ENGINEERING PLASTICS & APPLICATIONS ALOK KUMAR CENTRAL INSTITUTE OF PLASTICS ENGINEERING

1. ENGINEERING PLASTICS&APPLICATIONS ALOK KUMAR CENTRAL INSTITUTE OF PLASTICS ENGINEERING & TECHNOLOGY,

2. USAGE OF PLASTICS IN MODERN CARS Dismantling of >40 modern European cars reveled that in 130 Kg plastics per car– 43% PP, 14% PU, 8%Nylons, 8%PE

3. GLOBAL PLASTICS USAGE 79 % Plastics consumed – PE+PP+PVC+Styrene's

4. THERMOPLASTICS IN SE ASIA

5. PLASTICS END USE PATTERN

6. PLASTICS-THE MATERIAL OF CHOICE • User Friendly • Versatility • Light-weight • Energy Efficient • Non-corrosive • Aesthetic • Abundant • Recyclable

7. PLASTICS – Emerging Material to meet Engineering Application Demands • Density • MFI (Melt flow Index) • Mechanical Properties • Impact Strength • Stiffness • Toughness • Creep Resistance • Abrasion Resistance • Tear Resistance • Optical Properties • Gloss Clarity & Opacity

8. PLASTICS – Emerging Material to meet Engineering Application Demands • Environmental Stress Cracking Resistance • Chemical Resistance • Acid Resistance • Alkali Resistance • Hazardous Chem. Resistance ( Pesticide / Insecticide) • Barrier Properties • Water Vapour Transmission Rate • Oxygen Transmission Rate • Aroma Transmission Rate

9. PLASTICS – Emerging Material to meet Engineering Application Demands • Easy Processibility • Printability • Sealing Property • Seal Strength • Cost Effectiveness • Product Design Flexibility

10. CALASSIFICATION OF PLASTICS

11. DEFINATION COMMODITY THERMOPLASTICS Very High Volume, Low cost,Low strength, Low Heat Distortion Temp. ENGINEERING PLASTICS High strength, High HDT, Low Volume, High Cost SPECIALITY THERMOPLASTICS Very Low Volume, Very High Cost, Excels in Specific Performance Requirements.

12. MAJOR COMMODITY PLASTICS • LOW DENSITY POLYETHYLENE (LDPE) • LINEAR LOW DENSITY POLYETHYLENE (LLDPE) • HIGH DENSITY POLYETHYLENE (HDPE) • POLY PROPYLENE (PP) • POLY VINYL CHOLORIDE (PVC) • POLY STYRENE (PS)

13. MAJOR ENGINEERING THERMOPLASTICS • ACRYLO NITRILE BUTADIENE STYRENE (ABS) • STYRENE ACRYLONITRILE (SAN) • POLYMETHYL METHACRYLATE (PMMA) • POLYAMIDE - (PA) • POLYETHYLENE TEREPHTHALATE- (PET) • POLYBUTYLENE TEREPHTHALATE- (PBT) • POLYOXYMETHYLENE - (POM) • POLY CARBONATE - (PC) • HIGH IMPACT POLYSTYRENE (HIPS)

14. MAJOR SPECIALITY PLASTICS • POLYTETRA FLUOROETHYLENE (PTFE) • THEROPLASTIC POLYURETHANE (TPU) • POLY SULPHONE (PSO) • POLY ETHER SULPHONE (PES) • POLYPHENYLENE SULPHIDE (PPS) • POLYPHENYLENE ETHER (PPE) • POLY ETHER ETHER KETONE (PEEK) • POLY ACRYLATE • POLY AMIDE – IMIDE (PAI) • POLY ETHER – IMIDE (PEI) • LIQUID CRYSTAL POLYMERS (LCP)

15. MAJOR THERMOSET PLASTICS • PHENOL FORMALDEHYDE (PF) • UREA & MELAMINE FORAMLDEHYDE • EPOXY RESINS • UNSATURATED POLYESTER RESIN • POLYURETHANES • SILICONES

16. Thermal Properties of Thermoplastics

17. CRITERIA FOR PERFORMANCE TPU PA 6/6 HI PBT TPE PPO PCA – PC/ABS PC PA 11 PA 6/12 POM PA 6 PA 6/10 PA 6/6 PA 12 High Performance PEI PSU PES PEEK PPS LCP Engineering Temperature Commodity ABS SAN PS HDPE PP Mechanical Property retention

18. TOP SEVEN ENGINEERING PLASTICS

19. MAJOR ENGINEERING PLASTICS STRENGTHS AMORPHOUS (PC, PPO, ABS) • Constant mechanical properties versus temperature • Dimensional stability • Creep Resistance • Low Shrinkage • Transparency possible CRYSTALLINE (PP, POM, PBT/PET) • Resistance to hydrocarbons • Good flow behaviour • Wear and Fatigue resistance

20. POLYAMIDES • Several types are available based on raw material used • Most widely used polyamides are Nylon 6 & 66 • Condensation reaction of dicarboxylic acids and diamins (Commercially through the route of intermediate salts) ---- Nylon 6,& 66 • Ring opening reaction of lactam – Nylon 6, Nylon 12 etc. • Condensation reaction of amino acids – Nylon 7, Nylon 11 etc.

