Polymer Materials

1
Most plastics are thermoplastics. Most
thermoplastics are commodity.
2
Engineering Thermoplastics

• The most common!!
• Acrylonitrile Butadiene Styrene (ABS)
• Polycarbonate (PC)
• Polyamides (PA or Nylon)

3
Polymer Materials

• Engineering Resins
• ABS
• Nylon
• Polycarbonate
• Acetal
• Acrylic
• Cellulosics
• Ionomer

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Polymer Materials

• Engineering Resins (cont)
• PBT
• PET
• PPO

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Acrylonitrile Butadiene Styrene

• ABS

6
Acrylonitrile Butadiene Styrene (ABS)

• This is an ethenic engineering plastic
• i.e. basic monomer structure as ethylene just
  modifying polystyrene by
• Adding plasticizer and copolymers of styrene
  butadiene and styrene acrylonitrile to produce a
  polystyrene terpolymer of acrylonitrile,
  butadiene and styrene (ABS).

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ABS
butadiene
8
ABS

• Major Uses
• Appliance Housings
• Canoes
• Typewriter Keys
• Pipes Pipe Fittings
• Telephone Housings

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ABS

• Why would you want to use it?
• Low to Medium Cost
• Good Impact Strength
• Good Chemical Resistance
• High Gloss Surface Finish
• Good Flexural Properties

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ABS

• Processes
• Injection Molding
• Extrusion
• Blow Molding
• Thermoforming

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ABS

• Long Term Service Temperature
• Max 135
• Min Already below Tg

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ABS
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ABS

• Material Suppliers
• GE
• Monsanto
• DOW

14
Other Styrenic Blends

• HIPS
• SAN
• SMA - Styrene Maleic Anhydride
• EPS

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Nylon

• PA - Polyamide

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Nylon
/ copolymer for example, nylon 6/10
copolymers of nylon 6 and 10. The numbers refer
to how many methyl units (-CH2-) occur on each
side of the nitrogen atoms (amide groups). The
difference in number of methyl units influences
the property profiles of the various nylons. See
link below

• Types
• Most Common
• Nylon 6
• Nylon 6/6
• Nylon 6/10
• Nylon 6/12
• Nylon 11
• Nylon 12

http//www.sdplastics.com/nylon.html
http//www.ides.com/generics/Nylon/Nylon_typical_p
roperties.htm
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Nylon

• Suffixes refer to number of carbon atoms involved
  in the condensation polymerization process. EX

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Nylon

• Crystalline Yes, very flexible
• Hygroscopic Yes (O and N)
• Glass Transition (135 F)
• Flammability Varies depending on additives,
  but will usually self extinguish because of N

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Nylon

• Major Uses
• Structural parts!! (i.e. replacement for cast
  aluminum 380 series)
• Electrical Connectors
• Gears
• Bearings
• Cable Ties
• Fishing Line
• Automotive Valve Covers/Oil Pans
• Sports/Exercise Equipment

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Nylon

• Why would you want to use it?
• High Strength among the highest of all
  engineering plastics
• Good Heat Resistance
• Good Chemical Resistance
• Excellent Wear Resistance
• Good Fatigue Resistance

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Nylon

• Processes
• Injection Molding
• Extrusion
• Blow Molding
• Rotational Molding
• Thermoforming

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Nylon 6
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Nylon 6/6 most common
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Nylon

• Material Suppliers
• Dupont
• Hoechst Celanese
• Monsanto
• BASF
• Bayer

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More on Nylon

• One of the first engineering plastics (30s).
• Crystalline thermoplastic
• Can have tensile properties comparable to soft
  aluminum.
• Types 6 and 6/6 are the most common!!
• Biggest disadvantage tendency to absorb
  moisture after prolonged period

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Su 35 ksi!!
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Polycarbonates (PC)
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• Polycarbonate

• Crystalline No, too rigid
• Hygroscopic Yes (O)
• Glass Transition High (300 F)
• Flammability No (High number of double carbon
  bonds will extinguish soot)

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Polycarbonates (PC)

• Polycarbonates are amorphous linear polyesters
  with excellent moldability.
• Good impact strength, temperature resistance.
• Transparent (aka Plexiglas)
• Tensile strength similar to ABS and nylon except
  impact strength can be 10X greater! ButCosts
  more and susceptible to environmental stress
  cracking.

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Polycarbonates (PC)

• Uses include
• Helmets (football and hard hats), face shield,
  power tool housings, cell phones, automotive
  dashboards, window cranks, small gears, etc.

