ALOK KUMAR ENGINEERING PLASTICS & APPLICATIONS CENTRAL INSTITUTE OF PLASTICS ENGINEERING & TECHNOLOGY,

USAGE OF PLASTICS IN MODERN CARS Dismantling of >40 modern European cars reveled that in 130 Kg plastics per car– 43% PP, 14% PU, 8%Nylons, 8%PE

GLOBAL PLASTICS USAGE 79 % Plastics consumed – PE+PP+PVC+Styrene's

THERMOPLASTICS IN SE ASIA

PLASTICS END USE PATTERN Area % Consumption Defense & others 2.0 Consumer Durables 5.0 Transport 6.0 Packaging 23.0 Plasticulture 22.0 Infrastructure 24.0 Telecom/ Electronics 16.0 Health & Medicare

PLASTICS-THE MATERIAL OF CHOICE User Friendly Versatility Light-weight Energy Efficient Non-corrosive Aesthetic Abundant Recyclable

PLASTICS – Emerging Material to meet Engineering Application Demands Density MFI (Melt flow Index) Mechanical Properties Impact Strength Stiffness Toughness Creep Resistance Abrasion Resistance Tear Resistance Optical Properties Gloss Clarity & Opacity

PLASTICS – Emerging Material to meet Engineering Application Demands Environmental Stress Cracking Resistance Chemical Resistance Acid Resistance Alkali Resistance Hazardous Chem. Resistance ( Pesticide / Insecticide) Barrier Properties Water Vapour Transmission Rate Oxygen Transmission Rate Aroma Transmission Rate

PLASTICS – Emerging Material to meet Engineering Application Demands Easy Processibility Printability Sealing Property Seal Strength Cost Effectiveness Product Design Flexibility

CALASSIFICATION OF PLASTICS

DEFINATION COMMODITY THERMOPLASTICS Very High Volume, Low cost,Low strength, Low Heat Distortion Temp. ENGINEERING PLASTICS High strength, High HDT, Low Volume, High Cost SPECIALITY THERMOPLASTICS Very Low Volume, Very High Cost, Excels in Specific Performance Requirements.

MAJOR COMMODITY PLASTICS LOW DENSITY POLYETHYLENE (LDPE) LINEAR LOW DENSITY POLYETHYLENE (LLDPE) HIGH DENSITY POLYETHYLENE (HDPE) POLY PROPYLENE (PP) POLY VINYL CHOLORIDE (PVC) POLY STYRENE (PS)

MAJOR ENGINEERING THERMOPLASTICS ACRYLO NITRILE BUTADIENE STYRENE (ABS) STYRENE ACRYLONITRILE (SAN) POLYMETHYL METHACRYLATE (PMMA) POLYAMIDE - (PA) POLYETHYLENE TEREPHTHALATE- (PET) POLYBUTYLENE TEREPHTHALATE- (PBT) POLYOXYMETHYLENE - (POM) POLY CARBONATE - (PC) HIGH IMPACT POLYSTYRENE (HIPS)

MAJOR SPECIALITY PLASTICS POLYTETRA FLUOROETHYLENE (PTFE) THEROPLASTIC POLYURETHANE (TPU) POLY SULPHONE (PSO) POLY ETHER SULPHONE (PES) POLYPHENYLENE SULPHIDE (PPS) POLYPHENYLENE ETHER (PPE) POLY ETHER ETHER KETONE (PEEK) POLY ACRYLATE POLY AMIDE – IMIDE (PAI) POLY ETHER – IMIDE (PEI) LIQUID CRYSTAL POLYMERS (LCP)

MAJOR THERMOSET PLASTICS PHENOL FORMALDEHYDE (PF) UREA & MELAMINE FORAMLDEHYDE EPOXY RESINS UNSATURATED POLYESTER RESIN POLYURETHANES SILICONES

Thermal Properties of Thermoplastics

CRITERIA FOR PERFORMANCE High Performance PEI PSU PES PEEK PPS LCP Engineering PC PA 11 PA 6/12 POM PA 6 PA 6/10 PA 6/6 PA 12 TPU PA 6/6 HI PBT TPE PPO PCA – PC/ABS Temperature Commodity ABS SAN PS HDPE PP Mechanical Property retention

TOP SEVEN ENGINEERING PLASTICS TYPICAL PROPERTIES PA 6 PC PPO POM PBT PPCP ABS IZOD Notched (Kg. cm/cm) 16 85 23 10 6 15 20 HDT (ºc) 104 132 120 110 55 60 82 Water Absorption (%) 1.5 0.15 0.07 0.3 0.08 Neg. 0.4 Flammability UL94 (1.47mm) HB V2 Sp. Gravity 1.14 1.20 1.06 1.42 1.31 0.9 1.05 Tensile Strength (Kg/Sq .Cm) 340 600 500 650 300 400 Flex. Mod. (Kg/Sq. Cm) 9500 24000 25000 26000 23000 13000

MAJOR ENGINEERING PLASTICS STRENGTHS AMORPHOUS (PC, PPO, ABS) Constant mechanical properties versus temperature Dimensional stability Creep Resistance Low Shrinkage Transparency possible CRYSTALLINE (PP, POM, PBT/PET) Resistance to hydrocarbons Good flow behaviour Wear and Fatigue resistance

POLYAMIDES Several types are available based on raw material used Most widely used polyamides are Nylon 6 & 66 Condensation reaction of dicarboxylic acids and diamins (Commercially through the route of intermediate salts) ---- Nylon 6,& 66 Ring opening reaction of lactam – Nylon 6, Nylon 12 etc. Condensation reaction of amino acids – Nylon 7, Nylon 11 etc.

