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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
viii Contents
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
xvi Contents
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