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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Recycling

Various topics related to sustainability in plastics, including bio-related, environmental issues, green, recycling, renewal, re-use and sustainability.

E-Coat Sustainable Long-Fiber Thermoplastic Composites for Structural Automotive Applications

Raman Chaudhari, September 2008

Polypropylene and glass fibre (PP/GF) based Long Fibre Reinforced thermoplastics (LFT) are nowadays established as state of the art materials for semi-structural applications in the automotive industry. However PP/GF LFT materials are limited for producing automotive components for use in general assembly. The use of LFT based components for structural applications and their implementation directly into the body in white assembly is still a challenge for the automotive industry. In order to develop LFT materials for such applications a feasibility study to investigate the e-coating process sustainability of LFT materials was conducted. The current article addresses the developed LFT formulations and their basic mechanical properties. For this purpose polyamide / glass fibre (PA/GF) based LFT materials were thoroughly investigated. The change of mechanical performance of the LFT materials due to applied temperatures of the e-coating process was investigated by benchmarking of non-temperature-treated against tempered LFT specimens. In addition the combined influence of temperatures and chemicals on the LFT properties was evaluated by running the LFT specimens through the actual painting line that included e-coating and subsequent painting and drying processes. Finally it was found that it is possible to manufacture LFT parts capable of withstanding the e-coating process without causing major changes in the performance of the LFT materials.

High Performance Plastic Components for Engine Mount Applications

Hans-Juergen Karkosch, Holger Klink, September 2008

In the face of dwindling resources rising energy prices and increasing environmental pollution reductions in consumption and emissions are topics of increasing importance in all fields of technology. To achieve these goals specifically in the automotive industry new engine concepts are needed in connection with thorough-going implementation of lightweight construction. Whereas weight-optimized plastics components are already utilized in many vehicle subsystems and components steel and/or aluminum structures are usually used for load-bearing structural elements. This statement also applies fundamentally for the engine mounting subsystem. In this area plastics components have been used previously only for subordinate moderately loaded semi-components. Now for the first time a mechanically highly-loadable torque reaction mount has been conceived as a plastics structural part and implemented in the series production of a vehicle with a transverse-mounted engine. In addition to weight reduction it also helps create a more advantageous load distribution on the axles. Load reduction on the front axle has positive effects on driving dynamics and safety. The paper begins by stating fundamental requirements for components of engine mounting systems. The principle procedure in developing load-bearing plastics components includes the topics of integrative simulation laboratory component tests and in-vehicle testing.

Lightweight Structural Parts with Rigid Integral PUR Foams

Stephan Schleiermacher, September 2008

With climate change and the current situation regarding energy and environmental policy dominating the agenda car manufacturers are faced with the complex problem of drastically lowering the fuel consumption of their vehicles in order to reduce CO2 emissions. One way of tackling the problem is to pursue a consistent strategy of lightweight construction. Self-activated as well as thermally activated rigid integral polyurethane foams from BaySystems can help to realise reductions in weight. They are ideal for use in structural parts. The presentation covers some of their state of the art solutions and techniques followed by a vision of a new composite design for roof modules which combines the aforementioned polyurethanes and their processing technologies with a sprayed polyurethane barrier layer.

Natural Fibers Plastic Composites for Automotive Applications

Jay Amarasekera, September 2008

The use of natural fibers in composite plastics is gaining popularity in many areas and particularly the automotive industry. The use of natural fibers in polymers can provide many advantages over other filler technologies and areas of application appear limitless. The automotive industry is currently shifting to a “green” outlook as consumers are looking for environmentally friendly vehicles. Natural fibers are a renewable natural resource and are biodegradable which is an important characteristic for components that must be disposed of at the end of their useful life. They are recyclable and can be easily converted into thermal energy through combustion without leaving residue. Among the natural fibers with potential application as reinforcement for polymers curauá fiber is one that recently received special attention from researchers. Curauá is a plant from the Bromeliad family cultivated in the Brazilian Amazon region. The fiber is extracted from its leaves providing a high mechanical strength over traditional fibers like sisal jute and flax. We have developed thermoplastic composites using either curauá fiber or wood flour. These materials provided a lighter weight product with good physical properties and unique surface aesthetics. This paper reviews the properties of these bio composites in comparison with glass and mineral filled products. The products were tested in some automotive applications and the results will be discussed.

