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.
Sarah Schirmer, Danielle Froio, Christopher Thellen, Matthew Mannarino, Jeanne Lucciarini, Jo Ann Ratto, May 2007
Retort is a high temperature sterilization process that is used to prolong the shelf life of military rations. Ethylene co-vinyl alcohol (EVOH) /montmorillonite layered silicate (MLS) nanocomposites were co-extruded with retort grade polypropylene (PP) into a multilayer cast film to determine if the addition of MLS to EVOH improved barrier, mechanical, thermal and retort properties. The PP/EVOH-MLS/PP structure showed an improvement in some properties such as water vapor transmission rate, Young's modulus, and seal strength before retort in comparison to the PP/EVOH/PP structure; however, the improvement in properties was lost after the retort process.
Dana Hnidáková, Roman ?ermák, Lenka Chvátalová, Jana Výchop?ová, Martin Obadal, May 2007
The effect of ?-nucleation on structure and properties of cast films manufactured from isotactic polypropylenes has been studied. Two commercial-available polypropylenes – homopolymer and random copolymer – were modified by 0.03 wt.% of specific ?-nucleating agent NJ Star NU 100. Cast films were extruded from both starting and nucleated polypropylenes using a slit die and water-cooled chill roll. Supermolecular structure of the films was evaluated using wide-angle X-ray scattering. Tensile testing was used for the preliminary measurement of mechanical properties. A significant effect of the nucleation and solidification temperature on structure and properties of the films was found.
Norwin Van Riel, Nigel Shields, Marisa Calhoun, Steve Rogers, May 2007
The character and impression of an automobile interior is greatly influenced by the gloss and appearance of the interior components. This can have far reaching implications on the choice of polymer for molded-in-color parts. Acrylonitrile-Butadiene-Styrene (ABS) and talc filled Polypropylene (PP) resins are both widely used in such applications and each have their advantages and disadvantages, especially in respect to low gloss aesthetics and scratch resistance. Dow Automotive has recently developed a next generation of super low gloss ABS resins for interior applications, called MAGNUM* SLG ABS.Tool and part design for low gloss aesthetics using ABS resins and talc filled PP resins requires specific attention with respect to filling pattern and process conditions. Talc filled and impact modified PP resins are widely used for interior applications including instrument panels, door parts and pillars due to the versatility in part design and superior aesthetics. The impact-stiffness balance of mass-solution produced high impact ABS is very similar to talc filled impact modified PP, but ABS exhibits superior scratch resistance. Often, the Automotive Original Equipment Manufacturer (OEM) will set sixty degree gloss targets, for example between 1.8 and 2.5 for talc filled PP on specific grain types and/or textures. Achieving these gloss targets, whilst maintaining good scratch and mar behavior is heavily dependent on the texture applied on the mold surface. In an attempt to balance this demand between gloss and scratch and mar performance, additional mold surface treatments are becoming increasingly widespread in the industry. While in the first instance following seemingly opposing routes to achieve the same goal, we shall highlight the synergy achieved between super low gloss resins and secondary mold etching technologies.With this new development the aesthetical shortcomings of ABS resins have been resolved giving the part designer another material option for uncovere
Javier C. Cruz, Tim A. Osswald, Mark Kemper, May 2007
Reactions of many thermosetting materials may be monitored by the use of Raman Spectroscopy. It allows accurate online reaction monitoring for precise curing analysis. Curing is monitored through direct molecular changes thus reducing inaccuracies present when relating macroscopic variables to molecular level reactions. From the spectral changes in peak height or peak area, the curing behaviors were monitored. A high pressure reaction vessel has been designed with a fully automated temperature control, for monitoring the curing of unsaturated polyester and other thermosetting materials under high pressure or vacuum. Processing conditions such as heating rate and pressure will be related to the reaction conversion and material properties. The curing results for unsaturated polyester and epoxy reactions at constant pressures up to 2000psi will be presented.
Henk P. Blom, Mary Ann Murphy, Robert M. Wojnarowski, Michael T.K. Ling, Martin F. Miller, Zenichiro Kai, Lecon Woo, May 2007
Large-volume flexible solution containers are gaining in popularity in the medical products arena in recent years. The composition of these products often involve materials other than PVC. These products present peculiar engineering challenges, particularly in relation to the formation of panel leaks during packaging, storage, and distribution, due in large part to the volume of solution in the container. An extensive investigation of these panel leaks led to the elucidation of a multi-step failure mechanism. Understanding the failure mechanism directed efforts to enhance the robustness of the final product.
