Modern Plastics Handbook 2011 Part 1 pptx

Modern Plastics Handbook Modern Plastics and Charles A. Harper Editor in Chief Technology Seminars, Inc. Lutherville, Maryland McGraw-Hill New York San Francisco Washington, D.C. Auckland Bogotá Caracas Lisbon London Madrid Mexico City Milan Montreal New Delhi San Juan Singapore Sydney Tokyo Toronto 0267146_FM_Harper_Plastics_MHT 2/24/00 4:39 PM Page iii Library of Congress Cataloging-in-Publication Data Modern plastics handbook / Modern Plastics, Charles A. Harper (editor in chief). p. cm. ISBN 0-07-026714-6 1. Plastics. I. Modern Plastics. II. Harper, Charles A. TA455.P5 M62 1999 668.4—dc21 99-056522 CIP Copyright © 2000 by The McGraw-Hill Companies, Inc. Printed in the United States of America. Except as permitted under the United States Copyright Act of 1976, no part of this publication may be reproduced or distributed in any form or by any means, or stored in a data base or retrieval system, without the prior written permission of the publisher. 1 2 3 4 5 6 7 8 9 0 DOC/DOC 0 6 5 4 3 2 1 0 ISBN 0-07-026714-6 The sponsoring editor of this book was Robert Esposito. The editing supervisor was David E. Fogarty, and the production supervisor was Sherri Souffrance. It was set in New Century Schoolbook per the MHT design by Paul Scozzari and Deirdre Sheean of McGraw-Hill’s Professional Book Group, in Hightstown, N.J. Printed and bound by R. R. Donnelley & Sons Company This book was printed on recycled, acid-free paper containing a minimum of 50% recycled, de-inked fiber. McGraw-Hill books are available at special quantity discounts to use as premiums and sales promotions, or for use in corporate training programs. For more information, please write to the Director of Special Sales, Professional Publishing, McGraw-Hill, Two Penn Plaza, New York, NY 10121-2298. Or contact your local bookstore. McGraw-Hill Information contained in this work has been obtained by The McGraw- Hill Companies, Inc. (“McGraw-Hill) from sources believed to be reliable. However, neither McGraw-Hill nor its authors guarantee the accuracy or completeness of any information published herein and neither McGraw- Hill nor its authors shall be responsible for any errors, omissions, or damages arising out of use of this information. This work is published with the understanding that McGraw-Hill and its authors are supplying information but are not attempting to render engineering or other pro- fessional services. If such services are required, the assistance of an appropriate professional should be sought. 0267146_FM_Harper_Plastics_MHT 2/24/00 4:39 PM Page iv Contributors Anne-Marie Baker University of Massachusetts, Lowell, Mass. (CHAP.1) Carol M. F. Barry University of Massachusetts, Lowell, Mass. ( CHAP.5) Allison A. Cacciatore TownsendTarnell, Inc., Mt. Olive, N.J. ( CHAP.4) Fred Gastrock TownsendTarnell, Inc., Mt. Olive, N.J. ( CHAP.4) John L. Hull Hall/Finmac, Inc., Warminster, Pa. ( CHAP.6) Carl P. Izzo Consultant, Murrysville, Pa. ( CHAP. 10) Louis N. Kattas TownsendTarnell, Inc., Mt. Olive, N.J. ( CHAP.4) Peter Kennedy Moldflow Corporation, Lexington, Mass. ( CHAP. 7, SEC. 3) Inessa R. Levin TownsendTarnell, Inc., Mt. Olive, N.J. ( CHAP.4) William R. Lukaszyk Universal Dynamics, Inc., North Plainfield, N.J. ( CHAP. 7, SEC. 1) Joey Meade University of Massachusetts, Lowell, Mass. ( CHAP.1) James Margolis Montreal, Quebec, Canada ( CHAP.3) Stephen A. Orroth University of Massachusetts, Lowell, Mass. ( CHAP.5) Edward M. Petrie ABB Transmission Technology Institute, Raleigh, N.C. ( CHAP.9) Jordon I. Rotheiser Rotheiser Design, Inc., Highland Park, Ill. ( CHAP.8) Susan E. Selke Michigan State University, School of Packaging, East Lansing, Mich. ( CHAP. 12) Ranganath Shastri Dow Chemical Company, Midland, Mich. ( CHAP.11) Peter Stoughton Conair, Pittsburgh, Pa. ( CHAP. 7, SEC. 2) Ralph E. Wright Consultant, Yarmouth, Maine ( CHAP.2) 0267146_FM_Harper_Plastics_MHT 2/24/00 4:39 PM Page ix Preface The Modern Plastics Handbook has been prepared