Plastic Product Material and Process Selection Handbook

by Rosato; Rosato; Rosato

• ISBN13: 9781856174312
• ISBN10: 185617431X
• Format: Paperback
• Copyright: 2004-09-01
• Publisher: Elsevier Science

Summary

This book is for people involved in working with plastic material and plastic fabricating processes. The information and data in this book are provided as a comparative guide to help in understanding the performance of plastics and in making the decisions that must be made when developing a logical approach to fabricating plastic products to meet performance requirements at the lowest costs. It is formatted to allow for easy reader access and this care has been translated into the individual chapter constructions and index. This book makes very clear the behaviour of the 35,000 different plastics with the different behaviours of the hundreds of processes. Products reviewed range from toys to medical devices, to cars, to boats, to underwater devices, containers, springs, pipes, aircraft and spacecraft. The reader's product to be designed and/or fabricated can be directly or indirectly related to plastic materials, fabricating processes and/or product design reviews in this book.

Table of Contents

List of Figures	xix
List of Tables	xxvi
Preface, Acknowledgement	xxix
About the Authors	xxxiii
Chapter 1 INTRODUCTION	1	(39)
Overview	1	(2)
Classifying plastic	3	(5)
Thermoplastic: crystalline or amorphous	4	(3)
Liquid crystalline polymer	7	(1)
Thermoset	7	(1)
Crosslinked plastic	8	(1)
Property and behavior	8	(3)
Molecular structure/property/process	10	(1)
Viscosity: Newtonian and Non-Newtonian	11	(1)
Rheology and viscoelasticity	12	(1)
Processing and thermal interface	13	(2)
Compounding and alloying	15	(1)
Introduction to property	16	(1)
Plastic behavior	17	(14)
Thermal behavior	17	(1)
Residence time	17	(8)
Plastic memory	25	(1)
Thermal conductivity	26	(1)
Specific heat	27	(1)
Thermal diffusivity	27	(1)
Coefficient of linear thermal expansion	27	(1)
Temperature index	28	(1)
Corrosion resistance	29	(1)
Chemical resistance	29	(1)
Fire property	30	(1)
Steel and plastic	30	(1)
Permeability	30	(1)
Radiation	31	(1)
Craze/crack	31	(1)
Drying plastic	31	(3)
Variable	34	(2)
Advantage and limitation	36	(1)
FALLO approach	37	(3)
Chapter 2 PLASTIC PROPERTY	40	(90)
Overview	40	(4)
Plastic performance	44	(1)
Thermoplastic	45	(55)
Polvolefin	45	(1)
Polyethylene	46	(10)
Linear polyethylene	48	(1)
Low density polyethylene	49	(1)
Ultra low density polyethylene	50	(1)
Linear low density polyethylene	51	(1)
High density polyethylene	51	(1)
Ultra high molecular weight polyethylene	52	(1)
Crosslinked polyethylene	52	(1)
Polyethylene wax	52	(1)
Chlorinated polyethylene elastomer	53	(1)
Polymethylpentene	53	(1)
Polvolefin elastomer	53	(1)
Polvolefin thermoplastic elastomer	54	(1)
Ethylene-propylene elastomer	54	(1)
Polypropylene	54	(1)
Polybutylenc	55	(1)
Cyclic polybutylenc terephthalatc	56	(1)
Vinyl	56	(7)
Polyvinyl chloride	57	(3)
Ultra high molecular weight polyvinyl chloride	60	(1)
Polyvinyl acetate	60	(1)
Polyvinyl chloride acetate	61	(1)
Polyvinyl chloride, chlorinated	61	(1)
Polyvinyl alcohol	61	(1)
Polyvinyl butvral	62	(1)
Polyvinyl carbazolc	62	(1)
Polyvinyl pyridine	62	(1)
Polyvinyl pyrrolidone	62	(1)
Polyvinyl fluoride	62	(1)
Polyvinyl formal	62	(1)
Polyvinylidene chloride	62	(1)
Polyvinylidene fluoride	63	(1)
Polystyrene	63	(4)
