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.

EFFECT OF ENVIRONMENTAL STRESS CRACKING AGENTS ON FATIGUE AND CREEP OF A MDPE PIPE

R. Ayyer , A. Hiltner , E. Baer, May 2008

The effect of concentration of Igepal CO 630 on slow crack propagation in MDPE pipe was investigated. The kinetics and mechanism of crack propagation in fatigue at R=0.1 and creep at 50 ?øC were compared to those in air. The fatigue and creep behavior followed the same stepwise crack growth mechanism as in air at all the concentrations used. As the concentration increased to 0.01 vol. % the creep lifetime decreased significantly whereas the lifetime in fatigue gradually increased. At higher concentrations the lifetime was similar in creep and fatigue.

THERMAL DEGRADATION OF FIBER-REINFORCED BIO-BASED RIGID POLYURETHANE FOAMS

Andres Garcia , Patricia Alvarado , Maria Sibaja , Guillermo Jimenez , Jose Vega, May 2008

Rigid polyurethane (PU) foams were prepared by a multi- step procedure using a polyol blend of poly(ethylenglycol) PEG-200/pineapple molasses and 4 4'-diisophenylmethane diisocyanate (MDI) with a NCO/OH ratio of 1.2. Such material was reinforced with fibers from banana rachis with a fiber composition ranging from 18% to 40% wt.Thermal and themooxidative degradation properties of these composites were assessed. Thermal degradation of PU60 showed the highest polymer lifetime values.

TOWARDS QUALITY PRODUCTS FROM BIO-BASED PLASTICS

Rolf Koster, May 2008

The importance of three inter-dependent factors, i.e., (1) materials, (2) manufacturing, and (3) design and engineering, is generally recognized. All factors are indispensable and equally important for product development. Manufacturing is often the least structured factor and many designers and materials experts do not consider themselves capable to deal with it. Fortunately, expertise is sufficiently available and the best professionals are able to utilize plastics expertise properly in collaborative product development.

FEASIBILITY STUDY OF THE USE OF DDGS PLASTIC COMPOSITES

David Grewell , Gowrishankar Srinivasan , Maria Baboi, May 2008

Recently, an increase in the demand for ethanol as a fuel additive has resulted in a dramatic increase in its coproducts namely distiller’s dried grains with solubles (DDGS). This work studied a composite of DDGS and conventional petrochemical plastics (polyvinyl chloride) for applications in windows construction. The goal was to characterize the composite and its processibility for “green” plastics. The experiments showed that DDGS can be effectively extruded with PVC; at low filler levels (5- 10%) of DDGs strengthening of the PVC was seen. However, higher filler levels (>10%) of DDGS degraded the mechanical properties of PVC/DDGS composites. Also, ground DDGS perform better as reinforcement agents compared to standard DDGS. Caustic pretreatment was also studied and it was found not to effect the mechanical properties significantly. Also, the addition of PVA had little effect on the properties of the composite.

NEW LOW GLOSS POLYCARBONATE BLENDS FOR AUTOMOTIVE APPLICATIONS

Marina Rogunova , Jim Mason , Robyn Francis, May 2008

Automotive original equipment manufacturers are consistently looking for low-gloss materials for interior applications that can stand up to years of wear and tear and environmental exposure yet maintain aesthetic quality without painting. Bayblend?? LGX 300 resin is specifically developed for automotive interior applications requiring a material that is inherently low in gloss with extra flowability, good weathering and good scratch and mar resistance. Another important attribute of Bayblend LGX 300 is its low-emission characteristic, which is particularly important as automotive manufacturers strive to reduce the levels of VOCs in their automobiles to improve the interior environment and meet federal regulations. Because LGX 300 resin is a low gloss, high-flow polycarbonate (PC) blend with good heat and impact performance; thin-wall part design can be achieved without painting.

NEW LOW GLOSS POLYCARBONATE BLENDS FOR AUTOMOTIVE APPLICATIONS

Marina Rogunova , Jim Mason , Robyn Francis, May 2008

Automotive original equipment manufacturers are consistently looking for low-gloss materials for interior applications that can stand up to years of wear and tear and environmental exposure yet maintain aesthetic quality without painting. Bayblend® LGX 300 resin is specifically developed for automotive interior applications requiring a material that is inherently low in gloss with extra flowability good weathering and good scratch and mar resistance. Another important attribute of Bayblend LGX 300 is its low-emission characteristic which is particularly important as automotive manufacturers strive to reduce the levels of VOCs in their automobiles to improve the interior environment and meet federal regulations. Because LGX 300 resin is a low gloss high-flow polycarbonate (PC) blend with good heat and impact performance; thin-wall part design can be achieved without painting.

