PLASTICS:

PREPARATION-PROPERTIES-
PERFORMANCE

Dr. PRAKASH TRIVEDI

GHARDA CHEMICALS LTD.
IPI - PLASTICS FOR NON-
PLASTICS PROFESSIONALS
MUMBAI
11 JAN. 2002.
 WHAT ARE POLYMERS?
• MOST ORGANIC/INORGANIC
COMPOUNDS ARE OF LOW MOLE.
WTS. <1000.
• POLYMERS HAVE MOLE. WTS.
RANGING FROM 10000 TO SEVERAL
MILLIONS! THEY ARE BUILT FROM
SMALL MOLECULES - MONOMERS -
BY COVALENT BONDS.
 NATURAL POLYMERS
• DNA/RNA: POLYPHOSPHATE
• PROTEINS, SILK, HAIR: POLYAMIDES
• WOOD, COTTON: CELLULOSICS
• NAT.RUBBER: POLYISOPRENES
 INORGANIC POLYMERS
• SILICONE OILS AND RUBBER
• POLYSULFIDES
• POLYPHOSPHAZENES
• HYBRIDES, SOL-GELS
 TYPES OF POLYMERS: 1
• ELASTOMERS: Tg < -100 TO -20°C, NO
OR LOW CRYSYTALLINITY. NAT.
RUBBER, PBd, SBR, EPDM, NBR
• TOUGH, FLEXIBLE, RETRACTABLE,
RESISTANT TO OIL, SOLVENT, UV,
ABRASION.
• USED IN PLASTICS AS IMPACT
MODIFIERS.
 TYPES OF POLYMERS: 2
• FIBRES: HIGH Tm & CRYSTALLINITY.
PE, PET, NYLONS, POLYIMIDES.
• HIGH STRENGTH, INFLEXIBLE,
RESISTANT TO CHEMICALS, WATER,
DYEABLE
• STRUCTURELY SAME AS PLASTIC
COUNTERPARTS, ONLY MOLE. WTS
ARE DIFFERENT, USUALLY LOWER.
 TYPES OF POLYMERS: 3
• RESINS: USED FOR COATINGS, PAINTS,
ADHESIVES, SEALENTS, GLUES. PVAc,
ACRYLATES, CYANOACRYLATES,
EPOXIES, SBS
• SOLVENT OR EMULSION BASED OR HOT
MELTS, LOWER Tg, CAN BE CURED TO
GIVE TOUGH FILMS WHICH STICKS ON
A GIVEN SURFACE OR TWO SURFACES
•
 TYPES OF POLYMERS: 4
• THERMOSETS: CROSSED LINKED
POLYMERS OF HIGH STRENGTH AND
THERMAL STABILITY.
FORMALDEHYDE POLYMERS WITH
PHENOL, UREA, MELAMINE, EPOXY,
PU, POLYIMIDES
• RESISTANT TO CHEMICALS, HEAT,
ABRASION
 SYNTHETIC ORGANIC
PLASTICS
• CRYSTALLINE/LOW Tg, LOW Tm <180°C:
LDPE, LLDPE, HDPE, PP
• AMORPHOUS/HIGH Tg >80°C: PS, SAN,
ABS, PVC, PMMA, PVAc
• AMORPHOUS/V. HIGH Tg >130°C: PC, PPE,
PSU, PEI, PPSU, PES
• CRYSTALLINE/HIGH Tm >220°C: PET, PBT,
POM, NYLONS, PPS, PTFE, LCP, PEEK
 INDIAN SCENARIO: 1
• LDPE: IPCL
• HDPE: IPCL, RIL, GAIL, HALDIA
• LLDPE: IPCL, RIL, GAIL, HALDIA
• PP: RIL, IPCL, HALDIA
• PS/HIPS: LG, SUPREME, BASF
• PVC: RIL, IPCL, SRC, FINOLEX,
CHEMPLAST
• ABS: BAYER, BHANSALI
• PMMA: GSFC
 INDIAN SCENARIO: 2
• PET: DSM, PEARL, RIL
• NYLON 6: GSFC, SRF
• PTFE: HIND. FLUORO
• PI: ABR ORG.
• PES, PSU, PPSU, PEEK: GCL - PANOLI
• SP. COMOUNDERS: GEP, DUPONT,
DSM, GCL, SRF
 TYPES OF PLASTICS
• COMMODITY: LDPE, LLDPE, HDPE, PP
PS, HIPS, SAN, ABS, PVC, PMMA
• ENGINEERING: PET, PBT, POM, CPVC,
PVDC, PVDF, NYLONS, PPE, PC, PU
• SPECIALTY: PSU, PES, PPSU, PEI, PPS,
LCP, PEEK, PTFE
• THERMOSETS: PH, UF, MF, EPOXY,
 GCL
THERMOPLASTICS
PYRAMID
P
^ ^
D
E E
R PPSU PAEK V
C
F PES LCP R O
O P PSU PEI E L
PPS
R R A U
M I S M
C PC PA E
A POM I
E PPE
N PET/PBT N
ABS
C G
E PMMA PS LLDPE HDPE
PVC LDPE

