CBE 4009 Polymer Processing - 3. Introduction To Polymer Processing

CBE 4009 Polymer Processing – Introduction to Polymer Processing
Introduction to
Polymer Processing
Polymer Processing
the operations carried out on polymeric materials or

systems to increase their utility
Chemical operation
Physical operation
Machine and Equipment Design

Plant Design and Operations
Product Development: the physical and chemical evaluation
of materials
Classification of Polymer Processing

Shaping(Froming)
Extrusion(압출성형), Coextrusion(공압출성형),
Calendering, Blown film, Fiber Spinning,
Injection Molding(사출성형), Compression Molding(압축성형),
Blow molding(중공성형), Thermoforming(열성형),
Resin transfer molding(수지이동성형), Pultrusion, Casting,
Bonding
Heat sealing, Laminating, Coating
Modification
Mixing and Compounding, Surface activation,
Polymer modification(crystallization and orientation)
Post Shaping
Structuring, Decorating, Fastening, Sealing, Welding, Dyeing,
Electroplating, Vaccum metallizing, Printing, Painting, etc.
성형 공정에 따른 플라스틱의 소모비율
Polymer and Additives
Feed T ( t ) 
Preparation P (t ) 
 
G ( t ) 
 
 X ( t )
Feeding
Extruder Mold or Die
Mechanical Energy
Product
Cooling
Conveying Melting Pumping Forming and Post-
Mixing Forming
Operations
Product
• Film
• Sheet
Heat • Moldings
• Bottles
Fig. . Schematic of Generalized Extrusion Process • Fibers
• Coated Wire
• Pipe
Fig. Sectional view of a single screw plastic extruder and

various types of screw
extruder
Fig. Schematic view of an inverted L calender plant for

the production of plastics sheeting
Fig. Schematic view of

a film blowing operation
extruder
Coextrusion film
Stage 1. Injection Feed hopper

Mold partially filled Barrel
Screw
advances
Heater band
Stage 2. Holding Pressure
and Plastication
Screw rotates
at the end of
holding
Mold filled and part is cooled
Stage 3. Ejection
Nozzle breaks off

Mold opens and part is ejected
Fig. Schematic representation of injection molding process.

Extrusion Blow molding

Stretch Blow Molding

PET stretch blow molding simulation
Initial Step.
Thickness Distribution
The pressure P1(18bar) is

applied to the inside of preform.
The plug starts

to push the preform.
(V=92.5cm/s)
P2(32bar) is applied
The plug reached

bottle base
Fig. Twin sheet thermoforming process

(a)
A B
Preform placement Resin injection and cure Part removal

RRIM SRIM
(milled fiber) (fiber mat)
(b)
Polymerizing mixture
Monomer A
Ratio Mixer
control
Mold
Monomer B
Fig. 1. Schematics of liquid composite molding (LCM) process. (a) resin

transfer molding (RTM) (b) structural reaction injection molding (SRIM)
Fig. Schematic diagram of pultrusion process

Fig. Schematic of a forward roll coating and magnified view of the

nip region (a) a flooded inlet (b) a starved inlet
Interrelationship between Processing and Property
Material Processing Article
Machinery in
process industry
Processing
properties
+ =
Intrinsic Article
material properties
Objective properties Subjective
standard standard
Process-Structure-Property Relationships
Property
Processing
Mechanical
Thermal history Optical
Stress/Strain history Chemical
Chemical modification Solid state
Structure
Crystallinity
Crystal size and structure
Orientation
Residual stress/strain
A STRUCTURAL BREAKDOWN OF POLYMER PROCESSING

Raw Finished
Material Product
Handling of
ELEMENTARY STEPS Particulate Solids Die Forming
SHAPING METHODS
POST SHAPING
Melting Molding & Casting
Pressurization
& Pumping Secondary Shaping
Mixing Calendering
& Coating
Devolatilization
and Stripping Mold Coating
Structuring of Polymers in Processing

Transport Mixing Solid Polymer Polymer Polymer
Pheonomena Principles Mechanics Rheology Physics chemistry
Engineering Principles Polymer Science

The Historical Evolution of Polymer Processing
1850-1950 1950-2000 Transition (present) Future

Time
Frame Rubber and Plastic Classical Polymer Polymer Processing Macromolecular
Technology Processing for Structuring Engineering
New products and
Product Process and machine Product design
Focus structuring
machine invention design (micro-structuring)
“Pushing the Limits”
Transport phenomena
Macromolecular
Full rheology
Transport phenomena physics, chemistry,
Melt/solid physics
GNF rheology rheology
Discipline Inventive praxis Interfacial phenomena
Computational fluid Multiscale transport
Polymer chemistry
mechanics and computation
In-line characterization
Molecular scale probe
Thermodynamics
New generation of
New class of Ability to process Customized globally applicable
Benefits materials very diverse structure/properties polymer
New industry polymers Value-added materials Truly advanced
polymer

CBE 4009 Polymer Processing - 3. Introduction To Polymer Processing

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CBE 4009 Polymer Processing - 3. Introduction To Polymer Processing

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CBE 4009 Polymer Processing – Introduction to Polymer Processing

the operations carried out on polymeric materials or

Machine and Equipment Design

Classification of Polymer Processing

Polymer and Additives

Fig. Sectional view of a single screw plastic extruder and

Fig. Schematic view of an inverted L calender plant for

Fig. Schematic view of

Stage 1. Injection Feed hopper

Nozzle breaks off

Fig. Schematic representation of injection molding process.

Extrusion Blow molding

Stretch Blow Molding

PET stretch blow molding simulation

The pressure P1(18bar) is

The plug starts

The plug reached

Fig. Twin sheet thermoforming process

Preform placement Resin injection and cure Part removal

Fig. 1. Schematics of liquid composite molding (LCM) process. (a) resin

Fig. Schematic diagram of pultrusion process

Fig. Schematic of a forward roll coating and magnified view of the

Interrelationship between Processing and Property

Material Processing Article

A STRUCTURAL BREAKDOWN OF POLYMER PROCESSING

Structuring of Polymers in Processing

Engineering Principles Polymer Science

1850-1950 1950-2000 Transition (present) Future

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