as a third member of the well-known and highly respected team of publications which includes Modern Plastics magazine and Modern Plastics World Encyclopedia. The Modern Plastics Handbook offers a thorough and comprehensive technical coverage of all aspects of plastics materials and processes, in all of their forms, along with coverage of additives, auxiliary equipment, plastic product design, testing, specifications and standards, and the increasingly critical subject of plastics recycling and biodegradability. Thus, this Handbook will serve a wide range of interests. Likewise, with presentations ranging from terms and defin- itions and fundamentals, to clearly explained technical discussions, to extensive data and guideline information, this Handbook will be use- ful for all levels of interest and backgrounds. These broad objectives could only have been achieved by an outstanding and uniquely diverse group of authors with a combination of academic, professional, and business backgrounds. It has been my good fortune to have obtained such an elite group of authors, and it has been a distinct pleasure to have worked with this group in the creation of this Handbook. I would like to pay my highest respects and offer my deep appreciation to all of them. The Handbook has been organized and is presented as a thorough sourcebook of technical explanations, data, information, and guide- lines for all ranges of interests. It offers an extensive array of property and performance data as a function of the most important product and process variables. The chapter organization and coverage is well suited to reader convenience for the wide range of product and equipment categories. The first three chapters cover the important groups of plas- tic materials, namely, thermoplastics, thermosets, and elastomers. Then comes a chapter on the all important and broad based group of additives, which are so critical for tailoring plastic properties. Following this are three chapters covering processing technologies and 0267146_FM_Harper_Plastics_MHT 2/24/00 4:39 PM Page xi equipment for all types of plastics, and the all important subject of auxiliary equipment and components for optimized plastics process- ing. Next is a most thorough and comprehensive chapter on design of plastic products, rarely treated in such a practical manner. After this, two chapters are devoted to the highly important plastic materials and process topics of coatings and adhesives, including surface finishing and fabricating of plastic parts. Finally, one chapter is devoted to the fundamentally important areas of testing and standards, and one chapter to the increasingly critical area of plastic recycling and biodegradability. Needless to say, a book of this caliber could not have been achieved without the guidance and support of many people. While it is not pos- sible to name all of the advisors and constant supporters, I feel that I must highlight a few. First, I would like to thank the Modern Plastics team, namely, Robert D. Leaversuch, Executive Editor of Modern Plastics magazine, Stephanie Finn, Modern Plastics Events Manager, Steven J. Schultz, Managing Director, Modern Plastics World Encyclopedia, and William A. Kaplan, Managing Editor of Modern Plastics World Encyclopedia. Their advice and help was constant. Next, I would like to express my very great appreciation to the team from Society of Plastics Engineers, who both helped me get off the ground and supported me readily all through this project. They are Michael R. Cappelletti, Executive Director, David R. Harper, Past President, John L. Hull, Honored Service Member, and Glenn L. Beall, Distinguished Member. In addition, I would like to acknowledge, with deep appreciation, the advice and assistance of Dr. Robert Nunn and Dr. Robert Malloy of University of Massachusetts, Lowell for their guidance and support, especially in selection of chapter authors. Last, but not least, I am indebted to Robert Esposito, Executive Editor of the