AMORPHOUS CRYSTALLINE
 THERMOPLASTICS : GCL

A COMPARISON
_________________________________________________
ITEMS COMMODITY ENGINEERING SPECIALTY
PRICE 1-2 1-6 8 - 70
$ / Kg

VOLUME > 97 3. 5 < 0 . 15

MMT / A

CONT. USE 80 80 - 150 180 - 320

TEMP ° C
 TYPES OF
POLYMERIZATIONS: 1
• ADDITION OR CHAIN GROWTH PZN.
• SOLUTION, SUSPENSION, EMULSION,
MASS
• GAS PHASE, LIQUID PHASE, SOLID-MELTS
• ONE OR MORE MONOMERS, HOMO OR CO
PZN: RANDOM, BLOCK, GRAFT
• STEREOSPECIFIC OR NON-SPECIFIC
• MOST COMMODITY PLASTICS
 TYPES OF
POLYMERIZATIONS: 2
• CONDENSATION-STEP GROWTH:
• ONE OR TWO MONOMERS
• SOLUTION OR MASS PZN.
• HIGH TEMP. ORGANIC SOLVENTS
• HIGH VISCOSITY
• REMOVAL OF SOLVENT IMP.
• MAINLY ENG. & SP. PLASTICS,
THERMOSETS
 POLYETHYLENES
• HOMOPOLYMERS - LDPE, HDPE. GAS PHASE
OR SLURRY PZN. USING FREE RADICAL OR
ZIEGLER-NATTA TYPE CATALYSTS. MAJOR
PLAYERS DOW, EXXON, BOREALIS, BP,
SOLVAY.
• LOWER DENSITY, GOOD TOUGHNESS &
ELONGATION, GOOD ELECTRICALS
SOLVENT RESISTANCE. EASY
PROCESSIBILITY.
• PACKAGING, COATING, ELE. CABLE
SHEATHS, PIPES, TANKS, W. SACKS
 POLYPROPYLENES
• GAS OR SLURRY PHASE ZIEGLER-
NATTA OR METALOCENE CATALYST
BP, BASEL, EXXON, SOLVAY, MOBILE
• TOUGH, V.LIGHT, CAN BE FIILED,
HIGH TEMP. RESISTANCE &
STRENGTH
• AUTO BUMPERS, DASHBOARDS,
EQUIPMENT PARTS, W. SACKS,
FURNITURE, FILMS, TAPES
FILAMENTS, PLUMBING, SPORTS
 STYRENICS - 1
• PS HOMOPOLYMER, MASS FREE
RADICAL PZN. MAJOR MANF. DOW,
BASF, HUNTSMAN
• TRANSPARENT, COLORABLE, HIGH
STRENGTH, HIGH GLOSS, GOOD
PROCESSIBILITY, ELECTRICAL
PROPERTIES, GOOD RIGIDITY
• APPLIANCES, PACKAGING, TOYS,
FRIDGE CABINETS, CUTLERY
 STYRENICS - 2
• HIPS & SAN MNF. MASS FREE
RADICAL PZN. OF STYRENE, WITH
PBD OR ACRYLONITRILE. DOW, BASF
• PBD IMPROVED IMPACT STRENGTHS
• AN IMPROVED CHEMICAL & HEAT
RESISTANCE & PHYSICALS
• TV & RADIO CABINET, APPLIANCES,
AUDIO/VIDEO COVERS, BLENDING
WITH OTHER POLYMERS
 ABS
• GRAFT TERPOLYMER OF STYRENE,
ACRYLONITRILE & PBD PLUS SAN,
MAJOR MNF. GEP, BAYER, BASF,
• HIGH IMPACT, HIGH GLOSS,HIGH
DIMENTION STABILITY,
COLORABILITY, CHEM. RESISTANCE
• AUTO, OFFICE EQUIPMENTS, TOYS,
LUGGAGE, BLENDING WITH OTHER
PLASTICS LIKE PVC, PC
 PVC
• SUSPENSION, MASS OR EMULSION PZN. OF
VCM, MNF. SHINETSU, EVC, SOLVAY, ELF,
GOODRICH
• RIGID, SEMIRIGID OR FLEXIBLE AS
PLASTICISED
• PIPES & FITTINGS, WINDOW PROFILE,
SCABLE SHEATH, SHOES, LEATHERCLOTH
 Comparison of Thermal Properties of Thermoplastics GCL

