Plastic Knowledge Base

August 1, 2009

Polypropylene

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Other names:
Polypropene
Polipropene 25 [USAN]
Propene polymers
Propylene polymers
1-Propene

Polypropylene or polypropene (PP) is a thermoplastic polymer, made by the chemical industry and used in a wide variety of applications, including packaging(e.g. plastic bottle caps, textiles (e.g. ropes, thermal underwear and carpets), stationery, plastic parts and reusable containers of various types, laboratory equipment, loudspeakers, automotive components, and polymer banknotes. An addition polymer made from the monomer propylene, it is rugged and unusually resistant to many chemical solvents, bases and acids.

Polypropylene was first polymerized on March 11th 1954 by Giulio Natta. At first it was thought that it would be cheaper than polyethylene.

The Chemical and physical properties of polypropylene
Molecular formula:  (C3H6)x

Polypropylene

Density:
0.855 g/cm3, amorphous
0.946 g/cm3, crystalline

Melting point: ~ 160 °C

Polypropylene has a melting point of ~160°C (320°F), as determined by Differential scanning calorimetry (DSC).

Most commercial polypropylene is isotactic and has an intermediate level of crystallinity between that of low density polyethylene (LDPE) and high density polyethylene (HDPE); its Young’s modulus is also intermediate. PP is normally tough and flexible, especially when copolymerised with ethylene. This allows polypropylene to be used as an engineering plastic, competing with materials such as ABS. Polypropylene is reasonably economical, and can be made translucent when uncolored but is not as readily made transparent as polystyrene, acrylic or certain other plastics. It is often opaque and/or coloured using pigments. Polypropylene has good resistance to fatigue.

The MFR (Melt Flow Rate) or MFI (Melt Flow Index) is a measure of PP’s molecular weight. This helps to determine how easily the melted raw material will flow during processing. Higher MFR PPs fill the plastic mold more easily during the injection or blow molding production process. As the melt flow increases, however, some physical properties, like impact strength, will decrease.

There are three general types of PP: homopolymer, random copolymer and block copolymer. The comonomer used is typically ethylene. Ethylene-propylene rubber or EPDM added to PP homopolymer increases its low temperature impact strength. Randomly polymerized ethylene monomer added to PP homopolymer decreases the polymer crystallinity and makes the polymer more transparent.

July 30, 2009

How It Works for Plastic Injection Molding

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All of this material started out generally as plastic pellets. The pellets are feed into one of the massive molding machines, these machines often weigh around 25 tons. The machine heats the plastic until it is liquid. This liquid is then forced through injectors into molds.

These molds can be made to almost any shape or size. To put it simply, injection molding is the process of forcing melted plastic in to a mold cavity. Once the plastic has cooled, the part can be ejected. It is useful when the parts are too complex or cost prohibitive to machine. With this process, many parts can be made at the same time, out of the same mold.

The process has normally six steps:

1. Clamping: the machine has three parts. The mold, the clamp and the injection unit. The clamping unit holds the mold at a certain pressure, this ensure uniformity in the units that are outputted. Molds are normally made from two parts.

2. Injection Unit: this is where the plastic pellets are loaded into a hopper at the top of the injection unit. The pellets are fed into the main cylinder; this is where they are heated until they are liquefied. Inside the injection unit there is a screw which turns and mixes the plastic. Once this liquid plastic has reached the optimum for this product the injection process starts. The plastic is forced through a sprue and the pressure and speed are controlled by the screw or sometimes a ram depending on the type of machine.

3. Dwelling: this is a pause in the process while some pressure is applied to ensure all the mold cavities have been completely filled. This is very important within the process as it will result in scrap of units if the mold is not filled correctly.

4. Cooling: this part of the process lets the mold cool for the required period. If it is done too quickly the units can stick or become deformed once out of the machine.

5. Mold Opens: The clamping unit is opened to separate the mold. Molds are used over and over again; they are often the most important single part in the whole process. The tooling of mold can be very expensive.

6. Ejection: the finished product is ejected from the injection mold machine. Often the finished product will continue on a production line or be stacked to go to a production line as parts for larger products, e.g. car steering wheel.

The products that use injection molding are used every day by all of us. Many cars would not be so affordable if it was not for injection molding, however there are some disadvantages to the process. The machinery is very expensive and involves a high capital investment, design of parts must bear in mind the production process, and the process is not economically for short runs of products.

