PLASTIC

C
 INTRODUCTION
• A plastic material is any of a wide range of synthetic or semi-
synthetic organic solids that are mouldable.
• Plastics are typically organic polymers of high molecular mass,
but they often contain other substances.
• They are usually synthetic, most commonly derived from
petrochemicals, but many are partially natural.
• Synthetic resigns may be phenol, formaldehyde, cellulose vinyl,
alkyl, etc.
• The moulding compounds are binders, catalysts, fillers, hardeners, lubricants,
pigments, plasticizers, solvents, etc.

• Binders: bind various constituents together. This consists of cellulose derivatives,

phenol, urea, shellac and many other type f materials.

• Fillers: It is to provide the plastic with properties that binder cannot provide and
used in thermosetting moulding.

• Plasticizer: mainly thermo plastics to improve flow qualities ,impact resistance,

flexibility of material. Generally these are oil liquid such as methyl and ethyl
phthalates
• Catalyst: these are chemicals which accelerate chemical reaction of
constituents without undergoing any change .These are added to
thermosetting plastic moulding

• Pigments: these are added to impart colors to finished products

• Lubricants: to reduce internal friction in the moulding compounds.

• To prevent striking of moulding compounds to the moulds. lubricants such as

stearates or graphite are also added to the moulding compounds.
• POLYMERIZATION: The simplest substances consisting of one
primary chemical are known as the monomers or monoliths.

• They are to be combined or synthesized to form polymers by the

process known as the polymerization.

• POLYMER : The word polymer literally means “ many parts “.

• A polymeric solid material may be considered as to be one that

contains many chemically bonded parts or units which themselves
are bonded together to form a solid.

• .
• Two industrially important polymeric materials are:
1.Plastics
2.Elastomers

• Plastics are a large and varied group of synthetic materials

which are processed by forming or molding into shape.

• Just as we have many types of metals such as aluminum

and copper, we have many types of plastics such as
polyethylene and nylon
• Plastics can be divided into two classes.
1.Thermo plastics
2.Thermo setting plastics

depending on how they are structurally and

chemically bonded.
 THERMO PLASTICS
• Thermo plastics: These plastics can be softened by heating
and hardened by cooling any number of times without
changing the properties of the material.
• It is thus possible to shape and reshape these plastics by
means of heat and pressure.
• One important advantage of this variety of plastics is that
scrap obtained from old and warnout articles can be
effectively used again.
• Properties :
1.Softens and liquefies on heating and hardens up to
cooling.
2.Retains shape after manufacture.
3.Suitable for recycling.
4.Can be reshaped by heat.
5.It may melt before passing to a gaseous state.
6.Allow plastic deformation when it is heated.
7.They are soluble in certain solvents.
8.Swell in the presence of certain solvents.
• THERMO PLASTIC MATERIALS :

1. Polyvinyl chloride ( P V C )
PROPERTIES : Rigid , tough , elastic to feel.
Uses : Plumbing pipes and sanitary fittings are manufactured out of this
material. Shower curtains , window frames, flooring , corrugated roofing
sheets , plastic coating to steel sheets tanks, water cisterns, etc.
 2. Acrylic :
PROPERTIES: Glass clear , some what brittle sound when tapped. Uses
: Glazing , bath rooms and sinks.
3. Polyethylene ( or polythene ) – low density:
PROPERTIES: Flexible, feels like paraffin wax.
Uses ; bottles, buckets, sheeting water tanks.
4. Polyethylene ( or polythene )- high density :
PROPERTIES: stiff and hard, coarser than the polythylene of low density
used as large storage bottles, water tank.
5. Polypropylene :
PROPERTIES : smooth, rigid, lightest of all plastics – it floats in
water.
Uses : wc cisterns, sink traps, washing machine bids, food containers,
appliances , car fender.
6. Polystyrene : Solid ( glassy ) state at room temperature, but flows if heated
above its glass transition temperature and becoming solid again when cooling
off.
Pure solid polystryrene is a colourless, hard plastic with limited flexibility.
Polysterene can be transparent or can be made to take on various colours.
Uses : Refrigerator containers , food trays, packaging, food containers, disposable
cups, plates, cutlery, CD and cassette boxes.
7. Nylon : PROPERTIES : High density polythene but
smoother to feel.
Uses : Textiles , brush bristles, carpeting , surgical trays ,
bearings , pressure tubing.
 THERMOSETTING PLASTICS
• These plastics are either originally soft or liquid or they soften once
upon heating, they harden permanently.

• When they are heated in the temperature of 127 degree centigrade to 177
degree centigrade , they set permanently and further application of heat does
not alter their form of soften them.