Characteristics of Polyamides Semi-crystalline material Polar in nature Resistant to hydrocarbon solvents, grease, lubricants Hygroscopic High to medium rigidity – improved by glass fibre filling Good electrical insulation – adversely affected by moisture absorption. Good abrasion resistance and low coefficient of friction Flame retardant versions are difficult process. Dimensions affected by humidity. Not good temp. resistance under load – improved by glass fibre filling.

POLYAMIDES APPLICATIONS OF POLYAMIDE Gear, Cams, bushes, Bearings Valve Seats Terminal Blocks Connectors Automotive Exterior Under bonnet Automotive Parts Motor Housing Optical fibre Sheathing (Nylon 12) Insulating liners (Railways Hair combs

PA In AIR CRAFT Application: Aircraft Engine Components Material: - PA46-GF30 Airbus Injection moulding Highly complex shape minimize the noise level Design freedom at low costs High impact properties in a wide temperature range wall sections as thin as possible- thus reducing valuable weight.

PA in Agricultural film Application: Agricultural Barrier Film Material: PA6-unfilled Extrusion Processing Technology Barrier Film for agricultural use with environmental benefits. When used to cover the soil together with the injection of fumigation chemicals, lower levels of the fumigant can be used. As the film keeps the active agent in the soil for longer.

PA in Automotive, Air/fuel management Application: Air duct Material:- PA6-GF20 Blow Molding Processing Technology Air-duct design offers the best combination of the demanding requirements for: high temperature air ducts. · higher cold impact than other similar materials · higher stiffness at high temperatures (150°C) allowing thinner walls to be designed. · high melt strength and a low melt viscosity for optimum Production

PA in AUTOMOTIVE, AIR/FUEL MANAGEMENT Application: Air inlet manifold Material: PA6-GF30 Injection Molding Ford UK

PA6: The material of choice for air inlet manifolds ‘Fuel economy’ & ‘weight reduction’ Single molding and replacing aluminium and steel by plastics Provides the chemical, temperature and vibration resistance required to survive the expected life of vehicles. lower system costs compared to metals through part and function integration, Easier assembly and longer tool life. Temperature resistance and a higher burst pressure resistance after welding. Providing safer solutions or more design freedom, as well as lower system costs as a result of an easier Processibility and better surface appearance.

POLY CARBONATE POLYCARBONATE Poly carbonate was first developed in the laboratory of GE in 1953. It was first commercialised in 1958 by GE under the Trade name of LEXAN Polycarbonate Lexan is an ester of carbonic acid. LEXAN is commercially produced by polycondesation of Bisphenol A and Phosgene

POLY CARBONATE CHARACTERISTICS : Highest impact strength High rigidity High dimensional stability High heat distortion temp Usability in the temperature range of -50 deg. To 135 deg. Flame retardancy and low combustibility High optical clarity Good electrical insulation properties Good strain resistance Low water absorption Food grades available. Good low temp. impact strength

POLY CARBONATE APPLICATIONS: AUTOMOTIVE HEADLAMPS, REFLECTORS AND LENSES INDICATORS AND BLINKERS DASH BOARD COMPONENTS CRASH HELMETS TELECOM CONNECTORS DOMESTIC ELECTRICAL SWITCHES TRAFFIC SIGNAL LENSES SIGNAL HOUSINGS TELEGRAPHIC POLE INSULATOR TERMINAL BLOCKS LIGHT DIFFUSER STREET LAMP CANOPIES BUSINESS MACHINE COMPONENTS

POLY CARBONATE APPLICATIONS BABY FEEDING BOTTLES, MIXIE JARS BLOOD OXYGENATORS I.V. CANNUELA FACTORY ROOFINGS RAILWAYS PLATFORMS FOOFINGS/BUS STOPS SAFETY GLAZINGS TELEPHONE BOOTHS OFFICE AND FACTORY PARTITIONS COMPACT DISKS AND OPTICAL DATA STORAGE DISKS RETURNABLE WATER AND MILK BOTTLES.

PC in AUTOMOTIVE, AUTO LIGHTING Application: Head lamp bezel Material: PC-unfilled Injection molding. Audi Headlamp bezels require Excellent surface finish & aesthetics Good heat resistance and be warpage free Metallic effect and an exceptional appearance.

