Professional Documents
Culture Documents
Synthetic Resins and Plastics
Synthetic Resins and Plastics
Synthetic Resins and Plastics
Cabral, Charlette A. Francisco, Janine Therese J. Mellendrez, Kristine Jhalene M. Pineda, Jermaine Marianne F.
Plastics
The word plastics is from the Greek word Plastikos, meaning able to be shaped and molded Plastics is a material that contains a polymerized organic substance of large molecular weight as an essential ingredient, is solid in its finished state, and at some stage in its manufacture or its processing into finished articles can be shaped by flow. Toughness Water Resistance Excellent resistance to corrosion Ease of fabrication Remarkable color range
Plastics
Basic Raw Materials:
Coal Petrochemicals Cotton Wood Gas Air Salt Water
Synthetic Resins are the largest source of plastics with Cellulose derivatives ranking next
History of Plastics
Commercial phenolic resin (1990) by Baekland was the start of the synthetic plastic industry. Cellulose Nitrate(Celluloid)
First plastic of industrial significance and was discovered about the middle of the 19th century. First used in 1869 by Hyatt who was searching for an ivory substitute.
History of Plastics
Cellulose Acetate
Developed in 1894 as a less flammable material and was used extensively as a base for photographic film and as a dope for airplane coverings during World War I.
Silicone
Polyethylene Fluorocarbons Epoxy Cystalline polypropylene Phenoxy
1942
1943 1946 1948 1957 1962
Classification of Plastics
Examples include:
Chemical-resistant containers e.g. Food Containers
Hinges
Polypropene/ Polypropylene
Fishing nets Bottle crates Medical equipment e.g. syringes
Polyethene/ Polyethylene
LDPE: Packaging film Carrier bags TV cable Toys Detergent 'squeezy' bottles
Wood adhesives
Urea-Formaldehyde
Range of Products
Plastics Bags Plastic Packaging Film and Sheet Non-packaging Film and Sheet Plastics Profile Shapes Plastics Pipe & Pipe Fittings Laminated Plate, Sheet and Shape Polystyrene Foam Products Urethane and Other Foam Products Plastic Bottles Plastic Plumbing Fixtures Resilient Floor Covering Plastics Products, Not Classified Elsewhere
(Source: Probe Economics, Inc. 2004)
Engineering Plastics
High-strength high performance materials that can be substituted for many metal uses These materials show better resistance to:
Wear Impact Corrosive chemicals Excellent electrical properties
Engineering Plastics
Some uses:
Automobile bumpers and dashboards Pumps Valves Gears Driveshafts and transmission in heavy-duty equipment
Engineering Plastics
Phenol
The principal process in use in US is the Peroxidation of Cumene (isopropyl benzene),
Formaldehyde
Results from the exothermic oxidation and endothermic dehydrogenation of methanol
Hexamethylenetetramine
Evaporation of the reaction product of formaldehyde and ammonia
Uses
Urinary Antiseptic (Urotropine) Rubber Industry Preparation of Explosive Cyclonite Phenol-Formaldehyde Resins
Vinyl Esters
Addition of acids to acetylene furnishes esters
Phthalic Anhydride
One of the most important intermediates for plastics industry Preparation of phthalic anhydride are controlled oxidation of o-xylene or naphthalene
The conventional method for preparing MMA has been by the reaction of hydrogen cyanide with acetone and subsequent treatment with methyl alcohol
Natural Products
Cellulose
The structural material of the plant world, is itself a polymer composed of 50 to 100 units of the disaccharide cellobiose
Plasticizers
Organic compounds added to plastics
To improve workability during fabrication To extend or modify the natural properties of the plastics To develop new, improved properties no present in the original resin
Reduce the viscosity and make shaping and forming easier Also impart flexibility and other desired properties to finished product
Manufacturing Processes
Polymerization
a process of reacting monomer molecules together in a chemical reaction to form three-dimensional networks or polymer chains.
Bulk Polymerization
commonly referred to as mass polymerization in the industry May be carried out in liquid/vapor state carried out by adding a soluble initiator to pure monomer into liquid state. Monomers & activator are mixed in a reactor and heated or cooled as needed
Solution Polymerization
Often used when exothermic heat is too great to be controlled in bulk polymerization Monomer & initiator are dissolved in a nonreactive solvent The polymer concentration has to be low to avoid too high viscosity Produces polymers of low to medium MW
Flow Diagram
Suspension Polymerization
Monomer is suspended in water by agitation and stabilizers such as talk, fullers earth and bentonite are added Initiator is soluble in the monomer Each monomer globule polymerizes as a spherical pearl of high MW This process is used in the production of most PVC
Emulsion Polymerization
Similar to suspension polymerization but monomer Is broken up into droplets that form aggregates called micelles Are rapid and can be carried out at relatively low temp Monomer is on the interior of the micelles, initiator is in the water Soap is used to stabilize micelles Initiator diffuses into the micelle to start polymerization Produces polymers of very high MW
Condensation-Polymerization Products
Phenolics Amino resins Polyester resins Alkyd resins Polycarbonates Epoxy Resins Polyimides
Condensation polymerization,
a form of step-growth polymerization, process by which two molecules join together, resulting loss of small molecules which is often water. The type of end product resulting the reaction is dependent on the number of functional end groups of the monomer which can react.