Polystyrene copolymer	64	(1)
Polystyrene, expandable	64	(1)
Polystyrene maleic anhydride	64	(1)
Crystal clear polystyrene	64	(1)
Flame retardant polystyrene	65	(1)
Polystyrene film, heat-sealable	65	(1)
High gloss polystyrene	65	(1)
High impact polystyrene	65	(1)
Syndiotactic polystyrene	66	(1)
Polystyrene-acrylonitrile	66	(1)
Polystyrene-polyethylene blend	66	(1)
Polystyrene-polyphenylene ether blend	66	(1)
Advanced styrenic	66	(1)
Styrene-butadiene	67	(1)
Polyalphamethylstyrene	67	(1)
Acetal	67	(1)
Acrylic	67	(2)
Acrylic elastomer	68	(1)
Polymethacrylic acid	68	(1)
Polymethylacrylate	68	(1)
Polyethylmethacrylate	68	(1)
Polyglutarimide acrylic copolymer	68	(1)
Acrylonitrile	69	(3)
Acrylonitrile-butadiene rubber	69	(1)
Acrylonitrile-butadiene-styrene	69	(1)
Acrylonitrile-butadiene-styrene, transparent	70	(1)
Acrylonitrile-chlorinated polyethylene-styrene copolymer	70	(1)
Acrylonitrile-ethylene/propylene-styrene copolymer	70	(1)
Acrylonitrile-ethylene-styrene	70	(1)
Acrylonitrile-methylmethacrylate	71	(1)
Acrylonitrile-styrene	71	(1)
Acrylonitrile-styrene-acrylate	71	(1)
Polymethacrylonitrile	71	(1)
Polyvinylcyanide	71	(1)
Cellulosic	72	(1)
Chlorinated polyether	72	(1)
Ethylene-vinyl acetate	72	(1)
Ethylene-vinyl alcohol	72	(1)
Fluoroelastomer	73	(1)
Fluoroplastic	73	(4)
Polytetrafluoroethylene	74	(1)
Polychlorotrifluoroethylene	75	(1)
Polyhexafluoropropylone	76	(1)
Polyvinyl fluoride	76	(1)
Polyvinylidene fluoride	76	(1)
Fluorinated ethylene propylene	76	(1)
Chlorofluorohydrocarbon	76	(1)
Polyfluoroalkoxyphosphazene	77	(1)
Ionomer	77	(1)
Nylon (polyamide)	77	(2)
Parylene	79	(1)
Phoenix	79	(1)
Polyallomer	80	(1)
Polyamide	80	(1)
Polyamide-imide	80	(1)
Polyarylate	81	(1)
Polyaryletherketone	81	(1)
Polyarylsulfone	82	(1)
Polyeutylene terephthalate	82	(1)
Polycarbonate	83	(2)
Polycyclohexylenedimethylene terephthalate	85	(1)
Polyelectrolyte	85	(1)
Polyester, thermoplastic	85	(1)
Polyester reinforced urethane	85	(1)
Polyester water-soluble	85	(1)
Polyetherketone	86	(1)
Polyetheretherketonc	86	(1)
Polyether, chlorinated	87	(1)
Polyetherimide	87	(1)
Polyethylene naphthalate	88	(1)
Polyethylene terephthalate	88	(1)
Polyethylene terephthalate glycol	89	(1)
Polyhydroxybutyrate	89	(1)
Polyimidazole	90	(1)
Polyimide	90	(1)
Polyimide powder	91	(1)
Polyetterimide	91	(1)
Polyketone	92	(1)
Polyetheretherketone	92	(1)
Polyetheretherketoneketone	92	(1)
Polylactide	92	(1)
Polyorganophosphazene	93	(1)
Polyoxymethylene	93	(1)
Polyparamethylstyrene	93	(1)
Polyperfluoroalkoxy	93	(1)
Polyphenylene ether	93	(1)
Polyphenylene oxide	94	(1)
Polyphenylene sulfide	95	(1)
Polyphosphazene	95	(1)
Polyphthalamide	95	(1)
Polysulfone	96	(2)
Polyethersulfone	97	(1)
Polyphenyl sulfone	97	(1)
Polyphenylethersulfone	98	(1)
Polyphthalamide	98	(1)
Polysaccharide	98	(1)
Polyterpene	98	(1)
Polythiophene	98	(1)
Polyurethane, thermoplastic	98	(2)
Polyurethane elastomer	99	(1)
Polyurethane isoplast	99	(1)
Polyurethane virtually crosslinked	100	(1)
Thermoset plastic	100	(15)
Alkyd	100	(1)
Allyl	100	(1)
Amino	101	(1)
Chlorosulfonated polyethylene elastomer	101	(3)
Crosslinked polyethylene	101	(3)
Diallyl phthalate	104	(1)
Epoxy	104	(1)
Epoxy vinyl ester	104	(1)
Fluorosilicone elastomer	104	(1)
Melamine formaldehyde	105	(1)
Neoprene	105	(1)
Phenol-formaldehyde	105	(1)
Polybenzimidazole	106	(1)
Polybenzobisoxazole	107	(1)
Polybutadiene	107	(1)
Polychloroprene	107	(1)
Polydicyclopentadiene	107	(1)
