ENGINEERING PLASTICS&

APPLICATIONS

ALOK KUMAR

CENTRAL INSTITUTE OF PLASTICS ENGINEERING CENTRAL INSTITUTE OF PLASTICS ENGINEERING & TECHNOLOGY,& TECHNOLOGY,

Dismantling of >40 modern European cars reveled that in130 Kg plastics per car– 43% PP, 14% PU, 8%Nylons, 8%PE

USAGE OF PLASTICS IN MODERN CARS

PE

36%

PP

21%

PVC

17%

PET

7%

PS/SAN/ABS

15%

PC

2%Nylon 6 & 66

1%

0.44%

0.43%

0.26%

Acrylics

1%

PE Acetal PP PBT

PET PVC EPS PS/SAN/ABS

Nylon 6 & 66 PC Acrylics

s

79 % Plastics consumed – PE+PP+PVC+Styrene's

GLOBAL PLASTICS USAGE

PP24%

LL/LLDPE17%

GP-HIPS8%

PET4%

EPS3%

PC2%

Other ETPs2%

PVC20%

ABS/SAN6%

HDPE14%

PP PVC LL/LLDPE HDPE GP-HIPS

ABS/SAN PET EPS PC Other ETPs

THERMOPLASTICS IN SE ASIA

PLASTICS END USE PATTERN

Plasticulture

22%

Telecom/elec.16%

Infrastructure

24%

Defence & other

2%

Packageing23%

Health2%

Transport6%

Consumer5%

Area % Consumption

Defense & others 2.0

Consumer Durables

5.0

Transport 6.0

Packaging 23.0

Plasticulture 22.0

Infrastructure 24.0

Telecom/ Electronics

16.0

Health & Medicare

2.0

PLASTICS-THE MATERIAL OF CHOICE

• User Friendly• Versatility• Light-weight• Energy Efficient• Non-corrosive• Aesthetic• Abundant• Recyclable

PLASTICS – Emerging Material to meet

Engineering Application Demands• Density

• MFI (Melt flow Index)

• Mechanical Properties

• Impact Strength

• Stiffness

• Toughness

• Creep Resistance

• Abrasion Resistance

• Tear Resistance

Optical Properties

Gloss Clarity & Opacity

PLASTICS – Emerging Material to meet

Engineering Application Demands

Environmental Stress Cracking Resistance

• Chemical Resistance

Acid Resistance

Alkali Resistance

Hazardous Chem. Resistance

( Pesticide / Insecticide)

Barrier Properties

Water Vapour Transmission Rate

Oxygen Transmission Rate

Aroma Transmission Rate

PLASTICS – Emerging Material to meet

Engineering Application Demands

• Easy Processibility

Printability

Sealing Property

Seal Strength

Cost Effectiveness

Product Design Flexibility

CALASSIFICATION OF PLASTICS

PLASTICS

THERMO-PLASTICS THERMO-SETTING

COMMODITY ENGINEERING

SPECIALITY

DEFINATION

COMMODITY THERMOPLASTICS

Very High Volume, Low cost,Low strength, Low Heat Distortion Temp.

ENGINEERING PLASTICS

High strength, High HDT, Low Volume, High Cost

SPECIALITY THERMOPLASTICS

Very Low Volume, Very High Cost, Excels in Specific Performance Requirements.

MAJOR COMMODITY PLASTICS

1. LOW DENSITY POLYETHYLENE (LDPE)

2. LINEAR LOW DENSITY POLYETHYLENE (LLDPE)

3. HIGH DENSITY POLYETHYLENE (HDPE)

4. POLY PROPYLENE (PP)

5. POLY VINYL CHOLORIDE (PVC)

6. POLY STYRENE (PS)

MAJOR ENGINEERING THERMOPLASTICS

1. ACRYLO NITRILE BUTADIENE STYRENE (ABS)

2. STYRENE ACRYLONITRILE (SAN)

3. POLYMETHYL METHACRYLATE (PMMA)

4. POLYAMIDE - (PA)

5. POLYETHYLENE TEREPHTHALATE- (PET)

6. POLYBUTYLENE TEREPHTHALATE- (PBT)

7. POLYOXYMETHYLENE - (POM)

8. POLY CARBONATE - (PC)

9. HIGH IMPACT POLYSTYRENE (HIPS)

MAJOR SPECIALITY PLASTICS

1. POLYTETRA FLUOROETHYLENE (PTFE)2. THEROPLASTIC POLYURETHANE (TPU)3. POLY SULPHONE (PSO)4. POLY ETHER SULPHONE (PES)5. POLYPHENYLENE SULPHIDE (PPS)6. POLYPHENYLENE ETHER (PPE)7. POLY ETHER ETHER KETONE (PEEK)8. POLY ACRYLATE9. POLY AMIDE – IMIDE (PAI)10. POLY ETHER – IMIDE (PEI)11. LIQUID CRYSTAL POLYMERS (LCP)

