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A free radical is a molecule that has no charge, but, is highly reactive because it has
an unpaired valence electron. Usually, free radical monomer attacks double bond of
another monomer to form bond and propagate the free radical.
The thermal decomposition of benzoyl peroxide, which takes place between 60 and
90°C, involves the homolytic cleavage of the O–O bond to yield benzoyl free radicals that
may react to yield phenyl radicals and carbon dioxide.
Azobisisobutyronitrile
Initiator is a relatively unstable molecule that decomposes into a free radical. The
stability of a radical refers to the molecule's tendency to react with other compounds. An
unstable radical will readily combine with many different molecules. However a
stable radical will not easily interact with other chemical substances.
The alkoxy free radical combines with a molecule of chloroethene to form a new free
radical:
This new free radical can then combine with another molecule of chloroethene:
This new free radical can react with another chloroethene molecule to form a new
free radical, etc, etc until a very large polyvinyl chloride molecule has been built. The
polymerization stops when two free radicals react with each other.
a. Td – decomposition temperature
Temperature where decomposition of initiator undergoes auto acceleration.
Thermal energy released from decomposition of an initiator molecule aids the
decomposition another initiator molecule.
Temperature where the rate of enthalpy generated from the decomposition of the
peroxide serves to provide sufficient energy for further decomposition.
Di t-butylperoxide 80⁰C
AZO COMPOUNDS
Can be the precursor of two carbon-centered radicals (R● and R’●) and nitrogen gas upon
heating and/or by irradiation
2,2-azobisisobutyronitrile
25⁰C
(AIBN)
INITIATOR EFFICIENCY
Not all initiator radicals initiate polymerization. Due to side reactions and
inefficient synthesis of the radical species, chain initiation is not 100%. The efficiency
factor, f, is used to describe the effective radical concentration. The maximum value of f is
1.0, but values typically range from 0.3-0.8. The following is a list of reactions that
decrease the efficiency of the initiator.
Primary recombination
Other recombination pathways
Side reactions
Side reactions. On radical is produced instead of the three radicals that could be
produced.
The field of polymer processing has been traditionally and consistently analyzed in
terms of the prevailing processing methods, that is, extrusion, injection molding, blow
molding, calendering, mixing and dispersion, rotational molding, and so on. In analogy
to chemical engineering, these processes have been viewed as the ‘‘unit operations’’ of
polymer processing.
2. Melting
Subsequent to an operation involving solids handling, the polymer must be melted
or heat softened prior to shaping. Often this is the slowest, and hence the rate-
determining step in polymer processing. Severe limitations are imposed on attainable
melting rates by the thermal and physical properties of the polymers, in particular, the
low thermal conductivity and thermal degradation. The former limits the rate of
heat transfer, and the latter places rather low upper bounds on the temperature and
time the polymer can be exposed. On the other hand, beneficial to increasing the rate of
melting is the very high polymer melt viscosity. All these factors emphasize the need
to find the best geometrical configuration for obtaining the highest possible rates of
melting, and for determining the processing equipment needed for rapid and efficient
melting.
4. Mixing
Reviewing the various shaping methods practiced in the industry, we can classify them in
the following groups:
2. Die forming
Die forming, which is perhaps the most important industrial shaping operation,
includes all possible shaping operations that consist of forcing a melt through a die.
Among these are fiber spinning, film and sheet forming, pipe, tube, and profile forming,
and wire and cable coating. This is also a steady continuous process, in contrast to the
last three shaping methods, which are cyclic.
3. Mold coating
The term ‘‘mold coating’’ is assigned to shaping methods such as dip coating, slush
molding, powder coating, and rotational molding. All these involve the formation of a
relatively thick coating on either the inner or the outer metal surfaces of the molds.
5. Stretch shaping
Finally, stretch shaping, as implied by the name, involves shaping of preformed
polymers by stretching. Thermoforming, blow molding, stretch blow molding, and cold
forming can be classified as secondary shaping operations. The first three are very
widely used.
When heated thermoplastics soften and become fluid when additional heat is
applied. Due to no chemical bonding takes place in a thermoplastic material, the curing
process is completely reversible and it also allows thermoplastic to be remolded and
recycled to form other thermoplastic material without negatively affecting the material’s
physical properties.
