Transcript File

ENGINEERING PLASTICS
&
APPLICATIONS
ALOK KUMAR
CENTRAL INSTITUTE OF PLASTICS ENGINEERING
& TECHNOLOGY,
USAGE OF PLASTICS IN MODERN
CARS
Dismantling of >40 modern European cars reveled that in
130 Kg plastics per car– 43% PP, 14% PU, 8%Nylons, 8%PE
GLOBAL PLASTICS USAGE
0.43%
PP
PET
21%
0.44%
7%
PVC
PE
17%
36%
0.26%
PC
Acrylics
1%
2%
s
PS/ SAN/ ABS
Nylon 6 & 66
15%
1%
PE
PET
Acetal
PVC
PP
EPS
Nylon 6 & 66
PC
Acrylics
PBT
PS/SAN/ABS
79 % Plastics consumed – PE+PP+PVC+Styrene's
THERMOPLASTICS IN SE ASIA
LL/LLDPE
17%
PVC
20%
HDPE
14%
PP
24%
PC EPS
2% 3%
PET
4%
GP-HIPS
8%
ABS/SAN
6%
Other ETPs
2%
PP
PVC
LL/LLDPE
HDPE
GP-HIPS
ABS/SAN
PET
EPS
PC
Other ETPs
PLASTICS END USE PATTERN
Health
2%
Telecom/el
ec.
16%
Defence &
other
Consumer
2%
5%
Transport
6%
Infrastructur
e
24%
Packageing
23%
Plasticultur
e
22%
Area
%
Consumption
Defense & others
2.0
Consumer
Durables
5.0
Transport
6.0
Packaging
23.0
Plasticulture
22.0
Infrastructure
24.0
Telecom/
Electronics
16.0
Health &
Medicare
2.0
PLASTICS-THE MATERIAL
OF CHOICE
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User Friendly
Versatility
Light-weight
Energy Efficient
Non-corrosive
Aesthetic
Abundant
Recyclable
PLASTICS – Emerging Material
to meet
Engineering Application Demands
• Density
• MFI (Melt flow Index)
• Mechanical Properties
• Impact Strength
• Stiffness
• Toughness
• Creep Resistance
• Abrasion Resistance
• Tear Resistance

Optical Properties
 Gloss Clarity
& Opacity
PLASTICS – Emerging Material
to meet
Engineering Application Demands

Environmental Stress Cracking Resistance
• Chemical Resistance
 Acid Resistance
 Alkali Resistance
 Hazardous Chem. Resistance
( Pesticide / Insecticide)
 Barrier Properties
 Water Vapour Transmission Rate
 Oxygen Transmission Rate
 Aroma Transmission Rate
PLASTICS – Emerging Material
to meet
Engineering Application Demands
• Easy Processibility