21. POLYAMIDES Characteristics of Polyamides • Semi-crystalline material • Polar in nature • Resistant to hydrocarbon solvents, grease, lubricants • Hygroscopic • High to medium rigidity – improved by glass fibre filling • Good electrical insulation – adversely affected by moisture absorption. • Good abrasion resistance and low coefficient of friction • Flame retardant versions are difficult process. • Dimensions affected by humidity. • Not good temp. resistance under load – improved by glass fibre filling.

22. POLYAMIDES APPLICATIONS OF POLYAMIDE • Gear, Cams, bushes, Bearings • Valve Seats • Terminal Blocks • Connectors • Automotive Exterior • Under bonnet Automotive Parts • Motor Housing • Optical fibre Sheathing (Nylon 12) • Insulating liners (Railways • Hair combs

23. PAIn AIR CRAFT Application: Aircraft Engine Components Material: - PA46-GF30 • Airbus • Injection moulding • Highly complex shape minimize the noise level • Design freedom at low costs • High impact properties in a wide temperature range • wall sections as thin as possible- thus reducing valuable weight.

24. PA in Agricultural film Application: Agricultural Barrier Film Material: PA6-unfilled Extrusion Processing Technology • Barrier Film for agricultural use with environmental benefits. • When used to cover the soil together with the injection of fumigation chemicals, lower levels of the fumigant can be used. As the film keeps the active agent in the soil for longer.

25. PA in Automotive, Air/fuel management Application: Air duct Material:- PA6-GF20 Air-duct design offers the best combination of the demanding requirements for: high temperature air ducts. · higher cold impact than other similar materials · higher stiffness at high temperatures (150°C) allowing thinner walls to be designed. · high melt strength and a low melt viscosity for optimum Production Blow Molding Processing Technology

26. PA in AUTOMOTIVE, AIR/FUEL MANAGEMENT Application: Air inlet manifold Material: PA6-GF30 Injection Molding Ford UK

27. PA6: The material of choice for air inlet manifolds • ‘Fuel economy’ & ‘weight reduction’ • Single molding and replacing aluminium and steel by plastics • Provides the chemical, temperature and vibration resistance required to survive the expected life of vehicles. • lower system costs compared to metals through part and function integration, • Easier assembly and longer tool life. • Temperature resistance and a higher burst pressure resistance after welding. • Providing safer solutions or more design freedom, as well as lower system costs as a result of an easier • Processibility and better surface appearance.

28. POLY CARBONATE POLYCARBONATE • Poly carbonate was first developed in the laboratory of GE in 1953. • It was first commercialised in 1958 by GE under the Trade name of LEXAN • Polycarbonate Lexan is an ester of carbonic acid. • LEXAN is commercially produced by polycondesation of Bisphenol A and Phosgene

29. POLY CARBONATE CHARACTERISTICS : • Highest impact strength • High rigidity • High dimensional stability • High heat distortion temp • Usability in the temperature range of -50 deg. To 135 deg. • Flame retardancy and low combustibility • High optical clarity • Good electrical insulation properties • Good strain resistance • Low water absorption • Food grades available. • Good low temp. impact strength

30. POLY CARBONATE APPLICATIONS: • AUTOMOTIVE HEADLAMPS, REFLECTORS AND LENSES • INDICATORS AND BLINKERS • DASH BOARD COMPONENTS • CRASH HELMETS • TELECOM CONNECTORS • DOMESTIC ELECTRICAL SWITCHES • TRAFFIC SIGNAL LENSES • SIGNAL HOUSINGS • TELEGRAPHIC POLE INSULATOR • TERMINAL BLOCKS • LIGHT DIFFUSER • STREET LAMP CANOPIES • BUSINESS MACHINE COMPONENTS

31. POLY CARBONATE APPLICATIONS • BABY FEEDING BOTTLES, MIXIE JARS • BLOOD OXYGENATORS • I.V. CANNUELA • FACTORY ROOFINGS • RAILWAYS PLATFORMS FOOFINGS/BUS STOPS • SAFETY GLAZINGS • TELEPHONE BOOTHS • OFFICE AND FACTORY PARTITIONS • COMPACT DISKS AND OPTICAL DATA STORAGE DISKS • RETURNABLE WATER AND MILK BOTTLES.

32. PC inAUTOMOTIVE, AUTO LIGHTING Application: Head lamp bezel Material: PC-unfilled Injection molding. Audi Headlamp bezels require Excellent surface finish & aesthetics Good heat resistance and be warpage free Metallic effect and an exceptional appearance.

33. PC in Electrical /Electronics, Telecommunication Application: Mobile phone travel charger Material: - PC-unfilled Injection Molding Philips A charger for a mobile phone require : - Very high aesthetic - Withstand severe drop tests - Resistant to all kind of chemical substances,like hand lotions & soaps. - Flame retardant and has to pass the pressure test at 125 ºC.

