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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The Use of Ethylene/Styrene Interpolymers in Crosslinked Foams for the Footwear Industry
Ethylene/Styrene Interpolymers (ESI) currently under development by The Dow Chemical Company can be effectively crosslinked using current commercial equipment to produce extruded sheets, bun foams, and injection molded foams (IMF) for footwear parts providing properties that enhance and/or outperform current foams of crosslinked ethylene vinyl acetate copolymers (EVA). Crosslinked EVA foams with density ranging from 0.12 to 0.35 g/cc are becoming increasingly popular in many athletic, ladies high heel, and casual shoes, for the fabrication of insoles, midsoles, and unisoles where light weight, comfort, aesthetics, low cost, and performance are the key. ESIs can be blended with EVA or used pure to give light weight, softer foams with better compression set while maintaining or improving on resiliency, heat shrinkage, and split tear.
Plasma Polymerized Films for Optoelectronic Applications
Photovoltaic devices and light emitting diodes are now being developed from thin films of conjugated polymers and other organic systems. The potential to create lightweight, flexible, and inexpensive structures are the main advantages of using conjugated polymers over the conventional inorganic systems. However, the challenge is to create organic devices that are more efficient than inorganic devices already in existence. Currently, we are conducting research at the University of Cincinnati using plasma polymerization to produce optical quality thin films of Benzene, Furan, and other polymers for photovoltaic devices and light emitting diodes (LEDs).
Environmental Lining Systems - Raising the Standards
Annually, the United Kingdom deposits around 20 million tonnes(1) and the United States around 2 billion tonnes(2) of waste into landfill. To protect the environment from the harmful effects of leachate from the waste, landfill sites are protected using a system of thermoplastic liners, typically made from polyethylene. Due to manufacturing limitations on the size of the lining sheets, welding is employed to join adjacent sheets at the landfill site. This paper reviews current welding practices, the industry approach to quality, and discusses the moves towards certification of welding personnel in order to raise standards across the industry.
Improved Part Quality Using Cavity Pressure Switchover
This study examined the improvements in injection molded part quality using cavity pressure to initiate switchover from injection pressure to holding pressure. Cavity pressure produced more controllable and uniform part dimensions than the time and position switchover typically employed in older, point controlled injection molding machines. The controller was relatively easily incorporated into an older machine. When the cavity pressure set point was determined from the position switchover conditions, the pressure may not have been optimized, but provided better parts than the other transfer techniques. Direct determination of the cavity pressure set point is still being evaluated.
Improving the Fracture Resistance of Short Glass Fiber Composites under Impact
The impact behavior of short glass-fiber composite was reported earlier by the authors. It was found that the first failure was a longitudinal crack followed by a perpendicular crack on the tensile side. The objective of the current work is to evaluate a method for improving the impact properties of these materials. The primary focus will be on the addition of ductile polymer layer to the extruded composite. Instrumented drop weight impact technique was extensively used to evaluate the impact properties of the composite. This work showed that the addition of the ductile layer improved the impact properties significantly.
An Advanced High Modulus (HMG) Short Glass-Fiber Reinforced Nylon 6: Part I-Role and Kinetic of Fiber-Glass Reinforcements
Resent developments were oriented on two high-flow, high-modulus fiber-glass reinforced nylon 6 (HMG series) grades for automotive and other industrial applications requiring high stiffness and high strength. These materials combined the following improved technological (injection molding, vibration welding, etc.) and mechanical performance properties such as greater dimensional stability, higher short-term (strength and stiffness) and long-term (fatigue and creep). The current and possible applications of these plastics includes auto mirror housing brackets, clutch pedals, clutch master cylinders, ski bindings, steering wheels, levers, auto seat frames, door handles and door lock mechanisms. In Part I of this paper, we are presenting results of reinforcement analysis with the influence of level of loading and geometrical parameters of used fiber-glass.
A Study on the Bottom Design of Petaloid Carbonated PET Bottle to Prevent Bottom Crack
Petaloid shape in bottom design for carbonated PET bottle is wide spread. Through this paper we investigated the causes of bottom crack. We then redesigned petaloid bottom to prevent bottom crack. We examined the material property variations according to the stretch ratio of PET and analyzed stretches of bottom in blowing processes. We also performed crack test to observe a crack phenomena. The effective stress and maximum principal stress were examined by computer simulation. We concluded that the bottom crack occurs because of not only insufficient strength of material due to the insufficient stretch of PET but also coarse design of petaloid shape. The crack in bottom of bottle occurred through crazing. The highest maximum principal stress occurred at valley in petaloid bottom of bottle and this strongly affected the crack in bottom. We redesigned petaloid shape to minimize maximum principal stress, and this result in increasing the crack resistance.
