Polymer Processing

Polymer Processing
Preshaping steps:
Solids handling and conveying: most processes usually involve feed in particulate form Plastication: The creation of a polymer melt from a solid feed. Mixing: often required to achieve uniform melt temperature or uniform composition in compounds Pumping : The plasticated melt must be pressurized and pumped to a shaping device

Shaping:
The polymer melt is forced through the shaping devices to create the desired shape.

Shape stabilization:
Involves the solidification of the polymer melt in the desired shape, through heat transfer

Extrusion
Extrusion is a process in which solid thermoplastic material is melted and forced through an orifice (Die) of desired shape and then cooled.

Extruded products:
Sheet Film Tube Profile (e.g. PVC window frames) Cable coating

Process based upon screw extrusion:

Injection moulding

Injection blow moulding Extrusion blow moulding

This section covers the basics of extrusion. There are many products made via extrusion and most of them involve machinery for melting the plastic (an extruder) and the means to shape the plastic melt (a die).
So the processing steps involved in extrusion are : Feeding (Add the resin).

Melting ( add heat to the polymer).

Pumping (transport of the melt). This can be accomplished by generating melt at a high pressure or by using an actual pump (like a gear pump) Forming ( shaping the melt ).

Cooling (remove excess heat so that the material becomes rigid and 4 retains its shape ).

Sketch of Extrusion Line

Thus the function of the extruder is to : - melt the plastic - pump the plastic

The Single Screw Plasticating Extruder

Pellets, powders or flakes are drawn by gravity from a hopper to the gap between a rotating screw and a heated barrel. They are transported forward, compacted, melted and pumped through a die where the melt is shaped prior to solidification by cooling.

Film Blowing
Blown, or tubular, film extrusion is one of the major processes used for manufacturing plastic films. In this process, plastic pellets are fed into the hopper and melted in the extruder. After exiting the extruder barrel, the molten resin enters an annular die. The resin is forced around a mandrel inside the die, shaped into a sleeve, and extruded through the round die opening in the form of a rather thick-walled tube. The molten tube is then expanded into a bubble of the desired diameter.

Film Blowing
Extrude a tube upwards through vertical die Inflate tube till it becomes a film Collect film and process as needed

Film Blowing
Nip Rollers

Sizing Basket

Frost Line Windup

Extruder

Die/Blower Assembly

Injection Molding Process

Injection molding is a versatile process that can produce small parts that weight in fraction as well as large parts that weight in kg.
During this process, molten plastic is forced (injected) into a mold and cooled until the melt solidifies. When the part is cooled sufficiently, the mold is opened, the part is ejected from the mold, and the mold is closed again to repeat the cycle.

Products Market Sectors

Automotive.

Computers, telecoms & optical disks.

Construction. Medical. Packaging. Appliances. Home & Leisure.

Products Telecoms and Computers

Injection Molding Machine

Single Stage Reciprocation Screw

Reaction Injection Molding (RIM)

The reaction injection molding is quiet different from
conventional thermoplastic molding. RIM involves two or more liquid reactants flowing into a mixing chamber and begin to polymerize as they flow into the mold. The basic difference from thermoplastic processing is that the RIM process involves polymerization in the mold rather than cooling a molten polymer to form a part. Because the reactant, typically isocynate and polyol, are low viscosity , so low pressure is required to fill the mould.

Reaction Injection Molding (RIM)

Commercially Important Polymer

PRODUTION AND PROPERTIES POLYETHYLENE TEREPHTHALATE Commonly abbreviated PET, PETE It is a thermoplastic polymer resin of the polyester family and is used in synthetic fibers, beverage bottles, food and other liquid Container, thermoforming applications; and engineering resins often in combination with glass fiber.. Depending on its processing and thermal history, polyethylene terephthalate may exist both as an amorphous (transparent) and as a semi-crsytalline polymer. The semi-crystalline material might appear transparent or opaque and white (particle size up to a few microns) depending on its crystal structure and particle size. Its monomer can be synthesized by the esterification reaction between terephthalic acid and ethylene glycol with water as a byproduct. Polymerization is through a Polycondensation reaction of the monomers (done immediately after esterification) with water as the byproduct.

Terephthalic Acid Process In the Terephthalic acid process, esterification of ethylene glycol and Terephthalic acid is conducted directly at moderate pressure (2.75.5 bar) and high temperature (220260 C). Water is eliminated in the reaction, and it is also continuously removed by distillation

n C6H4(CO2CH3)2 + n HOCH2CH2OH *(CO)C6H4(CO2CH2CH2O)]n + 2n H2O (PTA) (Ethylene Glycol) (PET) (Water)

PET in its natural state is a colorless, semi-crystalline resin. PET can be semi-rigid to rigid, and it is very lightweight. About 60% crystallization is the upper limit for commercial products, with the exception of polyester fibers. Besides, about 60% crystalline polymer about 40% of the polymer chains remaining amorphous. Clear products can be produced by rapidly cooling molten polymer to form an amorphous solid. Amorphous PET forms when its molecules are not given enough time to arrange themselves in an orderly, crystalline fashion as the melt is cooled. When allowed to cool slowly, the molten polymer forms a more crystalline material. Its excellent wear resistance, high flexural modulus, and superior dimensional stability make it a versatile material for designing mechanical and parts.