Engineering Plastics

Engineering plastics are a group of plastic materials that exhibit superior mechanical and thermal properties in a wide range of conditions over and above more commonly used commodity plastics. The term usually refers to thermoplastic materials rather than thermosetting ones. Engineering plastics are used for parts rather than containers and packaging. Examples of engineering plastics include: Acrylonitrile butadiene styrene (ABS) Polycarbonates (PC) Polyamides (PA) Polybutylene terephthalate (PBT) Polyethylene terephthalate (PET) Polyphenylene oxide (PPO) Polysulphone (PSU) Polyetherketone (PEK) Polyetheretherketone (PEEK) Polyimides Polyphenylene sulfide (PPS)

Engineering thermoplastics are sold in much lower quantities and are thus more expensive per unit weight. Despite this, they are widely used in everyday products. For example ABS is used to manufacture car bumpers, dashboard trim and Lego bricks, polycarbonate is used in motorcycle helmets and polyamides (nylons) are used for skis and ski boots. an engineering plastic is chosen for its range of enhanced physical properties e.g. polycarbonate is highly impact resistant and polyamides are highly resistant to abrasion. In these types of applications, designers are looking for plastics that can replace traditional engineering materials such as wood or metal. The advantage gained is the inherent formability (ease of manufacture) of plastics as opposed to metal-working or fabrication. Other properties exhibited by various grades of engineering plastics include high heat resistance, mechanical strength, rigidity, chemical stability and flame retardency.

Acrylonitrile Butadiene Styrene (ABS)

Acrylonitrile butadiene styrene (ABS) (chemical formula (C8H8)x (C4H6)y(C3H3N)z). It is a copolymer made by polymerizing styrene and acrylonitrile in the presence of polybutadiene. The proportions can vary from 15 to 35% acrylonitrile, 5 to 30% butadiene and 40 to 60% styrene. The result is a long chain of polybutadiene criss-crossed with shorter chains of poly(styrene-coacrylonitrile). The nitrile groups from neighboring chains, being polar, attract each other and bind the chains together, making ABS stronger than pure polystyrene. The styrene gives the plastic a shiny, impervious surface. The butadiene, a rubbery substance, provides resilience even at low temperatures. For the majority of applications, ABS can be used between 25 and 60 C as its mechanical properties vary with temperature.

Properties
The most important mechanical properties of ABS are impact resistance and toughness. A variety of modifications can be made to improve impact resistance, toughness, and heat resistance. Impact resistance does not fall off rapidly at lower temperatures. Generally ABS would have useful characteristics within a temperature range from -40 to 100 C. Fibers (usually glass fibers) and additives can be mixed in the resin pellets to make the final product strong and raise the operating range to as high as 80C.

Applications
ABS is a common thermoplastic used to make light, rigid, molded products such as piping, musical instruments, golf club heads, automotive body parts, wheel covers, enclosures, protective headgear, buffer edging for furniture and joinery panels. Camper tops, Communications equipment, Refrigerator liners etc. Large components for recreational vehicles, Luggage shells, Boat hulls etc.

Polycarbonates (PC)
Polycarbonates, commonly known by the trademarked name Lexan, are a particular group of thermoplastic polymers. They are easily worked, moulded, and thermoformed. Polycarbonate can be synthesized from bisphenol A and phosgene (carbonyl dichloride, COCl2). The first step in the synthesis of polycarbonate from bisphenol A is treatment of bisphenol A with sodium hydroxide. This deprotonates the hydroxyl groups of the bisphenol A molecule.The deprotonated oxygen reacts with phosgene through carbonyl addition to create a tetrahedral intermediate, after which the negatively charged oxygen kicks off a chloride ion (Cl-) to form a chloroformate.The chloroformate is then attacked by another deprotonated bisphenol A, eliminating the remaining chloride ion and forming a dimer of bisphenol A with a carbonate linkage in between.Repetition of this process yields a polycarbonate with alternating carbonate groups and groups from bisphenol A.

Lenax

Properties
Polycarbonates are engineering thermoplastics with high molecular weight and impact strength, and good electrical and insulating characteristics. Tough, transparent, heat and flame resistant, these materials are normally not affected by greases, oils or acids. In unreinforced states, polycarbonates can withstand temperatures as low as -65F, and once molded, be exposed to boiling water without dimensional changes of more than 0.0001 in. / in. after being returned to room temperature.

