CLASSIFICATIONS

OF PLASTICS
ACCORDING TO:
Thermal (Thermomechanical
Response)
Society of the Plastics Industry (SPI),
1988
- to help consumers and recyclers properly
recycle and dispose of each different type based
on its chemical makeup
According to:

THERMAL
(THERMOMECHANCAL)
RESPONSE
 1. Thermoplastics

Soften and flow under the action of heat and

pressure
Upon cooling, the polymer hardens and
assumes the shape of the mold (container)
When compounded with appropriate
ingredients, can usually withstand several of
these heating and cooling cycles without
suffering any structural breakdown. This
behavior is similar that of candle wax.
 Examples of Thermoplastics

Polystyrene
Polyethylene

Nylon
 2. Thermosets

Or thermosetting plastics are synthetic

materials that undergo a chemical change
when they are treated, creating a three-
dimensional network.
After they are heated and formed, these
molecules cannot be re-molten and reformed.
Historical Milestones of Thermosets
Goodyear discovered
1839 vulcanization of rubber.
Historical Milestones of Thermosets
Goodyear discovered
1839 vulcanization of rubber.
Baekeland granted his Heat
1909 and Pressure patent for
phenolic resins.
 Historical Milestones of Thermosets
Goodyear discovered
1839 vulcanization of rubber.
Baekeland granted his Heat
1909 and Pressure patent for
phenolic resins.

1926 Alkyd was introduced.

Historical Milestones of Thermosets
Urea formaldehyde was
1928 introduced commercially.
Historical Milestones of Thermosets
Urea formaldehyde was
1928 introduced commercially.

Ellis patented unsaturated

1933
polyester resins.
 Historical Milestones of Thermosets
Urea formaldehyde was
1928 introduced commercially.

Ellis patented unsaturated

1933
polyester resins.

Henkel made melamine-

1935
formaldehyde resins.
Historical Milestones of Thermosets
Melamine was introduced
1938 commercially.
Historical Milestones of Thermosets
Melamine was introduced
1938 commercially.

1939 First patent on epoxy.

 Historical Milestones of Thermosets
Melamine was introduced
1938 commercially.

1939 First patent on epoxy.

Epoxy introduced
1947
commercially.
 2. Thermosets

Properties:
Cross-linking
Can melt and take shape only once
Irreversible chemical reaction
Retain their strength even when heated
Production of Thermosets
 2. Thermosets
Specific methods of molding thermosets are:
Reactive injection molding
- used for objects such as milk bottle crates
Extrusion molding
- used for making pipes, threads of fabric and
insulation for electrical cables
Compression molding
- used to shape SMC and BMC thermosetting plastics
Spin casting
- used for producing fishing lures and jigs, gaming
miniatures, figurines, emblems as well as production
and replacement parts
Categories of Thermosets
 Examples of Thermosets
NAME PROPERTIES PRINCIPAL USES

Good electrical insulator,

Casting and
hard, brittle unless
Epoxy Resin encapsulation, adhesives,
reinforced, resists
bonding of other materials
chemicals well
Stiff, hard, strong, resists Laminates for work
Melamine Formaldehyde some chemicals and surfaces, electrical
stains insulation, tableware
Stiff, hard, brittle unless
Casting and
laminated, good electrical
Polyester Resin encapsulation, bonding of
insulator, resists
other materials
chemicals well
Electrical fittings, handles,
Stiff, hard, strong, brittle,
Urea Formaldehyde and control knobs,
good electrical insulator
adhesives
According to:

SOCIETY OF THE
PLASTICS INDUSTRY
(SPI), 1988
 Polyethylene terephthalate
(PETE or PET)
A plastic resin and the most common type of
polyester
Two monomersmodified ethylene glycol
and purified terephthalic acidare
combined to form the polymer called
polyethylene terephthalate
Discovered and patented
1 in England in 1941
 Polyethylene terephthalate
(PETE or PET)
Physical Properties:
Has an excellent level of wear resistance compared to
other plastics
Has a high flexural modulus (making it flexible)
Has a superior level of stability making it versatile and
strong
Has a low coefficient of friction making it useful in
various applications in which other plastics are not
The plastic's chemicals do not leak into the fluid or
food stored within it - making it one of the most
important products for food storage
 Polyethylene terephthalate
(PETE or PET)
Uses:
Commonly used in bottles and other plastic
containers. This includes soda bottles, bakery
products, water bottles, peanut butter jars and
even in frozen foods packaging.
Used to hold cosmetics. Since it is easy to mold,
manufacturers can create very specific shapes
for a variety of cosmetic products.
Commonly used for the storage of chemicals,
including household cleaners.
 Examples of PETE or PET