New Methods to Produce Reinforced Polyamide-6 for Improved Material Properties in Engineering Plastic Applications

Ab van Geenen, September 2008

Polyamide-6 is widely used in many mechanical applications also in automotive replacing more and more traditional materials such as metals thermosets and elastomers. Good process ability along with outstanding physical properties also long term stability under tough conditions and a high value recycling ability make this thermoplastic material also commercial interesting for new demanding machinery parts. A broad variety of materials is achieved by producing PA-6 “in situ” by anionic polymerisation of Caprolactam which can be performed on extruders on RIM machines or in different casting processes. Nano-Clay or Glass fiber reinforced granules short or long-glass fiber reinforced molded parts glass-mat reinforced manhole covers or wind turbine blades are some examples of Brüggemann’s AP-Nylon® Material applications completed by NYRIM® the wide range impact modified grades. This paper gives an overview of the new developments in this field we were involved in during the last 2 years.

Opportunities and Development of Bio-Based Materials for SMC (Sheet Molding Compound)

Dwight Rust, September 2008

Current and future changes in the automotive industry present an increased opportunity for thermosets. Bio-based materials in SMC present an opportunity to help automotive manufacturers in the US to meet the 2020 Freedom Car weight and 14.9 km/L (35 mpg) CAFÉ requirements as currently mandated by the federal government. Developments in the industrial bio-technology sector are also leading to knowledge to provide opportunities to use bio-based materials to provide solutions using SMC to lower costs and weight. The National Composite Center is leading collaborative efforts in the development of biobased resins fillers and reinforcements. The result of these collaborations in both biobased materials and the interface of nano technology are presented. The opportunities exist for the development of biobased materials to produce a lighter weight SMC.

Renuva Soy-Based Polyol RIM for Automotive Exterior Applications

Dow Automotive & Magna/Decoma International, September 2008

There are many formative trends in today’s OEM composite marketplace which are driving the investigation and development of alternative feedstocks from natural or renewable resources in the plastics industry such as environmental sustainability reduced dependence on crude oil and the high cost of petroleum-based derivatives. This paper will describe the development of a novel soy oil based polyol (under the RENUVA™tradename) which has technological advantages in terms of odour physical properties compatibility and processability in polyurethane application over existing soy-based polyol. The paper will further describe the development partnership undertaken by The Dow Chemical Company and Polycon Industries (a division of Magna International) to utilize this “green” polyol to develop a Reaction Injection Moulded (RIM) polyurethane formulation suitable for painted exterior applications. The paper will outline the development aliterations done to accomplish this goal and to maximize the soy-based polyol content in the RIM composite for physical property and processability optimization. The paper’s conclusion will demonstrate the viability of a 50% soy-based polyol solution to meet the processability paintability and physical property specification of a current Original Equipment Manufacturer (OEM) RIM program through direct comparison of extensive trial work done on series production fascia tooling at Polycon. The paper will extend this development work into potential opportunities for the RIM polymer involving exterior composite applications for heavy equipment or agricultural machinery where natural resource feedstocks would have clear market desirability.

A PLASTICS EDUCATION OUTREACH PROGRAM FOR MIDDLE SCHOOL AGED GIRLS

Elizabeth Dell, May 2008

This paper describes a plastics education program for middle school girls. The goals of the program were to expose the girls to science and engineering and to educate them about plastics. The program included an overview of plastics and hands-on experimental investigations. Experiments included making a polymer environmental issues and the structure and properties of polymers. In addition to giving detailed descriptions of the program this paper includes recommendations for further improvements of the program.