NOVEL NANOBIOCOMPOSITES WITH ANTIMICROBIAL AND BARRIER PROPERTIES OF INTEREST IN ACTIVE PACKAGING APPLICATIONS

M.D. Sanchez-Garcia , E. Gimenez , M.J. Ocio , J.M. Lagaron, May 2008

It is well-known that the nanocomposites technology can significantly enhance among others the thermal mechanical and barrier properties of plastics. It is also known that most bioplastics including the thermoplastic biopolymers have lower than desired levels for certain properties which makes their use in certain packaging applications problematic. The combination of active technologies such as antimicrobials and nanotechnologies such as nanocomposites can synergistically lead to bioplastic formulations with balanced properties and functionalities for their implementation in packaging applications. The present work presents the development and characterization of novel nanocomposites of polycaprolactone (PCL) with enhanced barrier properties and with controlled-release of biocide natural extracts.The antimicrobial nanocomposites of biodegradable materials were prepared in solution by a casting method.The morphology of the biocomposites was visualized by transmission electron microscopy (TEM) and by Atomic Force microscopy (AFM) the thermal properties were investigated by differential scanning calorimetry (DSC) and the solubility and kinetics of released biocide were determined by Attenuated Total Reflection Fourier Transformed Infrared (ATR-FTIR) spectroscopy. Water and limonene barrier properties were also enhanced in the biocomposites.

PROCESSING AND BLENDS OF BIOPLASTICS

Stephen P. McCarthy, May 2008

Biopolymers are generally defined as polymers that are found in nature derived from nature or utilized as medical implants. Polymeric biomaterials which are utilized as medical implants are typically characterized for enduse performance as well as processability. While lactic acid is found in the human body polylactic acid is derived from natural resources and utilized as medical implants. This paper will utilize poly(lactic acid) as an example of a bioplastic where the morphological and isomeric structure has an influence on end-use properties such as mechanical properties biodegradability and biocompatibility.

RESPONSIVE STARCH-BASED MATERIALS

J. L. Willett, May 2008

Starch a low-cost annually renewable resource is naturally hydrophilic and its properties change with relative humidity. Starchƒ??s hygroscopic nature can be used to develop materials which change shape or volume in response to environmental changes (eg humidity). For example starch-based graft copolymers have been produced using reactive extrusion for potential superabsorbent and hydrogel applications. Besides absorbing large quantities of water some of these copolymers display large volume changes in aqueous alcohol depending on solvent quality. Other examples include starch-poly(methyl acrylate) graft copolymer films which shrink at high humidities. Various levels of shrinkage can be triggered in response to changes in relative humidity. (AAm) and varying amounts of 2-acrylamido-2-methyl- 1-propane sulfonic acid (AMPS) display various degrees of swelling in aqueous solutions and approximately discontinuous volume changes in aqueous ethanol solutions over narrow ethanol concentrations. Blown films of starch-PMA graft copolymers display controlled shrinkage in response to increases in relative humidity.

SOLID STATE SHEAR PULVERIZATION AND CHEMICAL RECYCLING OF POLYMERS

Hossein Hosseini , Mohammad Mosaddegh , Behzad Shirkavand-Hadavand, May 2008

Solid state shear pulverization is a novel technology in polymer processing for production of new polymeric materials. By implementation of this technology various processes such as polymer recycling compounding and improving of mechanical-chemical properties of polymers can be enhanced. This is a continuous and one-stage process with low energy consumption. During this process polymers are subject to high pressure and shear forces. In this paper this technology and its applications to polymer processing is perused. At the end recycling of PET wastes by this technology is presented that have higher efficiency in comparison with existing methods.

TOWARDS QUALITY PRODUCTS FROM BIO-BASED PLASTICS

Rolf Koster, May 2008

The importance of three inter-dependent factors i.e. (1) materials (2) manufacturing and (3) design and engineering is generally recognized. All factors are indispensable and equally important for product development. Manufacturing is often the least structured factor and many designers and materials experts do not consider themselves capable to deal with it. Fortunately expertise is sufficiently available and the best professionals are able to utilize plastics expertise properly in collaborative product development. For bio-based plastics which are rapidly emerging in some specific markets it is already clear that the relation between the three factors is different and more varied than for the currently well-known plastics. Critical factors for increased successful application of bio-based plastics will be product manufacturing and the expectations of applicators and consumers. From interviewing a variety of professionals it was found that clear true and complete information is currently not accessible for most whereas some assumptions are not realistic or not correct particularly the ones related to degradability and to environmental effects. Better and well-structured information will be needed resulting in fulfillment of elementary consumer expectations.

