CHAPTER 16: PLASTICS

Plastics - are synthetic materials (artificial or manufactured). Synthesis means that "something is
put together," and synthetic materials are made of building blocks that are put together in
factories. The building blocks for making plastics are small organic molecules - molecules that
contain carbon along with other substances. They generally come from oil (petroleum) or
natural gas, but they can also come from other organic materials such as wood fibers, corn,
or banana peels. Each of these small molecules is known as a monomer ("one part"),
it's capable of joining with other monomers to form very long molecule chains
called polymers ("many parts") during a chemical reaction called polymerization.

TYPES OF PLASTICS
Plastics are classified into two categories according to what happens to them when they're
heated to high temperatures.
Thermoplastics - which melt when heated and can be remolded easily.Upon heating, the
plastic softens. Upon cooling, the plastic hardens. Good examples are
acrylic (e.g.-aircraft windows), polypropylene (e.g. Tupperware, margarine
containers, syrup bottles, prescription bottles),polystyrene (e.g. Styrofoam),
polyvinyl chloride or PVC and (e.g. pipes). polythene (e.g. food packaging, gas pipes)
Thermosets - which are formed by heat process but are then set (like concrete) and
cannot change shape by reheating. Good examples are melamine (e.g. kitchen worktops),
Bakelite (e.g. black saucepan handles), polyester and epoxy resins.

PLASTIC MANUFACTURING
The production of plastics can be divided into four categories:

1. Acquiring the raw material or monomer

Historically, resins derived from vegetable matter were used to produce most plastics.This included
such materials as cellulose (from cotton), furfural (from oat hulls), and oils (from seeds).Today, most
plastics are produced from petrochemicals which are widely available and tend to be cheaper
than other raw materials. However, the global supply of oil is exhaustible, so researchers are
investigating other sources of raw materials, such as coal gasification.

2. Synthesizing the basic polymer

The first step in plastic manufacturing is polymerization. The two basic methods by which
polymerization can occur are addition and condensation reactions. These can occur in the gaseous,
liquid and occasionally solid phase. Sometimes the polymer synthesis can take place at the
interface of two immiscible liquids in which the monomers are dissolved.

3. Compounding the polymer into a material that can be used for fabrication
Chemical additives can be used in the production of plastics to achieve certain characteristics.
These additives include: antioxidants to protect the polymer from degradation by ozone or oxygen,
ultraviolet stabilizers to protect against weathering, plasticizers to increase the polymers flexibility,
lubricants to reduce friction problems, pigments to give the plastic color, flame retardants, and
antistatics

4. Molding or shaping the plastic into its final form

Methods of Forming plastics

a.)
plastic
granules

hopper

Injection Molding

Final Object

section
mold

heater

The Die

motor and
hydraulic
pump

This technique is widely used for forming thermoplastic materials. It is similar to the
casting technique used to form metal components. The plastic (in a powdered or granular
form) is put in a hopper. A screw thread turns forcing the plastic material through a heater,
melting it. When all the materials are melted, the screw thread then acts as a ram and forces
the plastic into mold, where it cools and solidifies.
Uses: Precision technique capable of complicated shapes: medical components;
Cheap products produced in very large numbers: Lego, machine housings,
washing-up bowls

b.)
plastic granules

hopper

Extrusion Molding
heater

die

cold water in

the Die
the extrusion
extrusion
solid

motor and
hydraulic
pump

water out

The extrusion process is similar to injection molding. Plastic granules are heated in a hopper
and a screw thread forces the material through a die. The material is then cooled. Extrusion
can only be used for simple shapes and the end product generally has a poor quality finish.
Uses: Anything with a constant cross section: fibres, tubing, pipes, sheets, films,
profiles (e.g. curtain rails or window frames)

Rotational Molding

e.)

Plastic beads are

put into the mold

Mold is closed,Heat is
applied while mold is
rotated in 2 directions
simultaneously

Mold is then
cooled

Mold is split and

product is extracted

A measured amount of material is placed in a mold which is rotated on two axes

at low speed within an oven. The molten plastic then covers and adheres to the inner
surface of the mold. The mold is then cooled while still rotating and the product is
released.
Uses: Only for products with uniform wall thickness and where the inner surface
of the product can be inferior to its outer surface which replicates the surface
of the mold. Usually large simple forms: storage tanks, traffic bollards

f .)

Blow Molding
extrude plastic

air blown in

tubular
die

tube takes
the shape of
the mold

hot plastic tube

solid
plastic

tube squeezed
and gripped by
the mold

Blow mo lding is used to manufacture bottles and containers with very thin walls. Blow
molding first requires a tube of plastic to be extruded. The tube of molten plastic is extruded
between the two halves of a mo ld. Before the plastic cools the two halves of the mo ld are
brought together and air is blown into the center of the material through a blow pin. This
forces the plastic out forming the shape of the mold. The plastic can then be cooled and
removed.
Uses: Hollow articles, usually with openings of smaller diameter than the body, such as
bottles or containers

Vacuum Forming

c.)

reusable pattern

molded sheet

heater
sheet of
plastic

atmospheric pressure

sheet of plastic

molded sheet

air sucked out

Vacuum forming is used to make simple molds using thin sheets of thermoplastic.
High impact polystyrene sheet (HIPS) is what is used in school. PVC can also be used.
A mold is created from wood or epoxy resin and this is placed on the table
of the vacuum forming machine. The sheet plastic is heated until it becomes soft.
The table with your mold on is lifted into position and a vacuum is used to draw the plastic
over the mold. Vacuum forming only works with thin plastics and molds with no undercuts.
The plastic can then be trimmed to the required shape.
Uses: Shallow forms: baths and boat hulls, bowls, margarine and yogurt pots

d.)

Compression Molding
plastic
granules

split mold

pressure

pressure

heater

split mold
heater

cured
molding

This is how thermosets are formed. The reaction occurs in the mold as the granules
are heated and compressed. UF or urea formaldehyde and MF melamine formaldehyde are
formed by this method.
Uses: Radio and telephone housings, plugs and sockets, tableware, ashtrays, bowls
and boxes