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
Polyurethane Coatings Based on Soybean Oil Prepolymers and Crosslinkers
I. Javni, V. Karajkov, Z. Petrovic, May 2001
Four series of coatings were prepared by using a soybean oil based isocyanate prepolymer and two types of the soybean oil based polyols as the crosslinkers. Water (humidity from the air ) was also used as a co-crosslinker. The isocyanate prepolymer and the polyols were prepared according to the original, proprietary methods. Varying the hydroxyl number of the polyol and polyol/ water ratio in the crosslinker varied the structure and properties of the coatings. The coatings were tested for hardness, elasticity (bending test), scratch resistance and adhesion. DSC, TGA, TMA, tensile strength and swelling were used to assess the glass transition and crosslinking density of the films.
Generation of Thermotropic Liquid Crystalline Polymer/Thermoplastic Polymer Strands for Producing Wholly Thermoplastic Composite Materials
Jianhua Huang, Donald G. Baird, Wei Huang, May 2001
Thermotropic liquid crystalline polymer (TLCP) reinforced thermoplastic polymer (TP) strands were spun and used in injection molding to form wholly thermoplastic composite materials. While keeping the strand size suitable for injection molding, effort was made to increase the orientation and aspect ratio of the TLCP fibril that would remain in the final product as reinforcement. The pelletized strand can be injection molded without disturbing the TLCP reinforcing fibrils. The samples have similar mechanical properties, lower density and smoother surfaces compared with glass fiber reinforced samples.
Rheology beyond One Million Reciprocal Seconds
David W. Riley, May 2001
In the wire and cable industry the speed of the insulated copper wire through the die is very fast. In 1963 a 24 gage wire was coated with plastic with a clearance in the die of only 5 mils (1 mm = 40 mils, i.e., 5 mils = 0.125 mm) at a speed that exceeded 2500 feet/min (almost 1 kilometer/minute). The shear rate calculates to be in excess of one million reciprocal seconds (actually this is 4 x 106 sec-1). Drastic changes were discovered in the molecular structure of the plastic. Shearing the polymer chain causes changes in the molecular structure that can be advantageous or severely detrimental. These running conditions and the effect on the PVC is the concern of this paper.
Re-Inventing the Wheel: Breaking New Ground with Rotary Shuttle Technology
Brian L. Dowler, Rolf Weingardt, May 2001
Long-stroke shuttle machines have developed a well-defined role in the extrusion blow molding of calibrated neck bottles. However, these machines have limitations due to factors such as the long axial length of the stroke and the need for large multiples of tooling, knives, dies, punches and In-Mold Labeling (IML) tooling sets per the number of mold sets. Many of these limitations have been overcome through the incorporation of an indexing rotary motion. The end result is a technologically advanced, small footprint machine that can produce IML bottles with very little cycle time penalty. Further, the multi-layer containers are de-flashed before exiting the machine with positive bottle transfer between stations with a true single-point product discharge. All of this is accomplished using fewer die pins, bushing sets, cut-off knives, trim dies, punches, and IML deployment heads than typically required. This paper discusses the technical hurdles that were overcome to re-invent" the shuttle machine and open up new possibilities in extrusion blow molding."
Do You Want Some Salsa with Those Chips?
Bruce M. Mulholland, May 2001
In the world of coloring plastics, there has been an apparent decline in the understanding and application of color technology. This is particularly noticeable the farther down and away from the source of the colored product you go. Retirements, downsizing, consolidations and other factors have contributed this knowledge base loss. This paper looks at this issue and what we can do to build it back up.
How Social and Cultural Influences Affect Automotive Design, Styling and Decoration
Larry DeBow, Edward Assad, May 2001
A discussion of how social and cultural influences in fashion, architecture, interior and product design affect automotive design, styling and decoration, and how these influences are brought to reality.