Gregory S. Layser, Aaron S. Cassebeer, John P. Coulter, May 2007
This study investigates the effect of locally induced molecular orientation imparted by dynamic melt manipulation based injection molding has on the biaxial stress in an injection molded coupon. Melt manipulation refers to a process where the polymer melt is manipulated during molding beyond normally encountered in conventional injection molding. The technique studied in this paper is Vibration Assisted Injection Molding, where a conventional injection molding machine is augmented by oscillating the injection screw (in the axial direction) during the injection and packing phases. The localized final molecular orientation and morphology that results dictates the resultant product response. Typically improved mechanical properties are observed. For this study the ultimate tensile strength of injection molded polystyrene was investigated. A previous study showed a dramatic tensile strength increase in the regions of higher melt manipulation induced molecular orientation along the direction of flow. To elicit the effect on the strength in the transverse direction, smaller test specimens were machined uniformly perpendicular to the flow length and tested. Comparisons were made with specimens tested axial to the flow.
Two hydrosilylated polyolefin compounds, a polydimethylsiloxane (PDMS) end-capped PP and a lightly crosslinked PE sample, are annealed in supercritical carbon dioxide (scCO2). The contact angle, instead of Si concentration, of both samples is found to increase with annealing temperature. Increasing the scCO2 pressure leads to higher Si concentration on the surfaces of both samples, but opposite trends in contact angle: an increase in contact angle on the hydrosilylated PP and a decrease on hydrosilylated PE. The hydrosilylated PP surface shows SiO2 particles after annealed in CO2 at 120 °C.
In most cases, the injection molding conditions significantly affect the morphology and subsequently the bulk mechanical properties of the product. This effect is more pronounced when polymer blends or composites are used where the extent of dispersion and orientation of the disperse phases or reinforcements would affect the final property of the molding. In film insert moldings, it is important to ensure that the film is firmly attached to the substrate. Hence, the distribution of the disperse phases (Acrylonitrile-butadiene-styrene in polycarbonate) at the interface is investigated to establish correlations between phase anisotropy, film-substrate adhesion and bulk mechanical properties.
Clarified polypropylene (PP) continues to find increasing uses as polymer and additive improvements allow for its incorporation into applications where resins such as polystyrene or acrylics have traditionally been used [1]. Second and third generation clarifiers have improved the clarity, processing properties, and the organoleptic properties (residual odor and taste), opening the way for more extensive food contact applications [2,3]. With the expanded use of clarified polypropylene comes the need appropriate colorants which will give high clarity, low haze, deep coloration, and no migration. Polymeric colorants have shown to possess these properties, further expanding the market potential for clarified polypropylene. This paper will explore the use of various modified wax compounds and their effects on the residual haze of clarified PP molded with GemToneTM Polymeric Colorants.
S.-H. Zhu, N.T. McManus, C. Tzoganakis, A. Penlidis, May 2007
A polydimethylsiloxane (PDMS) modified polyolefin (PMPO) was found to facilitate the extrusion of linear low density polyethylene (LLDPE). In comparison to pure LLDPE, the apparent viscosity is reduced, and the extrudate surface roughness only occurs at higher shear rates. The throughput per unit input energy in single-screw extrusion nearly doubles. These are attributed to the decreasing surface free energy of the PMPO with an increasing PDMS content. The friction coefficients of pure PMPO and PMPO/LLDPE blends decrease as a result of the presence of PDMS.
An approach for controlling the injection speed is developed using a new form of predictive control termed extended predictive control (EPC). EPC is a practical scheme that can be implemented on a wide range of industrial processes. The major contribution of EPC is that only one tuning parameter is used in a simple and effective way to tune the process closed-loop response. The main features of EPC are practically illustrated on controlling the injection speed of a 150 tonne machine and three temperature zones on a steel cylinder that used to melt the plastic material inside the barrel. The control performance of EPC is compared with other predictive controllers with improved results.
Jiang Li, Zhigang Sun, Jacques Tatibouët, Cheng-Kuei Jen, May 2007
The orientation and relaxation behaviors of a low density polyethylene melt after undergoing a shear flow in a restricted channel were investigated by using ultrasound. A capillary rheometer was used to force the polymer melt through a slit die equipped with pressure, temperature, and ultrasound sensors, and the variation of ultrasound velocity traversing the melt was measured. Experimental results revealed that due to different mechanisms involved, the relaxations of orientation and disorientation processes show different dependences on temperature and shear rate.