MAJOR THERMOSET PLASTICS

1. PHENOL FORMALDEHYDE (PF)

2. UREA & MELAMINE FORAMLDEHYDE

3. EPOXY RESINS

4. UNSATURATED POLYESTER RESIN

5. POLYURETHANES

6. SILICONES

0

50

100

150

200

250

300

PC POM PSU PET PEI PES PPS PEEK

Heat Deflection Temperature (°C)

Continuous Use Temperature (°C)

Thermal Properties of ThermoplasticsThermal Properties of Thermoplastics

ABSSAN PS HDPE PP

PC PA 11 PA 6/12 POM PA 6 PA 6/10 PA 6/6 PA 12

TPU PA 6/6 HI PBT TPE PPOPCA – PC/ABS

Commodity

Engineering

High Performance

PEIPSUPESPEEKPPS

LCP

Tem

pera

ture

Mechanical Property retention

CRITERIA FOR PERFORMANCE

TOP SEVEN ENGINEERING PLASTICS

TYPICAL

PROPERTIESPA 6 PC PPO POM PBT PPCP ABS

IZOD Notched

(Kg. cm/cm)

16 85 23 10 6 15 20

HDT (ºc) 104 132 120 110 55 60 82

Water Absorption (%)

1.5 0.15 0.07 0.3 0.08 Neg. 0.4

Flammability

UL94 (1.47mm)

HB V2 HB HB HB HB HB

Sp. Gravity 1.14 1.20 1.06 1.42 1.31 0.9 1.05

Tensile Strength

(Kg/Sq .Cm)

340 600 500 650 500 300 400

Flex. Mod.

(Kg/Sq. Cm)

9500 24000 25000 26000 23000 13000 23000

MAJOR ENGINEERING PLASTICSSTRENGTHS

AMORPHOUS (PC, PPO, ABS)• Constant mechanical properties versus

temperature• Dimensional stability• Creep Resistance• Low Shrinkage• Transparency possible

CRYSTALLINE (PP, POM, PBT/PET)• Resistance to hydrocarbons• Good flow behaviour• Wear and Fatigue resistance

POLYAMIDES

• Several types are available based on raw material used

• Most widely used polyamides are Nylon 6 & 66• Condensation reaction of dicarboxylic acids and

diamins (Commercially through the route of intermediate salts) ---- Nylon 6,& 66

• Ring opening reaction of lactam – Nylon 6, Nylon 12 etc.

• Condensation reaction of amino acids – Nylon 7, Nylon 11 etc.

POLYAMIDES

Characteristics of Polyamides• Semi-crystalline material• Polar in nature• Resistant to hydrocarbon solvents, grease, lubricants• Hygroscopic• High to medium rigidity – improved by glass fibre filling• Good electrical insulation – adversely affected by moisture

absorption.• Good abrasion resistance and low coefficient of friction• Flame retardant versions are difficult process.• Dimensions affected by humidity. • Not good temp. resistance under load – improved by glass

fibre filling.

POLYAMIDES

APPLICATIONS OF POLYAMIDE

• Gear, Cams, bushes, Bearings• Valve Seats• Terminal Blocks• Connectors• Automotive Exterior• Under bonnet Automotive Parts• Motor Housing• Optical fibre Sheathing (Nylon 12)• Insulating liners (Railways• Hair combs

PA In AIR CRAFT

Application: Aircraft Engine ComponentsMaterial: - PA46-GF30

• Highly complex shape minimize the noise level • Design freedom at low costs• High impact properties in a wide temperature range• wall sections as thin as possible- thus reducing valuable weight.

•Airbus

•Injection moulding

PA in Agricultural film Application: Agricultural Barrier FilmMaterial: PA6-unfilled

Barrier Film for agricultural use with environmental benefits.

