Polymers

You may think of polymers as being a relatively

modern invention however naturally occurring
polymers have been used for thousands of years
wood, rubber, cotton, wool, leather, silk,.. etc
Artificial polymers are, indeed, relatively
recent and mostly date from after WWII
in many cases, the artificial material is both
better and cheaper than the natural alternative
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A polymer is a large molecule made by linking together

repeating units of small molecules called monomers

Polymerization
Addition Polymerization
Condensation Polymerization

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Occurs in the presence of a Lewis acid

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Properties and uses

Good fibre-forming material and is converted into
commercial fibres.
Such fibres have high stretch resistance, high crease
and wrinkle resistance.
Highly resistant to mineral and organic acid, but is less
resistant to alkalies.
Used for making synthetic fibres like terylene, dacron
etc.
For blending with wool to provise better crease and
wrinkle resistance.
A glass reinforcing material in safety helmets, aircraft
battery boxes, etc.
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Bakelite formation (condensation)

hexamethylenediamine

adipoyl chloride

Nylon 6 6 (condensation polymer)

2-methyl-1,3-butadiene

Natural rubber cis-polyisoprene

The word plastics is from the Greek word Plastikos,

meaning able to be shaped and molded

The word plastics is from the Greek word Plastikos,

meaning able to be shaped and molded

Why Design with Plastics?

Light weight, high weight to strength ratio,

Corrosion resistance
Low electrical and thermal conductivity, insulator
Easily formed into complex shapes, can be
formed, casted and joined.
Wide choice of appearance, colors and
transparencies
Relatively low cost compared to metals and
composites

Disadvantages of using Plastics

Low strength
o
Low useful temperature range (up to 600 F)
Less dimensional stability over period of time
(creep effect)
Aging effect, hardens and become brittle over time
Sensitive to environment, moisture and chemicals
Poor machinability

Classification of polymers
There are two major classifications of polymers
Thermoplastics
As the temperature is raised above the melting point, the secondary bonds
weaken, making it easier to form the plastic into any desired shape. When
polymer is cooled, it returns to its original strength and hardness. The process
is reversible. Polymers that show this behavior are known as thermoplastics.

Thermosetting Plastics (thermosets)

Thermosetting plastics are cured into permanent shape. Cannot be re-melted to
the flowable state that existed before curing, continued heating for a long time
leads to degradation or decomposition. This curing (cross-linked) reaction is
irreversible. Thermosets generally have better mechanical, thermal and
chemical properties. They also have better electrical resistance and dimensional
stability than do thermoplastics.

Manufacturing Processes for Plastics

Molding: conversion of solid polymer material into
desirable size and shape
Injection Molding
Ejector pin

Molded part
Heaters

Granular
plastic

Plunger
Torpedo

Advantages:
High speed production
Low cost in mass production
Very low loss of materials.
Flexibility to make parts with complex shapes
High precision

Applications:
Bottle caps, buckets, mugs, dust-bins, chairs, automotive
dashboard etc.

Compression molding

Compression Molding
Charge is placed in cavity of matched
mold in the open position
Mold is closed by bring the two halves
together
Pressure is exerted to squeeze the resin
so that it fills the mold cavity
While under pressure the mold is heated
which cures the resin
Thermosets

Advantages:
Low initial set up cost
Very low lost of materials
Good surface finish
Fast setup time

Applications:
Electrical parts (switches and switch boards), buttons,
electronic device cases, cooker handles, appliance housing
and large container etc.

Compression Molding vs
Injection Molding
Compression Molding

Injection Molding

Heated mold

Cooled mold

Thermoset material

Thermoplastic material

Long cycle time (minutes)

Short cycle time (seconds)

Cant recycle flash or waste parts

Can reprocess flash and waste parts

Low part complexity

High part complexity

Additives in Plastics

Additives are added to polymers in order to obtain or improve

certain properties such as strength, stiffness, color, resistance
to weather and flammability.
Plasticizers are added to obtain flexibility and softness, most
common use of plasticizers are in PVC.

Ultraviolet radiation (sunlight) and oxygen cause polymers to

become stiff and brittle, they weaken and break the primary
bonds. A typical treatment is to add carbon black (soot) to the
polymer, it absorbs radiation. Antioxidants are also added to
protect against degradation.
Fillers such as fine saw dust, silica flour, calcium carbide
are added to reduce the cost and to increase harness,
strength, toughness, dimensional stability,..

Additives in Plastics
Colorants are added to obtain a variety of colors. Colorants
are either organic (dye) or inorganic (pigments). Pigments
provide greater resistance to temperature and sunlight.
Flame retardants such as chlorine, phosphorus and
bromine, are added to reduce polymer flammability. Teflon
does not burn and nylon and vinyl chloride are selfextinguishing.
Lubricants such as mineral oil and waxes are added
to reduce friction.