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Acetal
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• Polyoxymethylene (Acetal or POM)

• Crystalline Yes, very flexible
• Hygroscopic Yes (O)
• Glass Transition Low (-100 F)
• Flammability Yes (only C and O bonds)

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Acetal

• Major Uses
• Gears
• Bearings
• Faucet Components
• Fuel Pump Components
• Refrigerator Clips
• Zippers

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Acetal

• Why would you want to use it?
• Low to Medium Cost
• Good Chemical Resistance
• High Strength
• Excellent Fatigue
• Good Creep Resistance
• Lubricity
• Dimensional Stability at High Temperature

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Acetal

• Processes
• Injection Molding
• Extrusion
• Blow Molding
• Rotomolding

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Acetal

• Long Term Service Temperature
• Max 200
• Min -100

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Acetal
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Acetal

• Material Suppliers
• DuPont
• Hoechst Celanese
• BASF
• LNP

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Acrylic

• PMMA

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• Polymethylmethacrylate (Acrylic)

• Crystalline No, too rigid (dual methyl groups)
• Hygroscopic Yes (O)
• Glass Transition High (220 F)
• Flammability Yes (only C-H and CO bonds)

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Acrylic

• Major Uses
• Sheet
• Windows
• Displays
• Signs
• Surgical Instruments

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Acrylic

• Why would you want to use it?
• Low Cost
• Good Chemical Resistance
• Hardness
• Good Creep Resistance
• Transparency
• Best Polymer for Weatherability

43
Acrylic

• Processes
• Casting
• Injection Molding
• Extrusion
• Thermoforming

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Acrylic

• Long Term Service Temperature
• Max 80
• Min Already below Tg

45
Acrylic
46
Acrylic

• Material Suppliers
• AtoHaas
• Continental
• DuPont
• ICI

47
Cellulosic
48
Cellulosic

• Major Uses
• Tool Handles
• Safety Glasses
• Tooth Brush Handles
• Automotive and Furniture Trim
• Toys
• Tubing
• Writing Instruments

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Cellulosic

• Why would you want to use it?
• Low Cost
• Medium Chemical Resistance
• Hardness
• Transparency
• Rigid

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Cellulosic

• Processes
• Casting
• Injection Molding
• Extrusion

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Cellulosic

• Long Term Service Temperature
• Max 220
• Min Already below Tg

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Cellulosic
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Cellulosic

• Material Suppliers
• Albis
• Eastman
• Kleer
• Rotuba

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Ionomer
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Ionomer

• Major Uses
• Golf Ball Covers
• Automotive Bumper Pads
• Film for Food and Drugs

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Ionomer

• Why would you want to use it?
• Good Resilience
• Good Flexibility
• Abrasion Resistance
• Good Chemical Resistance

57
Ionomer

• Processes
• Injection Molding
• Extrusion

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Ionomer

• Long Term Service Temperature
• Max 100
• Min -40

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Ionomer
60
Ionomer

• Material Suppliers
• Amoco
• BASF

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THERMOSETS
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Polymer Materials

• Thermoset
• EPOXY
• Melamine
• Urea
• Phenolic
• Polyester
• Vinyl Ester

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EPOXY
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EPOXY

• Major Uses
• Encapsulating Electronic Components
• Bobbins for Coil Windings
• Adhesives

65
Epoxy

• Why would you want to use it?
• High Mechanical Strength
• Outstanding Adhesive Properties
• Good Resistance to Heat
• Good Chemical Resistance

66
Epoxy

• Processes
• Compression/Transfer Molding
• Injection Molding

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Epoxy
68
Epoxy

• Material Suppliers
• Ciba-Geigy
• Dow
• Shell

69
Melamine (Amino)
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Melamine

• Major Uses
• Molded Dinnerware
• Electric Shaver Housings
• Buttons
• Ashtrays
• Connector Bodies

71
Melamine

• Why would you want to use it?
• High Surface Hardness
• Good Heat Resistance
• Good Flame Resistance
• Resists Chipping and Breaking

72
Melamine

• Processes
• Compression/Transfer Molding
• Injection Molding

73
Melamine (Alpha Cellulose)
74
Melamine

• Material Suppliers
• American Cynamid
• BIP
• Bud Co.

75
Urea (Amino)
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Urea

• Major Uses
• Control Housings
• Wiring Devices
• Control Buttons
• Knobs

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Urea

• Why would you want to use it?
• High Surface Hardness
• Good Heat Resistance
• Good Flame Resistance
• Resists Chipping and Breaking

78
Urea

• Processes
• Compression/Transfer Molding
• Injection Molding

79
Urea (Alpha Cellulose)
80
Urea

• Material Suppliers
• American Cynamid
• BIP
• Bud Co.

81
Phenolic
82
Phenolic

• Major Uses
• Electrical Products
• Connectors
• Cooking ware (recall plate)
• Ashtrays
• Utensil Handles
• Elecrtic Motor Components
• Knobs

83
Phenolic

• Why would you want to use it?
• Good Heat Resistance
• Good Flame Resistance
• Good Rigidity
• Good Creep Resistance

84
Phenolic

• Processes
• Compression/Transfer Molding
• Injection Molding

85
Phenolic (Wood Floor)
86
Phenolic

• Material Suppliers
• Amoco Electronic
• Rogers
• Plenco

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Vinylester
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Vinylester

• Major Uses
• Pipe
• Electrical Equipment
• Grating
• Exhaust Stacks
• Washer Drums
• Chemical Tanks

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Vinylester

• Why would you want to use it?
• Good Heat Resistance
• Excellent Bonding to Fibers
• Good Chemical Resistance
• Good Rigidity
• Good Creep Resistance

90
Vinylester

• Processes
• Hand Lay-Up
• Compression/Transfer Molding
• Injection Molding

91
Vinylester (15 Glass Fiber)
92
Vinylester

• Material Suppliers
• Premix
• Glastic
• Reichold