However the disadvantage are out-weighed by the greater advantages, the speed at which parts can be made, low labor costs, minimal material waste, and finished parts often need no more finishing.

July 29, 2009

Plastic Categories, Characteristics & Dangers

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Individuals have a way to identify the type of plastic in many products, especially food storage containers and packaging. Many, but not all, such plastic products have a number – the resin identification code – molded, formed or imprinted in or on the container, often on the bottom. This system of coding was developed in 1988 by the U.S.-based Society of the Plastics Industry to facilitate the recycling of post-consumer plastics. It is voluntary for plastic manufacturers, but has become relatively standard on certain plastic products sold globally. Knowing the code for a particular product, consumers can then inform themselves of the characteristics of the plastic and the risks of using that product.

The seven plastic resin codes are each briefly described below to provide a quick snapshot detailing the name of the resin (i.e., the base material of the plastic), typical products it is found in, dangerous chemicals it leaches, and why they are dangerous.

Polyethylene terephthalate (PET or PETE) – Used in soft drink, juice, water, beer, mouthwash, peanut butter, salad dressing, detergent and cleaner containers. Leaches antimony trioxide and di(2ethylhexyl) pthalate (DEHP). Workers exposed to antimony trioxide for long periods of time have exhibited respiratory and skin irritation; among female workers, increased incidence of menstrual problems and miscarriage; their children exhibited slower development in the first twelve months of life. The longer a liquid is left in such a container the greater the concentration of antimony released into the liquid. DEHP is an endocrine disruptor that mimics the female hormone estrogen. It has been strongly linked to asthma and allergies in children. It may cause certain types of cancer, and it has been linked to negative effects on the liver, kidney, spleen, bone formation and body weight. In Europe, DEHP has been banned since 1999 from use in plastic toys for children under the age of three.

High density polyethylene (HDPE) – Used in opaque milk, water, and juice containers, bleach, detergent and shampoo bottles, garbage bags, yogurt and margarine tubs, cereal box liners. Considered a ’safer’ plastic. Our research on risks associated with this type of plastic is ongoing.

Polyvinyl chloride (V or Vinyl or PVC) – Used in toys, clear food and non-food packaging (e.g., cling wrap), some squeeze bottles, shampoo bottles, cooking oil and peanut butter jars, detergent and window cleaner bottles, shower curtains, medical tubing, and numerous construction products (e.g., pipes, siding). PVC has been described as one of the most hazardous consumer products ever created. Leaches di(2-ethylhexyl) phthalate (DEHP) or butyl benzyl phthalate (BBzP), depending on which is used as the plasticizer or softener (usually DEHP). DEHP and BBzP are endocrine disruptors mimicking the female hormone estrogen; have been strongly linked to asthma and allergic symptoms in children; may cause certain types of cancer; linked to negative effects on the liver, kidney, spleen, bone formation and body weight. In Europe, DEHP and BBzP and other dangerous pthalates have been banned from use in plastic toys for children under three since 1999. Not so elsewhere, including Canada and the United States.

Low density polyethylene (LDPE) – Used in grocery store, dry cleaning, bread and frozen food bags, most plastic wraps, squeezable bottles (honey, mustard). Considered a ’safer’ plastic. Our research on risks associated with this type of plastic is ongoing.

Polypropylene (PP) – Used in ketchup bottles, yogurt and margarine tubs, medecine and syrup bottles, straws, Rubbermaid and other opaque plastic containers, including baby bottles. Considered a ’safer’ plastic. Our research on risks associated with this type of plastic is ongoing.

Polystyrene (PS) – Used in Styrofoam containers, egg cartons, disposable cups and bowls, take-out food containers, plastic cutlery, compact disc cases. Leaches styrene, which is an endocrine disruptor mimicking the female hormone estrogen, and thus has the potential to cause reproductive and developmental problems; long-term exposure by workers has shown brain and nervous system effects; adverse effects on red blood cells, liver, kidneys and stomach in animal studies. Also present in secondhand cigarette smoke, off-gassing of building materials, car exhaust and possibly drinking water. Styrene migrates significantly from polystyrene containers into the container’s contents when oily foods are heated in such containers.

