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.
A.J. Bur, S.C. Roth, D.W. Baugh, K.A. Koppi, M.A. Spalding, J. Gunderson, W.C. Buzanowski, May 2004
We have used a temperature sensitive fluorescent dye, doped into polycarbonate, to monitor the true resin temperature during extrusion processing. For this measurement, a fluorescent dye, perylene, was doped into the polycarbonate at very low concentration. We apply this measurement concept to extrusion processing by using an optical sensor that accesses the machine at standard instrumentation ports. The sensor has a confocal optics design that permits the measurement of temperature profiles. With the sensor looking over the screw of a single extruder, temperature profiles from the barrel wall to the core of the screw were obtained as a function of screw speed, screw design and melt flow index.
Co-injection is a specialized injection molding process in which two or more materials are sequentially or simultaneously injected into a mold. The resulting plastic part will consist of a skin of the first material covering a core made of the second material. This can allow for an ergonomic surface finish without jeopardizing mechanical strength. It also can help reduce material costs by allowing lower quality material to be incorporated into the core. The focus of this research was to determine the effect of processing parameters and wall thickness on the core geometry and penetration depth. With a better understanding of the co-injection process, it can be implemented for more parts and a potential cost savings can be realized.
Imbalances occur in powder injection molding of multi cavity molds, which are sometimes opposite to the shear induced imbalances of conventional plastic materials. In a previous study it was found that melt rotation technology not only reduced imbalances, but also helped reduce differences between the mechanical properties of parts molded in multi-cavity molds. This paper presents the results of a study that expands on a previous work to include effects of fill rate, additional variations in runner geometries, and designs of melt rotation technologies for eliminating the variations.
During the startup and operation of new multicavity molds, it is expected that cavity-to-cavity filling variations will be found. This will occur despite the use of geometrically balanced runners. With cold runners, this imbalance is dominated by either steel variations in the mold, or shear induced variations developed in the runner. In order to correct the imbalances, it is important to be able to separate these two causes and to quantify their contribution. A method, here referred to as “The Five-Step Process” was developed for this purpose. This paper presents a study to determine how robust The Five Step-Process is in diagnosing steel variations in a mold.
In the plastics industry today it is generally accepted that full round runners provide the most efficient flow channel. However, when full round runners are implemented it is common for misalignment of the two halves of the runner to occur. This paper presents the effect that this misalignment has on mold filling and the resultant product. It is also common, in many instances and for many reasons, for other cross-sectional designs to be used. This paper also examines how subtle variations in runner design dramatically affects filling pressure, resulting in variations in molded parts. This study finds that there is a direct predictable relationship between the pressure drop through a runner and the ratio of the perimeter of the runner geometry to the cross sectional area of the runner.
Shear stresses developed during mold filling induce polymer orientation. This stress-induced orientation can be a significant contributor to a part’s residual stress, the development of anisotropic shrinkages and its tendency to warp. This paper presents a study that evaluates the relationship between the shear stress predicted from mold filling analysis software to its effects on a variety of different plastic materials. The study evaluates the impact of part wall thickness, melt temperature and fill rate. The study includes a variety of plastic materials, material fillers and reinforcements. Through a better understanding of the impact of predicted shear stress on different materials, a molder, or mold-filling analyst, will be able to minimize or avoid shear stress induced molding problems.
Trina R. Carl, Douglas French, Carl Caldwell, Eric D. Bowersox, May 2004
Injection molding requires a cooling phase within the cycle to cure the molten plastic that was just injected into a steel mold. The traditional method of cooling uses a mold cooling system to regulate the cooling. Pulse cooling, another method of cooling, is being studied to see how it compares in process stabilization and consistency to the traditional, constant flow, method of cooling.This study consists of an experiment using a constant flow cooling system to regulate cooling vs. using a pulse cooling system to regulate cooling. The data from the experiment is compared and the stabilization and consistency of the process using a pulse cooling system is compared to the standard cooling with constant flow.