Heat Deflection Temperature (°C)

Continuous Use Temperature (°C)

300

250

200

150

100

50

0
PC POM PSU PET PEI PES PPS PEEK
 TENSILE STRENGTH AS A FUNCTION OF TEMPERATURE OF GCL
TM
GLASS FILLED GAFONE PES
140

"3410" "3420" "3430"

120
Tensile Strength (MPa)

100

80

60
ABS

PP
40

20
0 R.T. 40 80 120 160 200
Temperature (° C)
 GCL
LOI & SMOKE DENSITY OF
SPECIALTY, ENGINEERING PLASTICS
PLASTICS LOI % SMOKE
DENSITY, D max.
PTFE 90 55
PEI 47 30
PPS 44-53 -
LCP 37 - 46 -
PES 38 40
PC 35 150
PAEK 35 10
PSU 30 90
ABS 19 780
 GCL
Radiation Resistance of Polymers
1.E+09

1.E+08
Gamma Dose (Rads)

1.E+07

1.E+06

1.E+05

1.E+04

1.E+03

1.E+02

1.E+01

1.E+00

PEEK Polyimide PSU PC Acetal PTFE

 IMPACT STRENGTH
700

600
Notched Impact (J/m)

500

400

300

200

100

0
Polycarbonate GAFONE S-PSU GAFONE-PES GATONE-PEEK GAFONE P-PPSU
 COMPOUNDING
• HEAT STABILIZER, ANTIOXIDANTS
• SP. ADDITIVES, FLAME, UV, SLIP, ETC
• NATURAL OR MYRIAD COLORS
• SP. TREATED GLASS FIBRE - 10 - 60%
• CARBON FIBRE - 10 - 40%
• MINERAL FILLERS - 10 -60%
• SP. FILLERS - PTFE, GRAPHITE, MICA.
• COMBINATION OF ABOVE!
 Tensile Strength (T.S.) & Flexural Modulus (F.M.) of Glass
TM
& Carbon Fiber Filled GATONE PEEK
250

200

150
MPa

100

50

0
UNFILLED 20%GF 30% GF 10% CF 30%CF
T.S. 95 115 138 155 201
F.M.X100 40 70 100 123.5 192
 MECHANICAL PROPERTIES OF GATONE - 5700, 5730 & 5760

300

250

200

150

100

50

0
GATONE 5700 GATONE 5730GF GATONE 5760GF

TENSILE STRENGTH (Mpa) FLEXURAL STRENGTH (Mpa) IMPACT STRENGTH (J/m)

 SPECIALTY POLYETHER SULFONES
(UNDER DEVELOPMENT)