Other – This is a catch-all category that includes anything that does not come within the other six categories. As such, one must be careful in interpreting this category because it includes polycarbonate – a dangerous plastic – but it also includes the new, safer, biodegradable bio-based plastics made from renewable resources such as corn and potato starch, and sugar cane. Polycarbonate is used in many plastic baby bottles, clear plastic “sippy” cups, sports water bottles, three and five gallon large water storage containers, metal food can liners, some juice and ketchup containers, compact discs, cell phones, computers. Polycarbonate leaches Bisphenol A (some effects described above), and numerous studies have indicated a wide array of possible adverse effects from low-level exposure to Bisphenol A: chromosome damage in female ovaries, decreased sperm production in males, early onset of puberty, various behavioural changes, altered immune function, and sex reversal in frogs.

Important Note: Two other types of plastic that fall under code 7 are acrylonitrile styrene (AS) or styrene acrylonitrile (SAN), and acrylonitrile butadiene styrene (ABS). Both AS/SAN and ABS are higher quality plastics with increased strength, rigidity, toughness and temperature and chemical resistance. AS/SAN is used in mixing bowls, thermos casing, dishes, cutlery, coffee filters, toothbrushes, outer covers (printers, calculators, lamps), battery housing. The incorporation of butadiene during the manufacture of AS/SAN, produces ABS, which is an even tougher plastic. ABS is used in LEGO toys, pipes, golf club heads, automotive parts, protective head gear. Our research on risks associated with AS/SAN and ABS is ongoing.

WHAT THIS MEANS FOR YOUR EVERYDAY PLASTIC USE: You may wish to seriously consider your – and especially your children’s – use of plastics numbered 1, 3, 6 and 7 (polycarbonate), all of which have been shown to leach dangerous chemicals. This does not necessarily mean the others are completely safe, just that they have been studied less to date.

So if you have to use plastic, it is safest to stick to numbers 2, 4, 5 and 7 (other than polycarbonate) whenever possible.

If an item does not have a plastic code on it, or if the type of plastic is unclear from the code (e.g., with #7, it likely will not say it is polycarbonate), your best bet is to contact the manufacturer and ask them directly what type of plastic was used to make the product.

Plastic Tips

Here are some simple tips to help you in working toward a life without plastic, or a life of safer, more informed plastic use.

o Avoid polycarbonate (#7) baby bottles and sippy cups. For baby bottles, try and use glass, polyethylene or polypropylene instead. Sippy cups made of stainless steel (e.g., Kleen Kanteen, Purica), or of polypropylene or polyethylene are safer. Be sure to check the bottle or cup to be sure of the type of plastic it contains. As for baby bottle nipples, try and use silicone. which does not leach the carcinogenic nitrosamines that can be found in latex.

o If you must use polycarbonate (#7) bottles, avoid heating food and drink in the bottle. Heat it in a separate container and transfer it to the bottle once it is warm enough for the child to eat or drink. If the plastic is showing signs of wear – scratched, cloudy – discard the container.

o For drinking water, try and avoid plastic bottles. If you do use plastic bottles made from #1 or #2 plastic try not to reuse them as they are intended only for single use. One alternative is a stainless steel water bottle. For storing large quantities of water, glass and stainless steel containers are also available. If you use a #1 water bottle, try to consume the contents as soon as possible because leaching of antimony increases with time.

o Try to avoid heating foods in plastic containers, especially in the microwave oven, which can cause the plastic to degrade and leach chemicals faster. As well, leaching increases when plastic comes into contact with oily or fatty foods, or when the plastic is scratched, worn, cracked, or sticky.

o Use plastic wraps with caution, especially in the microwave, and try to keep the plastic from touching the food. Alternatives include wax paper or paper towels.

o Try and use alternatives to plastic packaging and storage containers. Cloth, paper or cardboard are possibilities for transporting groceries. Stainless steel and glass food storage containers are available.

o Avoid plastic dishes and utensils for meals. Alternatives include glass, ceramic, wood, stainless steel, and lacquer ware. Offer your child or grandchild a non-plastic dish set made of either stainless steel or wood (safely coated with a non-toxic lacquer).

These days, plastic is so omnipresent it can be difficult to imagine life without plastic. Yet, our ancestors managed just fine without it. All it takes is a little imagination, determination and discipline.

