Contents

Lzst of Fzhuves Lzst of Tables Pveface, Acknondedg-e~k~ent About the Aztthovs

Chapter 1 INTRODUCTION O\~erview ClassiQing plastic

Thermoplastic: crystalline or amorphous Liquid crystalline polynler

Thermoset Crosslinked plastic

Property and behavior Molecular structure/property/process

Viscosity: Newtonian and Non-Newtonian Rheology and viscoelasticity Processing and thermal interface Compouilding and alloying Introduction to property Plastic behavior

Thermal behavior Residence time Plastic memory Thermal conductivity Specific heat Thermal diffusivity Coefficient of linear thermal expansion Temperature index Corrosion resistance Chemical resistance

xix xxvi xxix

xxxiii

iv Contents

Fire property Steel and plastic

Permeability K~diation Craze/craclz

Drying plastic Variable Advantage and limitation FALL0 approach

Chapter 2 PLASTIC PROPERTY 40 Overview 4 0 Plastic performance 44 Thermoplastic 4 5

Polyolefin 4 5 I'olyethylene 46

Linear polyethylene 48 Low density polyethylene 49 Ultra low density polyethylene 5 0 Linear low density polyethylene 5 1 High density polyethylene 5 1 Ultra high molecular weight polyethylene 52 Crosslinked polyethylene 52 Polyethylene wax 5 2 Chlorinated polyethylene elastomer 5 3 Polymethylpentene 5 3 Polyolefin elastomer 5 3 Polyolefin thermoplastic elastomer 54 Ethylene-propylene elastomer 54 Polypropylene 54 Polybutylene 55 Cyclic polybutylene terephthalate 56

Vinyl 5 6 Polyvinyl chloride 57 Ultra high molecular weight polyvinyl chloride 60 Polyvinyl acetate 60 Polyvinyl chloride acetate 6 1 Polyvinyl chloride, chlorinated 6 1 Polyvinyl alcohol 61 Polyvinyl butyral 62 Polyvinyl carbazole 62 Polyvinyl pyridine 62 Polyvinyl pyrrolidone 62

Contents v

Polyvinylfluoride Polyvinyl formal Polyvinylidene chloride Polyvinylidene fluoride

Polystyrene Polystyrene copolymer Polystyrene, expandable Polystyrene nlaleic anhydride Crystal clear polystyrene Flame retardant polystyrene Polystyrene film, heat-sealable High gloss polystyrene High impact polystyrene Syndiotactic polystyrene Polystyrene-acrylonitrile Polystyrene-polyethylene blend Polystyrene-polyphenylene ether blend Advanced styrenic Styrene- butadiene Polyalphamethylstyrene

Acetal Acrylic

Acrylic elastomer Polymethacrylic acid Polymethylacrylate Polyethylmethacrylate Polpglutarimide acrylic copolymer

Acrylonitrile Acrylonitrile-butadiene rubber Acrylonitrile-butadiene-styrene Acrylonitrile-butadiene-styrene, transparent Acrylonitrile-chlorinated polyethylene-styrene copolymer Acrylonitrile-ethylene/propylene-styrene copolymer Acrylonitrile-ethylene-styrene Acrylonitrile-methylmethacrylate Acrylonitrile-styrene Acrylonitrile-styrene-acrplate Polymethacrylonitrile Polyvinylcyanide

Cellulosic Chlorinated polyether

vi Contents

Ethylene-vinyl acetate Ethylene-vinyl alcohol Fluoroelastomer Fluoroplastic

Polytetrafluoroethylene Polychlorotrifluoroethylene Polyhexafluoropropylone Polyvinyl fluoride Polyvinylidene fluoride Fluorinated ethylene propylene Chlorofluorohydrocarbon Polytluoroalkoxyphosphazene

Ionomer Nylon (polyamide) Parylene Phoenix Polyallomer Polyamide Polyamide-imide Polyarylate Polyaryletherketone Polyarylsulfone Polybutylene terephthalate Polycarbonate Polycyclohexylenedimethylene terephthalate Polyelectrolyte Polyester, thermoplastic Polyester reinforced urethane Polyester water-soluble Polyetherketone Polyetheretherketone Polyether, chlorinated Polyetherimide Polyethylene naphthalate Polyethylene terephthalate

Polyethylene terephthalate glycol Polyhydroxybutyrate Polyimidazole Polyimide Polyimide powder Polyesterimide Polyketone

Polyetheretherketone

Contents vii

Polyetheretherketoneketone Polylactide Polyorganophosphazene Polyoxymethylene Polyparamethylstyrene Polyperfluoroalkoxy Polyphenylene ether Polyphenylene oxide Polyphenylene sulfide Polyphosphazene Polyphthalamide Polysulfone

Polyethersulfone Polyphenyl sulfone Polyphenylethersulfone

Polyphthalamide Polysaccharide Polyterpene Polythiophene Polyurethane, thermoplastic

Polyurethane elastomer Polyurethane isoplast Polyurethane virtually crosslinked

Thermoset plastic A1 kyd Ally1 Amino Chlorosulfonated polyethylene elastomer

Crosslinked polyethylene Diallyl phthalate

Epoxy Epoxy vinyl ester Fluorosilicone elastomer Melamine formaldehyde Neoprene Phenol-formaldehyde Polybenzimidazole Polybenzobisoxazole Polybutadiene Polychloroprene Polydicyclopentadiene Polyester, thermoset

Polyester, water-soluble

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Polyimidazopyrrolone Polyisobutylene butyl Polyisoprene