Tg: 325°C
330

310

Tg: 275°C
290

270

Tg: 235°C
250 Tg: 224°C
Tg°C

230

210

190

170

150
GAFONE™PES GAFONE™R-PES GAFONE™E-PES GAFONE™I-PES
 PMMA
• SUSPENSION AS BEADS OR MASS
PZN. AS SHEETS, MAJOR MNF. ICI,
ROHM, ASAHI, BASF, MITSUBISHI
• HIGH STRENGTH, TRANSPARENT, UV
RESISTANT, HIGH GLOSS, BRIGHT
COLORS
• AD BOARDS, AUTO LIGHTS, LENS,
BATHTUBS, GLAZZING, OPTICAL
CABLES, ADDITIVES
 POM
• SOLUTION HOMO /CO PZN OF HCHO &
EO, BLENDING WITH RUBBER. MAJOR
MNF. DUPONT, TICONA, BASF DAICEL
• HIGH TOUGHNESS, FRICTION/WEAR
& CHEMICAL RESISTANCE, PART
CRYSTALLINE
• PARTS OF EQUIPMENTS, GEARS,
SPOOLS, HOUSING, PUMPS, BEARING,
AUDIO/VIDEO PARTS
 NYLONS
• MASS PZN. OF CAPROLACTAM FOR NYLON 6
& ADIPIC ACID/HMDA FOR NYLON 66. MANY
COMBINATIONS AVAILABLE FROM DUPONT,
BASF, DSM, HULS, ELF, ALLIED, AKZO,
• CRYSTALLINE, HIGH STRENGTH, HIGH TEMP.
SOLVENT, WEAR & FRICTION RESISTANT,
MACHINABLE
• FIBERS & FILAMENTS, GEARS, SEALS
BEARINGS, AUTOPARTS, BRISTLES NETS,
FILMS, IMPELORS, BLOWMOLD CABLE
JACKATING, BLENDING
 PET/PBT
• MASS PZN. OF PTA OR DMT WITH MEG
AND PTA/DBA. MNF. DUPONT, ICI, BASF,
AKZO, EASTMEN, BAYER
• HIGH STRENGTH & STIFFNESS, HIGH
CHEM. & CREEEP RESISTANCE, GOOD
PROCESSIBILITY, GLASS FILLING, V.
GOOD IMPACT, TRANSPARENCY.
• TEXTILES, INSULATION & MAGNETIC
TAPES, PHOTO FILMS, BOTTLES,
PACKAGING, ELE. MOLDINGS, AUTO
COMPONENTS, GEARS, APPLIANCES
 PU
• CONDENSATION POLYMERISATION OF MGI/PDI
WITH POLYOL USING DIAMINE CHAIN EXTENSION.
• MAJOR PLAYERS
BASF, BAYER, GOODRICH, ICI
• VERSATILE IN RANGE OF HARDNESS, CHEMICAL
RESISTANCE, CAN BE FOAMED.
• FOAMS USED AS INSULATION, CUSHIONING FOR
CARPET, FURNITURE, AUTOMOBILES.
• ELASTOMERS: FOOTWEAR, MACHINERY
HOUSINGS.
 PC
• INTERFACIAL PZN. OF BISPHENOL A +
PHOSGENE OR MASS PZN OF DIPHENYL
CARBONATE WITH BIS A. MNF. GEP,
BAYER, DOW, TEIJIN
• MOST IMPACT RESISTANT, HIGH
STRENGTH, CRYSTAL CLEAR, GOOD
ELECTRICALS, WEATHERING, COLORABLE
• OPTICAL DATA STORAGE, WINDOWS,
TRAFIC LIGHTS, REFLECTORS, GREEN
HOUSES, AUTOBODY, HELMETS, GLASS
REPLACEMENT
 POLYSULFONES
• HIGH TEMP. SOLUTION PZN. OF DCDPS
WITH DIHYDROXY COMP. MNF. BY
SOLVAY, BASF, SUMITOMO
• V.HIGH STRENGTH, IMPACT,
TRANSPARENCY, FLAME, SOLVENT,
