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Polymers
Introduction
Definition
Polymers Terminology
Development of Polymers
What are polymers?
Raw Materials
Additive Agents in Plastics & their
Purpose
General Properties
Applications
Polymers
Polymerization
Polymerization Reactions
Categories of Polymers
Polymer Microstructure
Comparison b/w Thermoplastic &
Thermosetting materials
Thermoplastic materials
Thermosetting plastics
Special applications
Major Polymer Processes
Recycling
All Materials
Simple
Liquids
Gases
Metals
Ceramics
Solids
Polymers
(polymeric molecules)
Thermoplastics
Heat Forming
Thermosets
Heat Setting
Elastomers
Terminology
A polymer is any substance made up of many of repeating
units, building blocks, called mers.
When in form ready for further working, they are called
resins.
Polymers - seldom used in their neat form,
most often compounded with various
material is referred as a plastic.
Plastic: a polymer that can be molded when hot and retains its
shape when cooled
Frequently, polymers,
interchangeably.
resins,
plastics
are
used
Development of
Polymers
First synthetic polymers:
Polyvinyl chloride
(PVC) in 1838
Polystyrene in 1839
Polyvinylchloride(PVC)
Polymers Categories
Two Categories:
Natural polymers:
Wood, rubber,
wool, cotton,
leather, silk
Synthetic polymers:
Fibers
Plastics
Elastomers
Purpose
Coloring agentspigments)
Impart color
Flame
ester
retardants-
(dyes
and
phosphate
Reduce flammability.
Retard degradation due to heat or
General Properties
include:
Light weight: Most polymers have specific gravities between 1.1
and 1.6, compared with about 1.75 for magnesium (the lightest
engineering metal).
Corrosion resistance: Many polymers perform well in hostile,
corrosive, or chemical environments. Some are notably resistant
to acid corrosion.
Electrical resistance: polymers are widely used as insulating
materials.
Low thermal conductivity: polymers are relatively good thermal
insulators.
Variety of optical properties: Many polymers have an almost
unlimited colour range, and the colour goes throughout, not just on
the surface. Both transparent and opaque materials are available.
General Properties
Formability or ease of fabrication:
Objects can frequently be produced in a single operation.
Raw material can be converted to final shape through such
processes as casting, extrusion, and molding.
Relatively low temperatures are required for the forming of plastics.
Surface finish: The same processes that produce the shape also
produce excellent surface finish. Additional surface finishing may not be
required.
Applications
In less than a century, use of plastic has increased
tremendously throughout the
are limitless.
The United States currently produces more plastic than steel,
aluminum, and copper combined.
artificial organs,
Applications
Used in
packaging and container applications,
due to their light weight, attractive appearance, and
ease of fabrication
Applications
insulation on electrical wires and handles for hot articles
Soft, pliable, foamed plastics used extensively as cushioning
material.
Rigid foams are used inside sheet metal structures to provide
compressive strength.
Nylon has been used for gears, acrylic for lenses, and
polycarbonate for safety helmets and unbreakable windows.
Polymerization
Polymerization is a
process of reacting
monomer molecules
together in a
chemical reaction to
form three
dimensional networks or polymer
chain.
Polymerization
Two methods are used to achieve polymerization:
Addition / Chain polymerization, where two or more
similar monomers directly react to form these long-chain
molecules; and
Polymerization
Two methods are used to achieve polymerization:
condensation polymerization (Step reaction),
where two or more dissimilar monomers react to form
long-chain molecules plus the by-product water.
Not Cross-Linked
90% of market
Thermosets/Elastomers
Will not reform
Cross-linked
10% of market
Polyethylene
33%
Vinyls
16%
Polypropylene
15%
PMMA
ABS
Nylon
Polycarbonate
Saturated Polyester
PEEK
Polyurethane
Some are thermosets as well.
PVC
Epoxy
Melamine Formaldehyde
Phenolic
Polyester (unsaturated)
Polyimide
Polyurethane
Some are thermoplastic as well.