Natural rubber and other elastomer Polynorbornene Polysulfide Polyurethane, thermoset Rubber, natural Rubber latex, natural Silicone

Silicone elastomer Styrene-butadiene elastomer Urea-formalde hyde

Elastomer Reinforced plastic Recycled plastic Plastic selection

Chapter 3 FABRICATING PRODUCT Overview

Processing and patience Processor certification Processing hndamental Machines not alike Plastic processing performance

Plastic memory Orientation Reinforced directional property Plastic deformation Coextrusion/coinjection: fabricating multilayer

Plasticator melting operation Screw

Feeding problem Screw/barrel bridging Multi-stage screw Drying via venting Barrier screw Screw tip Purging

Barrel Dou7nsizing machine Upsizing machine Rebuilding vs. Buying

168 168

Process control 168 Overview 168 Sensor 171 Pressure sensor 172 Temperature sensor 173

Fuzzy logic 175 Temperature controller 175 Processing m~indow 176 Control and monitoring 178 Process controller 184

Control choice 184 Intelligent processing 186

Intelligent setting and control 186 Program analysis 188 Fuzzy logic 189 Troubleshooting 190

Prototyping model 190 Safety 191

Chapter 4 INJECTION MOLDING Introduction Molding system

Clamping design Tie bar Machine control

Machine startup/shutdown Maximizing processing window control

Coinjection molding Coinjection foam low pressure molding Gas-assist molding Gas-assist \\~ithout gas channel molding Gas counterflow molding Water-assist molding Injection-compression molding Two-shot molding/over-molding In-mold molding Insert molding Thin-wall molding Soluble core molding Continuous molding Tandem machine molding

x Contents

Micro-molding Monosandwich molding Double-daylight molding Foamed gas counter pressure molding High pressure foam molding Lo\?: pressure foam molding Liquid molding Counterflow molding Melt flow oscillation molding Scrcwless molding Non-plastic molding

Magnesium molding Thixotropic molding

Summary

Chapter 5 EXTRUSION Introduction Component Extruder type/performance Operation

Startup Shutdown

Film and sheet Film

Blown film Flat film

Sheet Pipe and tube Profile Coating Wire and cable Fiber Coextrusion Orientation

Blown film Flat film Fiber

Other process Postforming Compounding Reclamation/recycling

Form, fill, and seal vs. Preform Form, fill, and seal with zipper in-line Multiple-step forming Matched mold forming Solid-state forming Rubber pad fbrming Mechanical forming Forging forming Twin sheet forming Cold forming Comoform cold forming Shrink wrap forming Scrapless forming Forming and spraying Solid-phase pressure forming Flow-compression forming Post forming Bend forming

Chapter 8 FOAMING Overview Blo\ving agent

Chlorofluorocarbon and alternate Type of foam Process

Extruding Casting Spraying Frothing Expandable plastic Molding Injection molding Structural foam Foam reservoir molding Polyurethane process

Chapter 9 CALENDERING Introduction Equipment Compounding/blending Processing

Marliet Calendering vs. Extrusion

Contents xiii

Chapter 10 COATING Overview

Type Plastic behavior Process

Overview Spray coating

Flame spray coating Roll-coat finish Spread coating Floating knife coater Fluidized bed coating Powder coating Electrostatic spraying Metal coil coating

Property Thermal control Germ-free coating

Chapter 11 CASTING Introduction Plastic Process Casting of acrylic Casting of nylon Solvent casting of film

Chapter 12 REACTION INJECTION MOLDING Introduction Equipment Mold

Runner and gate design Cost

Processing Process control

Material Conversion process Thermoplastic polyurethane Thermoset polyurethane Cure of thermoset Polymerization RRIM and resin transfer molding

Contents xv

Compression molding Flexible plunger Flexible bag molding Laminate

Hand lay-up Vacuum bag molding Vacuum bag molding and pressure Pressure bag molding Autoclave nlolding Autoclave press clave Wet lay-up Bag molding hinterspritzen Contact molding

Filament winding Fabricating RE' tank

Injection molding Marco process Pultrusion Reactive liquid molding Resin transfer molding Rotational molding Squeeze molding

Infusion molding SCRIMP process Soluble core molding

Lost-wax process Spray-up Stamping

Cold forming Comoform cold molding

Selecting process Tolerance

Chapter 16 OTHER PROCESS Introduction Pvc dispersion

Plastisol Organosol Slush molding Rotational molding

! Spray molding ! &

Continuous coating

F Nonfoam strippable vinyl

h

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Foam-vinyl strippable Open molding Closed molding Dip molding Dip coating Inli screening

Encapsulation Potting Liquid injection molding

Vacuum assisted lim Impregnation Chemical etching Twin screw injection molding extruder Melt compression molding

Chapter 17 MOLD AND DIE TOOLING Overview Material of constructioil Manufacturing Protective coating/plating Mold Die

Introduction Die type

Flat die Cast film die Sheet coathanger die Coating and laminating die Tubular die Blown film die Pipe die Fodm die Profile die Wire coating die Draw ratio baldnce Drawdown ratio Fiber die Netting and special forming die Pelletizer die Coextrusion die

Computer Tooling and prototyping

Contents xvii

Chapter 18 AUXILIARY EQUIPMENT Introduction Material/producr handling Decorating Joining and assembling Machining

Chapter 19 SUMMARY Overview Research and development

Theoretical vs. Actual value Smarter plastic

Equipment development Product development

Composite commercial airplane Bonding plastic Self-healing BP Airbus super-jumbo RP wing parts World's largest wind blade Bridge infrastructure and RP

Design demand Plastics in the forefront

REFERENCES

INDEX 597