• But at temperature of about 343 degree centigrade, the charring occurs.

The thermo setting plastics are durable, strong and hard.

• They are available in a variety of beautiful colours.

• They are mainly used in engineering applications of plastics.

• Properties :
1.Permanently hard on heating above a certain temperature.
2.Undergoes chemical changes during manufacture.
3.Cannot be melted and reshaped.
4.Little potential for recycling.
• Examples and uses:
1. Polyester fibreglass systems: sheet molding compounds and bulk molding
compounds)
2. Polyurethanes: insulating foams, mattresses, coatings, adhesives, car parts, print
rollers, shoe soles, flooring, synthetic fibers, etc. Polyurethane polymers are
formed by combining two bi- or higher functional monomers/oligomers.
3. Vulcanized rubber
4. Bakelite, a phenol-formaldehyde resin used in electrical insulators and
plasticware
5. Urea-formaldehyde foam used in plywood, particleboard and medium-
density fiberboard
6. Melamine resin used on worktop surfaces.
7. Epoxy resin used as the matrix component in many fiber reinforced plastics such
as
glass-reinforced plastic and graphite-reinforced plastic)
• THERMOSETTING PLASTIC MATERIALS

1. Melamine formaldehyde ( formica ):

PROPERTIES : Hardest of common plastics , heat resistant.

2. Phenolics (bakelite ) :
PROPERTIES : The cheapest. Heavy solid plastic material, fishy smell when burnt dark in
color. Heat resistant.

Uses : Bottle caps, plastic automobile parts, bonding plywood and chip board, glues,
laminates with other materials.
3. Urea formaldehyde :
PROPERTIES : Similar to phenolic but can be produced in lighter colours.

Uses : Door furniture, light switches, and electrical fittings, glues, bottoms, radio
cabinets, etc.

4.Epoxies:
PROPERTIES: Resin and hardener. Uses: Used as adhesives.

5.Polyesters :
PROPERTIES: produced as fibres and films.
Uses ; Used for reinforced plastics.
 CLASSIFICATION ACCORDING TO STRUCTURE OF ATOMS

According to this classification , the plastics are divided into 2 groups.

• HOMOGENEOUS PLASTICS : This variety of plastic contains carbon chain

ie, the plastics of this group are composed of carbon atoms only and they exhibit
homogeneous structure.

• HETEROGENEOUS PLASTICS : This variety of plastic is composed of the

chain containing carbon and oxygen, the nitrogen and other elements and they exhibit
heterogeneous structure.
 Physical and mechanical properties
• According to this classification, plastics are divided into four groups.
1.Rigid plastics
2.Semi –rigid plastics
3.Soft plastics
4.Elastomers.
• RIGID PLASTICS : These plastics have high modulus of elasticity and they retain their
shape under exterior stresses applied at normal or moderately increased temperatures.

• SEMI- RIGID PLASTICS: These plastics have a medium modulus of elasticity and the
elongation under pressure completely disappears, when pressure is removed.

• SOFT PLASTICS: These plastics have a low modulus of elasticity and the
elongation under disappears slowly, when pressure is removed.

• ELASTOMERS : These plastics are soft and elastic materials with a low modulous of
elasticity. They deform considerably under load at room temperature and return to their
original shape, when the load is released. The extension can range up to ten times their
original dimensions.
PROCESSING OF PLASTICS: -
1. COMPRESSION MOULDING 6. CALENDARING
2. TRANSFER MOULDING 7. THERMOFORMING
3. INJECTION MOULDING 8. ROTATIONAL MOULDING
4. EXTRUSION MOULDING 9. LAMINATING
5. BLOW MOULDING
 1. COMPRESSION MOULDING : -
• Compression moulding is the forming process.
• Compression moulding process is followed by two step first one
preheating and pressurizing.
• Measured charge of compound placed between halves of split mold
• Pressure is applied so that compound flows to fill mold cavity
• Compression moulding is generally used for thermosetting plastic.
• Example:- urea formaldehyde and phenol formaldehyde.
PROCESS DESCRIPTION
2. TRANSFER MOLDINGS : -
 It is similar to compressionmoulding.
 Thermoset polymers can be formed when a preset amount of material is
placed in a
separate cavity and heated.
 A plunger moves the material into the shaped mould with high pressure.
 3. INJECTION MOULDING : -
 It is a manufacturing technique for making parts from
Thermo plastic and thermoset materials .
 Injection moulding is a highly automated production process for producing large
quantities of identical items.
 A measured amount of molten thermoplastic is driven by a ram past a heating system
into the mould.
 The mould is split to allow finished object to be removed after cooling.
 Example : - Polystyrene, Nylon, Polypropylene, PVC, Acrylonitrile Butadiene
Styrene
 4. EXTRUSION MOULDING: -

