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Introduction to Polymer Processing
CBE 4009 Polymer Processing – Introduction to Polymer Processing
the operations carried out on polymeric materials or systems to increase their utility
Chemical operationPhysical operation
Machine and Equipment DesignPlant Design and OperationsProduct Development: the physical and chemical evaluation
of materials
CBE 4009 Polymer Processing – Introduction to Polymer Processing
Polymer Processing
Shaping(Froming) Extrusion(압출성형), Coextrusion(공압출성형), Calendering, Blown film, Fiber Spinning, Injection Molding(사출성형), Compression Molding(압축성형),Blow molding(중공성형), Thermoforming(열성형),Resin transfer molding(수지이동성형), Pultrusion, Casting,
BondingHeat sealing, Laminating, Coating
ModificationMixing and Compounding, Surface activation, Polymer modification(crystallization and orientation)
Post ShapingStructuring, Decorating, Fastening, Sealing, Welding, Dyeing, Electroplating, Vaccum metallizing, Printing, Painting, etc.
CBE 4009 Polymer Processing – Introduction to Polymer Processing
Classification of Polymer Processing
성형공정에따른플라스틱의소모비율
Polymer and Additives
FeedPreparation
Feeding
Conveying Melting PumpingMixing
FormingCoolingand Post-FormingOperations
Heat
Mec
hani
cal E
nerg
y
Pro
duct
T tP tG tX t
( )( )( )( )
Extruder Mold or Die
Product• Film• Sheet• Moldings• Bottles• Fibers• Coated Wire• Pipe
Fig. . Schematic of Generalized Extrusion Process
CBE 4009 Polymer Processing – Introduction to Polymer Processing
Fig. Sectional view of a single screw plastic extruder and various types of screw
CBE 4009 Polymer Processing – Introduction to Polymer Processing
Fig. Schematic view of an inverted L calender plant for the production of plastics sheeting
extruder
CBE 4009 Polymer Processing – Introduction to Polymer Processing
Fig. Schematic view of a film blowing operation
extruder
CBE 4009 Polymer Processing – Introduction to Polymer Processing
CBE 4009 Polymer Processing – Introduction to Polymer Processing
Coextrusion film
Stage 1. InjectionMold partially filled
Feed hopper
Barrel
Heater band
Screwadvances
Stage 2. Holding Pressure and Plastication
Screw rotatesat the end ofholding
Stage 3. Ejection
Mold opens and part is ejected
Nozzle breaks off
Mold filled and part is cooled
Fig. Schematic representation of injection molding process.
CBE 4009 Polymer Processing – Introduction to Polymer Processing
CBE 4009 Polymer Processing – Introduction to Polymer Processing
Extrusion Blow molding
CBE 4009 Polymer Processing – Introduction to Polymer Processing
Stretch Blow Molding
Initial Step.Thickness Distribution
PET stretch blow molding simulation
CBE 4009 Polymer Processing – Introduction to Polymer Processing
The pressure P1(18bar) is applied to the inside of preform.
Thickness Distribution
CBE 4009 Polymer Processing – Introduction to Polymer Processing
The plug startsto push the preform.