Phenolics
Phenol formaldehyde resins (PF) include synthetic thermosetting resins such as obtained by the reaction of phenols with formaldehyde are formed by a step-growth polymerization reaction that can be either acid- or base-catalysed Initial reaction HOC6H5 + CH2O ortho/para HOC6H4CH2OH
Amino Resins
a thermosetting resinous product made by condensation of a compound containing an amine (e.g., melamine or urea) with an aldehyde (e.g., formaldehyde): is used in making permanent-press fabrics and other products Urea formaldehyde and melamineformaldehyde condensates are the commercially important amino resins
A typical low-stage resin is formed when urea (or melamine) is mixed with formaldehyde
Polyester Resins
Complex esters formed when a difunctional alcohol is reacted with a dibasic acid or anhydride Since rxn takes place at both ends of the chain, long molecules are possible and a plurality of ester groups is obtained Unsaturated polyesters are produced when any of the reactants contain unsaturation, such as
Alkyd Resins
any synthetic resin made from a dicarboxylic acid, such as phthalic acid, and diols or triols: used in paints and adhesives Formed by the reaction of polyhydric alcohols and polybasic acids The most common method of preparation is the fatty acid method in w/c glyceride oil is catalytically treated w/ glycerol at 25250oC
Polycarbonates
Special variety of polyester in w/d a derivative of carbonic acid Is substituted for adipic, phthalic and a diphenol is substituted for the more conventional glycols
Epoxy Resins
Formed by the reaction of bisphenol with epichlorohydrin. Have excellent chemical resistance; excellent adhesion and electrical insulating poperties Epoxy resins have many different uses. For example, resins that are cured through exposure to ultraviolet light are commonly used in fiber optics, optoelectronics, and dentistry.
Polyimides
Very stable, linear polymers Compounds containing two anhydride groups w/c reacts with primary amines or isocyanates The polyimide materials are lightweight, flexible, resistant to heat and chemicals. Therefore, they are used in the electronics industry for flexible cables, as an insulating film on magnet wire and for medical tubing.
Polysulfones
Polysulfone describes a family of thermoplastic polymers. These polymers are known for their toughness and stability at high temperatures. Resistance to autoclave sterilization makes them useful for medical instruments and trays Other uses: microwave cookware, coffee decanters, and corrosion-resistant piping
Addition Polymerization
Polyolefins Vinyl resins Vinyl alcohol resins Vinylidene resins Styrene resins Acrylic resins and plastics
Addition polymerization
A chemical reaction in which simple molecules (monomers) are added to each other to form long-chain molecules (polymers) without by-products. The molecules of the monomer join together to form a polymeric product in which the molecular formula of the repeating unit is identical with that of the monomer. The molecular weight of the polymer so formed is thus the total of the molecular weights of all of the combined monomer units.
Polyolefins
a polymer produced from a simple olefin (also called an alkene with the general formula CnH2n) as a monomer. Industrial polyolefins: PE, PP have excellent chemical resistance and can only be adhesively bonded after surface treatment because they have very low surface energies used for blown film and heatshrink electrical insulation sleeves for crimped wire terminals, as well as rash guards or under garments for wetsuits. Polyolefin elastomer POE is used as a main ingredient in seat cushions, arm rests, spa pillows, etc.
Vinyl Resins
Synthetic materials made from cpds having a vinyl group Polyvinyl acetate, PVC, polyvinyl alcohol, polyvinyl acetals Largest branch of vinyl family is PVC due to wide range of applications, ease of processing and relatively low cost
PVC manufacture
Blends-mixtures that are not fully compatible Alloys-mixtures that are fully compatibles such as polyethylene oxide and polystyrene
appear as separate phases when viewed under microscope Problem: to make components adhere together Approach: to introduce compatibilizers Major polymer alloys are polyphenylene oxide/polystyrene, polycarbonate, PET
Natural Products
Cellulose Derivatives Cellulose Nitrate-a compound made by treating cellulose with nitric and sulphuric acids, used in plastics, lacquers, and explosives Cellulose Acetate-synthetic compound derived from the acetylation of the plant substance cellulose. Can be molded into solid plastic parts such as tool handles or cast into film for photography or food wrapping
Ethyl Cellulose plastics- thermoplastic and are noted for their ease of molding, light weight, and good dielectric strength. applications include football helmets, equipment housings, refrigerator parts, and luggage. Shellac- a resin secreted by the female lac bug, on trees in the forests of India and Thailand. It is processed and sold as dry flakes (pictured at right), which are dissolved in ethyl alcohol to make liquid shellac, which is used as a brush-on colorant, food glaze and wood finish.
Laminates
A laminate is a material that can be constructed by uniting two or more layers of material together. Laminated plastics are made largely from the thermosetting class of resins and have fibrous fillers such as glass, carbon, metal and some polymer Resin is dissolved in a suitable solvent (alcohol or water) with w/c the filler is coated
Vehicle windshields are commonly made by laminating a tough plastic film between two layers of glass. Plywood is a common example of a laminate using the same material in each layer. Glued and laminated dimensioned timber is used in the construction industry to make wooden beams
Foams
Syntactic Foams- A special class of closedcell which contains hollow particles embedded in a matrix material. Possible applications, such as dynamic structural support, flexible foam core, and expandable foam fill Integral skin foam- is a type of foam with a high-density skin and a low-density core. Examples of items produced using this process include arm rests, baby seats, shoe soles, and mattresses.