Soda bottles Cosmetic bottles

Household
Cleaner
Bottles
 High-density polyethylene
(HDPE)
Introduction:
Karl Ziegler and Erhard Holzkamp invented high-density
polyethylene (HDPE). The process included the use of
catalysts and low pressure, which is the basis for the
formulation of many varieties of polyethylene compounds.
Thermoplastic material composed of carbon and
hydrogen atoms joined together forming high
molecular weight products as shown in this figure:

2
 High-density polyethylene
(HDPE)
Available in both granular and powder form. The powder form
is cheaper but can give problems of materials handling and
feeding.

Sold in both compounded colors and as natural material for

coloring on the extrusion machine by techniques such as
masterbatching and dry coloring.

When dry coloring do not use adhesion promoters such as

paraffin. Control the mixing time precisely as too short a
mixing time gives poor dispersion and inadequate adhesion
while too long a mixing time may cause pigment compaction.
 High-density polyethylene
(HDPE)
Mechanical Properties:
Has good dynamic fatigue resistance but not as good as PP
and exhibits no living hinge effect. Compared to PP
homopolymer, HDPE has better resistance to low
temperature impact and to oxidation.
The shrinkage of HDPE is 1.5 - 4% ( and even 5% in
thick sections).
Have less chain branching giving higher levels of
crystallinity and therefore higher densities than LDPE.
Densities of 0.940 to 0.965 g/cm3.
Ductility of HDPE
 High-density polyethylene
(HDPE)
Chemical Properties:
Not attacked by concentrated salts, acids or alkalis at room
temperature and resists some oxidizing agents such as
hypochlorites.
Has no known solvent at room temperature but will dissolve
in aliphatic and aromatic hydrocarbons above 60 C. Such
materials will also cause swelling at room temperature.
Is attacked by UV light and the use of carbon black or UV
screens for outdoor exposure is essential.
 High-density polyethylene
(HDPE)
Chemical Properties:
Is affected by environmental stress cracking (ESC)
when it is subjected to external or internal stress in the
presence of polar liquids or vapors.
When this material is heated in a flame it ignites easily
then burns with a yellow-tipped, blue flame giving off
only a little smoke. It forms burning drops and when the
flame is extinguished gives off a smell like candle wax.
 High-density polyethylene
(HDPE)
Flow Characteristics:
Because the impact resistance of HDPE decreases
and notch sensitivity increases as molecular weight
falls the most commonly used grades of HDPE have
high molecular weights i.e. low values of melt flow
index (MFI). Using the traditional 2.16 kg weight at 190
C, HDPE extrusion grades all have values below 0.3.
 Applications of HDPE

Pipes
Waste Containers
Safety Related Service Water at
Callaway

Water
Pallets
Containers
 Polyvinyl chloride (PVC)

The world's third most widely produced

synthetic plastic polymer, after polyethylene and
propylene.
A thermoplastic material that can be melted repeatedly
at certain temperatures and will harden upon cooling.
It comes in two basic forms: rigid (sometimes
abbreviated as RPVC) and flexible.

3
 Polyvinyl chloride (PVC)
Properties:
Maximum continual use temperature: 60C or 140F
Chemical Stability
- PVC possess fire retarding properties, durability, and
oil/chemical resistance.
Fire retarding properties
- PVC has inherently superior fire retarding properties due to
its chlorine content, even in the absence of fire retardants.
Durability
- PVC is highly resistant to oxidative
reactions, and maintains its performance for a
long time.
 Polyvinyl chloride (PVC)
Properties:
Oil/Chemical Resistance
- PVC is resistant to acid, alkali and almost all inorganic
chemicals.
Mechanical Stability
- PVC is a chemically stable material.
Processability and Moldability
- PVC is not suitable for injection molding of large sized
products, since its melt viscosity is comparatively high.
.
 Polyvinyl chloride (PVC)

Other properties that make PVC versatile:

PVC has polar groups (chlorine), and is amorphous.