Printability

Sealing Property
 Seal Strength

Cost Effectiveness

Product Design Flexibility
CALASSIFICATION OF PLASTICS
PLASTICS
THERMO-PLASTICS
COMMODITY
THERMO-SETTING
ENGINEERING
SPECIALITY
DEFINATION
COMMODITY THERMOPLASTICS
Very High Volume, Low cost,Low
strength, Low Heat Distortion Temp.
ENGINEERING PLASTICS
High strength, High HDT, Low Volume,
High Cost
SPECIALITY THERMOPLASTICS
Very Low Volume, Very High Cost,
Excels in Specific Performance
Requirements.
MAJOR COMMODITY PLASTICS
1.
2.
3.
4.
5.
6.
LOW DENSITY POLYETHYLENE (LDPE)
LINEAR LOW DENSITY POLYETHYLENE (LLDPE)
HIGH DENSITY POLYETHYLENE (HDPE)
POLY PROPYLENE (PP)
POLY VINYL CHOLORIDE (PVC)
POLY STYRENE (PS)
MAJOR
ENGINEERING THERMOPLASTICS
1.
2.
3.
4.
5.
6.
7.
8.
9.
ACRYLO NITRILE BUTADIENE STYRENE (ABS)
STYRENE ACRYLONITRILE (SAN)
POLYMETHYL METHACRYLATE (PMMA)
POLYAMIDE - (PA)
POLYETHYLENE TEREPHTHALATE- (PET)
POLYBUTYLENE TEREPHTHALATE- (PBT)
POLYOXYMETHYLENE - (POM)
POLY CARBONATE - (PC)
HIGH IMPACT POLYSTYRENE (HIPS)
MAJOR SPECIALITY PLASTICS
1.
2.
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10.
11.
POLYTETRA FLUOROETHYLENE (PTFE)
THEROPLASTIC POLYURETHANE (TPU)
POLY SULPHONE (PSO)
POLY ETHER SULPHONE (PES)
POLYPHENYLENE SULPHIDE (PPS)
POLYPHENYLENE ETHER (PPE)
POLY ETHER ETHER KETONE (PEEK)
POLY ACRYLATE
POLY AMIDE – IMIDE (PAI)
POLY ETHER – IMIDE (PEI)
LIQUID CRYSTAL POLYMERS (LCP)
MAJOR THERMOSET PLASTICS
1.
2.
3.
4.
5.
6.
PHENOL FORMALDEHYDE (PF)
UREA & MELAMINE FORAMLDEHYDE
EPOXY RESINS
UNSATURATED POLYESTER RESIN
POLYURETHANES
SILICONES
Thermal Properties of Thermoplastics
Heat Deflection Temperature (°C)
Continuous Use Temperature (°C)
300
250
200
150
100
50
0
PC
POM
PSU
PET
PEI
PES
PPS
PEEK
CRITERIA FOR PERFORMANCE
High Performance
Temperature
Engineering
Commodity
PC
PA 11
PA 6/12
POM
PA 6
PA 6/10
PA 6/6
PA 12
TPU
PA 6/6 HI
PBT
TPE
PPO
PCA – PC/ABS
PEI
PSU
PES
PEEK
PPS
ABS
SAN
PS
HDPE
PP
Mechanical Property retention
LCP
TOP SEVEN ENGINEERING
PLASTICS
TYPICAL
PROPERTIES
PA 6
PC
PPO
POM
PBT
PPCP
ABS
IZOD Notched
(Kg. cm/cm)
16
85
23
10
6
15
20
HDT (ºc)
104
132
120
110
55
60
82
Water
Absorption (%)
1.5
0.15
0.07
0.3
0.08
Neg.
0.4
Flammability
UL94 (1.47mm)
HB
V2
HB
HB
HB
HB
HB
Sp. Gravity
1.14
1.20
1.06
1.42
1.31
0.9
1.05
Tensile Strength
(Kg/Sq .Cm)
340
600
500
650
500
300
400
Flex. Mod.
(Kg/Sq. Cm)
9500
24000
25000
26000
23000
13000
23000
MAJOR ENGINEERING
PLASTICS
STRENGTHS
AMORPHOUS (PC, PPO, ABS)
• Constant mechanical properties versus
temperature
• Dimensional stability
• Creep Resistance
• Low Shrinkage
• Transparency possible
CRYSTALLINE (PP, POM, PBT/PET)
• Resistance to hydrocarbons
• Good flow behaviour
• Wear and Fatigue resistance
POLYAMIDES
• Several types are available based on raw material
used
• Most widely used polyamides are Nylon 6 & 66
• Condensation reaction of dicarboxylic acids and
diamins (Commercially through the route of
intermediate salts) ---- Nylon 6,& 66
• Ring opening reaction of lactam – Nylon 6, Nylon 12
etc.
• Condensation reaction of amino acids – Nylon 7,
Nylon 11 etc.
POLYAMIDES
Characteristics of Polyamides
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Semi-crystalline material
Polar in nature
Resistant to hydrocarbon solvents, grease, lubricants
Hygroscopic
High to medium rigidity – improved by glass fibre filling
Good electrical insulation – adversely affected by moisture
absorption.
Good abrasion resistance and low coefficient of friction
Flame retardant versions are difficult process.
Dimensions affected by humidity.
Not good temp. resistance under load – improved by glass
fibre filling.
POLYAMIDES
APPLICATIONS OF POLYAMIDE
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Gear, Cams, bushes, Bearings
Valve Seats
Terminal Blocks
Connectors
Automotive Exterior
Under bonnet Automotive Parts
Motor Housing
Optical fibre Sheathing (Nylon 12)
Insulating liners (Railways
Hair combs
PA In AIR CRAFT
Application: Aircraft Engine Components
Material: - PA46-GF30
•Airbus
•Injection
moulding
• Highly complex shape minimize the noise level
• Design freedom at low costs
• High impact properties in a wide temperature range
• wall sections as thin as possible- thus reducing valuable weight.
PA in Agricultural film
Application: Agricultural Barrier Film
