THE WORLD OF PLASTICS

The synthetic or man-made

polymers, play a major industrial
role in our society today.
The polymer industry produces
more than 10,000 different
polymeric
products for numerous diverse uses.
Many of these products are referred
to as plastics
 Plastics have been used to replace natural
materials in existing products.
Their low cost and superior performance
as compared to wood, metals, and fabrics
have allowed industry to cut
manufacturing expenses, improve product
performance, and reduce cost to the
consumer.
Chemists are now learning to design
products with specific chemical and
physical properties for use in all new
applications.
 Since students are surrounded by
plastic products, they should have
general understanding of how these
products are processed in industry
to make the objects they are
familiar
 The objective of this module is to aid
students in developing an understanding
of the relationship between science and
technology as well as view science as a
human endeavor.
The simulation of the plastic
manufacturing processes of extrusion,
injection molding and blow molding will
provide the framework to reach these
objectives
Plastics Processing:

The plastics industry is composed of three

divisions.
One is the manufacture of resins or the pellets
made from starting materials such as crude oil.
For example polyethylene resins are made from
"cracking" or breaking the bonds of petroleum
molecules to make ethylene gas,C2H2.
Under high pressure and temperature, ethylene
molecules are joined together in a chain or
"polymerized" to form polyethylene.
 High density polyethylene (HDPE)
contains lots of straight chain molecules
that are thousands of units long.
Low density polyethylene (LDPE) contains
side branches of atoms to the parent
chain.
Both HDPE and LDPE are long-chained
molecules composed of carbon and
hydrogen atoms.
 A polymer of polyethylene where
each carbon atom bonded to two
hydrogen atoms are then bonded
carbon to carbon to form the
polymer.
 However, creating a polymer is just
the first step in making a useful
product. The second division in the
polymer industry involves the
manufacture of a compound with
either plastic or elastomeric
mixtures.
 (Elastomers are rubber and rubber-like products.)
Here the plastic resins or elastomers produced by
the first division are mixed with other ingredients
such as pigments, fillers, plasticizers, and other
chemicals.
The creation of various forms of the mixed
compounds allows ease of handling and these
include powders, flakes, granules, liquids or in the
case of elastomers, slabs or strips for processing
by the third division. The processing plant then
produces the plastic or elastomer objects for the
consumer.
 In the case of the plastic compound,
it can be either thermoset or
thermoplastic. If it is a thermoset
type of material, crosslinking takes
place while curing and it can not be
reshaped.
However, thermoplastic materials
can be shaped and reshaped
(Recycled).
 Three of the most common plastics processing
methods involved in the shaping or molding of
plastics are extrusion, injection molding, and blow
molding.
They all involve melting the molding compounds
by heat and pressure and forcing the melted or
softened plastic into a mold or through an
opening to shape the object.
In the case of the thermoplastic material, the
object must be cooled to stop the flow of plastic
and to allow the object to harden.
Extrusion:

Extrusion (Similar to a meat grinder) is a process that

involves forcing a melted plastic through a "die" or
nozzle. Dry plastic powder or granules are subjected to
heat and pressure as they go through an extruder.
As the plastic melts into a thick viscous material, it is
forced through a die or hole in the shape of the
finished product.
The extruded material then lands on a moving
conveyer belt which carries the plastic into a stream of
cool water or air.
This allows the manufacturer to continually produce a
product with a desired shape. Extruded pieces can then
be cut to specific lengths
 Examples of extruded products are; auto
trim, vinyl windows frames, house siding,
pipes, tubing, fibers, films (bags,
coverings and laminates), and coatings.
More examples can be identified if the
viewer looks for long, continuous pieces
with a consistent cross-sectional shape
(not tapered).
These pieces are typically cut to specific
lengths so they may also show a sharp
cut edge.
Extrusion Process
Extruded Parts
Injection Molding:
Injection molding is the most important
commercial method for transforming
thermoplastics into useful products.
A thermoplastic polymer is one that can
be reheated and reshaped many times.
Themoset plastics set in a desired shape
and cannot be reheated and remolded.
 During the injection molding process, plastics are
heated until they soften into a molten state. The
melted plastic is then forced at high pressure
through a nozzle into a cold mold.
The plastic cools in the mold and takes on the
molds shape. Once the plastic is cooled, the mold
opens and the product is released from the mold.
The resulting product often needs no further work
before being put into use since details such as
ribs and screw threads can be formed during this
process
 Examples of injection molded items are;
cabinets for computers, computer
screens, and computer keyboards
parts of plastic model or hobby kits,
plastic bottle caps, brake and engine
parts, reflectors and headlights,
circuit breakers, toaster oven panels,
power tool and lighting housings, and
even tableware.
Injection Molding Process
Injection Molded Toys
Blow Molding

Blow molding technology has been

adapted from the glass industry for
molding of hollow containers from
thermoplastic materials.
The most widely known blow molded
objects are bottles, jars, cans, and
containers of all types for the food,
beverage, cosmetic, medical,
pharmaceutical, and home products
industries
 Among other blow molded objects
are balls, toys, automobile fuel
tanks, and car bumpers. These
objects are hollow and thin walled.
Blow Molding
Examples of Blow Molded Toys