PVC is the only general purpose plastic that allows

free, wide and seamless adjustment of the required
physical properties of products.
 Uses of PVC
Rigid PVC

Construction
- - It is used in construction for pipe and in profile applications.
 Uses of PVC
Flexible PVC

Electrical
- Coated wires
and cables

Medical
- Surgical equipment,
pharmaceuticals, drug delivery,
medical packaging
Automotive
- Protective strips, moldings, exterior side moldings,
seat coverings, interior doors and pockets
 Low-density polyethylene
(LDPE)

A thermoplastic made from the monomer ethylene.

First grade of polyethylene, produced in 1933 by
Imperial Chemical Industries (ICI) using a high
pressure process via free radical polymerization.

4
 Low-density polyethylene
(LDPE)
Properties:
Has more branching than HDPE

LDPE HDPE
 Low-density polyethylene
(LDPE)
Properties:
Intermolecular forces (instantaneous dipole induced-dipole
attraction) are weaker
Its molecules are less tightly packed and less crystalline due
to the side branches
Compared to HDPE,
- Density is lower
- Tensile strength is lower
- Resilience is higher
 Low-density polyethylene
(LDPE)
Properties:
Not reactive at room temperatures, except at strong oxidizing
agents, and some solvents cause swelling.
Can withstand temperature of 80 0C continuously and 95 0C
for a short time
Made in translucent and opaque variations, it is quite flexible
and tough
 Chemical Resistance

SUBSTANCES RESISTANCE

Dilute and concentrated acids, alcohols, bases and

esters

Aldehydes, ketones and vegetable oils

Aliphatic and aromatic hydrocarbons, mineral oils, and

oxidizing agents

Halogenated hydrocarbons

Excellent Good Limited Bad

 History of LDPE

ICI developed the

autoclave process

1933 1938 WWII

Discovered by accident BASF developed the
in an experiment first tubular process
conducted by
Reginald Gibson and
Eric Fawcett in ICI
 Low-density polyethylene
(LDPE)
Process Theory:
Free radical reaction:
Initiation

I R. + R.
Initiators: Typically organic peroxides
Propagation
.
R + CH2CH2 RCH2CH2
.

. .
R(CH2CH2)n-1CH2CH2 + CH2CH2 R(CH2CH2)nCH2CH2
 Low-density polyethylene
(LDPE)
Process Theory:
Free radical reaction:
Termination
Combination:
.
Rx + Ry Px+y
.
Disproportioning:
. .
Rx + Ry Px + Py
 Low-density polyethylene
(LDPE)
Process Theory:
Other reactions:
Chain transfer important to control molecular weight
By monomer:
.
Rx + CH2CH2 Px + R1
.
By modifier:
.
Rx + M Px + M
.
Cracking results in shorter chains
.
Rx Py + Rx-y
.
 Low-density polyethylene
(LDPE)
Manufacturing Process:
Compression of gas
- Gaseous ethylene is supplied and melted with a part of
unreacted gas from the process in oreder to be compress in
the first reactor. This new compressed gas is melted again
with unreacted gas and compress in the second compressor.

Polymerization
- An initiator (organic peroxide) is added to the second
compressed gas into the reactor and the materials are mixed
inside the reactor through stirrer . Polymerization is obtained
in the reactor at a certain pressure and temperature.
 Low-density polyethylene
(LDPE)
Manufacturing Process:
Separation of Gas
- The unreacted gas is then separated by 3 levels of
separators. Those unreacted gas will be injected before the
compressor, notice than a part will be exclude from the
process.
Extrusion
- Once the unreacted gas is removed, the polymers can be
extruded and pelletized.
Storage and Packaging
- The pellets are dried through a dryer and classified pellets
by pellet size. The degassing is done by hot air injection.
 Low-density polyethylene
(LDPE)

Types of Manufacturing Process:

