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3.042 Materials Project Laboratory
Design Review
Team No-DripTania Chan
Michele Dufalla
Jacqueline Greene
3.042 Materials Project Laboratory
Design Review
Team No-DripTania Chan
Michele Dufalla
Jacqueline Greene
New Goal
http://www1.istockphoto.com/file_thumbview_approve/1168596/2/istockphoto_1168596_plastic_can_container.jpg, http://www.baproducts.com/spigot.jpg
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Plastic Joining• Fasteners• Hinges• Hot Die• Fusion and Hot Wire/Resistance Welding• Hot Gas Welding• Induction/Electromagnetic Welding• Press Fits/Shrink Fits• Snap Fits• Spin Welding• Staking/Cold Forming• Threads• Ultrasonic Welding• Vibration Welding• Lasers• Adhesives• Solvents
**List from Joining of Plastics by Jordan Rotheiser (2nd ed.)
Plastic Joining• Fasteners• Hinges• Hot Die• Fusion and Hot Wire/Resistance Welding• Hot Gas Welding• Induction/Electromagnetic Welding• Press Fits/Shrink Fits• Snap Fits• Spin Welding• Staking/Cold Forming• Threads• Ultrasonic Welding• Vibration Welding• Lasers• Adhesives• Solvents
**List from Joining of Plastics by Jordan Rotheiser (2nd ed.)
Hot Plate Welding(from Joining of Plastics by Jordan Rotheiser (2nd ed.)
HDPE vs. LDPE
• Max Temp = 120°C
• Melt Temp = 130°C
• Max Temp = 80°C
• Melt Temp = 120°C
http://www.dynalabcorp.com/technical_info_hd_polyethylene.asp
http://www.dynalabcorp.com/technical_info_ld_polyethylene.asp
Method
http://www.cooking.com/images/products/shprodde/743196.jpg, http://www.flagstaff.az.gov/images/pages/SC581/plastic%20bag.JPG
Extrusion
http://www.flagstaff.az.gov/images/pages/SC581/plastic%20bag.JPG
http://www.midi-classics.com/i/p19228.gif
Sample prep
• Plastic (HDPE, LDPE) was cut in 1x6 in strips
• Samples were welded together with a clothes iron, pressed together and allowed to cool at room temperature
• Last week tested initial control samples of varying thicknesses, as well as ability of LDPE to bond with HDPE.
INSTRON
90º Peel Test
Free-moving stage
1/8” HDPE
1/16” LDPE
3x1 in contact area
1 in wide
Shear Test1/8” HDPE
1/8” HDPE
4 layers of clear LDPE film (0.0006”) 3x1 in contact
area
Results of Peel Test
• 1/16 in LDPE was non-uniformly bonded to the 1/8 HDPE (due to greater thickness, more difficult to melt with iron)
• Maximum Load: 0.020 kN
• Could not test LDPE film:1/8 HDPE because strength of adhesion > than the tensile strength of LDPE which is 1700psi (22kN, http://www.mcmaster.com/)
Results of Shear Test
• The bond between the LDPE film and the 1/8 HDPE was greater than the tensile strength of the 1/8 HDPE! (4400psi / 30 MPa/ 58 kN, www.mcmaster.com). We could tell because the HDPE started necking rather than breaking the adhesive bond
• Max load = 2.070 kN, Stress at Peak 55 MPa
Shear Force 1/8 HDPE: LDPE film
necking
• Continue 90o Peel Test and Shear Test
Immediate Next Steps…
1/8” HDPE Substrate
-White LDPE Film
-Black LDPE Film
-1/16” LDPE Sheet
-1/16” HDPE Sheet
1/16” HDPE Substrate
-White LDPE Film
-Black LDPE Film
-1/16” LDPE Sheet
-1/16” HDPE Sheet
1/8” LDPE Substrate
-White LDPE Film
-Black LDPE Film
-1/16” LDPE Sheet
3 Sets of Control Samples:
Control Samples are Pure Polyethylene-no contaminations, impurities
-effects of thickness, colors, processing temperature and material density on polyethylene adhesion
Goals of the Materials Testing
Materials Testing Using Post-Consumer Polyethylene-ink, dye, processing agents
-nonuniform density
Ultimate Goal-Establish a range of temperature, pressure, time and
processing condition optimal for polyethylene welding
Materials Considerations:– Tube to be made from
recycled polyethylene– Sealing between the
flange and the containers surface
Design of the Tap
Basic Pop Rivet Design to Attach Pinch Tube at the Lid of Jerrycans
Design Considerations:– Simple design, reduce
production and materials costs
Continue with the idea of post-consumer polyethylene recycling
– Melt plastic bags and extrude melt into tubes
– Questions to be answered:• Is the process plausible?• How durable is the resultant products?• Can the procedure be done in the field?
Tube Production
• Plastic Welding Will Be Used to Attach Tap onto Jerrycans Lids
• Using the welding parameters (temperature, time and processing conditions) to attach tube to containers
• Challenges:– Tricky interface between tube and containers, how to apply
plastic welding?– Is plastic welding a water proof seal?– Can plastic welding withstand the chlorination in the water?
Tap Production and Plastic Welding
Revised Gantt Chart
2/6/07 2/16/07 2/26/07 3/8/07 3/18/07 3/28/07 4/7/07 4/17/07 4/27/07 5/7/07 5/17/07
Background Research
Recycling
Processing Cost
Material Cost
Target User
Materials Economic Analysis
Polyethylene Properties Research
Polyethylene Recycling Research
Plastic Welding Testings
90 Degree Peel Tests
Shear Tests
Production of Prototype #1
Extrusion of Plastic Tubes from Recycled Polyethylene
Design of Prototype #1 on SolidWorks
Designing Interface between Tab and Containers
Testing Plastic Welding Adhesion between Tab and Container
Production of Final Product
Increase Efficiency and Decrease Cost of Production
Troubleshoot Defects in Final Product
Preparation for Final Presentation
Completed Remaining