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
Nanolayered Next Generation High Energy Density Capacitors For Electric Vehicles
Michel Ponting, May 2018
Micro- and nanolayer processing, is a technique which combines conventional cast film coextrusion equipment with a multi-layered feedblock, or a series of layer multiplier dies, to enable continuous polymer film fabrication on industrially relevant processing scales. Films processed in this manner can readily be created with hundreds or thousands of layers resulting in individual alternating layered polymer domains with thicknesses ranging from several microns down to less than ten nanometers. Though initially patented in the 1960s, fabrication of micro- and nanolayered polymer films via coextrusion has only recently gained broader acceptance in the commercial products arena.1 Building on the strong fifty year academic and commercial layer multiplication technology advances in processing have enabled modern day production of highly uniform intra-film layers, graded thickness film layers, and construction of 2D ordered structures. Nanolayered films are of interest both as both a developmental research area and as a scalable, cost effective commercial production technique toward high value added materials systems from conventional polymer materials. A review highlighting historical nanolayered coextrusion energy storage film development toward commercial film production and low rate device manufacturing is presented. Technical and commercial product development activities, target markets, and layering enabled enhanced electrical material storage properties will be discussed for nanolayered film capacitor devices. The nanolayering development case study will address layered film scale-up requirements and challenges, uniformity, and additional manufacturing challenges presented when integrating the micro- or nanolayered film into product supply chains with a special focus on quality assurance challenges and procedures. Ref:1. D. Langhe and M. Ponting, Manufacturing and Novel Applications of Multilayer Polymer Films. Elsevier, New York, 2016. ISBN: 978-0-323-37125-4.
Advancements In Fiber Laser Workstations For Plastic Welding Applications
Ben Campbell, May 2018
Fiber Lasers integrated into a fully enclosed workstation provide industry ready and easy to operate laser plastic welding systems. MECCO, a leader in laser marking, has worked with a customer to successfully convert marking workstations into laser welding systems. The systems have been designed for traditional transmissive plastic welding and also direct butt joint welding through laser heating of the seam and pressing together of the parts. The customer has found the laser welding process to be cleaner and stronger than friction welding or spin welding and can be accomplished in a comparable processing time. MECCO has now delivered over a dozen systems to this customer and they have been used to successfully laser weld over one million plastic parts for the automotive industry, proving that the technology is viable for manufacturing applications.
Nylon6,6 Rich Co- And Terpolymers: How Tuning Thermal Behavior Enhances Functionality And Enables New Applicaiton Spaces
Jacob Ray, May 2018
Polyamide6,6 (PA66) is a semi-crystalline thermoplastic that has many useful functions such as high temperature resistance (melting point = 260 C), strength, toughness, barrier, and chemical resistance. Further, its fast rate of crystallization is often beneficial for fast cycle times of injection molded parts, yet it can be a limitation in many cases. For one, highly filled systems that may include glass fiber or other additives usually have fair to poor surface aesthetics. In the case of film extrusion, PA66 has many limitations such as but not limited to blown film processability, aesthetics (poor haze and gloss), and post orienting and thermo-forming. Through incorporation of additional monomers that do not co-crystallize with PA66 to produce PA66 rich co or terpolyamides, one can reduce crystallization rate up to 100 fold while maintaining semi-crystallinity and a high melting point (> 215 C). Through reducing the rate of crystallization, enhanced properties can be achieved that augments the high melting point enabled by a PA66-rich backbone; these enhanced properties include (1) improved aesthetics (i.e., higher gloss and clarity), (2) larger processing windows for extrusion or blow molding, and (3) toughness (i.e., puncture resistance). These functional benefits enable PA66-rich copolymers to bring value into a variety of film application spaces from monolayer cooking bags to multilayer films for industrial and food packaging. In a converse strategy, this disclosure will touch briefly on increasing melting and crystallization temperature, driven by incorporation of co-crystallizing monomers; this strategy empowers other functional improvements such as improved wear resistance and thermal aging performance that can bring value in a number of industrial and automotive applications.