A Robust Ultrasonic Mold Condition Monitor for Injection Molding
Charles L. Thomas, Russell Edwards, Rob Peterson, May 2001
An ultrasonic transducer was installed on an injection mold such that the sound pulse would strike the front surface of the mold cavity and reflect back to the transducer. Changes in the intensity of reflected echoes are shown to be sensitive to the presence of polymer in the mold. By monitoring this changing reflected echo a signal is produced that is sensitive to conditions in the mold during processing. The primary advantage of the transducer is that it can be mounted on the external surface of many molds, allowing an installation that requires no machining of the mold.
Effects of Chain Extension/Branching on the Viscoelastic Behavior of Styrene-Maleic Anhydride/Polyol Blends
Goknur Bayram, Ulku Yilmazer, Marino Xanthos, May 2001
Styrene Maleic Anhydride (SMAH) / Polytetramethylene Ether Glycol (PTMEG) blends were produced in a batch mixer in the presence or absence of hydrated zinc acetate catalyst. The oscillatory shear properties in the melt state and the Fourier Transform Infrared Spectra (FTIR) of the blends were studied. The SMAH/PTMEG/zinc acetate blend had higher storage modulus, G', loss modulus, G and complex viscosity ?* than the blend without the catalyst. The distribution of relaxation times was calculated by using the oscillatory shear data and a generalized Maxwell Model. In comparison to pure SMAH for all the blends higher relaxation strengths at longer relaxation times were obtained due to chain extension and branching. The FTIR spectra of the SMAH/PTMEG blend indicated ester formation confirming the existence of chain extension / branching reactions in batch mixing."
The Selection of Mould Design Variables in Direct Stereolithography Injection Mould Tooling
R.A. Harris, P.M. Dickens, May 2001
Models produced by rapid prototyping (RP) allow the validation of a parts design with respect to its geometry. Beyond this, the rapid prototyping technique Stereolithography (SL); when used to manufacture moulding cavities, has shown itself to be capable of rapidly and economically producing low volumes of plastic injection moulded parts prior to commitment to hard tooling. These parts are more complete prototypes, they imitate parts that would be produced by a hard tooling manner with respect to their material, geometry and production process. A major drawback of the SL injection moulding process is that the tools are susceptible to producing only a small number of parts before failure. SL tools may break under the force exerted by part ejection when the friction between a moulding and a core is greater than the tensile strength of the core resulting in tensile failure. Very few justified recommendations exist concerning the choice of mould design variables that can lower the part ejection force experienced and reduce the risk of SL tool failure. This research investigates the ejection forces resulting from injection moulding polypropylene (PP), acrylonitrile-butadiene-styrene (ABS) and polyamide 66 (PA66) parts from SL tools which are identical in all respects except for their build layer thickness (a process variable when generating the SL tooling cavities) and incorporated draft angles (a tooling design variable). This work attempts to identify appropriate evidence for recommendations with respect to these variables and SL injection moulding. The results show that linear adjustment of draft angle results in a fairly minor linear change of part ejection force according to the moulding material. A linear adjustment of the build layer thickness results in a greater change in part ejection force as a more non-linear relationship. In both cases greater ejection forces were experienced by PA66, then ABS and then PP parts, respectively. The results also show that the s
Modeling of Fluted Mixing Elements
Petra Samsonkova, Jiri Vlcek, May 2001
3D simulation helps to have a better understanding of material behavior in complicated flow geometries such as extrusion dies or mixing elements where a 2D simplification fails. In our study, we will simulate the material behavior in a fluted mixing element. The fluted mixing element is one of many used mixing elements. Its specific geometry influences a good or bad mixing performance as well as local heat generation because of the shear dissipation. The study is focused on parametrical study of the influence of mixing element dimensions on the material behavior (generated pressure drop, mixing quality etc.). It is also focused on the determination where and under which conditions the heat generation is occurring, what is the related temperature rise and how this high heating can be prevented.