McGraw-Hill Professional Book Group, for both his support and patience in my editorial responsibilities for this Modern Plastics Handbook. It is my hope, and expectation, that this book will serve its reader well. Any comments or suggestions will be welcomed. Charles A. Harper xii Preface 0267146_FM_Harper_Plastics_MHT 2/24/00 4:39 PM Page xii Contents Contributors ix Preface xi Chapter 1. Thermoplastics 1.1 1.1 Introduction 1.1 1.2 Polymer Categories 1.4 1.3 Comparative Properties of Thermoplastics 1.79 1.4 Additives 1.79 1.5 Fillers 1.82 1.6 Polymer Blends 1.83 References 1.85 Chapter 2. Thermosets, Reinforced Plastics, and Composites 2.1 2.1 Resins 2.1 2.2 Thermosetting Resin Family 2.2 2.3 Resin Characteristics 2.10 2.4 Resin Forms 2.10 2.5 Liquid Resin Processes 2.13 2.6 Laminates 2.29 2.7 Molding Compounds 2.38 References 2.88 Chapter 3. Elastomeric Materials and Processes 3.1 3.1 Introduction 3.1 3.2 Thermoplastic Elastomers (TPEs) 3.1 3.3 Melt Processing Rubbers (MPRs) 3.24 3.4 Thermoplastic Vulcanizates (TPVs) 3.26 3.5 Synthetic Rubbers 3.33 3.6 Natural Rubber 3.48 3.7 Conclusion 3.49 References 3.50 v 0267146_FM_Harper_Plastics_MHT 2/24/00 4:39 PM Page v Chapter 4. Plastic Additives 4.1 4.1 Introduction 4.1 4.2 Scope 4.2 4.3 Antiblock and Slip Agents 4.2 4.4 Antioxidants 4.6 4.5 Antistatic Agents 4.12 4.6 Biocides 4.16 4.7 Chemical Blowing Agents 4.19 4.8 Coupling Agents 4.23 4.9 Flame Retardants 4.26 4.10 Heat Stabilizers 4.36 4.11 Impact Modifiers 4.41 4.12 Light Stabilizers 4.46 4.13 Lubricants and Mold Release Agents 4.49 4.14 Nucleating Agents 4.54 4.15 Organic Peroxides 4.58 4.16 Plasticizers 4.62 4.17 Polyurethane Catalysts 4.66 Chapter 5. Processing of Thermoplastics 5.1 5.1 Material Concepts 5.2 5.2 Extrusion 5.18 5.3 Estrusion Processes 5.55 5.4 Injection Molding 5.84 References 5.121 Chapter 6. Processing of Thermosets 6.1 6.1 Introduction 6.1 6.2 Molding Processes 6.2 6.3 Techniques for Machining and Secondary Operations 6.24 6.4 Postmolding Operations 6.28 6.5 Process-Related Design Considerations 6.29 6.6 Mold Construction and Fabrication 6.34 6.7 Summary 6.37 Chapter 7. Auxiliary Equipment 7.2 Raw Material Delivery 7.5 7.3 Bulk Storage of Resin 7.8 7.4 Bulk Resin Conveying Systems 7.22 7.5 Bulk Delivery Systems 7.28 7.6 Blending Systems 7.35 7.7 Regrind Systems 7.38 7.8 Material Drying 7.43 7.9 Loading Systems 7.50 7.10 System Integration 7.57 vi Contents 0267146_FM_Harper_Plastics_MHT 2/24/00 4:39 PM Page vi 7.2 Section 1. Material Handling 7.3 7.1 Introduction 7.3 Section 2. Drying and Dryers 7.63 7.11 Why Do We Dry Plastic Materials? 7.63 7.12 Hygroscopic and Nonhygroscopic Polymers 7.65 7.13 Drying Hygroscopic Polymers 7.66 7.14 How Physical Characteristics of Plastics Affect Drying 7.71 7.15 How Dryers Work 7.72 7.16 Critical Dryer Components 7.77 7.17 Monitoring Drying Conditions 7.85 7.18 Drying System Configurations 7.89 7.19 Gas or Electric? 7.93 7.20 Handling Dried Material 7.94 Section 3. CAD, CAM, CAE 7.99 7.21 Introduction 7.99 7.22 Simulation and Polymer Processing 7.101 7.23 The Injection-Molding Process 7.104 7.24 History of Injection-Molding Simulation 7.106 7.25 Current Technology for Injection-Molding Simulation 7.109 7.26 The Changing Face of CAE 7.123 7.27 Machine Control 7.126 7.28 Future Trends 7.129 References on CAD, CAM, CAE 7.131 Chapter 8. Design of Plastic Products 8.1 8.1 Fundamentals 8.1 8.2 Design Fundamentals for Plastic Parts 8.49 8.3 Design Details Specific to Major Processes 8.79 References 8.116 Chapter 9. Finishing, Assembly, and Decorating 9.1 9.1 Introduction 9.1 9.2 Machining and Finishing 9.2 9.3 Assembly of Plastics Parts—General Considerations 9.16 9.4 Methods of Mechanical Joining 9.17 9.5 Adhesive Bonding 9.35 9.6 Welding 9.70 9.7 Recommended Assembly Processes for Common Plastics 9.80 9.8 Decorating Plastics 9.91 References 9.105 Chapter 10. Coatings and Finishes 10.1 10.1 Introduction 10.1 10.2 Environment and Safety 10.5 10.3 Surface Preparation 10.6 10.4 Coating Selection 