TEMP., RADIATION,HYDROLYSIS
RESISTANCE, AMBER, AMORPHOUS
• MEDICAL, MEMBRANE, COATINGS,
ELECTRONIC/ELECTRICAL, FOOD,
PLUMBING, INTERIORS
 PPS
• HIGH TEMP. PZN OF DCB WITH Na2S
IN NMP WITH CAT. MADE BY
PHILLIPS, TICONA, DAICEL
• HIGH STRENGTH & STIFFNESS, PART
CRYSTALLINE, HIGH FILLING, HIGH
RTI, V. HIGH SOLVENT, FLAME, HEAT
RESISTANT, ELECTRICAL PROPERTY
• AUTOPARTS, IMPELLORS, VALVES,
ELECTRICAL COMPONENTS,
COATING, MOLDED GOODS
 LCP
• MASS OR SLURRY PZN. AT V.HIGH
TEMP. GIVING LC POLYESTERS BY
DUPONT, TICONA, SOLVAY,
SUMITOMO,
• V.LOW VISCOSITY AT PROCESSING
TEMP. GIVING V.HIGH FLOW,
STRENGTH IN FLOW DIRECTION, HIGH
FILLER CONTENT
• ELE. CONNECTORS, MOLDED GOODS,
BLENDING, FILMS
 PEEK
• PZN. OF DFBP WITH HYDROQUINONE
AT 340C IN DPS BY VICTREX. PZN OF
PEEK ACID DERIVATIVE IN ACIDS AT
LOW TEMP. BY GCL.
• HIGHEST RTI, HIGH SOLVENT, FLAME
WEAR RESISTANCE, ELECTRICALS,
HIGH STREGTH, FILLED GRADES,
• FILAMENTS, STOCK SHAPE, GEARS,
VALVE SEATS, MOLDINGS FOR
ELECTRICAL/ELECTRONIC, FILMS,
 PTFE
• SUSPENSION PZN. OF TFE. ALSO
AVAILABLE AS COPO. MAJOR
PLAYERS DUPONT, AUSIMONT
• EXTREMELY INERT TO CHEMICALS,
HIGHLY CRYSTALLINE, MALEABLE,
NEEDS SP. PROCESSING, HIGH TEMP.
FLAME, FRICTION RESISTANT
• RODS, TAPES, VALVES, PIPE LININGS,
TUBES, CABLE INSULATION
 PROCESSING OF SP.
PLASTICS
• INJECTION, COMPRESSION MOLDING
• EXTRUSION STRANDS, SHEETS, FILM
• FOAMED & BLOWN
• POWDER COATING & BACKING
• FIBRE SPINNING & WEAVING
• PULTRUSION, SINTERING, ETC.
• FORMING, PRINTING, EL.PLATING,
METALISING, EMBOSSING, WELDING
 MAJOR APPLICATIONS
• PACKAGING - FOOD, GEN ITEMS
• ELECTRICALS & ELECTRONICS
• MEDICAL - IMPLANTS, STIRILIZABLE
• GEN. ENGINEERING - GEARS, SEALS
• CHEMICAL INDUSTRY - PIPES, TANKS
• TRANSPORT - AUTOMOBILES
• BUILDING CONSTRUCTION
 GCL

ELECTRICAL PARTS FROM GAFONE(TM) PES

 GCL

AUXILIARY SWITCH FROM GAFONETM PES

 GCL

BULB HOLDER FROM GAFONETMPPES 3420GF

 GCL

AUXILIARY SWITCH FROM GAFONETMPES 3420GF

 GCL

HEADLAMP REFLECTOR FROM GAFONETM -S PSU 1300

MILKING MACHINE PARTS FROM GAFONETM-S PSU
HALOGEN REFLECTOR FROM GAFONETM PSU
 GCL

DIALYSIS MEMBRANE FROM GAFONETM -S PSU

 GCL

INK CARTRIDGE FROM GAFONE(TM) -S PSU

INDUSTRIAL COMPONENTS FROM GATONE™ PEEK