Autoclave Process
Tubular Process
Autoclave Process
Tubular Process
 Autoclave vs. Tubular Process
AUTOCLAVE
Conversion up to 21% - adiabatic,
reaction heat removed by reactant
only
1300-2000 bar operating pressure
Higher capacity of hyper compressor
Organic peroxide initiators only
Specialty polymer capability EVA
copolymers over 40% vinyl acetate
Lower reactor capacity 150 kt/y
TUBULAR
Conversion up to 36% - reaction heat
partly removed by coolant
2500-3200 bar operating pressure
Lower capacity of hyper but higher
load
Cheaper oxygen initiator possible
Film grades with higher clarity, EVA
up to 10% vinyl acetate
Reactor capacity up to 400 kt/y
 Advantages and Disadvantages

Advantages Disadvantages

Low specific gravity Very low

Chemical resistance strength/stiffness
Impact strength Poor heat resistance
High coefficient of
thermal expansion
 Uses of LDPE
4%
5% 7%
8% Film
Extrusion Coating
Injection Molding
76%
Wire and Cable
Others
 Uses of LDPE
PROCESS USES
Cling film
Making film
Milk carton lining
Buckets
Injection molding
Bowls
Blow molding Squeezable bottles
Flexible water pipes
Extrusion
Cable jacketing
 Uses of LDPE

Cling Film Bucket Squeezable bottle

Flexible Water Pipes

Bowl Cable Jacketing

Milk Carton Lining
 Low-density polyethylene
(LDPE)
Recycling
Recycling company melts the plastic to eliminate the
contaminants.
As LDPE is heated, it turns from a solid to a viscous gummy
liquid and then to a mobile fluid as temperature is increased.
(Melting point: 115 0C)
Because of LDPEs nature of having such a low density and
melting point, it allows for a process called float-and-sink to
be used to separate it from other polymer chemicals.
Separation is performed in a flotation tank using water to
execute the separation.
 Low-density polyethylene
(LDPE)
Recycling
The material is fashioned into thin sheets, which the recycling
company sells to manufacturers.
Contrary to popular belief, recycled plastic bottles are NOT
turned into more plastic bottles. The degradation in the
materials makes LDPE useful in other applications such as
treating carpet or manufacturing clothing.
 Polypropylene (PP)
History:
Phillips Petroleum chemists J. Paul Hogan and
Robert L. Banks first polymerized propylene in 1951.
Propylene was first polymerized to a crystalline
isotactic polymer by Giulio Natta as well as by the
German chemist Karl Rehn in March 1954.
Syndiotactic polypropylene was also first synthesized
by Natta and his coworkers.

5
 Polypropylene (PP)

Mechanical Properties:
Density = 0.895 to 0.92 g/cc
Has the lowest density among commodity
plastics
Tough and flexible
Good resistance to fatigue
 Polypropylene (PP)

Thermal Properties:
Its melting point varies:
- Perfectly isotactic PP (171C or 340F)
- Commercial isotactic PP (160 to 166C or 320 to
331F)
- Syndiotactic PP with a crystallinity of 30% (130C or
266F)
 Polypropylene (PP)

Optical Properties:
Translucent
Often opaque or colored using pigments
 Polypropylene (PP)
Chemical Properties:
Resistant to fats and almost all organic solvents except
strong oxidants
Can be dissolved in non-polar solvents (e.g. xylene, tetralin
and decalin)
Chemically less resistant than PE
Liable to chain degradation from exposure to heat
and UV radiation such as that present in sunlight
Can be used as an implantable mesh in human body
 Polypropylene (PP)

Polypropylene is used:
In manufacturing piping systems (high-purity and ones
designed for strength and rigidity)
It is resistant to corrosion and chemical leaching
It is resilient against most forms of physical damage,
including impact and freezing, its environmental
benefits, and its ability to be joined by heat
fusion rather than gluing
 Applications of PP

Stacking Chairs
Yarns and
Textiles

Mint Box Lid Centrifuge Tubes

 Polypropylene (PP)

Polypropylene is used:
Plastic items for medical or laboratory
Can withstand heat in autoclave
Food containers made from it will not melt in
the dishwasher, and do not melt during
industrial hot filling processes
 Polypropylene (PP)

Polypropylene is used:
Polypropylene can also be made into disposable
bottles
Plastic pails, car batteries, wastebaskets, pharmacy
prescription bottles, cooler containers, dishes and
pitchers are often made of polypropylene or HDPE,
both of which commonly have rather similar
appearance, feel, and properties at ambient
temperature
 Polypropylene (PP)