Thermally Purified Carbons For Food Contact Applications – A Case Study On Eu Compliance
Rijo Jacob Robin, May 2018
Polymers are finding more and more application in the food handling and processing equipment in industries and households. Be it for metal replacement or lower cost or corrosion resistant purposes. Modified polymers using graphite are particularly suitable for demanding applications require the materials to be of conductive or lubricious. Graphite modified polymers are the best solution for self-lubricating parts in environments that can’t accommodate liquid lubricants. To ensure carbonaceous material be of technical quality and purity as stipulated in Plastics Regulation (EU) No 10/2011, Superior Graphite uses its proprietary electro-thermal purification technology, which exposes carbon and graphite materials to temperatures above to 2400°C. Result is a high carbon content and virtually free of impurities. Removing volatile gases and select heavy materials creates a highly ordered crystalline structure with exceptional purity, consistent quality, and increased resiliency, lubrication, and thermal and electrical conductivity.
3D Line Confocal Imaging: New High-Resolution Sensor Technology For Challenging Online & Offline Plastic Measurement Applications
Juha Saily, May 2018
This presentation introduces FocalSpec’s recently patented optical Line Confocal Imaging (LCI) technology that was developed to measure 3D features of various surfaces at sub-micron resolution. LCI enables quick and automatic microtopographic scan of challenging materials that are difficult or impossible to measure with traditional methods. Examples of such products include highly-reflective and transparent precision-molded parts; polymer films, sheets, coatings, profiles, filaments and medical tubing. LCI can be used to measure fast-moving surfaces in real-time as well as stationary product samples in laboratory.Operational principle of the LCI method is discussed. Several applications for LCI sensors are examined: 1. Online surface roughness measurement. 2. Online imaging of embossed and printed 3D features. 3. Online film, sheet and coating thickness measurement. 4. Other potential online imaging applications: Web edge height measurement and 3D wrinkle detection. The company's new Line Confocal Scanner UULA for off-line and at-line 3D metrology applications is introduced too.
The Importance Of How Online Rheometers Accurately Indicate Melt Flow Rate In An Extruder
Catherine Lindquist, May 2018
TITLE: The Importance of How Online Rheometers Accurately Indicates Melt Flow Rate in an ExtruderCOMPANY: Dynisco Azadeh Farahanchi, Rheological Scientist, PH. D.Bill Desrosiers, Vice President, Business DevelopmentCatherine Lindquist, Marketing Communications Manager1Dynisco Inc. 38 Forge Parkway, Franklin, MA 02038ABSTRACTAmong the various methods for developing new polymeric systems, the extrusion process has been increasingly used in the thermoplastics industry in complex applications such as continuous reactors for melt compounding, mixing, and a variety of reaction applications. In any extrusion system precise testing and analysis is necessary in order to maximize the processing efficiency. The rheological testing measurements on extrudate materials are commonly performed by processors to ensure that their products are meeting the desired qualities and understand the effect of adding various components to their materials. A newly designed on-line rheometer has been developed to continuously monitor the rheological parameters of in-process compounds namely melt flow rate (MFR), intrinsic viscosity (IV), and apparent viscosity. This helps compounders to have a real-time quality control on their products and reduce the failure rates or scraps. The present work aims to describe the design of the on-line rheometer and how it can be easily connected to the extruders using existing ports and flexible adaptors. It also has been explained how the proposed on-line rheometer can duplicate the test conditions of an off-line melt flow rate tester on an extruder in any compounding or manufacturing process. Furthermore, through calculation of activation energy in a specific material and introducing a temperature correlation, it has been investigated how the on-line rheometer considers the temperature dependency of material`s MFR and accurately measures this parameter at various operating temperatures.
Taking Injection Mold Cooling To The Next Level
Kenneth Johnson, May 2018
A Patent for the next generation process cooling technology for the plastics industry was awarded to MoldCool USA on February 14, 2012. With a dynamic process such as injection molding, the amount of heat being extracted from the mold needs to be controlled consistently. Conventional TCU’s control the temperature of the coolant but do not control the flow through the mold. The iCool® controls flow and calculates the instantaneous heat exchange rate with the mold using thermodynamic heat exchange formulas. Then using proprietary software adjusts the heat exchange rate as needed to maintain its consistency as the molding process is trending. Huge cycle reductions are available when the speed controlled gear pump delivers up to three times the coolant through the mold. In a good mold design 20-50% cycle reductions and even more are feasible. A Passive Variotherm technique called BoostMold™ is offered to put a customized repeatable timed flow of cooled or heated water through the mold. Cycle reduction of 50% and more with improved visuals are achievable.
