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Polymer Technology > Lecture 1: Design > Flashcards

Lecture 1: Design Flashcards

1
Q

A bag made of only Polyethylene will degrade in a few weeks. This doesn’t happen, why?

A

Additives

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2
Q

Polymer groups

A

Thermoplastics, thermosets, fibres, rubbers, bio based plastics

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3
Q

Thermoplastics

A

Bulk polymers: PE, PVC, PP, PS
Engineering plastics: PC, PA, PET, POM
High performance: PPO, PSU, PEEK

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4
Q

Thermosets

A

Matrix materials

Composites: including nanocomposites

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5
Q

Plastics

A

Polymers + additives

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6
Q

Additives

A

Fillers (to make the product cheaper, but can make it weaker)
Reinforcing agents (ex. reinforcement fillers)
Coupling agents (making polymer networks)
Plasticiser (ex. can handle heat better)
Antioxidants, stabilisers, flame retardants, nanofillers

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7
Q

Processing Methods

A

Injection moulding, extrusion, blow moulding, calendaring, rotational moulding, thermoforming

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8
Q

Rheology

A

Melt viscosity, shear- and elongation viscosity, shear thinning, die swell

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9
Q

Mechanical Properties

A

E-modulus, Tensile strength & elongation at break, Creep, Stress relaxation, Impact strength, Dynamical Properties, Time dependence, Fatigue

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10
Q

Life time

A

Degradation, Stabilization, Methods to estimate life time

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11
Q

Recycling

A

Reuse, Material recycling, Chemical Recycling, Energy Recycling

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12
Q

Material -> Processing -> Use

A

Materials: Polymers & Additives
Processing: Methods, Rheology, Design (recycling)
Use: Mechanical properties, life time (recycling)

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13
Q

Design 10 steps

A
  1. Definition of functions (function portfolio: colour, intended use), 2. Demand Profile (reflect light, strength etc.), 3. Coarse screening of material (challenge), 4. Property profile of possible materials (too good->too expensive), 5. Part design - recycling possibilities (might be in demand profile but not later than here), 6. Choice of processing methods, 7. Choice of material, 8. Tool preparation, 9. Prototype creation (verification of tool and product), 10. Adjusting of tool
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14
Q

Environmental aspects

A 
Feed stock consumption
Energy consumption
Environmental impact
Recycling
Bio based plastics
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15
Q

Solid Materials: Metals, Polymers (polymeric molecules), ceramics

A

Synthetic Polymers, Natural Polymers (wood, leather, cotton, hair)

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16
Q

Modified Natural Polymers

A

Celluloid, Cellophane

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17
Q

Synthetic Polymers

A

Do not occur naturally: Nylon, Polyester, Polyethylene

Occur naturally but made by non-natural process: synthetic rubber

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18
Q

Total annual production of synthetic polymers

A

250 million tons
60% Thermoplastics
15% Thermosets
20% Fibre

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19
Q

Most common thermoplastics

A
  1. Polyethylene
  2. PVC
  3. Polypropylene
  4. Polystyrene
  5. PET
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20
Q

Plastic 9 properties

A 
Low melting point
Large elongation
Low density
Low thermal conduction 
Electrical resistance
Optical clarity (some)
Easily coloured 
Solvent sensibility
Flammable
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21
Q

Low Melting Point

A

Advantage: Easy to process
Disadvantage: Lower temperature range

22
Q

Larg elongation

A

Less Brittle

Larger creep & lower yield strength

23
Q

Low density

A

Lightweight products

Low structural strength

24
Q

Low Thermal Conduction

A

Good thermal insulator

Low heat dissipation

25
Electrical resistance
Good electrical insulator | Poor conductivity
26
Optic Clarity
Optical applications | Influenced by sunlight (UV)
27
Easily coloured
No need for painting | Hard to colour match
28
Solvent Sensitivity
Can be dissolved (some) | Can be affected by solvents
29
Flammable
Waste can burned | May cause fume, fire hazard
30
Common mistakes designing plastic components
- Wrong selection of materials - Ignorance of differences between polymers and metals - Not thinking of processing method and design of the mould
31
Design Methodology
Inspiration, Concept, Prototype, Development, Final product
32
Work Protocol when designing with polymers
1. Recognise the needs, 2. Definition of function, 3. Establish a demand profile, 4. Coarse selection of materials, 5. Property profiles of possible materials, 6. Detailed design including recycling possibilities, 7. Choice of processing method, 8. Choice of material , 9. Tool preparation, 10. Production of test series: control of tool and product, 11. Revision and trimming of tool
33
Establish a demand Profile
Mechanical load, thermal and chemical environment, fire risks, health risks, life time, recycling, standards; rules & laws, cost
34
Coarse selection of materials
- Eliminating impossible materials - Specific demands indicating special materials - Temperature region - Chemical environment - Contact with food - Is a plastic material possible
35
Demand profile: Mechanical Properties
Shape preserving: E-modulus Load bearing: E- & G- modulus Cyclic load: Fatigue data, temperature increase? Time of load: Creep and relaxation properties Stress concentration: internal stress, brittleness at low T, anisotropy Wear: wear strength, hardness, self lubrication, friction properties, need of lubricants Heat: Expansion coefficient
36
Demand Profile: Thermal environment
Maximal application T, vicat temperature, heat distortion temperature, expansion coefficients, specific heat, heat conduction, Tg
37
Demand Profile: Chemical Environment
Chemical resistance for short and long time, corrosion, crack formation
38
Demand Profile: Electrical environment
Volume and surface resistivity, break down strength, loss factor
39
Demand Profile: Risk for fire
Fire class, ignition (electrical, heat) dripping, smoke formation
40
Demand Profile: Radiation environment
Ageing properties (UV, high energy radiation)
41
Demand Profile: Biological Environment
Toxicological recommendation, toxic properties
42
Demand Profile: Optical properties
Opaque/transparent, light transmission, refractive index
43
Demand Profile: Apperance
Shape, surface, colour
44
Demand Profile
Mechanical parameters, thermal-, chemical-, Electrical-, Radiation-, Biological Environment, Risk for fire, Optical properties, appearance.
45
Process Considerations
Processability, cutting ability, joining ability
46
Processability
- Tm & Tg - Viscosity - Heat of melting, cooling time - Mold and after shrink
47
Cutting ability
- cutting properties | - processing
48
Joining ability
- welding - adhesive bonding - riveting - snap joint - screwing
49
Process consideration properties
Surface treatment, processing cost, mould cost, density, price per kg, price per component, number details, degree of automatisation, recycling; material, energy, landfill, material availability, merit values
50
Detailed Design
- Matching between demand profile and specific property profile - Design vs possible processing methods - Design with respect to recycling
51
Choice of processing method
- The processing method influence the design - The choice is influenced of ex. Material and number of details to be made - Injection Molding of thermoplastics if long series - Compression Molding is suitable for Thermosets and short series - Compromises
52
Choice of materials from the pyramid
Top: High Performance Polymers Middle: Mid-range polymers Bottom: Common polymers Right: Semi-crystalline Left: Amorphous

Polymer Technology (2 decks)

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