10.11 10.5 Coating Materials 10.18 10.6 Application Methods 10.42 Contents vii 0267146_FM_Harper_Plastics_MHT 2/24/00 4:39 PM Page vii 10.7 Curing 10.55 10.8 Summary 10.58 References 10.59 Chapter 11. Plastics Testing 11.1 11.1 Introduction 11.1 11.2 The Need for Testing Plastics 11.1 11.3 Diverse Types of Testing 11.2 11.4 Test Methods for Acquisition and Reporting of Property Data 11.13 11.5 Uniform Reporting Format 11.66 11.6 Misunderstood and Misused Properties 11.70 11.7 Costs of Data Generation 11.73 Appendix 11.1 Selected ISO/IEC Standards/Documents 11.77 Appendix 11.2 Selected ASTM Standards 11.84 Appendix 11.3 List of Resources 11.87 Appendix 11.4 Some Unit Conversion Factors 11.92 References 11.92 Suggested Reading 11.94 Chapter 12. Plastics Recycling and Biodegradable Plastics 12.1 12.1 Introduction 12.1 12.2 Overview of Recycling 12.14 12.3 Design for Recycling 12.22 12.4 Recycling of Major Polymers 12.24 12.5 Overview of Plastics Degradation 12.71 12.6 Natural Biodegradable Polymers 12.80 12.7 Synthetic Biodegradable Polymers 12.92 12.8 Water-Soluble Polymers 12.97 12.9 Summary 12.99 References 12.100 Appendix A. Glossary of Terms and Definitions A.1 Appendix B. Some Common Abbreviations Used in the Plastics Industry B.1 Appendix C. Important Properties of Plastics and Listing of Plastic Suppliers C.1 Appendix D. Sources of Specifications and Standards for Plastics and Composites D.1 Appendix E. Plastics Associations E.1 Index follows Appendix E viii Contents 0267146_FM_Harper_Plastics_MHT 2/24/00 4:39 PM Page viii 1.1 Thermoplastics A M. M. Baker Joey Mead Plastics Engineering Department University of Massachusetts, Lowell 1.1 Introduction Plastics are an important part of everyday life; products made from plastics range from sophisticated products, such as prosthetic hip and knee joints, to disposable food utensils. One of the reasons for the great popularity of plastics in a wide variety of industrial applications is due to the tremendous range of properties exhibited by plastics and their ease of processing. Plastic properties can be tailored to meet spe- cific needs by varying the atomic makeup of the repeat structure; by varying molecular weight and molecular weight distribution; by vary- ing flexibility as governed by presence of side chain branching, as well as the lengths and polarities of the side chains; and by tailoring the degree of crystallinity, the amount of orientation imparted to the plas- tic during processing and through copolymerization, blending with other plastics, and through modification with an enormous range of additives (fillers, fibers, plasticizers, stabilizers). Given all of the avenues available to pursue tailoring any given polymer, it is not sur- prising that such a variety of choices available to us today exist. Polymeric materials have been used since early times, even though their exact nature was unknown. In the 1400s Christopher Columbus found natives of Haiti playing with balls made from material obtained from a tree. This was natural rubber, which became an important Chapter 1 0267146_Ch01_Harper 2/24/00 5:01 PM Page 1.1 [...]... acetate Cellulose acetate butyrate Cellulose acetate propionate 38–40 — — 3.5–4.5 13 15 36–38 — 1 2 1. 5–3.5 — 43–47 2–3 13 .1 58.6 6–50 13 .8– 51. 7 38–74 13 .8– 51. 7 35–60 6.6 13 2.7 1. 9 14 .3 39 12 0 9.9 14 9.3 6.6–23.8 29 11 7 13 .3 18 2.5 1. 9 19 .0 20 12 0 2.0–6.5 1. 0–4.0 1. 0–3.0 026 714 6_Ch 01_ Harper 2/24/00 5: 01 PM Page 1. 13 Thermoplastics 1. 13 pens, pencils, tooth brushes, packaging fim, and pipe.46 Cellulose acetates... low-temperature impact TABLE 1. 1 Selected Mechanical Properties of Common Celluloses Tensile strength, MPa Ultimate elongation, % Form Dry Wet Dry Wet Ramie Cotton Flax Viscose rayon Cellulose acetate 900 200–800 824 200–400 15 0–200 10 60 200–800 863 10 0–200 10 0 12 0 2.3 12 16 1. 8 8–26 21 30 2.4 6 13 2.2 13 –43 29–30 026 714 6_Ch 01_ Harper OCOC3H7 CH CH CH OCH CH H3COC O Figure 1. 