NatureWorks® Polylactide Biopolymer: A Sustainable Polymer for the 21st Century

Richard C. Bopp, March 2008

What is Impact of PLA Biopolymer on Corn Supply and Uses? Based on 2001 Harvest of 9.8 billion bushels (NCGA Data): Export 20%; Alcohol 1%; Other 2%; HFCS 6%; Sweeteners 2%; Starch 3%; Ethanol 7%; PLA 0.6%; Feed 59%

Polymeric Chain Extenders and Biopolymers

Roelof van der Meer, BASF Nederland, Volker Frenz, BASF AG, Germany, Marco Villalobos, Abiodun Awojulu, BASF Corporation, Wyandotte, MI, March 2008

Engineering polymers based on condensation thermoplastics like PET, PBT, Polyamides, Polycarbonates and Biopolyesters have to be reprocessed during recycling at very high temperature, where degradation of these polymers are extremely rapid. As the result of this regradation, the possiblities for reprocessing internal process regrind as well as postconsumer - recycle reclaims back into demanding application is very limited. The polymeric chain extender offer a possibility to rebuild molecular weight and melt strengths of these polyester, blends and related product and open a new window of opportunity for recycling.

Recycling of packaging products including biodegradable plastic materials such as PLA foam, plastic fibers and non-woven materials

Alberto E. Ramírez, March 2008

PALLMANN develops and manufactures size reduction machines and complete systems for the plastics and recycling industries. We have over 100 years in the industry, one of the largest R&D facilities, and a firm commitment to the sustainability movement. PALLMANN continues to offer innovative solutions to the industry, including Size Reduction technology and Agglomeration of Thermoplastics with our Plast- Agglomerator. Our innovating technology is presently applied in such processes as reclamation of carpet waste, packaging products including biodegradable plastic materials such as PLA foam, plastic fibers and non-woven materials, films, etc.

Can I Run PLA on My Existing Extruders? A Practical Application Guide

Edward L. Steward, March 2008

PLA (Polylactide resin) is one of the bio-plastics that has found some product applications and seems to be an extrudable material of growing interest. Any polymer that is made from a renewable resource and that it is a degradable and/or environmentally friendly material seems to gain favor in some markets, especially if it can be processed on existing machinery. This paper will discuss the requirements to efficiently extrude PLA on a single screw extruder with an optimum screw design and processing conditions. Different sizes of extruders will be looked at to give some guidelines as to the required equipment to successfully extrude this material.

Degradation of Biodegradable, UV-degradable and Oxodegradable Plastics with In-vessel Food Waste Composting Environment

Joseph Greene, Ph.D., Department of Mechanical Engineering Mechatronic Engineering, Joseph Greene, Ph.D., Department of Mechanical Engineering Mechatronic Engineering, and Manufacturing Technology, California State University and Fengyu Wang, NWS Jepson Prairie Organics Inc., March 2008

Biodegradable and oxodegradable plastics degraded in an in-vessel compost operation along with food waste from San Francisco, California. Biodegradable plastics included, corn starch based biobag, Mirel PHA bag, BioTuf Ecoflex bag, Husky corn starch based trash bag, PLA lids, sugar cane lids, and Kraft paper. Also buried were polyethylene shrink-wrap, UV degradable plastic bag, and oxodegradable plastic bag. The samples were placed in perforated plastic sacks and mixed with food waste at NorCal and Jepson Prairie Organics (JPO) composting operation in Vacaville, California. After 180 days, the materials that completely degraded included PLA lids, Mirel bags, Ecoflex bags, Husky bags, and corn starch trash bags. Small fragments of sugar cane lids and Kraft paper were visible. The sugar cane and Kraft paper fragments were very moist and would disintegrate when picked up. The Kraft paper and sugar cane fragments did not completely biodegrade due to the lack of mechanical agitation while in the plastic sacks. If the materials were placed in the compost soil, higher degradation would occur due to better interaction with the compost soil. The oxo-biodegradable plastic bags, LDPE plastic bags and UV-degradable plastic bag did not experience any degradation and did not fragment into smaller pieces.

Development and Implementation of Soy-Based Foam in Automotive Applications

Cynthia M. Flanigan, Christine Perry, Deborah F. Mielewski, Ford Research and Advanced Engineering Laboratory, Ford Motor Company, Systems Division, Lear Corporation, March 2008

