Processing of Polymers

Description

Polymers are converted into finished products through a series of steps which include mixing in additives and various types of forming. Following an introduction to polymer science and its importance to various fields, the author describes these processes from a practical, application-oriented perspective. Global suppliers of raw materials, machinery and equipment are also given, making this book an invaluable resource for industry practitioners. Gives a concise overview of the types, properties and applications of the polymers most often used in industry. Details all major processing steps, from extrusion to vacuum moulding. Cover Half Title Also if interest Processing of Polymers Copyright Preface Contents 1. Introduction to Polymers 1.1 The World of Polymers Bibliography 2. Basic Chemistry of Polymers 2.1 What Are Polymers? 2.2 Polymer Categories 2.2.1 Polymer Microstructures 2.2.2 Lengths of Polymer Chains 2.2.3 Polymer Morphology 2.2.4 Polymer Behavior – Melting Point 2.2.5 Polymer Behavior – Mixing 2.3 Polymer Blends 2.4 Polymer Composites 2.5 Cellular Polymers 2.6 Engineered Plastics 2.7 Bioplastics 2.8 Important Common Polymers 2.9 Polymer Degradation 2.10 Polymer Waste Disposal Bibliography 3. Types of Polymers 3.1 Common Polymers 3.1.1 Polyethylenes 3.1.2 Polystyrenes 3.1.3 Polypropylenes 3.1.4 Polycarbonates 3.1.5 Polyvinyl Chloride 3.1.6 Polyurethanes 3.1.7 Melamine Formaldehyde 3.1.8 Acrylonitrile Butadiene Styrene Bibliography 4. Properties of Polymers 4.1 Importance of Properties 4.2 Thermal Properties 4.2.1 Thermal Diffusivity 4.2.2 Linear Coefficient of Thermal Expansion 4.2.3 Thermal Degradation 4.3 Mechanical Properties 4.3.1 Tensile Strength 4.3.2 Melting Point 4.3.3 Young’s Modulus of Elasticity 4.3.4 Glass Transition Temperature 4.3.5 Mixing Behavior 4.3.6 Polymer Degradation 4.3.7 Density 4.3.8 Fatigue Tests 4.4 Environmental Effects 4.4.1 Water Absorption 4.4.2 Chemical Degradation 4.5 Viscoelastic Materials 4.5.1 Density 4.5.2 Firmness 4.5.3 Time 4.5.4 Temperature 4.5.5 Humidity 4.6 Electrical Properties 4.7 Optical Properties Bibliography 5. Additives for Polymers 5.1 What Are Polymer Additives? 5.2 Effects of Additives on Polymers 5.2.1 Plasticizing Agents 5.2.2 Pigments, Dyes and Masterbatches 5.2.3 Stabilizers 5.2.4 Lubricants 5.2.5 Blowing Agents 5.2.6 Catalysts 5.3 Influence of Additives During Processing 5.3.1 Discoloration and Degradation 5.3.2 Improving Molding Processability 5.3.3 Improving Durability 5.3.4 Use of Lubricants 5.4 Functions of Some Additives 5.4.1 Antioxidants 5.4.2 Antistatic Agents 5.4.3 Biodegradable Plasticizers 5.4.4 Blowing Agents 5.4.5 External Lubricants 5.4.6 Fillers/Extenders 5.4.7 Flame Retardants 5.4.8 Heat Stabilizers 5.4.9 Impact Modifiers 5.4.10 Light Stabilizers 5.4.11 Coloring Agents 5.4.12 Reinforcements Bibliography 6. Useful Data for Processing Polymers 6.1 Important Parameters 6.2 Coloring of Polymers 6.2.1 Introduction 6.2.2 Theory of Colors 6.2.3 The Color Wheel 6.2.4 Primary Colors 6.2.5 Secondary Colors 6.2.6 Tertiary Colors 6.2.7 Warm and Cool Colors 6.2.8 Tints, Shades and Tones 6.3 Purging Colored Material from Production Machinery 6.3.1 Masterbatches 6.3.2 Universal Masterbatches 6.3.3 Liquid Colorants 6.3.3.1 Special Effects Liquid Colorants 6.3.4 Precolored Resins 6.3.5 Cube Blends 6.3.6 Colored Specialty Compounds 6.4 Electrical Power Calculations 6.5 Compressed Air 6.6 Water Requirements 6.7 Safety Factors 6.8 Quality Control 6.8.1 X–R Control Chart 6.8.2 P–Chart 6.8.3 An SPC System in Operation – An Example 6.9 Preventive Maintenance for Machinery and Equipment 6.10 Key Factors for a Processing Plant 6.11 In-House Laboratory 6.12 In-House Workshop 6.13 Granulators/Shredders for Recycling Plastic Wastes Bibliography 7. Lean Processing for Efficiency and Profitability 7.1 The Concept of Lean 7.1.1 Identifying Value 7.1.2 Map the Value Stream 7.1.3 Creating Flow 7.1.4 Establish a Pull System 7.1.5 Constant Improvement 7.1.6 Lean Versus Six Sigma 7.2 Guidelines to Thinking Lean 7.2.1 What Are the Benefits? 