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1. INTRODUCTION
As we are aware of the material called polymer and also knows that these
are macromolecules which are form by linking together a much smaller molecules i.e.
defense, radars and communications. These has been increasing acceptance of plastic for
housing, electrical and electronics equipments leading to increased use of more general
purpose plastics.
plastic films for wrapping bags and sacks is well known. The automobile industry is the
In general area of medicine user range from spare parts of surgery such as
We use this material in various forms in our daily life. Sheets, tubes,
pipes, households, foams and many more. The different conventional processes are
required for converting these polymeric materials into finished and shaped product.
Extrusion.
2. STATISTICAL DATA
Following table represent the individual consumption of plastic in the country (India).
Material Year
1999-2000 2000-2001
HDPE 515,496 540,000
PVC 649,000 700,000
PP 789,480 905,000
PS 175,382 193,300
LDPE/LLDPE 723,860 820,000
has been used for converting the plastic into desired shape.
PROCESS PERCENTAGE
Extrusion 36%
Injection molding 32%
Blow molding 10%
Calendaring 6%
Coating 5%
Compression molding 3%
Powder form 2%
Other process 6%
Total 100
3. GENERAL EXTRUSION
This is the oldest techniques developed from aluminium extrusion, which
hopper into heated cylinder. The screw inside the cylinder forces the molten
molten material.
forcing of plastic or molten material through a shape die by using pressure. The
through the hopper of the extrusion machine as either powder or granules into a
cylinder having provisions for electrical heating for softening of material. The hot
revolving screw. The temperature of the plastic material rises owing to the
frictional heat produced by the compression of charge between the rotating screw
and the cylinder surface. During its journey from hopper to die the plastic
material passes through distinct zone named feed zone, compression zone and
metering zone. The final action of screw is to force the melted polymer through a
and heating arrangements. There are three zones named as feed zone, compression
Feed zone:
This is the first zone where the raw material is fed to the extruder
from hopper, from figure it is clear that maximum clearance is provided by screw
to accept the raw material or granules. In this zone, preheating is done and with
the help of screw movement the feed is conveyed to the compression zone.
Barrel
Barrel Heater
Screw
Die
Compression Feed
Metering zone zone
zone
Compression zone:
provided by keeping minimum clearance between screw flight and internal surface
Metering zone:
compression zone conveyed to the nozzle and die. The molten material is
CO-EXTRUSION :
that product.
VENTED EXTRUSION :
volatile harmful materials. Since some of the plastic materials are hygroscopic in
4. REACTIVE EXTRUSION
extruder is used as mini reactor. “ Reactive extrusion is the name given to the
process where by the plastic is manufactured in the extruder from base chemicals
and once produced it passes through a die of the desire shape, which gives shape
to the material.”
effective method for producing new polymer and polymer alloys. This system
well as highly reactive material which are generally difficult to handle with
particularly for small lot production. The main reason lays that the continuous and
low volume production and chemical composition control of polymers, their micro
structure, physical properties are readily possible with this method. On the other
hand, there are many plastic, currently being developed possessing excellent
extrude/process them or else showing the poor fluidity necessary for processing
due to the highly cross linking characteristics at molding temperature, Some kinds
molding system can efficiently handle such materials as well as the conventional
materials.
PROCESS:
In a typical reactive extrusion process the reactants are fed into the
extruder feed throat were the material is usually heated to initiate reaction or
increase the reaction rate. The reactant mixer is conveyed through sequential
barrel segments. Where degree of mixing and specific energy input bring the
reaction to the desired degree of completion within the limit of residence time in
the extruder. At this stage the reaction may be quenched or addition of catalyst
quencher may be done where applicable. Volatile by- products or excess reactants
may be removed.