Polyester, thermoset	107	(2)
Polyester, water-soluble	109	(1)
Polyimidazopyrrolone	109	(1)
Polyisobutylene butyl	110	(1)
Polyisoprene	110	(1)
Natural rubber and other elastomer	110	(1)
Polynorbornenc	110	(1)
Polysulfide	111	(1)
Polyurethane, thermoset	111	(1)
Rubber, natural	112	(1)
Rubber latex, natural	112	(1)
Silicone	113	(1)
Silicone elastomer	113	(1)
Styrene-butadiene elastomer	114	(1)
Urea-formaldehyde	114	(1)
Elastomer	115	(3)
Reinforced plastic	118	(1)
Recycled plastic	118	(1)
Plastic selection	119	(11)
Chapter 3 FABRICATING PRODUCT	130	(62)
Overview	130	(11)
Processing and patience	140	(1)
Processor certification	141	(1)
Processing fundamental	142	(7)
Machines not alike	149	(1)
Plastic processing performance	149	(7)
Plastic memory	151	(1)
Orientation	151	(2)
Reinforced directional property	153	(1)
Plastic deformation	154	(1)
Coextrusion/coinjection: fabricating multilaver	154	(2)
Plasticator melting operation	156	(1)
Screw	156	(10)
Feeding problem	160	(1)
Screw/barrel bridging	161	(1)
Multi-stage screw	162	(1)
Drying via venting	163	(1)
Barrier screw	163	(1)
Screw tip	163	(1)
Purging	164	(2)
Barrel	166	(1)
Downsizing machine	166	(1)
Upsizing machine	167	(1)
Rebuilding vs. Buying	167	(1)
Repair	168	(1)
Tooling	168	(1)
Process control	168	(22)
Overview	168	(3)
Sensor	171	(1)
Pressure sensor	172	(1)
Temperature sensor	173	(2)
Fuzzy logic	175	(1)
Temperature controller	175	(1)
Processing window	176	(2)
Control and monitoring	178	(6)
Process controller	184	(2)
Control choice	184	(2)
Intelligent processing	186	(9)
Intelligent setting and control	186	(2)
Program analysis	188	(1)
Fuzzy logic	189	(1)
Troubleshooting	190	(1)
Prototyping model	190	(1)
Safety	191	(1)
Chapter 4 INJECTION MOLDING	192	(35)
Introduction	192	(3)
Molding system	195	(5)
Clamping design	197	(1)
Tiebar	198	(1)
Machine control	199	(1)
Machine startup/shutdown	200	(8)
Maximizing processing window control	204	(4)
Coinjection molding	208	(1)
Coinjection foam low pressure molding	209	(1)
Gas-assist molding	209	(1)
Gas-assist without gas channel molding	210	(1)
Gas counter-flow molding	211	(1)
Water-assist molding	211	(1)
Injection-compression molding	212	(1)
Two-shot molding/over-molding	213	(1)
In-mold molding	213	(1)
Insert molding	214	(1)
Thin-wall molding	215	(1)
Soluble core molding	215	(1)
Continuous molding	216	(1)
Tandem machine molding	216	(1)
Micro-molding	216	(4)
Monosandwich molding	220	(1)
Double-daylight molding	220	(1)
Foamed gas counter pressure molding	221	(1)
High pressure foam molding	221	(1)
Low pressure foam molding	221	(1)
Liquid molding	222	(1)
Counterflow molding	222	(1)
Melt flow oscillation molding	222	(1)
Screwless molding	223	(1)
Non-plastic molding	223	(3)
Magnesium molding	225	(1)
Thixotropic molding	225	(1)
Summary	226	(1)
Chapter 5 EXTRUSION	227	(55)
Introduction	227	(4)
Component	231	(4)
Extruder type/performance	235	(3)
Operation	238	(5)
Startup	238	(4)
Shutdown	242	(1)
Film and sheet	243	(1)
Film	244	(5)
Blown film	244	(3)
Flat film	247	(2)
Sheet	249	(3)
Pipe and tube	252	(2)
Profile	254	(3)
Coating	257	(4)
Wire and cable	261	(2)
Fiber	263	(4)
Coextrusion	267	(2)
Orientation	269	(5)
Blown film	271	(2)
Flat film	273	(1)
Fiber	274	(1)
Other process	274	(1)
Postforming	274	(1)
Compounding	275	(1)
Reclamation/recycling	275	(7)
Chapter 6 BLOW MOLDING	282	(26)
Introduction	282	(2)
Blow molding process	284	(4)