Blends of Various Proteins with Poly(Hydroxy Ester Ether)
C. Wang, C.J. Carriere, J.L. Willett, May 2001
Blends of poly (hydroxy ester ether) (PHEE), a recently developed bisphenol A ether-based synthetic biodegradable thermoplastic polymer, with a soybean protein isolate and two hydrolyzed wheat glutens were studied. Blends of the proteins with PHEE were produced from 20-70% by weight of protein content. The Young's moduli of the protein/PHEE blends falls in the range of 0.8 - 1.5 GPa with the tensile strengths ranging from 10-30 MPa. Fracture strengths of the blends ranged from 9-2 MPa-m1/2 depending on the amount of protein added. Morphological analysis indicated acceptable adhesion between the protein and PHEE phases in the blends. In general, as the protein content was increased the materials lost ductility and failed in a brittle manner; however, the mechanical properties of several compositions were comparable to current commercial thermoplastics such as polystyrene.
Developing a System to Activate a Post-Molding Blowing Agent in the Application Field
Alicyn M. Haney, Kate L. Miller, May 2001
This experiment creates a process which allows injection molded parts to be foamed during assembly applications, resulting in optimal airtight sealing properties at the plastic interface.
Preparation and Testing of a Polyamideimide-Montmorillonite Nanocomposite
Derek Choi, Nandika D'Souza, May 2001
Samples of a polyamideimide and montmorillonite nanocomposite were developed and tested for exfoliation. Research suggests that such a compound will exhibit excellent electrical properties with increased structural strength. Various methods were used to prepare samples for testing with optical microscopy, spectrophotometry, x-ray diffraction (XRD), and scanning electron microscopy (SEM) to determine exfoliation. Testing the material's properties with dielectric spectrometer is also underway. Data gathered thus far show good exfoliation, little aggregation, and improved electrical properties.
Modification of Epoxies for Low Friction
Witold Brostow, Patrick E. Cassidy, Haley E. Hagg, Magdalena Jacklewicz, Pablo E. Montemartini, May 2001
The morphology, elastic modulus, and friction properties of a commercial epoxy resin + fluorinated poly(aryl ether ketone) (12F-PEK) system have been studied. The system was cured at 24°C and 70°C. We achieved significant friction lowering, namely 30% less than the value for plain epoxy, at the 12F-PEK concentration of only 10% after curing at 24°C. By contrast, after curing at 70°C, an increase in both static and dynamic friction is observed.
Correlating Creep Data with High Temperature Tensile Testing
W. Scott Miller, May 2001
Obtaining accurate creep data can be time consuming when the material supplier does not publish it. A faster method of predicting creep behavior could be a benefit when designing plastic products that will encounter long term loading. This experimental study will examine the feasibility of using elevated temperature tensile testing data as a means for predicting the tensile creep behavior of general-purpose acrylonitrile-butadiene-styrene (ABS). Injection molded specimens will undergo tensile testing at elevated temperatures for comparison to the respective tensile creep curves.
The Shelf Life of Filled Polymeric Material for Medical Device: Accelerated Thermal Aging Experiment and Kinetic Prediction
Xiaoping Guo, Richard E. Stehr, May 2001
In the present study, a kinetic method is suggested to determine the shelf life of a filled polymer material prepared for making medical device, including barium sulfate-filled polyethylene and poly(ether block amide), by using an well-designed accelerated thermal aging experiment. Accordingly, the effects of aging time and elevated temperature on mechanical performance of the material are mathematically defined by thermal aging index, namely the ratio of the elongation-at-break after to that before a period of thermal aging. A general m-order rate kinetics with Arrhenius-type temperature dependence is utilized to describe the deterioration of the mechanical properties during aging. An accelerated thermal aging experiment is performed to statistically measure various aging indices for the samples aged at various elevated temperatures within different short-term aging times. Kinetic parameters are acquired using nonlinear regression to the experiment. By assigning a permissible aging index, the shelf life of the material (or medical device) is kinetically predicted at storage temperature.