Automotive Lightweighting With Reduced Density Polyamide Blends
Ying Shi, May 2018
Schulamid RD “reduced density” nylon is obtained through an immiscible polymer blend which requires the optimization of the compatabilization system, component viscosities, and, most of all, design of the compounding process. In addition to low density, low moisture absorption is achieved which provides part designers with more predictable physical properties and part dimensions when their application is exposed to real environmental conditions. For processors, lower moisture absorption means less moisture to remove. Cost savings can be realized by the reduced melt temperatures that can be used due to the improved flow characteristics of Schulamid RD. Less heat added means less heat to remove which reduces energy consumption for the entire process. A tailored heat stabilization technology has allowed use in under the hood applications like active grille shutters, fan shrouds, and other components requiring temperatures up to 150C.
Laboratory Weathering For Plastics
Andy Francis, May 2018
Weathering testing is a critical component of research, quality control, qualification, and new product development for plastics and polymeric materials used in a variety of industries. Weathering test methods help engineers improve their products, minimize failures, and reduce raw material costs. Weathering testing is composed of two interdependent yet complementary parts: outdoor exposures and laboratory accelerated weathering tests. Outdoor testing is an important complement to accelerated testing as it provides real-time results and exposes test specimens to complex weathering patterns not easily duplicated in an accelerated laboratory environment.The most frequently used accelerated weathering testers are fluorescent UV and xenon arc devices. These accelerated laboratory weathering and lightstability testers are widely used for research and development, quality control, and material certification. They can provide fast and reproducible results. In recent years, laboratory accelerated weathering test standards have been developed that offer improved realism and correlation to outdoor exposures. This presentation compares and contrasts the light emission spectra, temperature control, methods of water simulation, and practical considerations regarding use of these two major types of accelerated testers. The inherent strengths and weaknesses of each test architecture will be discussed, including cost of ownership in addition to technical performance. Defining goals of weathering testing and development of appropriate weathering testing programs will also be presented.
Leveraging Advanced Edge Analytics For Improved Fault Detection In Discrete Manufacturing Processes
Andrew Wilson, May 2018
IntroductionMultivariate analytics data monitoring systems provides a significant fault detection improvement over typical SPC type, or Univariate, solutions currently being used in the discrete manufacturing process industry to allow manufacturers to eliminate manual and visual quality inspection and to achieve real-time process release or "lights out" manufacturing operations.Problem StatementCurrent method of Univariate SPC process control typically utilized by discrete manufacturing process industry is not fully capable to detect quality issues caused by combinations of signals acting jointly on a system. Process engineers also must make manual adjustments to process limits to accommodate for slowly drifting processes, or caused by environmental effects, incoming material issues, and equipment wear. How can the user be certain these limits adjustments will not result in quality issues?Solution The SenseLink™ QM system builds a multivariate model around the optimized process with an acceptable processing window, established from a design of experiments (DOE). The system generates application-specific & automatic limit setting, reducing the reliance on expert process engineers and operators tweaking process knobs causing variations to the process. New data is then compared in real-time to the alarm limits developed by the model. The multivariate alarms are then triggered if the new data is off-spec, sending a reject signal to a part containment device for real-time part containment.OverviewThe SenseLink™ QM system is a data acquisition system with a multivariate data analysis engine that was developed for any industrial manufacturing process, and used with manufacturing processes or secondary operations to provide improved process understanding. Each cycle is multivariate analyzed in real-time to provide variable contribution charts, which highlight process trends not seen by UVA (Univariate). Real world case studies have proven this solution effective.ConclusionUsing a Multivariate fault detection system in your industrial manufacturing processes will provide the highest level of in-process fault detection available along with contribution details which provide an understanding of your process not attainable from traditional SCADA and SPC approaches.MKS InformationAndrew Wilson | Product Marketing Specialist | Automation & Control Solutions | MKS Instruments, Inc.andrew_wilson@mksinst.com | Cell: 512.962.3598www.mksinst.comhttps://www.mksinst.com/product/product.aspx?ProductID=203
Surface Enhancement Via Polypropylene Metallic Compounds
Tanmay Pathak, May 2018
Light weighting and low emissions are desirable aspects for any compound developed for automotive applications. In addition the enhancement of an automotive surface for visual appeal and improved aesthetics is also a key area of research in polymer composites targeted for such applications. There has been considerable development on surface appeal via metallic polymer compounds using effect pigments which allows reduction of weight by metal replacement. However, during injection molding, these compounds could lead to weld line imperfections in parts especially where the flow fronts come together. This is essentially due to poor metallic pigment distribution. The current work shows the development of a Polypropylene metallic composite with the focus on weld line improvement by proper choice of material and tool design to allow injection molded metallic TPO for exterior class A. This development also provides lower costs and lower emissions as it eliminates painting of such TPO compounds.
