3.042 Materials Project Laboratory

Design Review

Team No-DripTania Chan

Michele Dufalla

Jacqueline Greene

3.042 Materials Project Laboratory

Design Review

Team No-DripTania Chan

Michele Dufalla

Jacqueline Greene

New Goal

http://www1.istockphoto.com/file_thumbview_approve/1168596/2/istockphoto_1168596_plastic_can_container.jpg, http://www.baproducts.com/spigot.jpg

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Plastic Joining• Fasteners• Hinges• Hot Die• Fusion and Hot Wire/Resistance Welding• Hot Gas Welding• Induction/Electromagnetic Welding• Press Fits/Shrink Fits• Snap Fits• Spin Welding• Staking/Cold Forming• Threads• Ultrasonic Welding• Vibration Welding• Lasers• Adhesives• Solvents

**List from Joining of Plastics by Jordan Rotheiser (2nd ed.)

Plastic Joining• Fasteners• Hinges• Hot Die• Fusion and Hot Wire/Resistance Welding• Hot Gas Welding• Induction/Electromagnetic Welding• Press Fits/Shrink Fits• Snap Fits• Spin Welding• Staking/Cold Forming• Threads• Ultrasonic Welding• Vibration Welding• Lasers• Adhesives• Solvents

**List from Joining of Plastics by Jordan Rotheiser (2nd ed.)

Hot Plate Welding(from Joining of Plastics by Jordan Rotheiser (2nd ed.)

HDPE vs. LDPE

• Max Temp = 120°C

• Melt Temp = 130°C

• Max Temp = 80°C

• Melt Temp = 120°C

http://www.dynalabcorp.com/technical_info_hd_polyethylene.asp

http://www.dynalabcorp.com/technical_info_ld_polyethylene.asp

Method

http://www.cooking.com/images/products/shprodde/743196.jpg, http://www.flagstaff.az.gov/images/pages/SC581/plastic%20bag.JPG

Extrusion

http://www.flagstaff.az.gov/images/pages/SC581/plastic%20bag.JPG

http://www.midi-classics.com/i/p19228.gif

Sample prep

• Plastic (HDPE, LDPE) was cut in 1x6 in strips

• Samples were welded together with a clothes iron, pressed together and allowed to cool at room temperature

• Last week tested initial control samples of varying thicknesses, as well as ability of LDPE to bond with HDPE.

INSTRON

90º Peel Test

Free-moving stage

1/8” HDPE

1/16” LDPE

3x1 in contact area

1 in wide

Shear Test1/8” HDPE

1/8” HDPE

4 layers of clear LDPE film (0.0006”) 3x1 in contact

area

Results of Peel Test

• 1/16 in LDPE was non-uniformly bonded to the 1/8 HDPE (due to greater thickness, more difficult to melt with iron)

• Maximum Load: 0.020 kN

• Could not test LDPE film:1/8 HDPE because strength of adhesion > than the tensile strength of LDPE which is 1700psi (22kN, http://www.mcmaster.com/)

Results of Shear Test

• The bond between the LDPE film and the 1/8 HDPE was greater than the tensile strength of the 1/8 HDPE! (4400psi / 30 MPa/ 58 kN, www.mcmaster.com). We could tell because the HDPE started necking rather than breaking the adhesive bond

• Max load = 2.070 kN, Stress at Peak 55 MPa

Shear Force 1/8 HDPE: LDPE film

necking

• Continue 90o Peel Test and Shear Test

Immediate Next Steps…

1/8” HDPE Substrate

-White LDPE Film

-Black LDPE Film

-1/16” LDPE Sheet

-1/16” HDPE Sheet

1/16” HDPE Substrate

-White LDPE Film

-Black LDPE Film

-1/16” LDPE Sheet

-1/16” HDPE Sheet

1/8” LDPE Substrate

-White LDPE Film

-Black LDPE Film

-1/16” LDPE Sheet

3 Sets of Control Samples:

Control Samples are Pure Polyethylene-no contaminations, impurities

-effects of thickness, colors, processing temperature and material density on polyethylene adhesion

Goals of the Materials Testing

Materials Testing Using Post-Consumer Polyethylene-ink, dye, processing agents

-nonuniform density

Ultimate Goal-Establish a range of temperature, pressure, time and

processing condition optimal for polyethylene welding

Materials Considerations:– Tube to be made from

recycled polyethylene– Sealing between the

flange and the containers surface

Design of the Tap

Basic Pop Rivet Design to Attach Pinch Tube at the Lid of Jerrycans

Design Considerations:– Simple design, reduce

production and materials costs

Continue with the idea of post-consumer polyethylene recycling

– Melt plastic bags and extrude melt into tubes

– Questions to be answered:• Is the process plausible?• How durable is the resultant products?• Can the procedure be done in the field?

Tube Production

• Plastic Welding Will Be Used to Attach Tap onto Jerrycans Lids

• Using the welding parameters (temperature, time and processing conditions) to attach tube to containers

• Challenges:– Tricky interface between tube and containers, how to apply

plastic welding?– Is plastic welding a water proof seal?– Can plastic welding withstand the chlorination in the water?

Tap Production and Plastic Welding

Revised Gantt Chart

2/6/07 2/16/07 2/26/07 3/8/07 3/18/07 3/28/07 4/7/07 4/17/07 4/27/07 5/7/07 5/17/07

Background Research

Recycling

Processing Cost

Material Cost

Target User

Materials Economic Analysis

Polyethylene Properties Research

Polyethylene Recycling Research

Plastic Welding Testings

90 Degree Peel Tests

Shear Tests

Production of Prototype #1

Extrusion of Plastic Tubes from Recycled Polyethylene

Design of Prototype #1 on SolidWorks

Designing Interface between Tab and Containers

Testing Plastic Welding Adhesion between Tab and Container

Production of Final Product

Increase Efficiency and Decrease Cost of Production

Troubleshoot Defects in Final Product

Preparation for Final Presentation

Completed Remaining