Applications
Vacuum-cleaner impellers and housings. Grills for fans and air conditioners . Bowls and cutting wheels for food processors. Automotive instrument panels . Indoor and outdoor lighting diffusers. Skylights and oudoor signs. Safety helmets. Microwave wear. Food-service wear.
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Polyamides (PA)
A polyamide is a polymer containing monomers of amides joined by peptide bonds. They can occur both naturally and artificially, examples being proteins, such as wool and silk, and can be made artificially through step-growth polymerization, examples being nylons, aramids, and sodium poly(aspartate). The amide link is produced from the condensation reaction of an amino group and a carboxylic acid or acid chloride group. A small molecule, usually water, or hydrogen chloride, is eliminated. The amino group and the carboxylic acid group can be on the same monomer, or the polymer can be constituted of two different bifunctional monomers, one with two amino groups, the other with two carboxylic acid or acid chloride groups.Amino acids can be taken as examples of single monomer reacting with identical molecules to form a polyamide.

Properties
Excellent Polarity, Crystallinity, Sharp meltpoint and Strength. It is Transparent (barely). It has good Anti-frictionToughness.

Excellent Fatigue resistance.

Applications
PA is used in circuit boards High temperature parts Low friction bearings, sliding parts Gears

Polybutylene terephthalate (PBT)

Polybutylene terephthalate (PBT), is a semi-crystalline thermoplastic polyester. It has a hard, durable surface and superior chemical resistance, especially to chlorine. It has better impact resistance and elongation than PET, and is less brittle.

Properties
It is a thermoplastic crystalline polymer, and a type of polyester. PBT is resistant to solvents, shrinks very little during forming, is mechanically strong. The heat-resistant is up to 150C (or 200C with glass-fibre reinforcement) and can be treated with flame retardants to make it noncombustible. It has low moisture absorption, good dimensional stability, low coefficient of friction, good ductibility, noise dampening qualities, no centerline porosity, and excellent wear resistance in wet or dry conditions.

Applications
It is used in manumacturing of Bearings, Bushings and Food contact parts. PBT is used in Spacers and Thrust washers. PBT is also usedin Insulators, Pump components and Seals

Polyethylene terephthalate (PET)

PET (Polyethylene Terephthalate also known as PETE), is a thermoplastic polyester that can be either amorphous or crystalline (or a mixture of both) depending on how it is processed. It is also known as APET (Amorphous Polyethylene Terephthalate). In its crystalline state for oven trays, it is known as CPET, and when used for oriented film, it is called OPET.

Properties
PET is a durable, tough plastic with good chemical, high energy radiation, weather, wear and abrasion resistance. It is a good electrical insulator with excellent dimensional stability and high strength and stiffness. It has a low coefficient of friction, low creep, a high modulus, and meets FDA regulations. It has 1/2 the moisture absorption of acetal and 10 times less than nylon.

Applications
In manufacturing of Carbonated soft drink and water bottles andFreezer to oven food packaging trays. In manufacturingof Valves, Bearings, Bushings, Guides, Insulators, Pump components and Seals. Exterior body parts, Electrical components.

Polyphenylene oxide (PPO)

PPO is a high-performance polymer and an engineering thermoplastic. Since most polymers are processed at high temperature in a liquid-like state, a heat-resistant polymer such as PPO will not liquefy at reasonable temperatures, and in its pure form it cannot be processed. For this reason, PPO is often made into blends with high-impact polystyrene (HIPS for short). Blending PPO with HIPS makes the PPO easier to process, plus it gives PPO some resilience. PPO needs this toughening because by itself PPO can be brittle in some situations. PPO is made by oxidative coupling polymerization of the monomer 2,6-dimethylphenol. Water is a byproduct, and so this is a condensation polymerization.

Properties
PPO has excellent Thermal stability. It has Good cold properties (-275o F). It has Low water absorption, Low heat expansion. Good solvent resistance, but can be solvent welded.

Applications
Used to replace stainless steel for surgical equipment. Used in Ball cocks and tank trim, Beverage dispenser components. In automotives it is used as Gauges and instrument parts, Coil forms and bobbins, Fender extensions, Mass transit seat housings. Used in Radio and TV components, Connectors and live guards, Motor controls and wiring devices.