Producing blow-molded bottles such as oval shaped cosmetics bottles requires the use of ovalized tooling. Currently the design of these dies is based the past experience. Simulation software can be used to eliminate extensive rework of the die, by allowing for the tooling design to be optimized without any steel being cut. The end result of this is a more uniform wall thickness distribution in the final product. 3D simulation software will be used to demonstrate its ability to construct and optimize the ovalizing of die and/or mandrel that could produce a parison for blowing oval shaped bottles. The results of this simulation can only be used with 3D simulation software.
Using simulation software, a computer can help to gain a basic parison profile and in turn be an effective way to validate a design. When molding parts, by using parison programming, the operator has the ability to maintain a uniform wall thickness. The majority of users who do simulations assume a constant wall thickness and a uniform cylindrical shape for the parison. However, in real world applications this is not true, and two major occurrences, die swell and sag, are overlooked. The inability for the blow molding simulation software to recognize these factors, can lead to greater cost in terms of lost time.In an attempt to verify the accuracy of the software simulation programs, a 2D axisymmetric model of the parison was created and then compared actual parisons created on a blow-molding machine using parison programming. After completing this study, it is our hope that this will help the people who run the software to perform better simulations.
This study looks at secondary design parameters that affect the strength of extrusion blow molded parts at the pinch-off. The effectiveness of secondary parameters on weld strength creates a greater understanding of pinch-off design. Pinch-off design is critical in extrusion blow molding since it welds the parison together in the mold. Weld strength is important because the part could fail in application if the weld strength is poor.This is a continuation of a prior experiment, which concluded flash pocket dimensions were the primary contributor to weld strength. This study focused on the secondary effects while keeping the flash pocket constant. The bottles for this experiment were made out of HDPE. A two-level Design of Experiment (DOE) was implemented to examine the effect of the parameters on weld line strength.
This study focused on the weld strength of different materials in the pinch-off area of an extrusion blow-molded bottle. Various materials of different densities were run through an extrusion blow-molding machine. This study determined how weld strength at the pinch off was affected by the density of the material being processed. The pinch off is the portion of the mold that welds the ends, and at times the interior portions, of the parison as well as cut the excess flash to aid in removal. Having a strong weld was extremely crucial to overall bottle quality and was a direct result of pinch off design. The reason the pinch off has an effect on quality is due to the weld probably being the weakest part of the bottle and bottle strength is only as strong as its weakest point. Strength was a key issue in determining overall quality and the research performed allows for a direct correlation between strength and material grade.
One objective of any blow molder is to create the strongest weld possible at the pinch-off region. In order to do this, a clear understanding of how the material’s viscosity interacts with processing variables to produce a weld line of certain thickness and strength is required. By varying mold closing time, mold temperature and relief angle on two melt viscosity variations of high density polyethylene (HDPE) this paper will show a clear relationship between these variables. Thus, allowing for the blow molder to produce the strongest and most optimum weld line for HDPE blow molded bottles. In doing so, this article will show that a slow mold closing time coupled with a high mold temperature will produce the strongest and thickest weld lines for both vicosity variations of HDPE.
The carboxylation of poly(ethylene-co-vinyl alcohol) (EVOH) was carried out utilizing varying amounts of succinic anhydride in a reactive extrusion process. The functionalized EVOH was then melt blended with polyamide 6,6 to investigate the effect of carboxylation on blend miscibility and/or phase behavior. All functionalization reactions and melt blending procedures were carried out on a co-rotating twin-screw extruder. The effectiveness of the functionalization reaction was determined through infrared spectroscopy (IR) and titration while the thermal and mechanical properties of the blends were investigated using differential scanning calorimetry (DSC) and tensile testing. IR spectroscopy showed the presence of a carbonyl peak after functionalization, indicating the carboxylation reaction was successful. These findings were reinforced by titration data. While the blends were all immiscible, the mechanical properties of the blends all increased with the carboxylation of EVOH.