July 25, 2009

Simple experiment for plastic moulding

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Below is an simple experiment for you to do with auto body filler:

  1. Make a simple mould by pressing a coin or some other pattern into plasticine (modelling clay). Carefully peel the plasticine away and mount it on a flat surface with the image of the coin facing up..
  2. For the next part you should wear gloves, and work on some newspaper so you don’t make a mess, and get an adult to help you..
  3. Following the directions on the pack of body filler, you mix a tiny amount of hardener with some (monomer) resin. Mix it really thoroughly so that you make a good reaction..
  4. Carefully spread the mixed up filler over the plasticine mould..
  5. While the filler is going hard, gently feel the temperature. If it is warm, it is a sure sign of a chemical reaction taking place..
  6. Leave your filler to go really hard. If you try to look at it too soon you might break it..
  7. Carefully peel the plasticine away, and you will have your own reaction moulded article.

Good Luck!

Plastic appliances & applications

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There are lots of things around your home that are made from plastic, Here are some more and how they are made:

Article How made Plastic
Tupperware Injection Polyethylene
Bucket Injection Polyethylene
Audio Cassette Injection Styrene
Ball point pen Injection Styrene
Ruler Injection Styrene
Shoe soles Reaction Polyurethane
Electric cables Extrusion PVC
Water pipes Extrusion PVC
Water pipes Extrusion PVC
Refrigerator liner Vacuum form ABS
Milk bottle Blow moulding Polyethylene
Plastic bag Blow extrusion Polyethylene

Doubtless, our life can not be plasticless!

Plastics are used a lot by doctors and dentists because they are hygienic and will not poison our bodies. Dentists use acrylic to make special white fillings. Can you think of ways that doctors use plastics?

Many clothes are made from synthetic fabrics. The fabrics are made from plastic fibres that have been spun out really fine, then made into yarns for knitting or weaving.

Plastic fibres are also used to make ropes that are very strong. Fishing lines are made of nylon.

Teflon coatings on saucepans and irons are sprayed on as dry powder then baked in a hot oven to make the particles melt together. This is called powder coating and it is also used to put a very tough layer of epoxy or polyester on metal articles like furniture.

Many glues are plastics.

PVA white glue is a solution of PVA dissolved in water. When it is used to glue two pieces of wood together, the water is soaked up by the wood. The PVA is soaked up with the water. When the water evaporates, the PVA stays behind in the joint, making a strong plastic bridge.

Hot melt glue is a thermoplastic. When it is hot it can be squeezed into a joint. When it cools down it goes hard.

Other common glues are epoxy, resourcinol, and urea formaldehyde. They are all thermoset plastics made by mixing two chemicals (glue + hardener) to react together. These glues are very important because they are waterproof. They are used to make boats and plywood.

Most paints are made from plastic resins. Some, like acrylic house paints and polyurethane varnish are dissolved plastics which dry to form a tough waterproof skin. Other polyurethane, epoxy and polyester paints have to be mixed with a hardener which makes a chemical reaction.

Fibreglass resin and automotive body fillers are polyester plastics that you can make yourself with a chemical reaction.

Plastics Degenerate

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As we see plastics do not rust or corrode like metals. Plastics are made up of long strings like congealed spaghetti. Solvents seep in between the strings, weakening the structure of plastic and making it swell. The material usually softens, and all other properties are also affected. Very strong solvents may even break up and dissolve the strings.

There are some chemicals conjoint with ultra violet light, cause the chain linking reactions of the plastic to continue and accelerate. The plastic becomes hard and brittle, and small cracks begin to appear at the surface. Once these cracks appear, they continue to grow throughout the material.

The cracks usually begin in zones of local stress caused by heating, bending, glueing, or welding. Moulded articles may also have internal stress caused by uneven flow of plastic in the moulding process. Internal stress can be thought of as neighbouring strings within the plastic being stretched by different amounts when the article is made. It is very important for the moulds to be properly designed.

July 24, 2009

Plastic Manufacturing Methods

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Plastics are made into shapes in many ways:

1. Compression Moulding
This is used for thermoset resins. Dry powder is put in a mould which is squeezed and heated until the plastic is cured. This is used for making ashtrays, cups and plates, and some electrical switches.

2. Extrusion
Hot molten plastic is squeezed through a nozzle to make long lengths of special shapes like pipes, spouting and wallboard joining strips. It is also used to make large thick sheets of plastic for fabrication.

3. Blow Extrusion (Figure 1)
This is used for making plastic films and bags. While it is still hot, an extruded tube is blown up like a balloon, with compressed air. This stretches the plastic and makes it thin. The balloon is made long enough to allow the plastic to cool. The end of the balloon is pinched together by rollers, to hold the air in and make it flat. The flat tube is then wound on to a big roll. You can see continuous rolls of plastic bags in a fruit shop.

blow extrusion blow film method

4. Injection Moulding
Hot molten plastic is squeezed into a mould to make lots of objects all the same. They can be very small like a washer or quite large, like a bowl or a clothes basket. Lots of everyday articles are made this way.