ADVANCED RESULTS OF A PROSPECTIVE STUDY ON FLEXIBLE PLASTIC PACKAGING IN ANDEAN COUNTRIES: SCENARIOS AND STRATEGIES FOR THE PERIOD 2003 ƒ?? 2013

María del Pilar Noriega , Juan Diego Sierra, May 2008

A prospective study on flexible plastic packaging was carried out in Andean Countries with the participation of two plastic research institutes and 20 companies including raw material manufacturers processors converters and end users.The inputs of this prospective study were a review of the state of the art on flexible packaging a benchmarking study considering the 10 most important companies a study using the Delphi method with national and international experts who identified the key variables to the development and progress of the flexible packaging in the region and workshops.This study generated new projects and products on the field of barrier smart and active packaging biodegradable materials among others; it shows that the Andean region is applying R&D and technological alliances in its industrial processes.

BENEFITS OF AN ENERGY USAGE INDICATOR FOR INJECTION MOLDING SIMULATION

Paul Brincat , Russell Speight, May 2008

With growing concern regarding our environmental impact greater focus has been placed on ways we can reduce our impact by improving our decisions designs and processes. The use of injection molding simulation has been shown to reduce material consumption reduce production scrap assist in recycling existing materials create better quality products that have a prolonged life and reduce energy consumption required during the manufacturing process. This paper will present the benefits of an additional measure called an Energy Usage Indicator that can assist part designers using injection molding simulation to easily identify the processing requirements of a polymer material.

BENEFITS OF AN ENERGY USAGE INDICATOR FOR INJECTION MOLDING SIMULATION

Paul Brincat , Russell Speight, May 2008

With growing concern regarding our environmental impact, greater focus has been placed on ways we can reduce our impact by improving our decisions, designs and processes. The use of injection molding simulation has been shown to reduce material consumption, reduce production scrap, assist in recycling existing materials, create better quality products that have a prolonged life and reduce energy consumption required during the manufacturing process. This paper will present the benefits of an additional measure, called an Energy Usage Indicator, that can assist part designers using injection molding simulation to easily identify the processing requirements of a polymer material.

FAILURE ANALYSIS OF A PLASTIC SLIDE VALVE ASSEMBLY

Ahamed Shabeer, May 2008

Premature cracks were observed during service in the slide valve assembly molded from an acrylonitilebutadiene- styrene resin. The investigation focused on the determination of nature and cause of the failure. The results obtained during the evaluation indicated that the failure was due to environmental stress cracking which occurred as a consequence of the presence of the residual stress and the stress cracking agent. This paper will focus on the testing used to characterize the failure mode and identify the cause of the cracking of the slide valve assembly.

FAILURE ANALYSIS OF A PLASTIC SLIDE VALVE ASSEMBLY

Ahamed Shabeer, May 2008

Premature cracks were observed during service in the slide valve assembly molded from an acrylonitilebutadiene- styrene resin. The investigation focused on the determination of nature and cause of the failure. The results obtained during the evaluation indicated that the failure was due to environmental stress cracking, which occurred as a consequence of the presence of the residual stress and the stress cracking agent. This paper will focus on the testing used to characterize the failure mode and identify the cause of the cracking of the slide valve assembly.

CHARACTERISATION OF BIOACTIVE POLYCAPROLACTONE

P. Douglas , G. Walker , D. Jones, May 2008

The effects of a bioactive [Nalidixic Acid - NA] and copolymers [Poly L-Lactic Acid (PLLA) and Polyethylene Glycol (PEG)] on the drug release morphology and mechanical properties of Poly -caprolactone [PCL] were studied. Release of NA increased with the addition of copolymers in the PCL with a maximum release of 55% in a blend containing 5%w/w each of PLLA PEG and NA. The filler effect of the NA was illustrated by an increase in viscosity in the blends. FTIR spectrums showed the blending of the PCL and the NA. The carbonyl bond present in the biodegradable polymers PCL and PEG allowed for some degree of miscibility also confirmed by the decrease in thermal conductivity from 0.26 to 0.2 Wm'C. Mechanical properties were decreased by the copolymers with the Young's Modulus decreasing by 15%.

