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
Challenges in Winding Flexible Packaging Film
Every Flexible Film Producer is faced with the challenge of producing quality rolls of film products. This paper will assist in overcoming the challenges in winding flexible packaging films. It addresses the definition of a quality roll of film and the importance of inwound tension in consistently producing good quality rolls. It then discusses the winding principles used on all winders to control inwound tension or roll hardness. It explains how to determine the proper amount of web tension for various types of films and the principles of nip and gap winding. Then the basic types of center, surface and combination center/surface winders will be compared with the advantages and disadvantages of each. After the discussion of how roll hardness is achieved, methods of measuring roll hardness are presented. Finally, other roll defects to avoid in producing quality rolls of film will be listed and the book Roll and Web Terminology" will be brought to the audience's attention for them to learn more about the causes and cures of common roll and web defects."
Chaotic Mixing as a Means to Develop Nano-Scale Structures in Polymeric Materials
Nanoscale materials are often produced either by breaking down larger structures or by assembling them directly from their smaller constituents. Another approach is to establish processing conditions where initially large component domains intermingle and refine over time to eventually give materials with nanoscale features. In this paper, the potential of chaotic mixing to develop in situ fine-scale structures and promote molecular-scale interactions are described. Due to induced chaotic motions, melt domains stretch and fold recursively. Structure is evolved in lieu of being broken down as occurs typically in common blending. Hierarchical associations among components can arise with relation to some natural materials. Examples of materials are shown that have been produced. Several opportunities are discussed that may allow the manufacture of bulk quantities.
Characterising the Biaxial Properties of Materials Used in Thermoforming and Blow Molding
In most thermoforming or blow molding processes a heated plastic sheet undergoes rapid deformation into the shape of a mold. Typically a wide range of deformation modes may be observed across its surface, ranging from planar through to equi-biaxial. Data from conventional uniaxial tests is often used to simulate this behavior, but it is recognized that neither the speed nor mode of deformation is correct. In this paper the development of a biaxial testing machine is described. Test results for a number of common materials are presented and the results are compared to uniaxial tests.
Characterization of Apparent Viscosity with Respect to a PVC-Wood Fiber Extrusion Process
Wood fiber-thermoplastic compounds were introduced into the marketplace during the mid-1990’s. These compounds are currently being molded or extruded into useful products.As these products grow in complexity, the variability within these compounds must necessarily be reduced in order to maintain or reduce scrap during these secondary processes. But just how much variability these processes can actually tolerate is a non-trivial problem involving design, process and material variables.This paper will discuss the results of a Design of Experiments conducted to determine the maximum apparent viscosity variability that a profile extrusion process is able to tolerate in a PVC-WF compound.
Characterization of Ethylene-Vinyl Chloride-Like Copolymers Synthesized by Ring-Opening Metathesis Polymerization (ROMP)
A series of chlorine containing ethylene copolymers with controlled molecular microstructure have been made using ring opening metathesis polymerization (ROMP). In contrast to traditional methods currently used in industry, this synthesis permits the control of the exact chlorine content along the macromolecular chain. In some cases, the placement of chlorine along the polymer backbone is also controlled. The properties of these ethylene vinyl chloride-like copolymers (EVC) are compared to traditionally chlorinated polyethylene (CPE) as well as to ethylene octene (EO) and ethylene styrene (ES), copolymers synthesized by metallocene catalysis.
Characterization of Fluorinated Polycarbonate Thin Films
SF6/Ar plasma treatment using an RF discharge was carried out for the surface fluorination of bisfenol-A polycarbonate films. The potential utility of this treatment for improving polycarbonate gas barrier properties was investigated. Treatment was done with variation on time exposure to plasma and SF6 concentration. Fourier transform infrared spectroscopy attenuated total reflection (FTIR-ATR), x-ray photoelectron spectroscopy (XPS), and contact angle measurements were used for surface characterization. It was found that plasma fluorinated surfaces lead to a considerable improvement on polymer gas barrier properties for all treatment conditions studied.
Characterization of Heat Sealing Part on Plastic Films
Mechanical properties of heat sealed part on plastic films consisting of oriented polypropylene (OPP) and cast polypropylene (CPP) films were investigated and the relationship between crystalline structure and the mechanical properties were discussed. The crystallinity of the heat sealed part affected the mechanical property. Consequently the high total crystallinity of both OPP and CPP gave the high mechanical properties, and also the orientation of the crystalline structure in OPP film was an important factor. The optimum condition for heat sealing was the temperature at which the highest crystallinity was obtained and also the orientation was not released.