N. O-Charoen, Y.W. Leong, M. Kotaki, H. Hamada, May 2007
The internal structures of the injection molded parts are complex and greatly affect on the mechanical properties. The closed-spiral flow injection molded technique was used to observe the microstructure development. Through thickness direction, different morphological structures were observed. The changes in morphology can be abrupt, especially at the regions closest to the external surface of the specimen, while a more gradual transition was observed with increasing depth of the specimen. The width of each layer and the characteristics (i.e. shapes and sizes) of the cavities are believed to have a direct impact on the final mechanical properties of the moldings. Hence, it is essential to understand the morphology of the moldings in order to effectively predict the final properties at different molding conditions.
M.Y. Serry Ahmed, S.G. Kim, C.B. Park, N. Atalla, May 2007
High internal phase emulsion (HIPE) polymerization foaming process is controlled for production of novel foams with various microcellular structures and morphologies. The objective is to produce lighter weight sound insulation packages with superior acoustical performance for passive noise control in automotive structures using microcellular foams. This was achieved through the control of the foaming process for production of variable microcellular structures and morphologies for the novel foams under investigation. As an attempt to reduce the cell size and increase microcellular density and open cell content without sacrificing the mechanical prosperities, the microcellular foams combining viscosity improvers into the conventional formulation of styrene and water system were prepared via high internal phase emulsion polymerization.
Elastomers are used to dampen vibrations and minimize structural damage caused by impact loads because of their low modulus, high damping and large extensibility. Applications include isolation bearings, engine mounts and shock pads, where the loads are dynamic in nature. A testing apparatus is developed to obtain the deformation and fracture properties of carbon-black filled natural rubber under impact loading in pure shear. The specimen and the grips are designed to be interchangeable with other existing test machinery such as an MTS servo hydraulic machine. Piezoelectric load cells and a high-speed video camera are used to measure forces and displacements, respectively.
Baeg-Soon Cha, Hyung-Pil Park, Byung-Ohk Rhee, May 2007
The development of plastic lens is advancing not only in the direction of micro size lenses but also for larger dimensions. Because of an excessive thickness of product, the cooling time for large lenses is much needed and dimensional accuracy of difficult to achieve. In this study, we produce molds for plastic lens using 3 kinds of methods, (a)using traditional method, (b)the process of Direct Metal Laser Sintering(DMLS), and (c)the Spray Formed Tooling(SFT), where conformal cooling channels are designed inside the molds of DMLS" and "SFT". The cooling efficiency of manufactured molds is then compared through injection molding experiments. We also analyzed the application potential of manufacturing mold in the industry field."
T. Ohta, Y.W. Leong, K. Yamada, H. Hamada, May 2007
Mechanical and morphological properties of injection moldings are known to be highly dependant on molding conditions, e.g. barrel and mold temperatures, injection speed, and injection pressure. However, the not all conditions impart the same degree of influence on the final properties of the moldings. Here, the properties of recycled poly(ethylene terephthalate) (RPET) were gauged based on accurately measured injection molding conditions, i.e. transducers embedded in the mold cavity were used to measure the resin pressure and speed. Initial investigations have shown that injection speed exerts more influence on the properties of RPET than injection pressure.
Gary F. Smith, James Mahood, Matt Pixton, Adam S. Zerda, Mark A. Sanner, May 2007
A series of new high heat polycarbonate copolymers have been prepared and commercialized. These transparent resins extend polycarbonate heat capability beyond 200 oC while maintaining excellent melt processability, good mechanical properties and strength as well as practical toughness and flame resistance. In addition, the copolymers demonstrate useful optical properties including low birefringence and high refractive index, which may be useful in lighting and lens applications. The new resins may be blended with a variety of additives, such as fiberglass, to make a family of amorphous high heat resins.
H. Park, C.B. Park, C. Tzoganakis, P. Chen, May 2007
The surface tension of polystyrene in supercritical carbon dioxide is determined experimentally by Axisymmetric Drop Shape Analysis-Profile (ADSA-P), where a high pressure and temperature cell is designed and constructed to facilitate the formation of a pendant drop of polystyrene melt. As pressures and temperatures increase, the surface tension of polystyrene decreases. A linear relationship is found between surface tension and temperature, and between surface tension and pressure. The slope of surface tension change with temperature is dependent on pressure.