Polypropylene is used:
Biaxially oriented polypropylene (BOPP)
- These BOPP sheets are used to make a wide variety
of materials including clear bags.
Polypropylene, highly colorfast, is widely used in
manufacturing carpets, rugs and mats to be used at
home.
 Polypropylene (PP)

Polypropylene is used:
For plastic moldings; examples include bottle tops,
bottles, and fittings
In the manufacture of loudspeaker drive units
As a concrete additive to increase strength and reduce
cracking and spalling
In polypropylene drums
 Polypropylene (PP)

Environmental Impact:
Polypropylene consumes the least amount of energy
during production and produces the lowest carbon
dioxide emissions when compared to other plastics.
Its lower density also means that switching to PP
reduces the absolute amount of waste.
 Polypropylene (PP)

Environmental Impact:
It also flows more easily as it degrades, without cross
linking, gel forming or off-gassing.
Parts made from PP can be recycled multiple times in
a wide variety of applications before incineration is
necessary.
When that time comes, it is possible to recover more
energy from PP during incineration than from any other
comparable plastic.
 Polystyrene (PS)

6
1 History of Polystyrene
Polystyrene was discovered in 1839 by Eduard Simon,
an apothecary from Berlin. From storax, the resin of the American
sweetgum tree styraciflua, he distilled an oily substance, a monomer
that he named styrol. Several days later, Simon found that the styrol
2 had thickened into a jelly he dubbed styrol oxide ("Styroloxyd")
because he presumed an oxidation.

Simon
1 History of Polystyrene
By 1845 Jamaican-born chemist John Buddle Blyth and German
chemist August Wilhelm von Hofmann showed that the same
transformation of styrol took place in the absence of oxygen. They
called the product "metastyrol"; analysis showed that it was chemically
2 identical to Simon's Styroloxyd.

3
1 History of Polystyrene
In 1866 Marcelin Berthelot correctly identified the formation of
metastyrol/Styroloxyd from styrol as a polymerization process. About
80 years later it was realized that heating of styrol starts a chain
reaction that produces macromolecules, following the thesis of
2 German organic chemist Hermann Staudinger (18811965). This
eventually led to the substance receiving its present name,
POLYSTYRENE.

Berthelot Staudinger
Styrene
 Polystyrene

Poly-
 Polystyrene (PS)
Properties:
Rigid, transparent thermoplastic
Solid or glassy state at normal temperature
Colorless
Relatively low melting point
Translucent
Can be put in a foamed state
Slow to break down
 Polystyrene (PS)
Physical Properties:
The density of polystyrene can vary from 10 kg/m3 to
50 kg/m3.
Unfilled polystyrene is amorphous, and has a glassy,
sparkling appearance. It is also known as crystal
polystyrene.
 Polystyrene (PS)
Physical Properties:
An important property of extruded polystyrene is its
buoyancy or ability to float in water. This makes it the
perfect choice for making floating boards.

The viscosity of polystyrene, like all other non-

Newtonian fluids, depends on the shear rate. It is the
ratio of the shear stress to shear rate.
 Physical Properties
PROPERTY UNIT VALUE

Specific gravity g/cm3 1.03 to 1.06

Apparent density g/cm3 0.60 to 0.65

Water absorption % 0.03 to 0.10

 Polystyrene (PS)

Chemical Properties:
Polystyrene is chemically inert, and does not react with
most substances.
It dissolves in some organic solvents. It is soluble in
solvents that contain acetone, such as most aerosol
paint sprays and cyanoacrylate glues.
 Polystyrene (PS)
Chemical Properties:
The transformation of carbon-carbon double bonds into
less reactive single bonds in polystyrene, is the main
reason for its chemical stability. Most of the chemical
properties of polystyrene are as a result of the unique
properties of carbon.
It is highly flammable and burns with an orange yellow
flame, giving off carbon particles or soot, as a
characteristic of all aromatic hydrocarbons.
Polystyrene, on complete oxidation, produces only
carbon dioxide and water vapor.
 Polystyrene (PS)
Applications:
Polystyrene is one of the most widely used plastics.
Polystyrene can be solid or foamed.
Polystyrene can be naturally transparent, but can be
colored with colorants.
 Forms Produced