• When used to cover the soil together with the injection of fumigation chemicals, lower levels of the fumigant can be used. As the film keeps the active agent in the soil for longer.

Extrusion Processing Technology

PA in Automotive, Air/fuel management Application: Air ductMaterial:- PA6-GF20

Blow Molding Processing Technology

Air-duct design offers the best combination of the demanding requirements for: high temperature air ducts.

· higher cold impact than other similar materials· higher stiffness at high temperatures (150°C) allowing thinner walls to be designed.· high melt strength and a low melt viscosity for optimum Production

PA in AUTOMOTIVE, AIR/FUEL MANAGEMENT

Application: Air inlet manifoldMaterial: PA6-GF30

Injection Molding

Ford UK

PA6: The material of choice for air inlet manifolds

• ‘Fuel economy’ & ‘weight reduction’• Single molding and replacing aluminium and steel

by plastics • Provides the chemical, temperature and vibration

resistance required to survive the expected life of vehicles.

• lower system costs compared to metals through part and function integration,

• Easier assembly and longer tool life. • Temperature resistance and a higher burst pressure

resistance after welding.• Providing safer solutions or more design freedom,

as well as lower system costs as a result of an easier• Processibility and better surface appearance.

POLY CARBONATE

POLYCARBONATE

• Poly carbonate was first developed in the laboratory of GE in 1953.

• It was first commercialised in 1958 by GE under the Trade name of LEXAN

• Polycarbonate Lexan is an ester of carbonic acid.• LEXAN is commercially produced by

polycondesation of Bisphenol A and Phosgene

POLY CARBONATE

CHARACTERISTICS :• Highest impact strength• High rigidity• High dimensional stability• High heat distortion temp• Usability in the temperature range of -50 deg. To 135 deg.• Flame retardancy and low combustibility• High optical clarity• Good electrical insulation properties• Good strain resistance• Low water absorption• Food grades available. • Good low temp. impact strength

POLY CARBONATE

APPLICATIONS:• AUTOMOTIVE HEADLAMPS, REFLECTORS AND LENSES• INDICATORS AND BLINKERS• DASH BOARD COMPONENTS• CRASH HELMETS• TELECOM CONNECTORS• DOMESTIC ELECTRICAL SWITCHES• TRAFFIC SIGNAL LENSES• SIGNAL HOUSINGS• TELEGRAPHIC POLE INSULATOR• TERMINAL BLOCKS• LIGHT DIFFUSER• STREET LAMP CANOPIES• BUSINESS MACHINE COMPONENTS

POLY CARBONATE

APPLICATIONS• BABY FEEDING BOTTLES, MIXIE JARS• BLOOD OXYGENATORS• I.V. CANNUELA• FACTORY ROOFINGS• RAILWAYS PLATFORMS FOOFINGS/BUS STOPS• SAFETY GLAZINGS• TELEPHONE BOOTHS• OFFICE AND FACTORY PARTITIONS• COMPACT DISKS AND OPTICAL DATA STORAGE DISKS• RETURNABLE WATER AND MILK BOTTLES.

PC in AUTOMOTIVE, AUTO LIGHTING Application: Head lamp bezelMaterial: PC-unfilled

Headlamp bezels require Excellent surface finish & aestheticsGood heat resistance and be warpage freeMetallic effect and an exceptional appearance.

Injection molding.

Audi

PC in Electrical / Electronics,

TelecommunicationApplication: Mobile phone travel chargerMaterial: - PC-unfilled

A charger for a mobile phone require :- Very high aesthetic - Withstand severe drop tests - Resistant to all kind of chemical substances,like hand lotions & soaps. - Flame retardant and has to pass the pressure test at 125 ºC.

Injection Molding

Philips

PC in ELECTRICAL LIGHTING Application: Lamp holder fluorescent lamp, Material:- PC

Fluorescent lamp holders require: Tough materials with good flow to be able to mold the components

easily-PC being easy flowing and with excellent mold release.

Injection molding.