Polyethylene LDPE

White waxy and translucent material

Density range 0.915-0.94 g/cm3
Melts in temperature range 107-120 degree Celsius.
Tg = -120 degree Celcius
Flexible and tough over wide range of temperatures
Chemically inert (good resistance to acids and alkalis)
High compact strength, low brittleness temperature, film
transparency, outstanding insulation properties
Applications:
Transparent films for food and garments packaging.
Squeeze bottles, paper coatings, wrappings, table cloths,
industrial containers and sheets, cable and wire insulations

HDPE

Density range 0.945-0.965 g/cm3. (more than LDPE)

Melts in temperature range 130-138 degree Celsius,
Tg = -20 degree Celsius
Greater rigidity than LDPE
Better chemical resistance than LDPE
Better stiffness, toughness, tensile strength, hardness and
heat resistance properties.
Opaque and less impact strength
Applications:
Dustbins, milk bottles, cans, drums, containers, fuel tanks,
pipes, wire and cable insulations.

PVC
Colourless, odourless, non-flammable and chemically inert
Resistant to light, atmospheric oxygen, inorganic acids and
alkalis
More stiffness and rigidity as compared to polyethylene
Applications:
Building and construction (rigid pipes, flooring)
Plasticized PVC used in wire and cable insulations and in
packaging
Flexible films and sheets used as pool liners and roof
coatings
Wall coverings and carpet backing, electrical outlet boxes
and parts for automotive bumpers.

PMMA

Amorphous and transparent plastic

Good optical clarity (refractive index =1.4)
Poor scratch resistance
Resistant to water, alkalis and inorganic salts but dissolves in
organic solvents
Good outdoor weathering property and dimensional stability
Tougher than polystyrene
Applications:
Automobile-lamp housing, street-light housing, aircraft
windows, signal boards.
Used in paints and adhesives
Used for making artificial teeth and contact lenses, laser disks
and DVDs, transparent bath tubs and wash basins.

Bakelite (Phenol-formaldehyde resin

Rigid, hard and scratch resistant material
Good electrical insulation properties
Thermal stability up to 200 degree Celsius and good
dimensional stability.
Resistant to water and low flammability
Applications:
Electrical equipment parts (switches, plugs, switchboards,
cooker handles, welding tongs, electrical iron parts and
telephone parts)
Hardness (golf ball and heads for typewriters)
Hot setting adhesives for plywood, cement for sealing
electric bulbs to their metal holders and lamination of
paper, cardboards and wood.

Urea formaldehyde resin

Used as adhesives for the particle board, plywood and

furniture industries
Casting material in textile finishing
UF foams used as artificial snow in cinema and televisin
productions

Melamine-Formaldehyde Resin

Manufacture of tableware
Outlet of trays, clock cases, radio cabinets (cellulose-filled)
Electrical applications, knobs, handles for kitchen utensils
(Mineral-filled)
Laminating applications, glazing agents, flame proofing agents

Why Design with Plastics?

Light weight, high weight to strength ratio,
Corrosion resistance
Low electrical and thermal conductivity, insulator
Easily formed into complex shapes, can be formed,
casted and joined.
Wide choice of appearance, colors and transparencies
Relatively low cost compared to metals and composites

Disadvantages of using Plastics

Low strength
o
Low useful temperature range (up to 600 F)
Less dimensional stability over period of time (creep
effect)
Aging effect, hardens and become brittle over time
Sensitive to environment, moisture and chemicals
Poor machinability

Classification of polymers
There are two major classifications of polymers
Thermoplastics
As the temperature is raised above the melting point, the secondary bonds
weaken, making it easier to form the plastic into any desired shape. When
polymer is cooled, it returns to its original strength and hardness. The process
is reversible. Polymers that show this behavior are known as thermoplastics.

Thermosetting Plastics (thermosets)

Thermosetting plastics are cured into permanent shape. Cannot be re-melted to
the flowable state that existed before curing, continued heating for a long time
leads to degradation or decomposition. This curing (cross-linked) reaction is
irreversible. Thermosets generally have better mechanical, thermal and
chemical properties. They also have better electrical resistance and dimensional
stability than do thermoplastics.

Manufacturing Processes for Plastics

Molding: conversion of solid polymer material into
desirable size and shape
Injection Molding
Ejector pin

Molded part
Heaters

Granular
plastic

Plunger
Torpedo

Advantages:
High speed production
Low cost in mass production
Very low loss of materials.
Flexibility to make parts with complex shapes
High precision

Applications:
Bottle caps, buckets, mugs, dust-bins, chairs, automotive
dashboard etc.