Sheet and Molded Foams Expanded

Polystyrene Polystyrene

Oriented
Polystyrene
Extruded
Polystyrene Foam
 Sheet and Molded Polystyrene
Molded sheets are for building insulation and packing
material ("peanuts") for cushioning fragile items inside
boxes.
 Foamed Polystyrene
Polystyrene foams are good thermal insulators and are
therefore often used as building insulation materials, such
as in insulating concrete forms and structural insulated
panel building systems.
 Expanded Polystyrene (EPS)
Expanded polystyrene (EPS) is a rigid and tough, closed-
cell foam. It is usually white and made of pre-expanded
polystyrene beads. EPS is used for many applications e.g.
trays, plates, bowls and fish boxes.
 Extruded Polystyrene (XPS)
Extruded Polystyrene (XPS) is a high performance rigid
insulation with a closed cell structure which makes it
impervious to moisture.
 Oriented Polystyrene (OPS)
Oriented Polystyrene (OPS) is a polystyrene film that is
stretched to reduce haziness and improve stiffness,
producing plastic sheet that is incredibly strong and clear.
OPS is a relatively inexpensive material that is used in
bakery, deli and freezer applications.
 Appliances

Refrigerator Blender
 Food Service

Hot Coffee Hot Noodle

Cup Cup
 Medical

Cell Culture Trays Test Tubes

 Packaging

CD Cases Egg Tray

 Polystyrene (PS)
Advantages:
Polystyrene is cheap and strong plastic that can be used in number
of ways.

Polystyrene can be used to insulate buildings which can make

buildings more energy efficient saving on heating and cooling costs.

Polystyrene can be used to create sterile disposable cutlery, plates

and bowls which can help reduce transferring bacteria and illness.

Polystyrene can be used as packaging to protect goods from

damage during transport, which can save on repairs and damage.

Polystyrene can be recycled into domestic building products.

 Polystyrene (PS)

Disadvantages:
Polystyrene dis-cared in the environment does not break
down and takes up precious space in landfill.

Polystyrene is easily blown by the wind, ending up as litter in

the environment where it can harm animals and marine life.

Animals can mistake polystyrene for food and it can be lethal

to bird and sea life that swallow it.
 Polystyrene (PS)
Environmental Impact:
1. Environmental Health Concerns
Possible Carcinogen
- The International Agency for Research on Cancer had
already established styrene as a possible human carcinogen
in 2002.
Occupational Health Hazards
- Some of the acute health effects experienced include
irritation of the skin, eyes, and the upper respiratory tract and
gastrointestinal effects.
 Polystyrene (PS)
Environmental Impact:
2. Air Pollution
Many of the chemicals used in the manufacturing process
are toxic, and workers who make them are at greatest risk.
Moreover, emissions from these factories can pollute the air,
and the liquid and solid waste produced need disposal.

When Styrofoam is burnt for energy or for disposal, it is

released into the environment leading to air pollution and
health problems when inhaled by people and animals.
 Polystyrene (PS)
Environmental Impact:
3. Effect on Global Warming
In the product manufacturing process as well as the use and
disposal of the products, energy consumption, greenhouse
gas effect, and total environmental effect, polystyrenes
environmental impacts were second highest.

Extruded polystyrene is usually made with hydro

chlorofluorocarbons blowing agents which have effects on
ozone depletion and on global warming.
 Polystyrene (PS)
Environmental Impact:
4. Marine Pollution
The lightweight and buoyant polystyrene travels easily through
gutters and storm drains, eventually reaching the ocean. Plastic from
urban runoff is the largest source of marine debris worldwide.
Pollution of waterways and waterfront negatively affects tourism and
quality of life. When polystyrene travels down waterways and storm
drains into the ocean, it breaks down into smaller, non-
biodegradable pieces that are ingested by marine life and other
wildlife thus harming or killing them.
As a result of the impacts on marine pollution and adverse effect to
marine wildlife, and cause flooding in our habitat.
 Polystyrene (PS)
Environmental Impact:
5. Heavily polluting resource
These products are made with petroleum, these chemicals
threaten human health and environment health.