Copolyester Based Wpc(Wood Plastic Composites)
Wood-plastic composites (WPC) are composite materials made of wood fiber/wood flour and thermoplastics. Since a polyolefin-based resin, generally used in WPC, exhibits hydrophobicity, it shows low interfacial adhesion when mixed with hydrophilic wood flour, which causes a problem in that flexural strength of WPC is lowered. In case of a polyvinyl chloride (PVC) resin, a phthalate-based plasticizer and stabilizers containing heavy metals can be used in order to enhance processability during the process to make WPC, which are easily extracted out from WPC, causing an environmental pollution problem. Both PP and PVC based WPC are vulnerable to climate changes due to its low dimensional stability according to temperatures, causing many defects and problems. In case of polyester (PET) resin, polyester base resins compatibilizes well with wood, but due to high processing temperature, the wood flour are burned during the process, which makes it impossible to use PET for WPC. Accordingly, in order to solve the above-described problems, ECOZEN® based WPC has been developed. ECOZEN® based WPC has improved physical properties which show superior flexural property (higher than 2 times compared to PP based WPC), impact strength, and lower thermal expansion (or shrinkage). Also it can be easily processed even without help of additional coupling agents, since ECOZEN® shows excellent interfacial adhesion with wood flour. This allows of WPC with higher content of wood flour, which benefits in terms of cost competitiveness and environmental friendliness.
Novel Approach To Controlled Migration Of Antifog Additives In Multilayer Packaging Films
Evgeni Zelikman, May 2018
One of the biggest applications of polymers is food packaging. Downgaging and multilayer structures are the main trends which lead the food packaging in the recent years. This is the main reason why multilayer polymer films rapidly increase their share in the global food packaging market.Controlling the surface properties of polymer films is of outmost importance for both the packaging process and package quality. The most accepted way of keeping up with market requirements when surface properties need to be altered is the use of migrating additives. Slips, antistatics and antifogs are most widely used. These migrating additives migrate throughout the film and form a thin layer on the surface, this way decrease the coefficient of friction (slip), dissipate the electrostatic charge (antistatic) or increase the surface energy of the film (antifog). Antifog additives mainly used in packaging of refrigerated food. Water droplets on the clear packaging impair product’s appearance and decrease its shelf life. Antifog additives migrate to films’s surface and dissolve in the condensate. Droplets are transformed into continuous and transparent water layer. The migration rate of the antifog additives is often influenced by a range of factors for example corona or flame treatment, lamination, tie layers and polar polymers, forcing the migrating additive to migrate towards an undesired direction. This can compromise other vital film properties, such as printability, lamination strength etc’…The ability of film producers to control the migration of antifog additives is of outmost importance.Tosaf’s novel barrier additive will direct the migration to the desired direction thus significantly decrease or completely prevent the migration throughout this additive containing layer. The BR7483PE is incorporated into the layer adjacent to the antifog containing layer (the inner layer). BR7483PE increases the rigidity of the amorphous phase, preventing antifog migration to the undesired direction.
Biodegradable PHA For Use In Fashion Textiles
Anne Schauer-Gimenez, May 2018
Mango Materials has developed an innovative platform technology to turn waste gas streams into ecofriendly, biodegradable materials at competitive economics. Utilizing a biological process, microorganisms convert the carbon from methane into polyhydroxyalkanoate (PHA), which can be formulated to produce various products. The recent application development of biodegradable bio-polyester production will be highlighted. By substituting persistent polyester with this biodegradable bio-polyester made of PHA, brands can finally produce truly sustainable garments. Until now PHA has never been developed into commercial textile fibers, making this discovery an opportunity to accelerate the market growth of PHA.