5. Reaction Injection Moulding
Two chemicals are mixed together and squirted into a mould. The chemicals react together. This is how they make car bumpers, some disposable cups and plates, and the meat trays you get from supermarkets.

6. Blow Moulding (Figure 2)
A little bit of hot soft plastic is squeezed into the end of a mould. Compressed air is used to blow a big bubble inside the plastic. The plastic swells out like a balloon until it fills up the whole mould. Many bottles, toys and money boxes are made this way.

blow_moulding_bottle_method

7. Rotational Moulding
Plastic powder is scooped into a mould. The mould is rotated over a big gas burner. As the mould gets hot, the plastic melts and sticks to the mould. This method is used for making big hollow things like water tanks and barrels.

8. Vacuum Forming ( Figure 3)
A sheet of plastic is clamped in a frame and heated until it is stretchy. Then it is sucked into a mould. This is how they make the inside of your refrigerator, bath and handbasin. It is also used to make a lot of packaging for cosmetics, chocolates, biscuits, some yoghurt containers and

some disposable cups.vacuum_forming_plastic_sheet_method

9. Fabrication
Some thermoplastics are fabricated like sheetmetal. Sheets of plastic are cut to shape. They can be folded by heating a narrow line through the plastic. When it is soft, the sheet will bend along the heated line. Sheets can be joined together by glueing, or by welding. The join is heated with hot air and a thin filler rod is forced into the gap. These fabrication methods are used to make acrylic signs and displays, and industrial tanks and equipment. Our company, Calibre Plastics Ltd, uses fabricating methods to manufactures laboratory fume cupboards and exhaust fans.

Thin flexible plastic sheets are used for making folders, wallets, swimming pool liners, inflatable toys and raincoats. The seams are welded by ultrasonic vibration.

10. A Special Note About Styrene Foam.
Styrene foam is made in little pellets. To make blocks of styrene foam, or complicated shapes like a cycle helmet, they scoop lots of pellets into a mould and heat it with steam. The steam makes the pellets swell up and stick together. When you break a moulded block you can see how all the pellets have squashed into each other.

What is Plastic – An introduction to plastics

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Plastic is a common name for Polymers: materials made of long strings of carbon and other elements. Each unit in a string is called a monomer, and is a chemical usually derived from oil.

The monomer is made into polymer by chain-linking reactions. This is like making a daisy chain. Instead of flowers, carbon atoms are joined together. The appearance of the daisy chain will be different if you use different coloured flowers, and so will polymers.

There are many different types of plastic, depending on the starting monomer selected, the length of polymer chains, and the type of modifying compounds added. Each plastic has been developed for a special purpose.

Plastic is all around us. It forms much of the packaging for our food and drink. For many of us, it is throughout shops, our home, our workplace, our car and the bus we take to and from work. It can be in our clothing, shoes, building, eyeglasses, teeth, computers, phones, dishes, utensils, toys. The list goes on, no endless.

Plastic is versatile, lightweight, flexible, moisture resistant, durable, strong and relatively inexpensive. It can be chemical resistant, clear or opaque, and practically unbreakable. These are wonderful useful qualities, and plastic plays many important roles in life on Earth, but the widespread use of plastic is also causing unprecedented environmental problems, and harbours serious health risks – especially for children. Plastic should be used wisely, with caution and only when suitable alternatives do not exist or are not available.

There are two main groups of plastics:

1. THERMOPLASTICS soften with heat and harden with cooling.

Some typical thermoplastics are:
Acrylic (Perspex)
Acrylo-nitrile (Nylon)
Polyethylene (Polythene)
Polypropylene
Poly Vinyl Acetate (PVA)
Poly Vinyl Chloride (PVC)
Polystyrene and ABS
PTFE (Teflon)

2. THERMOSETS are cured or hardened by heat.

Some typical thermosets are:
Bakelite
Epoxy
Melamine
Polyester
Polyurethane
Properties

Plastics are used because they are:
Attractive
Hard and slippery
Soft and rubbery
Tough and slippery
Flexible
Good insulators of heat or electricity
Light weight
Hygienic
Non-rusting
Easy to shape and colour
Cheap

Welcome to plastic knowledge base!

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