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

2. 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

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

4. THERMOPLASTICS IN SE ASIA

5. 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

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

7. 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

8. 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

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

10. CALASSIFICATION OF PLASTICS

11. 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.

12. 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)

13. 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)

14. 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)

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

16. Thermal Properties of Thermoplastics

17. 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

18. 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

19. 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

20. 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.

21. 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.

22. 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

23. 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.

24. 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.

25. 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

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

27. 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.

28. 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

29. 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

30. 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

31. 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.

32. 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.

33. 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.

34. 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.

35. 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

36. 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.

37. 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

38. 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

39. 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

40. 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

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

42. 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

43. 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

44. 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

45. 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.

46. 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.

47. 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

55. Thank you