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Polypropylene.
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REINHOLD PLASTICS
APPLICATIONS SERIES
^POLYPROPYLENE
by
THEODORE
O. J.^^KRESSER
Spencer Chemical
Gompany
Orange, Texas
NEW YORK
CHAPMAN &
HALL, LTD.,
LONDON
Copyright
1960 by
Number 60-53435
Reinhold Plastics
Applications Series
"Polypropylene"
or six
more
is
first
planned.
are in prospect.
The
series,
book
to
in plastics.
to be covered.
are
now
in preparation.
The process books will include volumes on Premix Molding, Blow Molding, Plastics in Tooling, and on Modern
Methods of Plastics Extrusion.
Production curves in the plastics
an
astonishing rate,
that this
volume
in
field
continue to rise at
sented.
Herbert R. Simonds
Editor
TITLES PUBLISHED
Horn
Amino
Epoxy
Plastics,
D.
J.
Thompson
Duffin
Don E. Floyd
Lawrence
Polyethylene, Theodore O.
J.
Kresser
Polyurethanes, Bernard
A Dombrow
.
Vinyl Resins, W.
Mayo Smith
M. Lewis
PREFACE
In this day
some
if
when
suspicion,
new
scientific
miracle really
is all
rightly
wonder, sometimes,
it is
a great pleasure
when it
come into volume production is a difficult
job. The technical journals each month bring
just starting to
but challenging
is
almost
irresistible.
As time
Company
This book could not have been written without their assistance.
The chapter on
is
make necessary
to read
it
corrections.
many
from these publications is grateacknowledged. The Montecatini Company was also very
Preface
viii
is
certainly
lems that have been solved with other materials, and they
will not long delay the
The only
fulfill
development of
this one.
present expectations
materials,
made by
propylene,
may be
similar
is
may
fail to
methods from
olefins other
than
will
At
is
equally applicable
is
no reason
to
much
it
will
in this
book
Preface
ix
collected
in the business.
neering,
Modern Packaging,
and many
Institute (Britain)
Particular thanks are due to the Spencer Chemical Company for permission to undertake this work, and especially to
S. P. Horkowitz, manager of the Spencer Technical Laboratory at Orange, Texas, and Dr. G. Ham, Technical Director
Theodore Kresser
Orange, Texas
November, 1960
CONTENTS
Preface
vii
1.
Introduction
2.
Properties of Polypropylene
3.
Chemistry of Polypropylene
65
4.
Production of Polypropylene
94
5.
Processing of Polypropylene
107
6.
Packaging Applications
163
7.
Durable-Goods Industries
192
8.
221
9.
Future Developments
246
Index
265
INTRODUCTION
1,
Polypropylene
is
volume of
its
first
this series.
Some understanding
is
come
the
plastic,
and continues
grow
to
at
has
to
made tremendous
its initial
come up
Polypropylene
is
is
used.
The
Ziegler catalysts,
we
first
catalysts to
are discussing,
and the
catalysts
propylene manufacture
is
The
of polyethylene into
etc.,
fields
Polypropylene
done much
to erase the
many
components of
as
now
seriously considered
and house-
hold goods.
Linear polyethylene manufacturers did a tremendous job
of
great
demand
stiffness,
and
all
their material.
This created a
and
and water transmission,
many
properties to reach
Polypropylene
the interest built
some
is,
up
cases, restrict
sufficient
its
useful-
improvement
in
large markets.
many
of
Polypropylene, however,
group of
When
is
sterically regulated
polymers.
polypropylene to the
scientific
world in 1954
announcement of a new
all
plastic material.
it
was greeted
proportion to the
Even though
it
was
furor stirred
Introduction
cell.
patent literature
effect of this
all
of stereospecific polymerization.
The
tremendous growth of
scientific effort.
resulted not in
rubbers.
The use
this
work
known for a
and there has been much speculation as to
the means whereby the living cell was able to direct the
growth of the rubber molecule into this regular pattern.
has a very regular structure. This fact had been
great
many
years,
Professor Natta's
sterically
ordered
Thousands of researchers all over the world immediately saw that this might be the clue to the long-sought
synthetic rubber that would really duphcate natural rubber.
Without going into detail at this point, subsequent research
proved this to be true. Several pilot plants have made quantities of new types of synthetic rubbers that come up to all
expectations, and large-scale capacity has begun to come on
dienes.
known
now
several
new ones
that can
be produced synthetically.
Like
all
became necessary
previously
field.
It
known
to
compare
art,
each
this
it
immediately
specialist
working
own
monomer
in his
Polypropylene
that
was known
to
polymers
say that
will
it
will
it is
safe to
by a
textile fibers.
textile fiber
use of rather
monomers
containing such
make
fibers that
is
were
as strong as the
fiber-forming materials
now on
fiber,
but in
field;
than natural
feel very
has spun
it
silk,
much
like wool.