Public Contamination

Polystyrene foam is often dumped into the environment as

litter. This material is notorious for breaking up into pieces
that choke animals and clog their digestive systems.
 Other

7
 History of Polycarbonate
1955
- - Bayer won the patent and
commercially produced it as
1953 Merlon
- Dr. Hermann Schnell of Bayer - - While GE named it Lexan
as linear PC
- Daniel Fox of GE independently
1898
synthesis a branched PC
- Alfred Einhorn but
was not
commercialized
 Other

Polycarbonate
Carbonate group as its main precursor
Amorphous/semi-amorphous
Copolymer
Can both be thermoplastic or thermoset
No unique resin identification code
 Other

Polycarbonate
Commonly produced by the reaction of bisphenol A
and phosgene:
1. Reaction of BPA with NaOH to get sodium salt of BPA
2. Then reacted w/ phosgene
3. Polymerized with the removal of water
 Other

Polycarbonate
Another type is one that is reacted with 2 allyl
radical that will produce a crosslinked PC.
This type are now usually used as the lenses
for eyeglasses.
 Other

PC as plastic:
Manufactured via:
Extrusion
Injection Molding
 Chemical Properties of PC
Formula C15H16O2

Melting Temp C 288 316

Molding Temp C 82 121

Heat Deflection C 140 @ 0.46 MPa

Tensile Strength 59 MPa

Flexural Strength 93 MPa

Specific Gravity 1.19

Shrink Rate 0.6 0.9 %

 Other

Physical Properties:
High durability
Shatter resistant
Transparency
Lightweight
Thermostability
 Other

Applications:
Automotive
Packaging
Electrical/Electronics
 Other

Recyclability
No traditional way, yet
Environmentally hazardous
Persistent compound
 History of Polylactide
2001
- 300 million pounds
produced at the Blair,
1997
1954 - Cargill Dow
Nebraska plant
- DuPont patented Polymers LLC
Carothers process forms
1932 extremely high cost of
- Carothers production
(DuPont) created
PLA
 Other

Polylactide
Highly versatile thermoplastic material
Made from 100% renewable resources
Lactic acid is derived from various sources
Corn
Sugar Beets
Wheat
 Uses and Applications of PLA

Extrusion Sheet, profile

Blow Molding Bottles, etc.

Vacuum Forming Blister packages

Injection Molding
 Other
Polylactide
Compares well with currently used packaging
materials
Clear/glossy like polystyrene
Odor barrier/gas permeability similar PET (used for soft
drinks and many other food products)
Nonvolatile and odorless, classified as GRAS by
FDA
GRAS - Generally Recognized as Safe
Safe for all food and packaging applications
 Products Made from PLA

Disposable Cup
Disposable Bag Bottle

Memory Stick Casing

Food Container Utensils

 Other

Production of PLA:
Start with starch from renewable resource
Unrefined dextrose processed from starch
Dextrose fermented into lactic acid
Lactide produced through condensation
Purification through vacuum distillation
Solvent-free melt polymerization
Production of PLA
 Non-Solvent Process to Prepare Polylactic Acid
By heating catalyst

Distillation
Fermentation Lactic Lactide
Prepolymer
Acid Formation

Dextrose

Distillation
Unconverted Polymer Meso
Lactide
PLA
Polymerization
Corn Polymer Low D
Coordination/Insertion
Lactide
Cargill Dow LLC Process. Gruber, et. al. 2000. Propagation
 Other

Unmaking PLA
Fully combustible in composting facilities
Can be converted back to monomer
Can be completely broken down to H2O, CO2,
and organics
Degradation time: weeks to months
 Degradation
Hydrolysis and cleavage of the
CH3 ester linkage
O CH3 CH3
O
O O O
HO O
O Opoly
O CH3 n O CH3 OH
H OH
O
High Molecular Weight
Prepolymer
H
Mw>100,000 CH3 O
O
O Opoly
n OH OH CH3
CH3
O CH3 CH3
O OH + Opoly
HO HO
O
O CH3 n O
O
Low Molecular Weight Prepolymer
Mw=2,000 10,000
 Other

Criticisms
PLA releases carbon dioxide and methane
during the biological breakdown phase
Fossil fuels still needed to produce PLA
Some believe that PLA will degrade too
slowly to make a difference in waste streams