Characterization of Metallocene EPDMs Crosslinked by Peroxide and ?-Radiation
Two metallocene EPDMs with the same weight fraction of ethylene were crosslinked by dicumyl peroxide and ?-radiation. Several amounts of peroxide were dispersed in a Leistritz corrotating twin-screw extruder at 85ºC, 55 rpm and 2 kg/h of mass flow rate. Besides, different ?-radiation doses were used. The gel content was determined in boiling decahydronaphtalene, and the crosslinking process was monitored by FTIR spectroscopy. The thermal properties were found by DSC and DMA. The mechanical properties, hardness (Shore A), compression set and tensile were also obtained.
Characterization of Molecular Weight Degradation of Polyamides by Gel Permeation Chromatography
Polyamides are susceptible to attack by environmental pollutants. The surface layer is degraded and the development of a critical thickness of this layer results in a catastrophic loss of mechanical properties. In this work nylon was exposed to nitrogen oxides and the fracture strength was measured. After a period of no change the fracture strength decreased dramatically. Exposed samples were microtomed and the molecular weight distribution of nylon was determined, as a function of depth from the surface, by Gel Permeation Chromatography (GPC). A critical depth for degradation was established beyond which the specimen exhibited unacceptably low fracture strength.
Characterization of Phase Partitioning of Additives in Rubber Modified Plastics
The phase partitioning of additives in polymer blends has a large impact on the performance of the blend. Since solubility characteristics and processing of the blends influences partitioning, it is necessary to be able to quantify the level of the additive present in each phase. An NMR method to quantify this partitioning has been developed and is based on the fact that the rubber phase and molecules dissolved therein, can be easily distinguished due to this phase’s enhanced motional characteristics. Examples will be presented for the quantification of phase partitioning within rubber modified styrenic materials.
Characterization of Phenolic Composites Reinforced with Jute/Cotton Hybrid Fabrics
The mechanical and dynamic-mechanical properties of novolac type phenolic composite reinforced with jute-cotton hybrid woven fabric were investigated as a function of fiber orientation and type. Scanning electron microscopy (SEM) was carried out to investigate the fiber-matrix adhesion. Results showed that the composite properties are strongly influenced by the test direction and yarns characteristics. The highest tensile, flexural and impact strengths and moduli (Young’s, flexural and storage) were found along the jute yarns direction and decreased with increasing test angle. Nevertheless, failure occurred in a catastrophic manner. Along the cotton yarns direction the composite exhibited a controlled failure mode. Jute fiber exhibited a better interaction with the matrix than cotton; the former has a higher irregular surface due to its multicellular nature, which promotes a mechanical adhesion at the interface. The combination of jute/cotton properties in this composite is suitable for lightweight structural applications, this is, jute promotes a higher reinforcing effect while cotton fiber avoid catastrophic failure.
Characterization of Polydimethylsiloxane Deposition on Hair by XPS and Imaging SIMS
The deposition of polydimethylsiloxane (PDMS) on hair for prototype shampoos was studied against competitive products as benchmarks. SIMS reveals uniform coverage of PDMS on hair for both the prototypes and the benchmarks. XPS and SIMS results show that the benchmarks leave substantially higher amount of PDMS on hair while the prototypes deposit 1-2 monolayers. The high PDMS deposition could be related to the consumer perception of smooth feeling, manageability and good rinsability, and could also be related to high conditioner build-up. The results provide insight towards an understanding of structure-performance relationship of hair care products, which helps deliver consumer benefits in a tailored manner.
Chemical Resistance of Elastomers in Harsh Environments
The performance of a wide range of elastomers exposed to fuel and hydraulic fluid at elevated temperatures was measured. The stability of the elastomers was determined by the degree of mass absorption, volume swell, change in hardness, and change in tensile properties. Other important parameters monitored included changes in glass transition temperature and the quantity of material extracted from the elastomer by the heated test fluids. Performance was measured after 3 and 28 days of immersion in the test fluids at either 107ºC or 135ºC. The classes of materials examined included PP/EPDM thermoplastic elastomers, thermoplastic and thermosetting polyurethane elastomers, nitrile rubbers and hydrogenated nitrile rubbers, epichlorohydrin elastomers, and several formulations of fluoroelastomers.
Chlorine Resistance Testing of UV Exposed Pipe
A test methodology to determine the effectiveness of Ultra-Violet Light (UV) stabilization on the oxidative stability of piping materials is examined. Chlorine Resistance (CR) testing is used to determine the impact of accelerated UV exposure on the oxidative resistance of crosslinked polyethylene (PEX) pipe. Following accelerated UV exposure, samples are tested to failure under accelerated test conditions designed to simulate chlorinated potable water end use environments. CR testing in conjunction with UV exposure is shown to be a sensitive method for the evaluation of the effectiveness of UV stabilization on the oxidative stability of PEX pipe. For the particular material examined, it is demonstrated that excellent retention of oxidative stability can be achieved when suitable UV protection is employed.