Extrusion vs. Injection blow molding	288	(1)
Extrusion blow molding	288	(7)
Parison head	290	(3)
Machine design	293	(2)
Injection blow molding	295	(2)
Stretch blow molding	297	(7)
Dip blow molding	300	(1)
Multiblow blow molding	300	(2)
Sequential extrusion	301	(1)
Blow/fill/seal	302	(1)
Blow molding 3-d	302	(1)
Blow molding with rotation	302	(2)
Mold	304	(4)
Chapter 7 THERMOFORMING	308	(25)
Introduction	308	(9)
Mold	317	(3)
Processing	320	(13)
Vacuum forming	321	(1)
Pressure forming	321	(1)
Vacuum-air pressure forming	322	(1)
Blow forming	322	(1)
Drape forming	322	(1)
Drape-vacuum forming	322	(1)
Drape-vacuum assist frame forming	322	(1)
Drape with bubble stretching forming	322	(1)
Snap-back	323	(1)
Plug assist forming	323	(1)
Plug assist and ring forming	324	(1)
Ridge forming	324	(1)
Billow forming	324	(1)
Billow plug assist forming	324	(1)
Billow-up vacuum snap-back	324	(1)
Billow snap-back forming	325	(1)
Air slip forming	325	(1)
Air slip plug assist forming	325	(1)
Blister package forming	325	(1)
Draw forming	326	(1)
Dip forming	326	(1)
Form, fill, and seal	326	(1)
Form, fill, and seal vs. Preform	327	(1)
Form, fill, and seal with zipper in-line	327	(1)
Multiple-step forming	327	(1)
Matched mold forming	328	(1)
Solid-state forming	328	(1)
Rubber pad forming	328	(1)
Mechanical forming	328	(1)
Forging forming	329	(1)
Twin sheet forming	329	(1)
Cold forming	329	(1)
Comoform cold forming	330	(1)
Shrink wrap forming	330	(1)
Strapless forming	330	(1)
Forming and spraying	331	(1)
Solid-phase pressure forming	331	(1)
Flow-compression forming	331	(1)
Postforming	331	(1)
Bend forming	332	(1)
Chapter 8 FOAMING	333	(36)
Overview	333	(4)
Blowing agent	337	(6)
Chlorofluorocarbon and alternate	342	(1)
Type of foam	343	(8)
Process	351	(18)
Extruding	352	(2)
Casting	354	(1)
Spraying	355	(1)
Frothing	355	(1)
Expandable plastic	356	(4)
Molding	360	(1)
Injection molding	361	(4)
Structural foam	365	(1)
Foam reservoir molding	365	(1)
Polyurethane process	365	(4)
Chapter 9 CALENDERING	369	(13)
Introduction	369	(2)
Equipment	371	(5)
Compounding/blending	376	(1)
Processing	377	(2)
Market	378	(1)
Calendering vs. Extrusion	379	(3)
Chapter 10 COATING	382	(12)
Overview	382	(1)
Type	383	(2)
Plastic behavior	385	(1)
Process	386	(6)
Overview	386	(1)
Spray coating	387	(2)
Flame spray coating	387	(2)
Roll-coat finish	389	(1)
Spread coating	389	(1)
Floating knife coater	390	(1)
Fluidized bed coating	390	(1)
Powder coating	390	(1)
Electrostatic spraying	391	(1)
Metal coil coating	391	(1)
Property	392	(2)
Thermal control	392	(1)
Germ-free coating	392	(2)
Chapter 11 CASTING	394	(12)
Introduction	394	(1)
Plastic	395	(1)
Process	395	(6)
Casting of acrylic	401	(2)
Casting of nylon	403	(1)
Solvent casting of film	404	(2)
Chapter 12 REACTION INJECTION MOLDING	406	(22)
Introduction	406	(3)
Equipment	409	(1)
Mold	410	(5)
Runner and gate design	413	(1)
Cost	413	(2)
Processing	415	(3)
Process control	417	(1)
Material	418	(10)
Conversion process	422	(3)
Thermoplastic polyurethane	425	(1)
Thermoset polyurethane	425	(1)
Cure of thermoset	425	(1)
Polymerization	426	(1)
RRIM and resin transfer molding	426	(2)
Chapter 13 ROTATIONAL MOLDING	428	(11)
Introduction	428	(2)
Process	430	(1)
Plastic	431	(3)
Plastic behavior	434	(1)
Performance	434	(1)
Machine	435	(1)
Mold	436	(2)
Design	438	(1)
Chapter 14 COMPRESSION MOLDING	439	(16)
Introduction	439	(5)
Mold	444	(3)
Machine	447	(1)
Plastic	448	(2)