34. PC in ELECTRICAL LIGHTING Application: Lamp holder fluorescent lamp, Material:- PC Injection molding. Fluorescent lamp holders require: Tough materials with good flow to be able to mold the components easily- PC being easy flowing and with excellent mold release.

35. PC in Electrical / Electronics : Application: ATM - PC-unfilled This processing technique makes it possible to attain a cost-saving of up to 300%, when for instance changing from cast aluminium to plastic mouldings for cash dispensers (ATM’s). This molding is by made the ‘low pressure foam process’ to produce a 7,5 kg moulded automated telling machine fascia. Although the main driving force is cost reduction, issues like weight reduction, torsional stiffness, vandal resistance, paint ability to class A surface finish, dimensional stability

36. THERMOPLASTIC POLY ESTER(PET & PBT) • Crystalline in nature • Based mainly on polybutylene terephthalate. A few grades based on polyethylene and polycyclohexane dimethanol terephalate are also available • The base resins are commercially manufactured by Esterification reaction of Terephthalic Acid and appropriate diols.

37. THERMO PLASTIC POLYESTER (PET & PBT) CHARACTERISTICS • High Mechanical Strength • Excellent chemical resistance • High temperature resistance in glass filled grades • High dimensional stability • Excellent Electrical tracking resistance • Can be made flame retardant • Effect of humidity minimal • Excellent flow

38. THERMOPLASTIC POLYESTER(PET & PBT) APPLICATIONS: • Connectors • TV Components • Industrial Switches/plug’s • Business machine components • Keyboard buttons • Steam irons • Cookers • Air vents • Plumbing • Auto ignition systems • Under bonnet connectors • Head lamp reflectors

39. PBT IN AUTOMOTIVE Application: Actuator, Gear housing window Lift Material: PBT-GF20 *Dimensional stability for reliable performance in all conditions *Automotive window lift mechanisms demand shock resistance over a wide temperature range,-40°C to +80°C, *Excellent dimensional stability and strength up to the maximum environmental temperature. *Reducing total assembly costs and weight. Processing Technology: Injection Molding Opel, Volvo

40. PBT IN AUTOMOTIVE Application: Air flow mass meter housing and sensor Material: PBT-GF30 • Stability and Narrow tolerances for parts close to the engine • This air-flow mass meter measures air flow speed for the motor management control system. • It has to maintain tight tolerances over the life of the vehicle and withstand the temperatures encountered close to the engine. • Exceptional dimensional stability and • strength over a wide temperature range. • The best balance of mechanical properties and good welding performance,facilitating manufacturing productivity. Processing Technology: Injection Molding Opel

41. PBT IN AUTOMOTIVE Application: Sensor, throttle position Material: PBT-GF30 Application: E-Box, Fusebox Material: PBT-GF10

42. PBT IN : Electrical / Electronics, Power distribution & circuit protect Application: Compact NS Schneider Material: PBT-GF30 Application: Bobbins Schneider Material: PBT-GF30 Processing Technology: Injection Molding. Schneider

43. PET IN AUTOMOTIVE, BREAKE /CLUTCH Application: Breake Booster Valve bodies Material: PET-GF35 • Glass fiber reinforced polyethylene terephthalate (PET) is the material of choice for automotive brake booster valve body applications. • It provides weight, performance and cost advantages over previously used thermosets. Processing Technology : Injection Molding ADI BMW

44. PET IN AUTOMOTIVE, BREAKE /CLUTCH Application: Tandem brake booster Material: PET-GF35 • Glass fiber reinforced polyethylene Terephthalate (PET) is the material of choice for automotive brake booster valve body applications. • It provides weight, performance, and cost advantages over previously used Thermosets. Processing Technology : Injection Molding Various

45. POLYACETAL (POM) • Polymer of formaldehyde, commonly known as Polyacetal, Acetal polymer or Polyoxymethylene was first commercialised by Du pont in 1959. • Copolymers were introduced by celanese corporation 1960 to overcome thermal stability problem at processing temp. • Polyacetal is commercially made by polymerisation of high purity formaldehyde in rapidly stirred inert medium like dry heptane with controlled traces of water added containing phosphine and amine initiators.

46. POLYACETAL (POM) CHARACTERISTICS OF POLYACETAL (POM) • High crystalline • High flammable • Resilient and good combination of stiffness and toughness • Creep resistant- superior to polyamide • Low static and dynamic co-efficient at friction • Very high degree of precision moulding possible • Not high temp. resistant • Resistant to organic solvents upto 70 degree.

47. POLYACETAL (POM) APPLICATIONS OF POLYACETAL (POM) • Gears • Conveyor belt links • Sprockets and chains • Blower wheels • Cams • Fan blades • Carburettor float and bodies • Aerosol containers • Lighter bodies • LPG Cylinder caps • Shower heads