COF Analysis of POP and LLDPE Films Containing Erucamide: Effect of Repetitive Testing
Erucamide is incorporated into polymer films to reduce their coefficient of friction (COF). Such a reduction in COF is important in packaging lines where the performance of the film in contact with rollers can be governed by the frictional characteristics of the film. This research explores the COF behavior of multilayer films with either POP or LLDPE as the skin layer. Film-on-metal COF testing was performed repetitively with the same piece of film to investigate the extent of COF change with the number of runs. Film-on-film studies were also performed for comparison with the film-on-metal tests. Complementary analysis was conducted with atomic force microscopy (AFM) to investigate whether erucamide was being removed from the film surface or simply being smeared over the surface.
Co-Injection Molding of PVC with Other Thermoplastics: Processing, Properties, and Applications
Rigid polyvinyl chloride (PVC) was co-injected with glass fiber reinforced PVC (GFR-PVC), polypropylene (PP), acrylonitrile-butadiene-styrene copolymer (ABS), and polycarbonate (PC) using the Mono-sandwich co-injection process. Up to three through-thickness skin-core morphologies were observed along the length of the sample. Near the gate, the core was always a single, continuous layer. In some cases, the core diverged into multiple or discontinuous layers. Further from the gate, flow of the core ceased, leaving a skin-only region. The skin and core layers were more uniformly distributed through the test plaque when injection speed was low. Adhesion between PVC and PP was poor. Skin and core layers delaminated and mechanical properties were poor. PVC adhered well to GFR-PVC, ABS and PC. No layer delamination occurred and mechanical properties were intermediate between those of the skin and core components alone. Dropped dart impact energy was controlled more by the skin layer than the core. In rigid PVC/GFR-PVC co-injected samples, impact energy was 2.5 times greater when GFR-PVC was the core than when GFR-PVC was the skin.
Commercialization of Gas-Assist Injection Molding or The Gas Wars""
Gas-assist injection molding was discovered in Germany 30 years ago. Even though this technology has demonstrated significant value, a relatively small number of components are manufactured utilizing this process.Since the basic technology is straightforward, why has the acceptance of gas-assist injection molding been so limited? A number of factors have played a role, including litigation, initial licensing approaches and the unfamiliarity of designer with this process.This presentation will examine a number of the key decisions made by the suppliers of this technology as well as the OEM’s and molders that impacted the acceptance and utilization and their implication on the commercialization of gas-assist injection molding.
Compact Slide Action Closure Mold Technology
The Compact Slide Action Mold Technology (CSAM) has been custom designed for tamper evident closure molds for carbonated and non-carbonated beverage bottle closures, as well as mineral water bottle closures.Existing mechanisms for opening and closing slides in a slide action mold typically include angled horn pins or delta cams mounted to the cavity plate and slide retainers to retain slides in an open position.The new compact slide action mechanism for lateral movement of slides has been developed with the use of an air driven rack and pinion arrangement. This paper discusses some of the common problems associated with the conventional mechanism and how the new mechanism overcomes these problems.
Comparative Investigations on Quasi-Simultaneous Welding on the Basis of the Materials PEEK and PC
Laser transmission welding of polymers is regarded as a promising alternative in a range of industrial applications by virtue of its characteristic properties. The new variant of laser transmission welding – quasi-simultaneous welding – can be seen as a pioneering technology offering advantages such as precise local and contact-free heating, small heat affected zone, negligible warpage, high flexibility, compensation of part tolerances, high achievable weld strengths, etc.Initial systematical investigations were carried out varying the parameters: laser beam intensity, scanning velocity, joining displacement, pigment content and joining pressure. Their influence on weld strength and welding time was recorded. A T-joint was used for welding PEEK, while both T-joints and butt joints were used for the material PC. Optimum process parameters were determined for each material.
A Comparative Study of Corn Starches with Different Amylose Content
In this work, corn starches with 21% and 1 % of amylose contents, processed in the presence of 30% (w/w) of glycerol (plasticizer), were characterized by X-ray diffraction, Dynamical Mechanical Thermal Analysis (DMTA), Tensile test and Scanning Electron Microscopy (SEM). The results showed differences in the crystalline structure and mechanical properties of the starches after processing. The 21 % amylose content starch showed fragile behavior and higher tensile at rupture than 1% amylose content starch, which showed higher elongation at break and ductile behavior.
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