Polytetrafluoroethylcne	449	(1)
Processing	450	(5)
Heater	452	(1)
Automation	452	(1)
Transfer molding	453	(1)
Compression-injection molding	453	(1)
Hydrostatic compression molding	454	(1)
Chapter 15 REINFORCED PLASTICS	455	(42)
Overview	455	(1)
Definition	456	(9)
Fibrous composite	460	(3)
Aspect ratio	463	(1)
Laminar composite	463	(1)
Particulate composite	464	(1)
Filler	465	(1)
Property	465	(3)
Orientation of reinforcement	468	(2)
Hetergeneous/homogeneous/anisotropic	469	(1)
Material of construction	470	(4)
Prepreg	471	(1)
Sheet molding compound	472	(1)
Bulk molding compound	472	(1)
Compound	473	(1)
Fabricating process	474	(2)
Preform process	474	(2)
Conventional process	476	(1)
Compression molding	476	(3)
Flexible plunger	477	(1)
Flexible bag molding	478	(1)
Laminate	478	(1)
Hand lay-up	479	(3)
Vacuum bag molding	480	(1)
Vacuum bag molding and pressure	480	(1)
Pressure bag molding	480	(1)
Autoclave molding	480	(1)
Autoclave press slave	480	(1)
Wet lay-up	480	(1)
Bag molding hinterspritzen	481	(1)
Contact molding	481	(1)
Filament winding	482	(4)
Fabricating RP tank	485	(1)
Injection molding	486	(1)
Marco process	486	(1)
Pultrusion	487	(1)
Reactive liquid molding	487	(1)
Resin transfer molding	488	(1)
Rotational molding	488	(1)
Squeeze molding	489	(1)
Infusion molding	489	(1)
SCRIMP process	489	(1)
Soluble core molding	489	(1)
Lost-wax process	490	(1)
Spray-up	490	(1)
Stamping	490	(1)
Cold forming	491	(1)
Comoform cold molding	491	(1)
Selecting process	491	(6)
Tolerance	494	(3)
Chapter 16 OTHER PROCESS	497	(15)
Introduction	497	(1)
Pvc dispersion	498	(9)
Plastisol	498	(2)
Organosol	500	(1)
Slush molding	501	(1)
Rotational molding	502	(1)
Spray molding	502	(1)
Continuous coating	502	(3)
Nonfoam strippable vinyl	504	(1)
Foam-vinyl strippable	505	(1)
Open molding	505	(1)
Closed molding	506	(1)
Dip molding	506	(1)
Dip coating	507	(1)
Ink screening	507	(1)
Encapsulation	507	(1)
Potting	508	(1)
Liquid injection molding	508	(1)
Vacuum assisted lim	509	(1)
Impregnation	509	(1)
Chemical etching	509	(1)
Twin screw injection molding extruder	510	(1)
Melt compression molding	510	(2)
Chapter 17 MOLD AND DIE TOOLING	512	(38)
Overview	512	(3)
Material of construction	515	(1)
Manufacturing	516	(3)
Protective coating/plating	519	(1)
Mold	520	(8)
Die	528	(19)
Introduction	528	(10)
Die type	538	(8)
Flat die	538	(1)
Cast film die	538	(1)
Sheet coathanger die	539	(1)
Coating and laminating die	539	(1)
Tubular die	539	(1)
Blown film die	539	(2)
Pipe die	541	(1)
Foam die	542	(1)
Profile die	542	(1)
Wire coating die	542	(1)
Draw ratio balance	542	(1)
Drawdown ratio	543	(1)
Fiber die	543	(1)
Netting and special forming die	543	(1)
Pelletizer die	544	(1)
Cocxtrusion die	545	(1)
Computer	546	(1)
Tooling and prototyping	547	(3)
Chapter 18 AUXILIARY EQUIPMENT	550	(20)
Introduction	550	(4)
Material/product handling	554	(6)
Decorating	560	(1)
Joining and assembling	561	(3)
Machining	564	(6)
Chapter 19 SUMMARY	570	(6)
Overview	570	(1)
Research and development	571	(2)
Theoretical vs. Actual value	571	(1)
Smarter plastic	571	(2)
Equipment development	573	(1)
Product development	573	(1)
Composite commercial airplane	573	(1)
Bonding plastic	573	(1)
Self-healing BP	574	(1)
Airbus super-jumbo RP wing parts	574	(1)
World's largest wind blade	574	(1)
Bridge infrastructure and RP	574	(1)
Design demand	574	(1)
Plastics in the forefront	575	(1)
REFERENCES	576	(21)
INDEX	597