Compression molding

Compression Molding
Charge is placed in cavity of matched
mold in the open position
Mold is closed by bring the two halves
together
Pressure is exerted to squeeze the resin
so that it fills the mold cavity
While under pressure the mold is heated
which cures the resin
Thermosets

Advantages:
Low initial set up cost
Very low lost of materials
Good surface finish
Fast setup time

Applications:
Electrical parts (switches and switch boards), buttons,
electronic device cases, cooker handles, appliance housing
and large container etc.

Compression Molding vs
Injection Molding
Compression Molding

Injection Molding

Heated mold

Cooled mold

Thermoset material

Thermoplastic material

Long cycle time (minutes)

Short cycle time (seconds)

Cant recycle flash or waste parts

Can reprocess flash and waste parts

Low part complexity

High part complexity

Additives in Plastics

Additives are added to polymers in order to obtain or improve

certain properties such as strength, stiffness, color, resistance
to weather and flammability.
Plasticizers are added to obtain flexibility and softness, most
common use of plasticizers are in PVC.

Ultraviolet radiation (sunlight) and oxygen cause polymers to

become stiff and brittle, they weaken and break the primary
bonds. A typical treatment is to add carbon black (soot) to the
polymer, it absorbs radiation. Antioxidants are also added to
protect against degradation.
Fillers such as fine saw dust, silica flour, calcium carbide
are added to reduce the cost and to increase harness,
strength, toughness, dimensional stability,..

Additives in Plastics
Colorants are added to obtain a variety of colors. Colorants
are either organic (dye) or inorganic (pigments). Pigments
provide greater resistance to temperature and sunlight.
Flame retardants such as chlorine, phosphorus and
bromine, are added to reduce polymer flammability. Teflon
does not burn and nylon and vinyl chloride are selfextinguishing.
Lubricants such as mineral oil and waxes are added
to reduce friction.

Polyethylene LDPE

White waxy and translucent material

Density range 0.915-0.94 g/cm3
Melts in temperature range 107-120 degree Celsius.
Tg = -120 degree Celcius
Flexible and tough over wide range of temperatures
Chemically inert (good resistance to acids and alkalis)
High compact strength, low brittleness temperature, film
transparency, outstanding insulation properties
Applications:
Transparent films for food and garments packaging.
Squeeze bottles, paper coatings, wrappings, table cloths,
industrial containers and sheets, cable and wire insulations

HDPE

Density range 0.945-0.965 g/cm3. (more than LDPE)

Melts in temperature range 130-138 degree Celsius,
Tg = -20 degree Celsius
Greater rigidity than LDPE
Better chemical resistance than LDPE
Better stiffness, toughness, tensile strength, hardness and heat
resistance properties.
Opaque and less impact strength
Applications:
Dustbins, milk bottles, cans, drums, containers, fuel tanks, pipes,
wire and cable insulations.

PVC
Colourless, odourless, non-flammable and chemically inert
Resistant to light, atmospheric oxygen, inorganic acids and
alkalis
More stiffness and rigidity as compared to polyethylene
Applications:
Building and construction (rigid pipes, flooring)
Plasticized PVC used in wire and cable insulations and in
packaging
Flexible films and sheets used as pool liners and roof coatings
Wall coverings and carpet backing, electrical outlet boxes and
parts for automotive bumpers.

PMMA

Amorphous and transparent plastic

Good optical clarity (refractive index =1.4)
Poor scratch resistance
Resistant to water, alkalis and inorganic salts but dissolves in
organic solvents
Good outdoor weathering property and dimensional stability
Tougher than polystyrene
Applications:
Automobile-lamp housing, street-light housing, aircraft
windows, signal boards.
Used in paints and adhesives
Used for making artificial teeth and contact lenses, laser disks
and DVDs, transparent bath tubs and wash basins.

Bakelite (Phenol-formaldehyde resin

Rigid, hard and scratch resistant material
Good electrical insulation properties
Thermal stability up to 200 degree Celsius and good
dimensional stability.
Resistant to water and low flammability
Applications:
Electrical equipment parts (switches, plugs, switchboards,
cooker handles, welding tongs, electrical iron parts and
telephone parts)
Hardness (golf ball and heads for typewriters)
Hot setting adhesives for plywood, cement for sealing
electric bulbs to their metal holders and lamination of
paper, cardboards and wood.

Urea formaldehyde resin

Used as adhesives for the particle board, plywood and

furniture industries
Casting material in textile finishing
UF foams used as artificial snow in cinema and televisin
productions

Melamine-Formaldehyde Resin

Manufacture of tableware
Outlet of trays, clock cases, radio cabinets (cellulose-filled)
Electrical applications, knobs, handles for kitchen utensils
(Mineral-filled)
Laminating applications, glazing agents, flame proofing agents