PC in Electrical / Electronics

: Application: ATM - PC-unfilled

This processing technique makes it possible to attain a cost-saving of up to 300%, when for instance changing from cast aluminium to plastic mouldings for cash dispensers (ATM’s). This molding is by made the ‘low pressure foam process’ to produce a 7,5 kg moulded automated telling machine fascia. Although the main driving force is cost reduction, issues like weight reduction, torsional stiffness, vandal resistance, paint ability to class A surface finish, dimensional stability

THERMOPLASTIC POLY ESTER(PET & PBT)

• Crystalline in nature

• Based mainly on polybutylene terephthalate. A few grades based on polyethylene and polycyclohexane dimethanol terephalate are also available

• The base resins are commercially manufactured by Esterification reaction of Terephthalic Acid and appropriate diols.

THERMO PLASTIC POLYESTER (PET & PBT)

CHARACTERISTICS • High Mechanical Strength • Excellent chemical resistance• High temperature resistance in glass filled grades• High dimensional stability• Excellent Electrical tracking resistance• Can be made flame retardant• Effect of humidity minimal • Excellent flow

THERMOPLASTIC POLYESTER (PET & PBT)

APPLICATIONS:• Connectors• TV Components• Industrial Switches/plug’s• Business machine components• Keyboard buttons• Steam irons• Cookers• Air vents• Plumbing• Auto ignition systems• Under bonnet connectors• Head lamp reflectors

* Dimensional stability for reliable performance in all conditions

*Automotive window lift mechanisms demand shock resistance over a wide temperature range,-40°C to +80°C,

*Excellent dimensional stability and strength up to the maximum environmental temperature.

*Reducing total assembly costs and weight.

Processing Technology: Injection Molding

Opel, Volvo

Application: Actuator, Gear housing window Lift

Material: PBT-GF20

PBT IN AUTOMOTIVE

•Stability and Narrow tolerances for parts close to the engine•This air-flow mass meter measures air flow speed for the motor management control system. •It has to maintain tight tolerances over the life of the vehicle and withstand the temperatures encountered close to the engine.• Exceptional dimensional stability andstrength over a wide temperature range. • The best balance of mechanical properties and good welding performance,facilitating manufacturing productivity.

Application: Air flow mass meter housing and sensor

Material: PBT-GF30

PBT IN AUTOMOTIVE

Processing Technology: Injection Molding

Opel

PBT IN AUTOMOTIVE

Application: Sensor, throttle position

Material: PBT-GF30

Application: E-Box, Fusebox

Material: PBT-GF10

Application: Compact NS Schneider Material: PBT-GF30

PBT IN : Electrical / Electronics, Power distribution & circuit protect

Application: Bobbins Schneider

Material: PBT-GF30

Processing Technology: Injection Molding. Schneider

Application: Breake Booster Valve bodies

Material: PET-GF35

•Glass fiber reinforced polyethylene terephthalate (PET) is the material of choice for automotive brake booster valve body applications.

• It provides weight, performance and cost advantages over previously used thermosets.

Processing Technology : Injection Molding

ADI BMW

PET IN AUTOMOTIVE, BREAKE /CLUTCH

PET IN AUTOMOTIVE, BREAKE /CLUTCH

Application: Tandem brake booster

Material: PET-GF35

•Glass fiber reinforced polyethylene Terephthalate (PET) is the material of choice for automotive brake booster valve body applications.

• It provides weight, performance, and cost advantages over previously used Thermosets.

Processing Technology : Injection Molding

Various

POLYACETAL (POM)

• Polymer of formaldehyde, commonly known as Polyacetal, Acetal polymer or Polyoxymethylene was first commercialised by Du pont in 1959.

• Copolymers were introduced by celanese corporation 1960 to overcome thermal stability problem at processing temp.

• Polyacetal is commercially made by polymerisation of high purity formaldehyde in rapidly stirred inert medium like dry heptane with controlled traces of water added containing phosphine and amine initiators.

POLYACETAL (POM)

CHARACTERISTICS OF POLYACETAL (POM)• High crystalline• High flammable• Resilient and good combination of stiffness and

toughness• Creep resistant- superior to polyamide• Low static and dynamic co-efficient at friction• Very high degree of precision moulding possible• Not high temp. resistant• Resistant to organic solvents upto 70 degree.

POLYACETAL (POM)POLYACETAL (POM)

APPLICATIONS OF POLYACETAL (POM)• Gears• Conveyor belt links• Sprockets and chains• Blower wheels• Cams• Fan blades• Carburettor float and bodies• Aerosol containers• Lighter bodies• LPG Cylinder caps• Shower heads

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