Robust Simulation for the Heating Stage in Thermoforming
A. Yousefi, A. Bendada, R. DiRaddo, May 2001
Process simulation traditionally relies on the exact knowledge of parameter inputs, such as material properties, process conditions and heat transfer properties. However, these parameters are never known exactly and a degree of uncertainty exists. This level of uncertainty affects the confidence in the results obtained. One therefore has two options, reduce the level of uncertainty or account for it in the simulation through appropriate sensitivity trials. This work reduces the level of uncertainty through accurate evaluation of the input parameters. Accordingly, the accuracy of the predictions is significantly improved.
Thermomechanical Modelling, Microstructure Development and Part Performance in Stretch Blow Moulding
D. Laroche, R. DiRaddo, J. Brace, May 2001
Blow moulding simulation can be used as a predictive tool for determining the bottle performance as a function of the stretch blow moulding operating conditions. Modelling the successive processing steps is necessary in order to obtain the final bottle geometry and the distribution of polymer microstructure. The container properties are then used to estimate top load resistance. The objective of this work is to integrate microstructure models in process simulation in order to better estimate part performance in service. The models are evaluated for the prediction of top load resistance of PET containers. Experimental validations of the integrated process and performance models were conducted for the one-stage injection stretch blow moulding process.
On the Effects of Migration of Filler Particles on Conductivity and Mechanical Properties
Sadhan C. Jana, Sashishekhar Doni, May 2001
Shear-induced migration of filler particles during molding and extrusion of filled polymer compounds of polypropylene and glass beads and conductive carbon particles was investigated. The high-shear flow conditions were generated in capillary rheometers with length to diameter ratio of 20 and 30 and in injection molding machine. Reduction of both surface and volume conductivities of injection molded samples was observed, especially in the cases of conductive compounds with conductive particle composition in the range of percolation volume fraction. Significant migration of glass beads was observed from the surface to the interior in blends with PP. Maleic anhydride grafted polypropylene (PP-g-MAH), used to promote binding with filler particles, reduced the extent of migration of glass beads, but improvement in conductivity of injection molded samples was not observed.
Are Fundamental Mechanistic Studies Useful? A Novel Study in the Thermal Degradation of PET during its Manufacture and Processing Will Be Discussed to Illustrate the Importance of Mechanistic Studies
Kishan C. Khemani, May 2001
PET polyesters for food packaging comprise one of the fastest growing polymer markets in the world. One of the biggest challenges in the PET industrial R&D sector for the past twenty years has been to find the means to reduce the amount of acetaldehyde (a PET polyester's degradation by-product) generated during PET production and processing. A novel approach for studying the mechanism of thermal degradation of PET polyesters and copolyesters is described in this study, which also suggests precisely the ways to significantly reduce the acetaldehyde content in these polyesters. In this study, the amount of acetaldehyde evolved was measured over time at an elevated constant temperature. We found that there was a gradual decrease in the amount of acetaldehyde generated with time, and that this decline eventually approached a near asymptotic value. A degradation mechanism was proposed which showed that acetaldehyde was generated by three different routes involving, first, the hydroxyl end-groups, second, the vinyl end-groups and finally, the mid-polymer chain-scission. It was further suggested that of these, the hydroxyl and the vinyl end-group based acetaldehyde generation routes depleted with time leaving behind the last, but inexhaustible, chain-scission route. From the data in this study, it was also possible to estimate the rate of acetaldehyde generation by this mid-polymer chain-scission route. This information was then applied together with the (a) amount of residual acetaldehyde in the resin, (b) HO-end group concentration and (c) vinyl- end group concentration, to calculate the amount of acetaldehyde generation possible over a given period of time. This calculated [acetaldehyde] compared very well with the actual observed [acetaldehyde] over the same period of time, thereby validating the proposed mechanisms. In agreement with the thermodynamic principles, a near doubling of the chain-scission acetaldehyde generation rate was also observed when the temperature

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