(V=92.5cm/s)
Thickness Distribution
CBE 4009 Polymer Processing – Introduction to Polymer Processing
Thickness Distribution
CBE 4009 Polymer Processing – Introduction to Polymer Processing
P2(32bar) is applied
Thickness Distribution
CBE 4009 Polymer Processing – Introduction to Polymer Processing
Thickness Distribution
CBE 4009 Polymer Processing – Introduction to Polymer Processing
Thickness Distribution
CBE 4009 Polymer Processing – Introduction to Polymer Processing
Thickness Distribution
CBE 4009 Polymer Processing – Introduction to Polymer Processing
Thickness Distribution
CBE 4009 Polymer Processing – Introduction to Polymer Processing
The plug reached bottle base
Thickness Distribution
CBE 4009 Polymer Processing – Introduction to Polymer Processing
Thickness Distribution
CBE 4009 Polymer Processing – Introduction to Polymer Processing
Thickness Distribution
CBE 4009 Polymer Processing – Introduction to Polymer Processing
Thickness Distribution
CBE 4009 Polymer Processing – Introduction to Polymer Processing
Thickness Distribution
CBE 4009 Polymer Processing – Introduction to Polymer Processing
Thickness Distribution
CBE 4009 Polymer Processing – Introduction to Polymer Processing
Thickness Distribution
CBE 4009 Polymer Processing – Introduction to Polymer Processing
Thickness Distribution
CBE 4009 Polymer Processing – Introduction to Polymer Processing
Thickness Distribution
CBE 4009 Polymer Processing – Introduction to Polymer Processing
Thickness Distribution
CBE 4009 Polymer Processing – Introduction to Polymer Processing
Thickness Distribution
CBE 4009 Polymer Processing – Introduction to Polymer Processing
Thickness Distribution
CBE 4009 Polymer Processing – Introduction to Polymer Processing
Fig. Twin sheet thermoforming process
CBE 4009 Polymer Processing – Introduction to Polymer Processing
(b)
(a)
Preform placement Resin injection and cure Part removal
A B
Ratiocontrol
Mixer
Monomer B
Monomer A
Poly
mer
izin
g m
ixtu
re
Mold
RRIM(milled fiber)
SRIM(fiber mat)
Fig. 1. Schematics of liquid composite molding (LCM) process. (a) resin transfer molding (RTM) (b) structural reaction injection molding (SRIM)
CBE 4009 Polymer Processing – Introduction to Polymer Processing
Fig. Schematic diagram of pultrusion process
CBE 4009 Polymer Processing – Introduction to Polymer Processing
Fig. Schematic of a forward roll coating and magnified view of the nip region (a) a flooded inlet (b) a starved inlet
CBE 4009 Polymer Processing – Introduction to Polymer Processing
Intrinsic material
properties
Processingproperties
Articleproperties
Material Processing Article
+ =
Machinery inprocess industry
Objectivestandard
Subjectivestandard
Interrelationship between Processing and Property
CBE 4009 Polymer Processing – Introduction to Polymer Processing
Process-Structure-Property Relationships
Processing
Thermal history Stress/Strain history
Chemical modification
Structure
CrystallinityCrystal size and structure
OrientationResidual stress/strain
Property
MechanicalOptical
ChemicalSolid state
CBE 4009 Polymer Processing – Introduction to Polymer Processing
ELE
ME
NTA
RY
STE
PS
Structuring of Polymers in Processing
Mixing
Handling ofParticulate Solids
Pressurization& Pumping
Devolatilizationand Stripping
Melting
Mold Coating
Calendering & Coating
Secondary Shaping
Molding & Casting
Die Forming
TransportPheonomena
Mixing Principles
SolidMechanics
Polymerchemistry
PolymerPhysics
PolymerRheology
Engineering Principles Polymer Science
SH
AP
ING
ME
THO
DS
PO
ST
SH
AP
ING
A STRUCTURAL BREAKDOWN OF POLYMER PROCESSINGRaw
MaterialFinishedProduct
CBE 4009 Polymer Processing – Introduction to Polymer Processing
The Historical Evolution of Polymer Processing
Time Frame
1850-1950 1950-2000 Transition (present) Future
Rubber and Plastic Technology
Classical Polymer Processing
Polymer Processingfor Structuring
Macromolecular Engineering
FocusProduct machine invention
Process and machine design
Product design(micro-structuring)
New products and structuring
“Pushing the Limits”
Discipline Inventive praxis
Transport phenomenaGNF rheologyComputational fluid
mechanics
Transport phenomenaFull rheologyMelt/solid physicsInterfacial phenomenaPolymer chemistryIn-line characterizationThermodynamics
Macromolecular physics, chemistry, rheology
Multiscale transport and computation
Molecular scale probe
BenefitsNew class of materialsNew industry
Ability to process very diverse polymers
Customized structure/properties
Value-added materials
New generation of globally applicable polymer
Truly advanced polymer
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