7.2.2 Continuous Improvement Initiatives 7.2.3 Push–Pull System 7.2.4 Kanban System Bibliography 8. Processing Systems for Polymers 8.1 Some Common Systems 8.2 Common Processing Systems for Thermoforming Resins 8.2.1 Extrusion 8.2.1.1 Some Types of Commercial Extruders 8.2.1.2 Co-Rotating Intermeshing Extruders 8.2.1.3 Counter-Rotating Nonintermeshing Extruders 8.2.1.4 Maintenance of Extruders 8.2.1.5 Some New Technologies in Extrusion 8.2.1.6 Recommended Shutdown Procedures 8.2.1.7 Recommended Restart Procedures 8.2.2 Injection Molding 8.2.2.1 Structural Web Injection Molding 8.2.2.2 Benefits of Structural Web Processes 8.2.2.3 Structural Foam Injection Molding 8.2.2.4 Hand-Operated Injection Molding 8.2.3 Blow Molding 8.2.4 Compression Molding 8.2.4.1 Transfer Molding 8.2.4.2 Applications 8.2.4.3 Molding Composites by Compression Molding 8.2.5 Dip Coating 8.2.5.1 Dip Coating Versus Dip Molding 8.2.5.2 Dip Coating Procedure 8.2.5.3 Hot Dip Coating in a Fluidized Bed 8.2.5.4 Hot Dip Coating in Vinyl Plastisol 8.2.5.5 Polymer Flock Spraying 8.2.6 Vacuum Forming 8.2.6.1 The Vacuum Forming Process 8.2.7 Direct Coating 8.2.8 Indirect Coating 8.2.9 Rotational Molding or Rotomolding 8.2.9.1 Solar-Powered Rotomolding Units Bibliography 9. Processing of Liquid Polymer Foaming Systems 9.1 Foaming Liquid Polymers 9.1.1 Polyvinyl Chloride Plastisol 9.1.2 Low-Density Polyethylene Foam 9.1.3 Integral Skin Foam 9.1.4 Direct Molded Foam Bibliography 10. Specialty Polymers and Polymeric Composites 10.1 What Are Specialty Polymers? 10.2 Applications of Specialty Polymers 10.3 Graphene – Properties, Processing and Applications in Brief 10.4 Graphene–Polymer Composites 10.5 Graphene Composites Can Reduce Atmospheric Pollutants 10.6 Fluoropolymer Specialty Insulation for Extreme Application Needs 10.7 Polyurethane Specialty Polymers 10.8 Electrical Conductivity of Conjugated Polymers 10.8.1 Flexible Conductive Film 10.8.2 Some Latest Automotive Specialty Polymers 10.9 Polymer Modified Bitumen 10.10 Reinforced Polymers with Coffee Chaff 10.11 Specialty Polymer Composites 10.12 Specialty Engineered Composites 10.13 Specialty Polymer Resins with Rice Hulls 10.13.1 Polymeric Composites with Rice Hulls for Injection Molding 10.13.2 Recommended Processing Guidelines 10.14 Expanded Polystyrene with Graphite 10.15 Polymeric Composites with Bamboo Fibers 10.16 New Polylactic (PLA) grade for 3D Printing Bibliography 11. Three Manufacturing Processes for Important Products 11.1 Molded Expanded Polystyrene Products 11.1.1 Preexpansion and Aging 11.1.2 Curing Phase 11.1.3 Molding Process 11.1.4 Shape Molding 11.1.5 Fabrication 11.1.6 Some EPS Molded Products 11.1.7 Expanded Polystyrene Properties and Key Benefits 11.1.7.1 Key Benefits 11.1.7.2 Properties 11.1.8 EPS in Building Construction 11.1.9 Food Packaging 11.1.10 Industrial Packaging 11.1.11 Safety and Recyclability 11.1.12 Extruded Polystyrene Insulation 11.1.13 The Extrusion Process for XEPS 11.1.14 Insulation Properties of XEPS Boards 11.2 Manufacturing Plant for EPS Products for an Entrepreneur 11.2.1 The Products 11.2.2 Machinery and Equipment 11.2.3 Raw Material 11.2.4 Production Method 11.2.5 Fabrication 11.3 Manufacture of Polymeric Composite Resins 11.3.1 Technology in Brief 11.3.2 Raw Materials 11.3.3 Polymers 11.3.4 Rice Hulls 11.3.5 Additives 11.3.6 Processing Machinery and Equipment 11.4 Manufacture of PUR Flexible Foam Mattresses 11.4.1 The Raw Materials 11.4.2 Machinery and Equipment 11.4.3 Calculating Density 11.4.4 Calculating Indentation Force Deflection 11.5 PUR Flexible Foam Manufacturing Methods 11.5.1 Manual Operation 11.5.2 Molds 11.5.3 Cutting and Fabrication 11.5.4 Production Method 11.6 The Intermittent Process to Make Large Foam Blocks 11.6.1 Production Example – Intermittent Process Bibliography Appendix A Appendix B Appendix C Glossary Acknowledgments Index