Comparison of the Stabilizing Efficiencies of Metal Carboxylate and Tin Stabilizers of PVC
In order to obtain detailed understanding of the mechanism and action of PVC stabilizers, a new exact method has been developed for the determination of the stabilizing efficiency of these compounds. This is based on the separation of the direct chemical stabilization, i. e. blocking according to the reversible blocking mechanism of PVC stabilization, and the HCl-scavenging capacity of stabilizers. This new method has been applied to investigate the stabilizing efficiency of different stabilizers, such as metal carboxylates and tin compounds. In this study, the stabilizing efficiencies of these stabilizers will be compared by carrying out PVC degradation under inert and oxidative conditions. The stabilizing efficiencies allowed setting an efficiency order for a variety of stabilizers. These studies also led to surprising findings for thermooxidative stabilization under the applied conditions.
In-Situ Polyamide 6/Polysulfone-Alloys
In order to develop a cost effective way to new Polyamide 6 (PA 6)-alloys and blends, solutions of Polysulfone (PSU) in ?-Caprolactam have been polymerized by the widely used hydrolytic process. The resulting materials have been characterized by various analytical techniques. Compared to melt blended PA 6/PSU-samples, materials prepared by the polymerization process reveal a unique morphology with dispersed PSU-particles having average particle diameters below 100 nm. This morphology is a consequence of in situ created copolymers, therefore these samples were designated as in situ PA 6/PSU-alloys. The in situ alloys offer improved heat distortion temperature and excellent toughness.
Influence of Low Molecular Weight Compounds on the Morphology of PSU/PA-Alloys
In order to develop a new polymeric material with a nice combination of high heat resistance, chemical resistance and flow, polysulfone (PSU)/ polyamide (PA) blends have been investigated. The incompatibility of these polymers can be overcome by the addition of functionalized PSU, especially anhydride terminated PSU (PSU-PhA). Since PSU-PhA sometimes contains traces of low molecular weight compound, the influence of such reactive impurities was investigated with phthalic anhydride (PhA) as model compound. The amount of in situ created PSU-PA-copolymers is significantly reduced by the addition of PhA during the extrusion process resulting in a coarsening of the morphology.
Wood Filled High Crystallinity Polypropylene
Over the past decade wood filled polyolefins have gained acceptance as a replacement for lumber in high value outdoor applications, especially decks [1-2]. Most of the products offered have used post consumer polyethylene as the polymer matrix, with wood flour as the typical filler. Polypropylene offers specific benefits over polyethylene in terms of higher stiffness, strength, heat deflection temperature (HDT), and better creep performance. In this paper we compare the properties of wood flour (WF) filled polypropylene and polyethylene at various WF levels. The polypropylene resins include both standard Zeigler-Natta homopolymer (HPP) and high crystallinity (ACCPRO) homopolymer, as well as an impact copolymer (ICP) resin. The polyethylene resins include high density polyethylene (HDPE) and low density polyethylene (LDPE). The effect of different levels of a maleated polyolefin coupling agent were also examined. A substantial improvement in stiffness, strength, and high temperature performance was observed for all of the PP based resins relative to that of the polyethylene based materials, and the ACCPRO based composites gave the highest level of performance.
Impact Enhancement of Clarified Polypropylene with Selected Metallocene Plastomers
The addition of selected metallocene plastomers can improve the drop impact strength of parts molded from clarified polypropylene with slight effect on haze and gloss. This paper demonstrates the effects of plastomer structure (melt index, density and comonomer type), on the optical, physical and impact properties of clarified PP. A thermal segregation experiment shows the preferred methylene sequence length to minimize haze. Crystalization half-time experiments show that the addition of plastomer does not seem to hinder the polypropylene crystallization process. Finally, SEM micrographs are provided showing the dispersion of plastomer in an injection molded container.
Shear Stress Nucleation in Microcellular Foaming Process
The effect of shear stress on the foaming process has been studied using the Foaming Process Simulator developed previously. The polymer samples were saturated with gas in the test chamber. A rotor was used to apply shear stress to the polymer samples. Foams were obtained by releasing the pressure quickly. Polystyrene, filled and unfilled, was used as the material. The cell density was analyzed with a scanning electron microscope. It was found that the cell density was significantly increased by introducing shear stress. The higher the shear stress the more significant the effect. A cell stretch model has been developed to explain the cell nucleation enhancement with shear stress. The nucleation sites are stretched under the shear stress. The stretched nuclei are much easier to expand for cell formation due to their larger surface areas and non-spherical shapes. The model prediction shows the same tendency of the effect of shear stress observed in the experiment. The key issue with shear stress nucleation is the transformation of mechanical shear energy into surface energy.