Continuous process used to produce both solid and hollow

products that have a
constant cross-section.
 Ex: - Window frames, hose pipe, curtain track, garden
trellis.
 5. BLOW MOULDING: -
 Blow Moulding is an automated process that is used extensively to make
bottles and other lightweight, hollow parts from thermoplastic materials.
 A hollow length of plastic, called a parison, is extruded down between the two
halves of the mould.
 Compressed air is blown into the inside of the parison which inflates it, pushing the
soft plastic hard against the cold surfaces of the mould.
 The mould is then opened the moulding ejected and the waste (called
flash) is trimmed off with a knife.
 Example : - high density polythene and low density polythene are used.
1. 2.

3. 4.
 6. CALENDARING : -
 It is a intermediate process where the extruded plastic sections are reduced to
sheet.
 Only used for thermoplastics.
 Involves rolling out a mass of premixed plastics material between large rollers to
form a continuous and accurately sized film.
 The process begins with the ingredients being blended and fluxed in a mixing mill
at approx. 100°c.
 Nip rollers control the thickness of the sheet material can be gradually reduced in
thickness.
 Rolls of semi-rigid PVC which will be used to manufacture transparent A4 folder
'pockets'.
Example: -
1. Flexible PVC :- Rainwear, Shower curtains, Tapes, etc.
2. Rigid PVC: - Credit cards, Lamination
 7. THERMOFORMING: -
 Process used to shape thermoplastic sheet into discrete parts.
Basic principles: -
i. Heat a thermoplastic sheet until it softens.
ii. Force the hot and pliable material against the contours of a mold by using either
mechanical, air or vacuum pressure
iii.Held against mold and allow to cool, and plastics retains its shape

 This can be done by: -vacuum and pressure forming.

 Lower pressures are required to thermoform.
 8. ROTATIONAL MOULDING : -
 Rotational moulding is a process used for producing hollow plastic products.Such
as road cones and storage tanks up to 3m³ capacity.
 A measured weight of thermoplastic is placed inside a cold mould.
 Heated to a temperature of 230-400 c whilst being rotated around both vertical
and horizontal axes.
 The mould moves into a cooling area or chamber where it is cooled by air or
water jets.
 The hollow moulding can be removed as soon as it is cool enough to hold its
shape.
The rotational molding
(roto-molding or roto-
casting) process. Trash
cans, buckets, and plastic
footballs can be made by
this process.

90% of rotational
mouldings are made from
polyethylene
9. LAMINATING: -
 Layers of materials are bonded with a resin into a strong solid structure, often
with heat and pressure.
 This can be done in following ways: -
 Gravure coating
 Wet bond laminating
 Dry bond laminating
 Solvent less laminating
 Extrusion laminating
 Example: -Foil, Snack food bag, Saran- coated nylon, Metallized propylene, etc.
 Extrusion die
Substrate B
Substrate A

Extrudate Three ply

Pressure laminate
roll
Strip-off roll
Nip roll

Extrusion laminating Dry bond laminating

Gravure coating
 PROPERTIES OF PLASTICS
The following properties are common with most of the plastics.
1.They are light in weight.
2. They have good resistance to most of the chemical.
3. They have high electrical strength and good corrosive resistance
4. Plastics can be moulded to any desired shape, size and transparent or color
5. They are cheap compared to metals.
6. All operations like drilling ,sawing, punching can be done on plastics.
7. Painting and polishing is not necessary.
8. The plastics posses excellent electric insulating properties.
9. The plastics, have low specific gravity, the average being 1.3 to 1.40.
 APPLICATIONS:
1. Transparent glass substitute.
2. Acrylic paint essentially consists of PMMA suspended in water; however
since PMMA is hydrophobic, a substance with both hydrophobic and
hydrophilic groups needs to be added to facilitate the suspension.
3. Laser cut acrylic panels have been used to redirect sunlight into a light pipe
or tubular skylight and, from there, to spread it into a room.
• ADVANTAGES OF PLASTICS OVER OTHER MATERIALS:

1. It can be moulded into finished products at a relatively low cost, compared to the
machining and fabricating costs for wood and metal.
2. It resists chemicals.
3. It poses a high strength to weight ratio.
4. It does not rust like iron.
5. It is non conductor of electricity.
6. It is light in weight.
7. It is easy to fabricate.

• DISADVANTAGE OF PLASTICS:

1. It has low modulus of elasticity.

2. It is not reliable with respect to weathering
Environmental effects

Most plastics are durable and degrade very slowly; the very chemical bonds that make them
so durable tend to make them resistant to most natural processes of degradation.