Using agricultural crops as material feedstock is becoming more prevalent as scientists search for alternative choices to petroleum based products. Soybeans are one crop within North America that is economical and readily available for use in plastic applications. Recently, we have been evaluating the use of soy as reinforcement and resin in a variety of polymer matrices, including flexible and rigid polyurethanes. Our main focus has been on using functionalized soybean oil in the manufacture and formulation development of flexible, polyurethane foams for seating applications. Soy-based foams reduce the environmental footprint compared with the manufacture of petroleum-based foams. These materials utilize a sustainable material, decrease our dependency on petroleum and reduce carbon dioxide emissions. Ford Motor Company has researched methods to overcome several technical issues such as reducing odor in the foam and maximizing soy content in foam formulations, while meeting rigorous, automotive interior applications. In a partnership between Ford Motor Company and Lear Corporation, we have demonstrated the feasibility of formulating and processing soy-based polyurethane systems that have the key properties required for automotive interior and seating foam applications. Prior to launch of this soy technology, numerous processing trials were completed on headrest, armrest and seating applications. We will review the main steps required in moving the technology from a laboratory research setting to production environment and launch of the soy technology in 2008 Mustang. We will also discuss the technical and commercial challenges and benefits of implementing soy-based foam.

Recycling of Long Glass Fiber Reinforced, Padded Instrument Panels

Robert Egbers, Sr., March 2008

The punched sections of composite substrate/foam/skin (punch outs) have traditionally gone to landfill, typically at a cost of $0.05/lb. to the Tier 1 supplier. Wipag Recycling in Germany has developed a process whereby the substrate material is recovered from the composite structure, separating the resin from the foam and skin. The resin has 99.8% purity and can be subsequently blended back into virgin resin for production at a specified percentage without statistically varying the physical properties of the LFPP IP substrate. The WIPAG laminate separation process has been in commercial operation at American Commodities Inc. (ACI) in Flint, MI for the past 7 years albeit with SMA, PC/ABS and TPO substrates. With regard to recycling LFPP, traditional wisdom dictates that the material properties of the resin will be reduced after each heat history due to glass fiber length attrition, caused from the processing of the material. This study shows that up to 30% of resin reclaimed from the composite substrate can be added to virgin material with a minimal effect on the properties of the final part.

Automotive Interior Material Recycling and Design Optimization for Sustainability and End of Life Requirements

Steven R. Sopher, March 2008

Advances in the field of polyolefin resins in the area of PP copolymers, PE homopolymers, and PP & PE blends have allowed for the creation of new and improved polyolefin bead foams. These polyolefin bead foams are capable of improved performance due to the advancements that have been made in the area of polyolefin resin catalyst systems and additives. The benefits of polyolefin bead foams allow for lower densities to be used where higher density extruded foams are currently being utilized. There is a move in the automotive industry to promote the use of sustainable products. Sustainability considerations in automotive design must include a variety of factors. These include: • Weight reduction • Commonization of materials • Use of more environmentally friendly materials • Ease of disassembly at vehicle’s End-Of-Life • Consideration of RoHS requirements • Compliance to OEM, Federal and Industry regulations • Recyclability of materials and current recycling stream • Component design and performance requirements • Vehicle and occupant safety While evaluating all of these considerations when designing for sustainability, it is necessary to understand the allowances for performance and cost trade-offs as they relate to meeting the needs of both the OEM and end user (or customer). This paper will explore the industry trends, particularly those published by the OEM’s as they relate to designing for sustainability and recyclability. This paper will compare some of the newer industry recycling guidelines, as well as vehicle End-Of-Life dismantling requirements. This paper will also explain the intention of the newer vehicle component part guidelines for sustainable development as they relate to automotive component design and ease of disassembly and recyclability. Case studies will be presented to evaluate component part design and the move toward the use of more commonly recycled and recyclable products. Industry trends will also be reviewed as they apply to market demand for more environmentally friendly materials. The pros and cons of using some of the new biobased materials will also be compared and contrasted.

Sustainable Automotive Component Manufacturing Solutions

Gordon C. Miller, March 2008

Being sustainable means that a product or service meets both today’s needs and results in minimized burden to our children and their children and to the environment for the future. This paper will present a proven alternative to environmental issues such as heavy metals used chrome plating for application to plastic components in the global automotive, light truck, and heavy truck industry. It will highlight how this technology, Fluorex® bright film, further contributes to a “greener” environment by eliminating environmental hazards and residual footprints from substances such as heavy metals by using film based solutions contributing to the development of lighter and potentially “greener” light weight vehicles. This translates in both better fuel economy in vehicles using this technology and reductions in emissions from the manufacturing processes. Other environmental benefits for other coating opportunities using Flourex® Paintfilm will be evaluated based on this technology that specifically involve more opportunities to minimize the environmental impact and improve recyclability while contributing to a more aesthetically pleasing environment by enhancing the appearance of vehicles worldwide. This is a solution for manufacturers to provide the appealing and marketable look of chrome or other pleasing surface characteristics on plastic components while being environmental compliant and responsible. This is a sustainable solution for coloring and coating – Fluorex® bright film and Fluorex® paintfilm – a “green” alternative to painting metal and plastic products that enhances the environmental benefits of plastics is both possible and here today.