5 O CH CH OCOCH3 OCH CH H9C4OCO... butyrate, and cellulose acetate propionate CH OCOC3H7 Page 1. 11 OCOC4H9 2/24/00 5: 01 PM OCOCH3 1. 11 026 714 6_Ch 01_ Harper 1. 12 2/24/00 5: 01 PM Page 1. 12 Chapter One strength, and dimensional stability CAP has the highest tensile strength and hardness Comparison of typical compositions and properties for a range of formulations are given in Table 1. 2.43 Properties can be tailored by formulating with different... polybenzimidazoles 026 714 6_Ch 01_ Harper 2/24/00 5: 01 PM Page 1. 27 Thermoplastics 1. 2 .10 1. 27 Polybutylene (PB) Polybutylene polymers are prepared by the polymerization of 1- butene using Ziegler-Natta catalysts The molecular weights range from 770,000 to 3,000,000 .15 6 Copolymers with ethylene are often prepared as well The chain structure is mainly isotactic and is shown in Fig 1. 16 .15 7 The glass transition... in Fig 1. 11 026 714 6_Ch 01_ Harper 2/24/00 5: 01 PM Page 1. 19 Thermoplastics 1. 19 There are five primary methods to polymerize nylon They are reaction of a diamine with a dicarboxylic acid, condensation of the appropriate amino acid, ring opening of a lactam, reaction of a diamine with a diacid chloride, and reaction of a diisocyanate with a dicarboxylic acid.90 The type of nylon (nylon 6, nylon 10 , etc.)... seals, mechanical parts for electronics, and engine components .14 1 The polymer in solution has application as a laminating resin for spacecraft, a decorative finish for kitchen equipment, and as wire enamel .14 2 Low coefficient of friction materials may be prepared by blending PAI with polytetrafluoroethylene and graphite .14 3 026 714 6_Ch 01_ Harper 2/24/00 5: 01 PM Page 1. 25 Thermoplastics 1. 2.8 1. 25 Polyarylate... internal F F2C CF2 Figure 1. 9 Preparation of PTFE C C F n F F n 026 714 6_Ch 01_ Harper 2/24/00 5: 01 PM Page 1. 17 Thermoplastics 1. 17 diameter Dispersion polymers are more difficult to process by the techniques previously mentioned The addition of a lubricant (15 to 25%) allows the manufacture of preforms by extrusion The lubricant is then removed and the part sintered Thick parts are not made by this... to be used as a coating for other thermoplastics for improved UV resistance of the part The good heat resistance of polyarylates allows them to be used in applications such as fire helmets and shields .14 8 O C Cl O H2N + CH2 NH2 Cl C C Cl O O C N N H + CH2 C C O O Figure 1. 14 Preparation of polyamide-imide n HCl 026 714 6_Ch 01_ Harper 1. 26 1. 2.9 2/24/00 5: 01 PM Page 1. 26 Chapter One Polybenzimidazole Polybenzimidazoles... temperature.94 O NH CH2 C 5 n Figure 1. 11 General structure of nylons O n H2N CH2 a NH2 + n HO C O CH2 C OH b O NH CH2 NH a C O C CH2 b n Figure 1. 12 Synthesis of nylon 026 714 6_Ch 01_ Harper 1. 20 2/24/00 5: 01 PM Page 1. 20 Chapter One Nylons are relatively insensitive to nonpolar solvents, however, because of the presence of the polar groups, nylons can be affected by polar solvents, particularly water.95 The presence... past each other Ideally, this region is modeled as representing viscous materials which obey Newton’s law : ؒ ␴ ϭ ␩ε 026 714 6_Ch 01_ Harper 2/24/00 5: 01 PM Page 1. 3 Thermoplastics 1. 3 Figure 1. 1 Relationship between elastic modulus and temperature Plastics can also be separated into thermoplastics and thermosets A thermoplastic material is a high molecular weight polymer that is not cross-linked A thermoplastic . vii 026 714 6_FM_Harper _Plastics_ MHT 2/24/00 4:39 PM Page vii 10 .7 Curing 10 .55 10 .8 Summary 10 .58 References 10 .59 Chapter 11 . Plastics Testing 11 .1 11. 1 Introduction 11 .1 11. 2 The Need for Testing Plastics. 11 .1 11. 3 Diverse Types of Testing 11 .2 11 .4 Test Methods for Acquisition and Reporting of Property Data 11 .13 11 .5 Uniform Reporting Format 11 .66 11 .6 Misunderstood and Misused Properties 11 .70 11 .7. 11 .70 11 .7 Costs of Data Generation 11 .73 Appendix 11 .1 Selected ISO/IEC Standards/Documents 11 .77 Appendix 11 .2 Selected ASTM Standards 11 .84 Appendix 11 .3 List of Resources 11 .87 Appendix 11 .4