Mark D. Wetzel, Marios Avgousti, Donald A. Denelsbeck, Susan L. Latimer, May 2007
Reactive extrusion is an important industrial compounding process. Usually, a product is manufactured by the product by process" approach without direct monitoring or control of the critical in-situ chemical reaction. By means of a rapid steady state throughput (Q) and screw speed (N) mapping method described in previous publicat mean residence time and physical properties. The reactions examined include polymer degradation (peroxide cracking of Polypropyleneions a reactive extrusion processes is characterized by several model parameters derived from the on-line monitoring of the mixing intensity and time as measured or estimated from power consumption Polyester degradation) and in-situ grafting (Polyamide 6/SMA). In this study the effects of Q and N on melting mixing and rates and extent of reactions that change viscosity were quantified process changes in reactive extrusion systems with linear models of power consumption and mean residence time. Since these reaction systems tend to be controlled by interfacial area generation the effects of mixing intensity and time were captured. Using the proposed method such as rate optimization can be made without compromising product quality e.g. extent of reaction."
Kim McLoughlin Senior Research Engineer, Global Materials Science Braskem
A Resin Supplier’s Perspective on Partnerships for the Circular Economy
About the Speaker
Kim drives technology programs at Braskem to develop advanced polyolefins with improved recyclability and sustainability. As Principal Investigator on a REMADE-funded collaboration, Kim leads a diverse industry-academic team that is developing a process to recycle elastomers as secondary feedstock. Kim has a PhD in Chemical Engineering from Cornell. She is an inventor on more than 25 patents and applications for novel polyolefin technologies. Kim is on the Board of Directors of SPE’s Thermoplastic Materials & Foams Division, where she has served as Education Chair and Councilor.
A Resin Supplier’s Perspective on Partnerships for the Circular Economy
About the Speaker
Gamini has a BS and PhD from Purdue University in Materials Engineering and Sustainability. He joined Penn State as a Post Doctorate Scholar in 2020 prior to his professorship appointment. He works closely with PA plastics manufacturers to implement sustainability programs in their plants.
A Resin Supplier’s Perspective on Partnerships for the Circular Economy
About the Speaker
Tom Giovannetti holds a Degree in Mechanical Engineering from The University of Tulsa and for the last 26 years has worked for Chevron Phillips Chemical Company. Tom started his plastics career by designing various injection molded products for the chemical industry including explosion proof plugs and receptacles, panel boards and detonation arrestors for 24 inch pipelines. Tom also holds a patent for design of a polyphenylene sulfide sleeve in a nylon coolant cross-over of an air intake manifold and is a Certified Plastic Technologist through the Society of Plastic Engineers. Tom serves on the Oklahoma Section Board as Councilor, is also the past president of the local Oklahoma SPE Section, and as well serves on the SPE Injection Molding Division board.
Joseph Lawrence, Ph.D. Senior Director and Research Professor University of Toledo
A Resin Supplier’s Perspective on Partnerships for the Circular Economy
About the Speaker
Dr. Joseph Lawrence is a Research Professor and Senior Director of the Polymer Institute and the Center for Materials and Sensor Characterization at the University of Toledo. He is a Chemical Engineer by training and after working in the process industry, he has been engaged in polymers and composites research for 18+ years. In the Polymer Institute he leads research on renewably sourced polymers, plastics recycling, and additive manufacturing. He is also the lead investigator of the Polyesters and Barrier Materials Research Consortium funded by industry. Dr. Lawrence has advised 20 graduate students, mentored 8 staff scientists and several undergraduate students. He is a peer reviewer in several journals, has authored 30+ peer-reviewed publications and serves on the board of the Injection Molding Division of SPE.
Matt Hammernik Northeast Account Manager Hasco America
A Resin Supplier’s Perspective on Partnerships for the Circular Economy
About the Speaker
Matt Hammernik serves as Hasco America’s Northeast Area Account Manager covering the states Michigan, Ohio, Indiana, and Kentucky. He started with Hasco America at the beginning of March 2022. Matt started in the Injection Mold Industry roughly 10 years ago as an estimator quoting injection mold base steel, components and machining. He advanced into outside sales and has been serving molders, mold builders and mold makers for about 7 years.
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