of its non-algorithmic nature, technologies and methodologies such as knowledge-based system (KBS), case-based reasoning (CBR) has been used to do the work. In this paper, a novel approach was proposed to map mold element design requirements onto the corresponding design scheme by using fuzzy logic. The proposed methodology follows three steps: (1) Design requirements for mold element is extracted and generalized. (2) Possible design schemes are presented. (3) The fuzzy mapping relationship between mold element design requirements and design scheme is established based on fuzzy composition and fuzzy relation transition matrices that are assigned by domain experts. A gate type selection example was presented to illustrate the feasibility of the proposed methodology.
Keeping It Straight: The Five Sided Box
Kurt Hayden, Paul Engelmann, Jay Shoemaker, Michael Monfore, May 2004
Every molder that has tried to maintain squareness in the corners of a plastic part has come to appreciate the unique cooling problems inherent to the five sided box. It has long been understood that corners where two sidewalls meet the top or bottom of a product provide substantially increased heat load to the core of the mold. This increased heat load yields differential cooling, thus corners tend to develop stress, causing the sidewall to warp in. This investigation studied the effect of various core materials to and their effect on the warpage of the sidewalls of a five-sided box. The relative cycle time required to achieve maximum squareness for a given core material was also investigated.
Ultrasonic Microforging for Production of Microscale Parts with Nanoscale Features
Naveen Huilgol, Charles L. Thomas, May 2004
An ultrasonic horn is used to investigate a manufacturing technique to produce microscale polymeric parts using continuous wave ultrasound. This technique of microforging has a potential to produce microscale parts in production quantities. It should be capable of replicating nanoscale features on the microscale part. Potential advantages of microforging include speed of production and easy handling of the parts compared to microinjection molding techniques.
Radiation Processing of Polymers: The Current Status and Prospects for the Future
David R. Kerluke, Song Cheng, May 2004
Radiation processing has been used for almost 50 years to improve both bulk and surface properties of polymer resins and formed components. This session will examine several specific applications of commercial radiation processing in depth. This presentation will provide background for this session.
Novel Resins through the Pre-Irradiation Modification of Polyethylenes
T.A. du Plessis, H. Seute, May 2004
The presentation describes the development of a new family of novel polymers made through the ionizing radiation modification of polyethylenes prior to the conversion thereof into end products.
Polymer Treatment Techniques with Energetic Electrons
S.V. Nablo, May 2004
Fluidized bed handling of polymer powders and granules has been evaluated using electron energies in the 0.25-1.0 Mev. range. Performance data are presented for two pilot systems used in the development of this process typically operating in the product velocity range of 300-2000 meters per minute.The application of electron beam processors to the disinfection and sterilization of polymer containers provides an efficient route to the high speeds offered by modern filling equipment. Some results for the post treatment extraction studies in high density polyethylene and polyester bottles are presented.""
Approach for a Mechanical Design of Plastics Injection Molds by Means of FEA
Ernst Schmachtenberg, Marco Thornagel, May 2004
At the design phase the injection mold maker should endeavor to ensure a maximum reliability of the mold to avoid additional costs for subsequent modifications. It is astonishing that today the mechanical design of injection moulds is predominantly done in a conventional and crude way. Finite element analysis has the potential to improve that practice. Hence an approach has been developed to couple iteratively the structural analysis of the injection mold with the filling simulation of the plastics part. That approach for an automatically coupled simulation has resulted in the first prototype version and has shown good results. This paper seeks to present the theoretical and experimental data for review.

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