PC in Electrical / Electronics, Telecommunication Application: Mobile phone travel charger Material: - PC-unfilled Injection Molding Philips A charger for a mobile phone require : - Very high aesthetic - Withstand severe drop tests - Resistant to all kind of chemical substances,like hand lotions & soaps. - Flame retardant and has to pass the pressure test at 125 ºC.

PC in ELECTRICAL LIGHTING Application: Lamp holder fluorescent lamp, Material:- PC Injection molding. Fluorescent lamp holders require: Tough materials with good flow to be able to mold the components easily- PC being easy flowing and with excellent mold release.

PC in Electrical / Electronics : Application: ATM - PC-unfilled This processing technique makes it possible to attain a cost-saving of up to 300%, when for instance changing from cast aluminium to plastic mouldings for cash dispensers (ATM’s). This molding is by made the ‘low pressure foam process’ to produce a 7,5 kg moulded automated telling machine fascia. Although the main driving force is cost reduction, issues like weight reduction, torsional stiffness, vandal resistance, paint ability to class A surface finish, dimensional stability

THERMOPLASTIC POLY ESTER (PET & PBT) Crystalline in nature Based mainly on polybutylene terephthalate. A few grades based on polyethylene and polycyclohexane dimethanol terephalate are also available The base resins are commercially manufactured by Esterification reaction of Terephthalic Acid and appropriate diols.

THERMO PLASTIC POLYESTER (PET & PBT) CHARACTERISTICS High Mechanical Strength Excellent chemical resistance High temperature resistance in glass filled grades High dimensional stability Excellent Electrical tracking resistance Can be made flame retardant Effect of humidity minimal Excellent flow

THERMOPLASTIC POLYESTER (PET & PBT) APPLICATIONS: Connectors TV Components Industrial Switches/plug’s Business machine components Keyboard buttons Steam irons Cookers Air vents Plumbing Auto ignition systems Under bonnet connectors Head lamp reflectors

PBT IN AUTOMOTIVE Application: Actuator, Gear housing window Lift Material: PBT-GF20 * Dimensional stability for reliable performance in all conditions *Automotive window lift mechanisms demand shock resistance over a wide temperature range,-40°C to +80°C, *Excellent dimensional stability and strength up to the maximum environmental temperature. *Reducing total assembly costs and weight. Processing Technology: Injection Molding Opel, Volvo

PBT IN AUTOMOTIVE Application: Air flow mass meter housing and sensor Material: PBT-GF30 Stability and Narrow tolerances for parts close to the engine This air-flow mass meter measures air flow speed for the motor management control system. It has to maintain tight tolerances over the life of the vehicle and withstand the temperatures encountered close to the engine. Exceptional dimensional stability and strength over a wide temperature range. The best balance of mechanical properties and good welding performance,facilitating manufacturing productivity. Processing Technology: Injection Molding Opel

PBT IN AUTOMOTIVE Application: Sensor, throttle position Material: PBT-GF30 Application: E-Box, Fusebox Material: PBT-GF10

Application: Bobbins Schneider Material: PBT-GF30 PBT IN : Electrical / Electronics, Power distribution & circuit protect Application: Compact NS Schneider Material: PBT-GF30 Application: Bobbins Schneider Material: PBT-GF30 Processing Technology: Injection Molding. Schneider

PET IN AUTOMOTIVE, BREAKE /CLUTCH Application: Breake Booster Valve bodies Material: PET-GF35 Glass fiber reinforced polyethylene terephthalate (PET) is the material of choice for automotive brake booster valve body applications. It provides weight, performance and cost advantages over previously used thermosets. Processing Technology : Injection Molding ADI BMW

PET IN AUTOMOTIVE, BREAKE /CLUTCH Application: Tandem brake booster Material: PET-GF35 Glass fiber reinforced polyethylene Terephthalate (PET) is the material of choice for automotive brake booster valve body applications. It provides weight, performance, and cost advantages over previously used Thermosets. Processing Technology : Injection Molding Various

POLYACETAL (POM) Polymer of formaldehyde, commonly known as Polyacetal, Acetal polymer or Polyoxymethylene was first commercialised by Du pont in 1959. Copolymers were introduced by celanese corporation 1960 to overcome thermal stability problem at processing temp. Polyacetal is commercially made by polymerisation of high purity formaldehyde in rapidly stirred inert medium like dry heptane with controlled traces of water added containing phosphine and amine initiators.

POLYACETAL (POM) CHARACTERISTICS OF POLYACETAL (POM) High crystalline High flammable Resilient and good combination of stiffness and toughness Creep resistant- superior to polyamide Low static and dynamic co-efficient at friction Very high degree of precision moulding possible Not high temp. resistant Resistant to organic solvents upto 70 degree.

POLYACETAL (POM) APPLICATIONS OF POLYACETAL (POM) Gears Conveyor belt links Sprockets and chains Blower wheels Cams Fan blades Carburettor float and bodies Aerosol containers Lighter bodies LPG Cylinder caps Shower heads

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