Feed Vent
Then molten polymer is extruded through the die and rapidly cooled
by contact with a fluid medium such as water. After cooling and solidification
The mixing devices recently employed for both single and twin
screw extruders are adequate for most reactive extrusion processes but some
beneficial for a high degree of back mixing of the sort typically found in a well
MATERIALS
1. POLYETHEREMIDES :
Chemistry :
Chemical Reaction:
O O NH2
|| |
CH3
O | O +
O C O
|| | NH2
O CH3 O
O O
||
CH3
N | N
O C O
|| |
O CH3 O
+ 2 H2O
Processing :
intermeshing screws and barrel length, Such that the average material. Residence
throat, where the material melt in zone 2 and begins polymerisation. Zone 2 is
only partially filled so that surface renewal allows removal of some of the water of
reaction through the first vent maintained at atmospheric pressure. A vacuum vent
at zone 4 removes the rest of the water. Fig. 2 shows the screw geometry in zone 3,
which promotes melt sealing to prevent Back mixing of material between zone 2
between zones.
diamine are fed to extruder as separate melt streams via a concentric tube feed
Dianhydride melt
Keeping the two molten reactants separate untill they can be mixed
2. POLYURETHANE :-
extruder reactors. The chemical required as 9 parts butane 1,4 diol chain extender
Chemistry :
Chemical Reaction:
O O
|| ||
H – { O – C – (CH2)4 – C – O –(CH2)4 } OH
O H H O
|| | | ||
{O–C–N– – CH2 – – N – C – O – (CH2)4 etc.
Polyurethane
functional groups – CN – and – OH – combines with each other through steps and
tends to consume all the groups present in that molecule or reaction mixture.
Processing :
Butane – 1, 4 diol chain extender and 91 parts low mol. wt. Polyester (OH number
= 51.9) prepared from Adipic acid and butane – 1, 4 – diol and 35 parts 4, 4’- di-
Zone at 90-1200C.
produces polyurethane sheet through a sheet die at 30-100 kg/h throughput and
The key to the success of this process is the presence of at-least two or at-most
three kneading zones each 240 mm long preceded by short metering segment. As
shown in fig.4
5. COMPARISON
Reactive.
Processing for a heat sensitive or Processing of a heat sensitive/highly
universally. process.
Morphology control is difficult or it No morphology changes. Obtained by
material.
6. ADVANTAGES
follows.
2) Product Purity :-
gaseous liquid or molten low mol. Wt. compound. A particular advantages of the
by motion of screw.
extruder, the temperature differential between adjacent barrels segment is often <
1000C because of slow heat transfer to and from reactant material. Typical
extruder residence time 10-600 sec. These values will vary for different reactions
and providing the appropriate screw segment with proper flight depth and
geometry to ensure efficient surface renewal and exposure of the reaction mixture
segregated from one another by melt seals formed by restricting the flow of
material both before and after the zone. Melt seals are commonly formed by using
reverse flight and/or shallow screw flight segment that prevent back mixing of
materials in adjacent zone, such technique used for high pressure differential
6) Efficient mixing:
better mixing and high heat transfer for viscous material. Running of two or more
extruder is possible in this technique , which increases the rate of reaction and
process.
done. So it reduces the time, heat losses requirement and leads to the economy.
7. DISADVANTAGES
required for reaction, but a large number of reactions are not rapid enough to be
2) Parameter stability:
bonding stability, boiling point and other parameter are not duplicated in a melt
process.
melts have low thermal conductivity especially when limited amounts of valuable
starting materials are involved most commercial reactive extruder involve simple
one step chemical reaction between inexpensive and Readily available starting
material.
4)Process limitation:
1000gm of material for a typical experiment, such extruder reactions may not be
materials are involved. Most commercial reactive extruder involve simple one step
8. APPLICATIONS
The important applications where the reactive extrusion technique can be used are
as follows.
If inorganic fillers or glass fibre are fed into a twin screw extruder or
a fabricated fibre material is inserted into the mold, fiber reinforced composites
can be obtained from this result this system can be applicable to more complicated
This system is not only suitable for research and development but
material has been developed by reactive extrusion combining the excellent sliding
properties of PTFE with the very good material and processing properties of
company, KTM for arts and crafts and for toy application.
only for highly reactive materials but also for thermally unstable materials to the
BIBLIOGRAPHY
2) Michael L. Berins, “SPI Plastic Engineering Handbook”, Fifth Edition, Chapman and
7) www.nap.edu