Material: PA6-unfilled
Extrusion
Processing
Technology
Barrier Film for agricultural use with environmental benefits.
•
When used to cover the soil together with the injection of
fumigation chemicals, lower levels of the fumigant can be
used. As the film keeps the active agent in the soil for longer.
PA in Automotive, Air/fuel management
Application: Air duct
Material:- PA6-GF20
Blow Molding
Processing
Technology
Air-duct design offers the best combination of the demanding requirements for:
high temperature air ducts.
· higher cold impact than other similar materials
· higher stiffness at high temperatures (150°C) allowing thinner walls
to be designed.
· high melt strength and a low melt viscosity for optimum Production
PA in AUTOMOTIVE, AIR/FUEL MANAGEMENT
Application: Air inlet manifold
Material: PA6-GF30
Injection
Molding
Ford UK
PA6: The material of choice for
air inlet manifolds
• ‘Fuel economy’ & ‘weight reduction’
• Single molding and replacing aluminium and steel by
plastics
• Provides the chemical, temperature and vibration
resistance required to survive the expected life of
vehicles.
• lower system costs compared to metals through part
and function integration,
• Easier assembly and longer tool life.
• Temperature resistance and a higher burst pressure
resistance after welding.
• Providing safer solutions or more design freedom,
as well as lower system costs as a result of an easier
• Processibility and better surface appearance.
POLY CARBONATE
POLYCARBONATE
• Poly carbonate was first developed in the laboratory
of GE in 1953.
• It was first commercialised in 1958 by GE under the
Trade name of LEXAN
• Polycarbonate Lexan is an ester of carbonic acid.
• LEXAN is commercially produced by
polycondesation of Bisphenol A and Phosgene
POLY CARBONATE
CHARACTERISTICS :
• Highest impact strength
• High rigidity
• High dimensional stability
• High heat distortion temp
• Usability in the temperature range of -50 deg. To 135 deg.
• Flame retardancy and low combustibility
• High optical clarity
• Good electrical insulation properties
• Good strain resistance
• Low water absorption
• Food grades available.
• Good low temp. impact strength
POLY CARBONATE
APPLICATIONS:
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AUTOMOTIVE HEADLAMPS, REFLECTORS AND LENSES
INDICATORS AND BLINKERS
DASH BOARD COMPONENTS
CRASH HELMETS
TELECOM CONNECTORS
DOMESTIC ELECTRICAL SWITCHES
TRAFFIC SIGNAL LENSES
SIGNAL HOUSINGS
TELEGRAPHIC POLE INSULATOR
TERMINAL BLOCKS
LIGHT DIFFUSER
STREET LAMP CANOPIES
BUSINESS MACHINE COMPONENTS
POLY CARBONATE
APPLICATIONS
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BABY FEEDING BOTTLES, MIXIE JARS
BLOOD OXYGENATORS
I.V. CANNUELA
FACTORY ROOFINGS
RAILWAYS PLATFORMS FOOFINGS/BUS STOPS
SAFETY GLAZINGS
TELEPHONE BOOTHS
OFFICE AND FACTORY PARTITIONS
COMPACT DISKS AND OPTICAL DATA STORAGE DISKS
RETURNABLE WATER AND MILK BOTTLES.
PC in AUTOMOTIVE, AUTO LIGHTING
Application: Head lamp bezel
Material: PC-unfilled
Injection
molding.
Audi
Headlamp bezels require
Excellent surface finish & aesthetics
Good heat resistance and be warpage free
Metallic effect and an exceptional appearance.
PC in Electrical / Electronics,
Telecommunication
Application: Mobile phone travel charger
Material: - PC-unfilled
Injection
Molding
Philips
A charger for a mobile phone require :
- Very high aesthetic
- Withstand severe drop tests
- Resistant to all kind of chemical substances,like hand lotions &
soaps.
- Flame retardant and has to pass the pressure test at 125 ºC.
PC in ELECTRICAL LIGHTING
Application: Lamp holder fluorescent lamp,
Material:- PC
Injection
molding.
Fluorescent lamp holders require:
Tough materials with good flow to be able to mold the components
easilyPC being easy flowing and with excellent mold release.
PC in Electrical / Electronics
: Application: ATM - PC-unfilled
This processing technique makes it possible to attain a cost-saving of up to
300%, when for instance changing from cast aluminium to plastic mouldings
for cash dispensers (ATM’s). This molding is by made the ‘low pressure foam
process’ to produce a 7,5 kg moulded automated telling machine fascia.
Although the main driving force is cost reduction, issues like weight reduction,
torsional stiffness, vandal resistance, paint ability to class A surface finish,
