1. 1 Processing of thermoplastic polymers Introduction Extrusion  Extruder  Processes  Tools and products  Elements of extrusion line Injection molding  The injection molding machine  Phases  Structure  Tools Hollow articles  Extrusion blow molding  Injection blow molding  Rotational molding Other technologies  Calendering  Thermoforming  Welding  Compression molding  Pretreatments, mixing  Mechanical fabrication

2. 2 Introduction Shear rate in the different processing techniques  Compression molding( = 1-10 s -1 )  Calendering( = 10-10 2 s -1 )  Extrusion( = 10-10 3 s -1 )  Injection molding( = 10 3- 10 5 s -1 ) Large productivity, unique properties Processing: non-equilibrium processes  Shearing

3. 3 Extrusion – extruder line, components Components: motor, gear, flexible coupling, feeder extruder feeder die caliber, cooling bath Pull-out assembly saw tipping tray

4. 4 Extrusion – plasticating unit Flexible coupling Thrust assembly Feeder Barrel Vacuum hole Pressure regulator Thermocouple, pressure sensor screw Heating, cooling Gear

5. 5 Extrusion – screw and other components Components: breaker plate, filter; die; sizing plate; cooling; pull-out assembly; extruder line Melt pumping zone Compression zone Solid transport zone

6. 6 Extrusion - processes Screw characteristics Solid transport Pumping flow Drag flow Leakage flow

7. 7 Extrusion – melting Melt, Rotating flow Screw flight Surface of barrel Melt film Melt/solid interface Solid

8. 8 Extrusion – rate distribution, transport Drag flow Barrel surface Pressure flow Screw surface Open dischargeClosed discharge

9. 9 Extrusion – flow rate, operational points Flow rate  Extruder  Tool

10. 10 Extrusion – tool, product Melt Air Core Tool body Caliber Ironing zone Product: pipes, profiles, sheets, cable insulation, multilayer films, granules

11. 11 Injection molding - machine Die headStandard extruder head Barrel Screw Feeder Tachometer drive Hydraulic motor Screw drive Thrust bearing Two hydraulic injection cylinders Heaters Non-return valve flow assembly Injection chamber

12. 12 Injection molding - machine a) Closed valve b) Open valve Components: driving unit, feeding, barrel and screw, non-return valve

13. 13 Injection molding – tool closing Solution: mechanical, hydraulic, hydro-mechanic Clamp ram Oil port return Product Oil port forward Moving platenStationary platen Tie rod Tool

14. 14 Injection molding – tool closing Ejector pins Backing plates Spure bush Opening plain I Opening plain II

15. Injection molding cycle Clamping Plasticating unit moves to the mold Injection molding Holding pressure Cooling, plasticating Mold opens, ejection 15

16. Injection molding cycle 16

17. 17 Injection molding - phases Plasticating, dose, melt quality JettingTurbulent flow melt Tool filling: free spring turbulentlaminar

18. 18 Injection molding – phases, cooling

19. 19 Injection molding – structure Cross section Direction of flow Skin Core

20. 20 Injection molding – structure, properties Orientation – anisotropic properties

21. 21 Injection molding – structure, properties Internal stresses

22. 22 Hollow articles – extrusion blow Extruder Extruder tool Blowing tool Cutting edge Preform Blowing

23. 23 Hollow articles – extrusion blowing Important question  Closing force  Waste  Calibration of neck  Welding lines  Stretching and swelling  Temperature distribution  Cooling  Surface quality

24. 24 Hollow articles – extrusion blow molding Whiskey and PET bottles

25. Injection blow molding Production of PET bottles Multistep processing technology  Injection molding of preforms  Blowing the preform Reasons  Transportation of preform is economic  The blowing step is toghether with filling of the bottle. Blowing is above 100 °C (clean) 25

26. Injection blow molding Production of PET bottles Technology 26

27. 27 Hollow articles – rotational molding Tool fillingCooling chamber Heated chamber Tool rotating motor Arm Door Air Air heating Ventilation Rail Tool Tool movement

28. Hollow articles – rotational molding 28

29. 29 Hollow articles - calendering Extruder Two-roll mill F-calender Pull-out Cooled rolls Rolling Main steps: introduction of components; premixing, homogenization; melting, gelation; melt homogenization; feeding of calender; calendering, forming; pull-out, cooling; printing, treatment; rolling, storage

30. 30 Hollow articles - themoforming Thermoforming  Cups (whipped cream)  Productivity Welding  Direct welding  Indirect welding Compression molding Pretreatment, mixing Mechanical fabrication Thick parts Thin corners and edges Products Sheet heating Fixing vacuum Insulation

31. Hollow articles - themoforming Production of yogurt cups 31

32. Hollow articles - themoforming 32