Silicone
Urea Formaldehyde
Types of Polymers
Types of Polymers
Polymer Microstructure
Polymer = many mers
mer
H H H H H H
C C C C C C
H H H H H H
mer
H H H H H H
C C C C C C
H Cl H Cl H Cl
Polyethylene (PE)
mer
H H H H H H
C C C C C C
H CH 3 H CH 3 H CH 3
Polypropylene (PP)
Linear
Branched
Cross-Linked
Network
Comparison of Polymers
Thermoplastics
:
--little cross
linking
--ductile
--soften w/heating
--Easily molded
--easily recycled
e.g.,
--polyethylene
--polypropylene
polycarbonate
Thermosets:
--large cross linking
(10 to 50% of
mers)
--hard, rigid and brittle
--do NOT soften
w/heating, heat resistant
e.g.,
--vulcanized rubber,
epoxies,
polyester resin,
phenolic resin
7
Thermoplastic materials
Thermoplastics require heat to make them formable and
after cooling retain the shape they were formed into.
These materials can be reheated and reformed into new
shapes a number of times without significant change in
their properties, as in the melting of paraffin. Recyclable.
may be used as additive to improve Impact strength of
rigid thermoplastics.
processed
by
injection,
blow
molding,
extrusion,
Thermoplastics
Polyethylene
Cheapest ands simplest synthetic polymer
Invented shortly before World War II
Made from CH2=CH2
Thermoplastics
Polyethylene
Has two forms
High-density polyethylene
(HDPE)
Low-density polyethylene
(LDPE)
Thermoplastics
Polyethylenes
The most used polymer,
corrosion resistant,
low heat resistant (<100C),
weak mechanical properties
but
strengthenable at
high molecular weight.
Applications:
PE Products
Polypropylene
Change a H to CH3
Harder and has higher melting point than
polyethylene
Thermoplastics
Polypropylenes (PP):
low density, as plastics or as fibre,
injection mouldable,
heat resistant (up to 160 C),
PP Gloves
water
Applications
food containers, synthetic carpets,
PP Chair
Polystyrene
Change a H to benzene ring
Widely used
Disposable cups
Insulation
Thermoplastics
Polystyrenes (PS):
hard plastic,
cheap,
Applications
3 different PS cups
computer casing,
kitchen appliances,
model cars and airplanes
hard plastic parts inside cars,
also in foam forms, for wrapping,
packing and as insulation
PS Foam
Vinyl Polymers
Change a H to Cl
Tough thermoplastic
Polyvinyl chloride (PVC)
Thermoplastics
Polyvinyl chlorides (PVC)
rigid or flexible,
corrosion resistant,
water resistant,
fire resistant,
Applications
plumbing pipes,
rain coat and shower curtains,
chemical containers,
vinyl clothing.
Polyamides: Nylon
Usually made from reaction of diacids with diamines, but
may also be made from a single monomer with an
amino group at one end and acid group at other.
Thermoplastics
Nylon (polyamides):
low coefficient of friction;
high strength in tension,
abrasion resistance and toughness;
excellent dimensional stability;
good heat resistance;
Uses
mostly used in fibre form,
as monofilaments for textiles
products
fishing line, and ropes
zip fasteners
used for small gears and bearings,
Nylon rain jacket
Polyesters
polymer of terephthalic acid and ethylene
glycol.
Made by the transesterification of the methyl
ester.
Polyester
Polyester is a
copolymer.
made from equal
amounts of two
different monomers.
Polyester is used to
make bottles and
fabrics.
Teflon
Change all H to F
CF very strong.
Resists heat and chemicals
Makes very unreactive polymer
Thermoplastics
Fluorocarbons (PTFE,
Teflon):
usable at high temperatures,
corrosion resistant,
low coefficient of friction,
Inert in most chemicals
Applications
Corrosion coatings,
thread seal tape,
non-lubricated bearings
nonstick coatings for cooking
utensils and electrical irons.
Polycarbonates
Esters of carbonic acid.
Carbonic acid is in equilibrium with CO2 and
water, but esters are stable.
React phosgene with bisphenol A to obtain
Lexan for bulletproof windows.
CH3
O
Cl
Cl
+ HO
OH
CH3
O
CH3
C O
C
CH3
O
O C O
n
Thermoplastics
Polycarbonates
(PC):
transparent,
good toughness,
Applications
sun glasses,
windows and
sunroofs
PC roof sheet
Thermoplastics
ABS
has excellent electrical properties,
high impact and tensile strength, and
is resistant to heat and chemicals.
Uses
Monofilaments of polypropylene are used in making rope, nets,
and textiles.
Other products are
hospital and laboratory ware,
toys, luggage,
furniture,
film for food packaging,
television cabinets, and electrical insulation.