Characterization Of Cure Of Polymeric Material By Dielectric Analysis (Dea)
A variety of questions may arise during the curing process for thermosetting resins. For example, at which temperature, or after how much time, does the resin begin curing? How high is the reactivity? When is curing complete? How can the curing cycle be optimized? Is there any potential for post-curing? The answers to questions such as these can be investigated by using Dielectric Analysis (DEA), not only in the laboratory environment, but also in-process.Dielectric Analysis (DEA) allows for the measurement of changes in the dielectric properties of a resin during UV curing. A sinusoidal voltage (excitation) is applied and the resulting current (response) is measured, along with the phase shift between voltage and current. These values are then used to determine the ion mobility (ion conductivity) and the alignment of dipoles. Of primary interest with regard to curing is the ion viscosity. This is the reciprocal value of the ion conductivity, which is proportional to the loss factor.This technique can be used in study of the curing behavior of thermosetting resins, adhesives, paints and coatings in nearly any application.Various application examples are included in the presentation, including cure by heat and UV cure.
A Novel Design Of Functionalized Organo-Modified Siloxanes For Surface Treatment Of Particles And Fillers
Ido Offenbach, May 2018
Fillers are widely used in thermoplastic polymers for cost reduction, enhancement of mechanical properties, enhancement of flame retardant performance, and more. Talc, ATH, MDH, calcium carbonate, glass fiber, aluminium oxide, and melamine cyanurate are examples of such common fillers. Because these fillers can come in different sizes and shapes, some can be comparatively difficult to disperse in the polymer matrix. This can lead to agglomerates of the fillers, which can result in high stiffness and low toughness of the final products. One way to improve the dispersion of fillers is using surface treatment additives. Evonik is one of the world leaders in specialty chemicals. Interface and Performance is a division of Evonik that specializes in developing additives for the polymer market. One of their recent developments is surface treatment additives for the fillers market, which behave as compatibilizers between fillers and polymer (thermoplastic and thermoset) matrixes. These surface treatment additives can be used by compounders as well as fillers manufacturers. Our newly developed Organo-Modified Siloxane (OMS) is an example of this technology. OMS technology is a unique polymeric substance that improves the compatibility of fillers with the polymer matrixes. In comparison to other surface treatment additives, OMS technology improves the hydrophobicity of the fillers’ surfaces. Our novel OMS surface treatment can also functionalize the surface of the fillers. Therefore, improvement in the mechanical performance of polyolefine and engineering resins can be achieved. This paper focuses on the TEGOPREN series, Evonik’s novel surface treatment additives. Specifically, this paper illustrates the benefit of using TEGOPREN in polymer compounds, and fillers which have been surface treated with TEGOPREN.
New Technology For Improving Halogen Free Flame Retardant Performance In Polymer Application
Ido Offenbach, May 2018
The recent health-risk and environmental concerns of using Halogen Flame Retardant (HFR) is driving companies to use Halogen Free Flame Retardant (HFFR) in their products. However, several challenges must be overcome to utilize HFFRs in polymer matrixes. Many of those challenges are related to the HFFR large dosing level, its low compatibility, and its poor dispersibility. These characteristics lead to impaired mechanical properties in the final product.Due to the health-risk and environmental concerns, Interface and Performance, which is a division of Evonik, has developed new technologies to enhance the properties of HFFR in polymer applications. Organo-Modified Siloxane (OMS) is an example of this technology. This technology is made up of unique polymeric substances that improve the compatibility of HFFR particles with polymer matrixes such as polyolefin and engineering polymers. Therefore, Combining OMS with HFFR improves UL 94 results at lower HFFR usage levels, mechanical properties of highly filled HFFR polymer compounds, melt flow indexes (improving the processing ability of highly filled HFFR compounds), amperage level use, and prevention of die drool. The OMS technology also improves the hydrophobicity of the compound, resulting in lower water absorption and better CTI values. This paper focuses on Evonik state-of-the-art OMS additives for filled HFFR (melamine cyanurate, phosphorus based materials, and others) in engineering polymer compounds (PBT, polyamide 6 and polyamide 6,6). These OMS additives can be used while compounding as well as in surface treated HFFR. The improvement of UL 94, CTI, mechanical properties, and melt flow indexes of filled HFFR in engineering polymer compounds will be demonstrated in this paper.