dimensional stability
THERMOPLASTIC POLY ESTER
(PET & PBT)
• Crystalline in nature
• Based mainly on polybutylene
terephthalate. A few grades based on
polyethylene and polycyclohexane
dimethanol terephalate are also available
• The base resins are commercially
manufactured by Esterification reaction of
Terephthalic Acid and appropriate diols.
THERMO PLASTIC POLYESTER
(PET & PBT)
CHARACTERISTICS
• High Mechanical Strength
• Excellent chemical resistance
• High temperature resistance in glass filled grades
• High dimensional stability
• Excellent Electrical tracking resistance
• Can be made flame retardant
• Effect of humidity minimal
• Excellent flow
THERMOPLASTIC POLYESTER
(PET & PBT)
APPLICATIONS:
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Connectors
TV Components
Industrial Switches/plug’s
Business machine components
Keyboard buttons
Steam irons
Cookers
Air vents
Plumbing
Auto ignition systems
Under bonnet connectors
Head lamp reflectors
PBT IN AUTOMOTIVE
Application: Actuator, Gear housing window Lift
Material: PBT-GF20
* Dimensional stability for
reliable performance in all
conditions
*Automotive window lift
mechanisms demand shock
resistance over a wide
temperature range,-40°C to
+80°C,
*Excellent dimensional stability
and strength up to the maximum
environmental temperature.
Processing Technology: Injection Molding
Opel, Volvo
*Reducing total assembly costs
and weight.
PBT IN AUTOMOTIVE
Application: Air flow mass meter housing and sensor
Material: PBT-GF30
Processing Technology: Injection Molding
Opel
•Stability and Narrow tolerances for
parts close to the engine
•This air-flow mass meter measures
air flow speed for the motor
management control system.
•It has to maintain tight tolerances
over the life of the vehicle and
withstand the temperatures
encountered close to the engine.
• Exceptional dimensional stability
and
strength over a wide temperature
range.
• The best balance of mechanical
properties and good welding
performance,facilitating
manufacturing productivity.
PBT IN AUTOMOTIVE
Application: Sensor, throttle position
Application: E-Box, Fusebox
Material: PBT-GF30
Material: PBT-GF10
PBT IN : Electrical / Electronics, Power distribution
& circuit protect
Application: Compact NS Schneider Material: PBT-GF30
Application: Bobbins Schneider
Material: PBT-GF30
Processing Technology: Injection Molding.
Schneider
PET IN AUTOMOTIVE, BREAKE /CLUTCH
Application: Breake Booster Valve bodies
Material: PET-GF35
•Glass fiber reinforced
polyethylene terephthalate
(PET) is the material of
choice for automotive brake
booster valve body
applications.
• It provides weight,
performance and cost
advantages over previously
used thermosets.
Processing Technology : Injection Molding
ADI BMW
PET IN AUTOMOTIVE, BREAKE /CLUTCH
Application: Tandem brake booster
Material: PET-GF35
•Glass fiber reinforced
polyethylene Terephthalate
(PET) is the material of
choice for automotive brake
booster valve body
applications.
• It provides weight,
performance, and cost
advantages over previously
used Thermosets.
Processing Technology : Injection Molding
Various
POLYACETAL (POM)
• Polymer of formaldehyde, commonly known as
Polyacetal, Acetal polymer or Polyoxymethylene was
first commercialised by Du pont in 1959.
• Copolymers were introduced by celanese
corporation 1960 to overcome thermal stability
problem at processing temp.
• Polyacetal is commercially made by polymerisation
of high purity formaldehyde in rapidly stirred inert
medium like dry heptane with controlled traces of
water added containing phosphine and amine
initiators.
POLYACETAL (POM)
CHARACTERISTICS OF POLYACETAL (POM)
• High crystalline
• High flammable
• Resilient and good combination of stiffness and
toughness
• Creep resistant- superior to polyamide
• Low static and dynamic co-efficient at friction
• Very high degree of precision moulding possible
• Not high temp. resistant
• Resistant to organic solvents upto 70 degree.
POLYACETAL (POM)
APPLICATIONS OF POLYACETAL (POM)
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Gears
Conveyor belt links
Sprockets and chains
Blower wheels
Cams
Fan blades
Carburettor float and bodies
Aerosol containers
Lighter bodies
LPG Cylinder caps
Shower heads
Thank you