Many hot water applications use crosslinked polyethylenes manufactured using methanol based silanes. Although ethanol based silanes are a higher cost material, the overall process using them would result in a lower cost alternative by removing an entire step of the manufacturing process. This experiment is a continuation of work performed on the silane crosslinking of polyethylene polymer chains. The experiment compares properties and manufacturability of methanol based silanes and ethanol based silanes. The results of this experiment are intended to aid in further research of the subject.
Part weight of plastic articles is reduced by use of foamed material or laminates that include a foamed layer. Traditionally rotationally molded parts may be filled with foam in a post-molding operation. The foam may, or may not, be the same material as the outer skin. It may, or may not, enhance properties. This paper describes the use of a two-step rotational molding process in which a LLDPE outer skin is molded followed by molding LLDPE with a blowing agent by opening a drop box containing the compound. Various ratios of skin-tofoam thickness were produced. ARM impact, tensile and flexural testing compare various ratios of laminate thickness. Results are compared to predictions from a laminate model.
Poly (l-lactide) (PLLA) has received considerable attention recently because it is environmentally friendly, derived from agricultural sources, and biodegradable. However, the mechanical properties of PLLA are typically low compared to other petroleum-based plastics. Recently, properties such as modulus and heat deflection temperature have been improved by creating polymer/clay nanocomposites. This study focuses on the effect of different organic modifiers for montmorrillonite clay on the thermal and mechanical properties of PLLA. Upon the addition of a small amount (1-10 wt %) of these modified clays, the storage modulus and Tg increases for all types of clays. The greatest increase in properties is found using quaternary ammonium ion having a pendant benzyl group.
Polymer composites were produced by mixing an inorganic clay hydrotalcite (HT), stearate coated (HTC) and uncoated (HTU) at 5 and 30% by weight with polypropylene and modified polypropylene. Torque profiles from blending in a batch mixer indicated significant viscosity changes depending on the type of the particular clay/polymer components. FTIR, MFI, DSC and TGA data suggested corresponding structural changes in the composites. The results showed that coated hydrotalcite produced the highest melt viscosity when added in the modified polypropylene. Tests are underway on flammability and rheology to shed more light into the interactions of the clay and the polymers.
Melt strength tests were conducted for blends of linear low density polyethylene (LLDPE) with cross-linked low density polyethylene (xLDPE) to study the effect of rheological modification on the development of low density, LLDPE foam with improved processability during extrusion foaming. Blends of LLDPE containing various concentrations of xLDPE, cross-linked with peroxide, were prepared in a Brabender batch mixer. Melt strength tests of the prepared blends were conducted through a capillary rheometer. It was found that melt strength increased with respect to increasing concentrations of xLDPE, suggesting optimum foamability at specific xLDPE content.
Kai Rine Caroline Mok, Har Boon Raymond Chia, Moshe Favelukis, May 2004
The deformation of a slender bubble in a Carreau-Yasuda liquid in a simple extensional and creeping flow has been theoretically studied. With the assumption of a constant pressure in the liquid, the deformation problem can be described by an ordinary differential equation, which was numerically solved. Analytical expressions for the local radius were obtained close to the center and the end of the bubble. The results for the shape of the bubble are presented as a function of four governing dimensionless numbers. The relevance of this work to polymer devolatilization and foam plastics is discussed.
Linda Caldwell, Steve Thompson, Gerry McNally, May 2004
This paper discusses the development of monitoring software to be used in a data acquisition system for a Killion KTS-100 extruder. Central to this computer-based system is LabVIEW software that is particularly good for data acquisition, analysis and data visualisation. Using LabVIEW, a graphical user interface was designed to facilitate the various operational requirements of the process. From here, the operator can set and observe the states of the many inputs and outputs of the system. The potential for such software to be developed to encompass additional functions will also be described.
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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How to reference articles from the SPE Library:
Any article that is cited in another manuscript or other work is required to use the correct reference style. Below is an example of the reference style for SPE articles:
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"Insert title of paper here in quotes,"
ANTEC 2016 - Indianapolis, Indiana, USA May 23-25, 2016. [On-line].
Society of Plastics Engineers, ISBN: 123-0-1234567-8-9, pp. 000-000.
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