Tuball™ Single Wall Carbon Nanotubes For Thermoplastics
Maus Christian, May 2018
TUBALL™ SINGLE WALL CARBON NANOTUBES FOR THERMOPLASTICSOCSIAL has developed Single Wall Carbon Nanotubes (SWCNT) which are now available at industrial scale under TUBALL tradename. SWCNT’s are the ultimate material for conductivity: they are only one carbon atom thick with a diameter of around 2 nanometers and a length of 5-10 microns. Traditional fillers used to bring electrical conductivity in plastics typically need to be added at a high dosage. The unique morphological characteristics of SWCNT’s enable the creation of conductive networks at much lower dosages than those required by CB’s or MWCNT’s for example. As a result, it is now possible to achieve high electrical conductivities without compromising the mechanical properties and other characteristics of plastics.In order to enable the full development of their benefits the SWCNT’s need to be very well dispersed and distributed inside the polymer matrix. Two routes related to melt mixing are considered for the SWCNT’s incorporation.From one side the compounding of SWCNT powder into polymers is envisaged, general recommendations for a two-step compounding approach involving high specific mechanical energy input are summarized. On the other side, OCSIAL has started to develop several concentrates of SWCNT’s that are designed for compounding into specific thermoplastics. Those concentrates have typically a high dosage of SWCNT (up to 10%) and are based on fluid carrier systems. Proposed under the MATRIX tradename, they facilitate the dispersion and eliminate the SWCNT powder handling. Details about dilutions parameters and examples of performances that have been recently achieved by a selection of MATRIX grades are given. The results obtained in ABS, PC, PE rotomolding and PVC plastisols are covered and the specific benefits enabled by the implementation of SWCNT’s are discussed. From those practical cases it can be concluded that SWCNT’s can be incorporated into plastics by melt mixing and that the pre-dispersed SWCNT concentrates provide opportunities for differentiation through new product development.
A Novel Synergist For Halogen Free Flame Retardants
Amit Paul, May 2018
Paxymer AB has developed a novel halogen-free flame retardant system based on a multi-mechanistic approach including a unique synergist based on functional polymers. The challenge for formulators aiming to achieve halogen-free flame retardant performance is high dosage of additives resulting in low processing and mechanical properties and high prices. Paxymer's synergistic line of products address this. Enabling formulators to reduce their total amount of flame retardant additive using functional polymers gives benefits in all aforementioned aspects. For example: cost reductions of 10% with retained mechanical performance and improved processing performance. Paxymer's functional polymers eliminate dripping and can therefore act as a halogen free replacement of the commonly used PTFE. The company has also developed a analytical toolkit for characterisation and formulation prediction for halogen free flame retardants. The presentation will introduce the new line of products based on the company's 2016 patent submission. It will give some insight into the mode of action of the functional polymers, briefly outline the analytical approach of the toolkit and present a comparative case study between Paxymer containing products and a reference.
Tailor-Made Uhmwpe By High Shear Polymer Modification
Binay Patel, May 2018
The physical properties for commodity polyolefins have steadily improved over the course of the last 30 years. Some of these developments have been accomplished by optimizing structure-process-property relationships. For example, it is known that the longest of polymer chains can act as tie molecules between crystalline lamella, thereby increasing toughness but decreasing processability. It is also known that a balance of properties is often achieved by tuning a resin’s molecular weight distribution (MWD) for a given application. There have also been improvements in single site catalysts that can be used either within the same reactor or within reactor cascades to better control the resulting MWD. Unfortunately, these improvements have not translated to new ultra high molecular weight polyethylene (UHMWPE) materials. Improvements developed for commodity polyolefins do not translate to polymerization control at very high molecular weights. Zzyzx Polymers, LLC has developed a high shear polymer modification (HSPM) process for producing tailor-made UHMWPE thereby expanding the commercial utility of UHMWPE. This technical marketing presentation will cover an overview of HSPM technology and highlight various examples for tailoring UHMWPE for improved material performance, processability and for developing commercially viable UHMWPE-based blends.

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