There are a lot of process that can be used to form a specific product but in
thermoplastic processing the common methods used are extrusion, injection modeling, blow
molding, and thermoforming.
A. Extrusion
The continuous process named extrusion is the method that is used to produce films,
sheet, profiles, tubes and pipes. The mechanism for the said process is:
1. The polymer material that will be formed into a different type of product for a specific
used will be loaded into the hopper.
2. The Material will then be fed into a long heated chamber that is moved due to the action
of the continuously revolving screw. The plastic will be melted by the mechanical work of the
screw that can be either single or a dual revolving screw depending on the design, and the
heat of the extruder wall.
4. At the end of the extruder, the molten polymer will be forced out through a small opening
called a die to form the shape of the finished product.
5. The polymer that is extruded from the chamber will either undergo a different process or it
will be fed into a conveyor belt or unto a rollers or by immersion to cool the formed polymer.
Examples of extruded products include lawn edging, pipe, film, coated paper,
insulation on electrical wires, gutter and down spouting, plastic lumber, and window trim.
1. The plastic material either in the form of pellet or powder will be fed into the hopper.
2. An extruder screw pushes the plastic through the heating chamber in where the material
will be melted so that it will be formed to a different type of product.
4. Once the product is cooled to a solid, the mold will open and the finish product will be
injected.
Injection Modeling process is usually to make items such as butter tubes, yogurt containers,
bottle caps, toys, fittings, and lawn chairs.
C. Blow Molding
Blow molding is a process used extensively for the production of bottles and other hollow
plastic items with thin walls. This process is used in conjunction with extrusion or injection
molding. Blow-molded objects may range in size from less than 1 Oz to a few hundred
gallons. The extrusion forms a continuous semi-molten tube of the thermoplastic material.
Then a chilled mold is clamped around the tube and compressed air with a pressure of
usually about 100psi is blown into the tube to form the desired product. The formed product
will be cooled until the plastic become solid then the clamp will be remove to get the blow
D. Thermoforming
The plastic sheet is clamped in place mechanically and heated. A vacuum is then
placed beneath the hot elastic sheet, and this makes atmospheric pressure push the sheet
down onto the contours of the cold mold. The plastic material cools down, and after an
appropriate time the cooled part is removed.
Mechanical Thermoforming
In this type of thermoforming the plastic sheet will be heated until its softened
enough to be molded into different type of products. In this process there will be no pressure
or air that will be used. In this Thermoforming the heated sheet will be clamped into the
female or draped over a male mold then the two will be close together and cooled until the
Air Thermoforming
Thermoset Processing
Thermoset polymers are polymers that when heated will degrade before it reaches its
you melting point hence in processing it the monomer will be polymerized while you form
your desired product. This is done by the addition of resins or catalyst at high temperature to
speed up the reaction and the polymer will be formed. There are two common processes
used in thermoset processing namely compression molding and transfer molding.
B. Transfer Molding
The mold interior surfaces may be gel-coated. If desired the mold is first pre-loaded
with a reinforcing fiber matrix or perform. Fiber content of a transfer molded composite can
be as high as 60% by volume. The fill material may be a preheated solid or a liquid. It is
loaded into a chamber known as the pot. A ram or plunger forces material from the pot into
the heated mold cavity. If feed-stock is initially solid, the forcing pressure and mold
temperature melt it. Standard mold features such as sprue channels, a flow gate and ejector
pins may be used. The heated mold ensures that the flow remains liquid for complete filling.
Once filled the mold can be cooled at a controlled rate for optimal thermoset curing.
A. Random Copolymer
C. Block Polymer
D. Graft Polymer
Sequences of one monomer (repeating unit) are “grafted” onto a backbone of the
another monomer type:
Ebewele, R. O. (2000). Polymer Science and Technology. Florida: CRC Press LLC.
https://www.slideshare.net/Amitsirohi2/polymer-53188708
production-process-of-polymers/
Tadmor, Z., & Gogos, C. G. (2006). Principles of Polymer Processing (2nd ed.). Hoboken, NJ:
Wiley.
Polymerization retrieved at
http://www.umich.edu/~elements/fogler%26gurmen/html/07chap/htm
l/polymerization.pdf
Ebewele, Robert Oboigbaotor. Polymer Science and Technology. Boca Raton: CRC, 2000.
Print.