CHARACTERIZATION OF BIODEGRADABLE ACRYLIC ACID GRAFTED POLY(?-CAPROLACTONE)/CHITOSAN BLENDS

Yeh Wang , Jiang-F. Yang, May 2008

Blend films of acrylic acid grafted polycaprolactone (PCLgAA) and chitosan (CS) with different compositions were prepared from aqueous acetic acid solution. DSC measurements showed that the melting temperatures and enthalpies of the blends decreased with increasing CS content. From FTIR results it can be seen that the amino groups of CS form covalent bonds with the carboxylic groups of PCLgAA in addition to hydrogen bonds between these components in the blends. Though the crystal structure of the PCLgAA component was not changed as proved by WAXD results blending CS suppressed the crystallinity of the blends. Furthermore the ductility of CS was increased during tensile testing in PCLgAA/CS blends due to enhanced affinity between the two components. However PCLgAA/CS blends showed greater resistance than PCL/CS blends to biodegradation in an enzymatic environment.

CHARACTERIZATION OF BIODEGRADABLE ACRYLIC ACID GRAFTED POLY(?-CAPROLACTONE)/CHITOSAN BLENDS

Yeh Wang , Jiang-F. Yang, May 2008

Blend films of acrylic acid grafted polycaprolactone (PCLgAA) and chitosan (CS) with different compositions were prepared from aqueous acetic acid solution. DSC measurements showed that the melting temperatures and enthalpies of the blends decreased with increasing CS content. From FTIR results it can be seen that the amino groups of CS form covalent bonds with the carboxylic groups of PCLgAA in addition to hydrogen bonds between these components in the blends. Though the crystal structure of the PCLgAA component was not changed, as proved by WAXD results, blending CS suppressed the crystallinity of the blends. Furthermore, the ductility of CS was increased during tensile testing in PCLgAA/CS blends due to enhanced affinity between the two components. However, PCLgAA/CS blends showed greater resistance than PCL/CS blends to biodegradation in an enzymatic environment.

DEVELOPMENT OF ANTIMICROBIAL PLA NANOCOMPOSITES WITH SILVER CONTAINING LAYERED NANOCLAYS FOR PACKAGING AND COATING APPLICATIONS

M.A. Busolo , M.J. Ocio , J. M. Lagaron, May 2008

This paper presents the development and characterization of the antimicrobial activity of a novel family of commercial food contact compliant silver-modified nanolayered clays and of their nanobiocomposites with polylactic acid. The antimicrobial nanolayered clays showed an antimicrobial effectiveness of 99.99% against Gram-negative Salmonella spp. In addition the PLA-clay nanocomposite also showed a significant antimicrobial activity and a synergistic water vapour permeability reduction of 32% with respect to neat PLA. The results indicate that these novel active nanolayered fillers can potentially exhibit numerous applications in plastic and bioplastic packaging and coatings where simultaneous barrier and antimicrobial performance are desirable.

DEVELOPMENT OF ANTIMICROBIAL PLA NANOCOMPOSITES WITH SILVER CONTAINING LAYERED NANOCLAYS FOR PACKAGING AND COATING APPLICATIONS

M.A. Busolo , M.J. Ocio , J. M. Lagaron, May 2008

This paper presents the development and characterization of the antimicrobial activity of a novel family of commercial food contact compliant silver-modified nanolayered clays and of their nanobiocomposites with polylactic acid. The antimicrobial nanolayered clays showed an antimicrobial effectiveness of 99.99% against Gram-negative Salmonella spp. In addition, the PLA-clay nanocomposite also showed a significant antimicrobial activity and a synergistic water vapour permeability reduction of 32% with respect to neat PLA. The results indicate that these novel active nanolayered fillers can potentially exhibit numerous applications in plastic and bioplastic packaging and coatings where simultaneous barrier and antimicrobial performance are desirable.

SCREW DESIGN CONSIDERATIONS FOR BIOBASED POLYMERS

Edward Steward, May 2008

The family of biobased polymers is ever growing in number and in popularity and the extruder/screw manufacturing businesses need to keep abreast of the machinery requirements of these polymers to insure that efficient processing is understood. This paper will look at the extrusion parameters and logic that are important to determining the most efficient screw designs and extrusion operating conditions for processing biopolymers. Vented and non-vented operation will be discussed. PLA data will be used as the basis for the conclusions.