Polyurethanes
Esters of carbamic acid, R-NH-COOH.
Urethanes are prepared by reacting an alcohol
with isocyanate.
Polyurethanes are prepared by reacting a diol
with a disocyanate.
O C N
N C O
+ HO CH2CH2 OH
CH3
H O
O H
N C O CH2CH2 O C N
H O
N C O CH2CH2
CH3
Thermoplastics
Polyurethane
Thermoplastic PU (TPU) have some
crosslinking, but purely by physical
means.
These
bonds
can
be
broken
as
in
molding
or
Thermoplastics
Polyurethane
Uses
Rigid foams: Laminated board
insulation, sprayed foam, packaging
stock,
Moldings,
Polyurethane applications
Other Polymers
Thermosetting plastics
Thermosets, also known as thermosetting
plastics, may also be formed upon heating.
The shape is permanently "set" on cooling by
a chemical reaction which cannot be reversed,
i.e. it is impossible to reshape by heating.
Heating to above a critical temperature will
only cause decomposition of the structure and
degradation of properties.
Not recyclable.
Thermosetting plastics
Thermosetting plastics usually have a highly cross-linked or
three-dimensional framework structure in which an atoms are
connected by strong, covalent bonds.
generally produced by condensation polymerization where
elevated temperature promotes an irreversible reaction, hence
the term thermosetting.
Once set, subsequent heating will not produce the softening
observed with the thermoplastics.
maintain their mechanical properties up to the temperature at
which they char or burn.
Thermosetting Plastics
Thermosetting polymers are significantly stronger and more
rigid than the thermoplastics.
can
resist
higher
temperatures
and
have
greater
dimensional stability,
but they also have lower ductility and poorer impact
properties.
are not heat reversible.
In a sense, curing a thermoset is like cooking an egg.
Once it is cooked, reheating does not cause re-melting, so it
cannot be remolded.
Thermosets
Phenolics:
good strength,
relatively fragile,
high temperature
applications
Applications
Pot and pan handles,
Bakelite (the original
plastic, substrates for
electronics.
Thermosets
Polyesters Resins:
Polyesters (can be thermoplastic or
thermoset):
Have strong and good resistance to
environmental influences,
good mechanical properties,
castable
Applications
uses include boat and car bodies,
pipes, vents and ducts,
textiles,
adhesives, coatings, and laminates
Fiberglass resin, automotive trims.
Fibreglass hull
Thermosets
Epoxies:
Epoxies are known for:
excellent adhesion
chemical and heat
resistance
high mechanical
resistance & high
corrosion resistance,
high resistivity,
very good electrical
insulating properties
Fiberglass/Epoxy
Epoxy based materials are
used for
coatings, adhesives and
composite materials
(resin for carbon fiber and
glass-reinforced plastic).
Adhesives (Araldite),
anti-corrosion paints,
over-moulding of ICs,
THERMOSETS
Melamines:
excellent resistance to heat, water, and
many chemicals;
full range of translucent and opaque colors;
excellent electric arc resistance; tableware
(but stained by coffee);
Uses
used extensively in treating paper and
cloth to impart water-repellent properties
THERMOSETS
Urea-formaldehyde:
properties similar to those of phenolics but
available in lighter colors;
useful in containers and housings, but not
outdoors;
used
in
lighting
fixtures
because
of
Special applications
Thanks
Extrusion
Injection Molding
Blow Molding
Thermoforming
Recycling
Polymer Processes
Extrusion
Extrusion Characteristics
The extrusion machine forms the basis of
nearly all other polymer processes.
Basically involves melting polymer pellets
and extruding them out through a two
dimensional die.
Produces long, thin products
Coating for electrical wire
Fishing Line
Tubes, etc.
Injection Molding
Thermoforming
Thermoforming Products
Recycling
Recycling of Plastics
The favorite
properties of plastics
are that they are
inert and won't react
with what is stored in
them.
They also are
durable and won't
easily decay,
dissolve, decompose
or break apart.
Polymer Recycling
1998 Approximately 20% of plastic
waste is recycled (optimistic estimate)
1998 Polymers account for
approximately 18% by volume of material
to landfills
Challenges
10-12 main
polymer types
Thousands of
blends
Additives
Impurities in
supply (labels,
glass, dirt, etc)
Thanks
Engineering Materials