Application of the Time Temperature Shift Principle to the Material Behaviour of Rubber under High Deformations
For the finite element analysis, the stress/strain behaviour of the material has to be given in mathematical formulations (material models). These material models include parameters, which have to be determined by material testing. The material testing has to be carried out at time/temperature conditions, which correspond to those of the rubber part. Depending on the number of different time/temperature conditions, this can lead to a time and costs consuming test effort. This paper describes the possibility of test effort reduction for a wide range of time/temperature conditions with a new method, which uses the time temperature shift principle (TTS-principle). Examples are presented for three rubber materials (NR, ACM and NBR/NR) using this new method in conjunction with the WLF-equation and the van't Hoff-equation.
Introducing New Injection Molding Technologies into Small and Medium-Sized Enterprises
Special injection molding techniques are well-suited to provide small and medium-sized injection molders with a technological advantage over their competitors. On the other hand the introduction of special processes demands careful and detailed planning in order to be successful, a requirement that often overburdens these enterprises, whose reduced personnel resources often do not permit the elaboration of a thorough concept. This contribution shows a systematic approach of how the project of implementing a new injection molding technology can be structured, regarding not only the technological, but also organizational and personnel-related aspects and the interconnections between them. A choice of these aspects is listed in Fig. 1.
Thermoforming Low Density Glass Reinforced Thermoplastic Sheet
Experimental studies were performed to assess the thermoformability of low-density polypropylene sheets reinforced with long discontinuous glass fibers. The effects of material parameters (glass fiber loading and sheet basis weight), mold parameters (cavity depth), and processing parameters (sheet temperature, and pressure) on part thickness, and glass fiber distribution were evaluated. The results indicate that, for the parts studied, pressure assist is required for thermoforming. Part characteristics were observed to be reproducible and constant over a wide range of sheet temperatures and pressure assist levels. Part dimensions were compared with those obtained using a thermoforming simulation package developed at the National Research Council's Industrial Materials Institute. Simulation results show that volume is not conserved when this low density material is thermoformed.
Chraracterization of Properties of Polypropylene Modified with Elastomers Based on Metallocene Catalyst Technology for Automotive Applications
The fast growing Indian automobile industry has accepted polypropylene (PP) and ‘value addded’ compounded polypropylene based products for wide range of application. Modern fuel-efficient car seen on Indian roads have accepted PP and PP-based compounds. Almost 30 kg of PP and PP based compounds find their way wide range of automobile components like bumpers, instrument panel, pillars, trims, brackets and consoles. For these application PP is modified with elastomers and/or fillers to achieve the best possible balance of melt flow and impact stiffness. Traditionlly, Indian compounding industry has worked with elastomers bazed on Ziegler-Natta catalyst technologies such ethylene propylene diene rubber (EPDM). The metallocene catalyst technoloogies has brought about a revolution in the field of elastomers. These are wide range of MFI, moony viscosity, refractive indices and mechanical properties “tailor made” to suit different applications.
Micro Assembly Injection Molding - Mold and Processing Technology
Micro injection molding is a suitable process not only for the production of microstructures, but for the assembly of microsystems as well. For that specific process, which is based on two-component and insert technologies, an appropriate mold technology has been developed. The process parameters are determined by several sensoric elements, including an endoscopical device. During the investigations the process is characterized with regard to the influence of temperatures, injection parameters, material combinations, as well as the behavior and influence of inlay parts. Different test structures are presented, for example two-component hinges, functional fluidic structures and microoptical fibre connections.
In-Mold Film Decoration - Advanced Process Technology for Innovative Applications
The requirements on the optical design and exclusiveness of molded parts particularly with regard to the automotive industry and consumer products place high demands on the injection molding process. The in-mold film decoration process is a technique to produce film-decorated, injection molded parts. High surface quality and a flexible surface design may be achieved by various kinds of decoration materials in combination with the advantages of a large scale integration and a highly automated production. New product development tools are necessary to fulfill the demands on quality and to seize new application opportunities despite of the increasing economical and ecological demands.
Gas-Assisted Rubber Injection Molding
Gas-assisted injection molding (GAIM) is not only for thermoplastics, which are limited in their physical properties, an interesting manufacturing technique, but also for rubber. In rubber processing, GAIM is an alternative to conventional manufacturing methods like extrusion. Using GAIM, the manufacture of highly integrated media ducts or hollow sealing systems is possible in one shot, which means a reduction of costs. Due to the different processing characteristics of rubber, the experience gained with GAIM in thermoplastics processing are not directly transferable. In this paper examinations about setting parameters, mold design, required material properties and equipment are presented.
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