Polysulphone (PSU)
Polysulfone describes a family of thermoplastic polymers. These polymers are known for their toughness and stability at high temperatures. They contain the subunit aryl-SO2-aryl, the defining feature of which is the sulfone group. Polysulfones were introduced in 1965 by Union Carbide. Due to the high cost of raw materials and processing, polysulfones are used in specialty applications and often are a superior replacement for polycarbonates.

Polysulphone repeating units

Properties
These polymers are rigid, high-strength, and transparent, retaining these properties between 100 C and 150 C. Polysulfone is highly resistant to mineral acids, alkali, and electrolytes, in pH ranging from 2 to 13. Mechanically, polysulfone has high compaction resistance, recommending its use under high pressures. Its glass transition temperature is 185 C.

Applications
Polysulfone is used as a dielectric in capacitors. Polysulfone is also used as a copolymer. Polysulfone is used as filtration media. The pore size can be very small, down to 0.2 m or less for use in filter sterilization. Polysulfone was the primary component of the gold-plated Lunar Extravehicular Visor Assembly, the iconic gold-film visor portion of the Apollo space-suits worn by Apollo astronauts during their lunar excursions.

Polyetheretherketone (PEEK)
Polyetheretherketone (PEEK), is a semi-crystalline thermoplastic with a high operating temperature that is used for injection molding, film, and advanced structural composites. PEEK polymers are obtained by step-growth polymerization by the dialkylation of bisphenolate salts. Typical is the reaction of 4,4'-difluorobenzophenone with the disodium salt of hydroquinone, which is generated in situ by deprotonation with sodium carbonate. The reaction is conducted around 300 C in polar aprotic solvents - such as diphenylsulphone.

Properties
PEEK is a semicrystalline thermoplastic with excellent mechanical and chemical resistance properties that are retained to high temperatures. The Young's modulus is 3.6 GPa and its tensile strength 90 to 100 Mpa. PEEK has a glass transition temperatures at around 143 C and melts around 343 C (662 F). It is highly resistant to thermal degradation as well as attack by both organic and aqueous environments. Unreinforced PEEK offers good wear resistance, while carbon reinforced PEEK has excellent wear capabilities.

Applications
PEEK is used in the nuclear, electronics, aerospace, petroleum and analytical as well medical equipment industries PEEK is used to fabricate items used in demanding applications, including bearings, piston parts, pumps, compressor plate valves, and cable insulation. It is used in manufacturing of Wire and cable coatings, Automotive engine parts, Woven monofilaments, Film, Liquid chromatography parts.

Polyphenylene sulfide (PPS)

Polyphenylene sulfide ("PPS") is an organic polymer consisting of aromatic rings linked with sulfides. Synthetic fiber and textiles derived from this polymer are known to resist chemical and thermal attack. PPS can be injection and blow molded, extruded and compression molded, and machined parts are available. PPS may be bonded to itself or other materials with adhesives or through thermal or ultrasonic welding. Polyphenylene sulfide is an engineering plastic, a highperformance thermoplastic. An easy way to identify the plastic is by the metallic sound it makes when struck.

Polyphenylene sulfide

Properties
It offers the best resistance to chemicals of any advanced engineering plastic, and is suitable for applications requiring thermal stability to 425 and structural integrity to 225. PPS is resistance to heat, acids and alkalies, and to mildew, to bleaches, aging, sunlight, and abrasion. Machinable to tight tolerances, it absorbs virtually no moisture, and has superior dimensional stability.

Applications
PPS is used as High pressure liquid chromatography components, Electronic test sockets and fixtures, Flow meter rotors, Engine sensors. Used in Halogen lamp sockets, Chemical processing, Medical and diagnostic devices, Valve and pump components. PPS is used to make filter fabric for coal boilers, papermaking felts, electrical insulation, specialty membranes, gaskets, and packings. Synthetic fiber and textiles derived from this polymer are known to resist chemical and thermal attack.

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References
www.wikipedia.com Engineered-plastics.pdf www.quadrantepp.com www.zeusinc.com Material Properties Data Harper C.A., Handbook of plastic and elastomers, McGraw-Hill, New York, 1975 WAVE Polymer Technology : PET (Polyethylene Terephthalate) flakes processing"

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