By
dyed in bright
near
Rome
Introduction
In
this
polypropylene
will
fiber; definite
be discussed in Chapter
9.
made
and
The entrance
polypropylene
distant.
of
field in
1959, through
its
into the
subsidiary AviSun,
the
Its
field.
is
new
material. In
1958 the
is
this country, in
stronger and
mendous rush
to obtain licenses to
make
the material.
tre-
By
1958, installed capacity for producing high-density polyethylene exceeded 350 million pounds per year. In that year
sales
it is
been made
now
as to its
Polypropylene
matter of fact
it
now appears that the major use of low-presmay be as a blending agent to upgrade the
sure polyethylene
The
began
was the
first
is
commercial producer;
1957.
number
of
Montecatini
resin.
of the
AviSun Corporation
in
having resin on the market a year after they started in business was
made
Both of
American Viscose and the Sun Oil
Introduction
Koppers
this plant
Company on
4-year contract.
it
At about
the
announced that
Bay
City facility
is
now
available.
in
it
an-
Longview, Texas.
Polypropylene
It
it
is
completed.
will build a
polypropylene
The
Industrial
in operation in
Since
it
is
it
not as
much concerned
and
may have
entered the
field
2.
PROPERTIES
OF POLYPROPYLENE
market,
its
plications
by considering
its
properties.
of
its
large
major ap-
number
of
many
various apphcations.
informative.
We
some commercially
of
look
available
at-
all
possible polypropylenes,
still
and
other resins.
later
They
names
now
of the materials
where given.
For the sake of simplicity we shall not hereafter refer to
any of these specific materials but will consider a representative polypropylene, keeping in mind that it may be possible
that some polypropylenes may differ appreciably from this.
9
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Properties of Polypropylene
Table
2.3.
13
Properties of "Escon'
is
shown
Escon
properties.
As
the
and surface hardness of the material also increase. Values for all of
upon how the sample is molded
and what, if any, treatment is given to the sample after molding.
Data
Property
General Properties
Density (73F) (g/cc)
Melt index (250C)
(g/10 min)
Method
0.897-0.910
ASTM
D1505-57T
1-10
ASTM
1238-57T
(load, 2,160 g)
Environmental
cracking
stress
(100%
"Ige-
None
Bell Labs.
Burning rate
Machining qualities
Slow
ASTM
D635
Mold
0.015-0.030
0.01
ASTM
D570-57T
3,800-5,100
ASTM
D638-58T
2,500-4,900
ASTM
D412-51T
13-18
ASTM
D638-58T
22-315
ASTM D4 12-5 IT
pal
CD-630")
Excellent
shrinkage (in./in.)
(2"/min)
Tensile strength, psi
(2'7min)
Yield elongation,
(2"/min)
Ultimate elongation,
(2"/min)
Impact strength
(ft-lb/in.)
Izod notched
Izod unnotched
Hardness
Rockwell R
Shore D
Elastic modulus, psi
(2'7min)
80-90
70-75
ASTM
ASTM
D785-51
D675-55
45,000-60,000
ASTM
D638-58T
16
14
Polypropylene
Table
Data
modulus
Flexural
(cont.)
2.3
Property
Method
of
111,000-176,000
ASTM
D790-58T
break-max load)
Compressive yield stress,
65,000-81,000
ASTM
D790-58T
psi (O.OS'Vmin)
Compressive strain @
yield,
(O.OS'Vmin)
Compressive elastic
modulus, psi (0.05'V
min)
5,300-6,400
ASTM
D695-54
15
ASTM
D695-54
53,000-63,000
95,000-150,000
100,000-128,000
ASTM
ASTM
ASTM
D695-54
D747-58T
D1043-51
elasticity, psi
(2"/min)
(O.OS'Vmin)
(no
Modulus of
elasticity, psi
29-32
load)
Thermal Properties
Melting point (F)
335
polarizing micro-
scope
Vicat softening point (1
kg) (F)
F @264
Coefficient
ASTM
ASTM
1525-58T
D648-56
ASTM
696-44
psi fiber
131
stress
F @66
266-293
temperature
Deflection
188
thermal
of
conductivity
(cal/cm/cm/sec/C)
2.80x10
(Btu/in./ft/hr/F)
1.13
Coefficient of linear
thermal expansion
0.00020
(in./in./C)
Specific
(cal/g)
heat
@73
F
0.46
Properties of Polypropylene
Table
2.3
15
{cont.)
Data
Property
Method
lectrical Properties
Volume
cm)
resistivity
(ohm6.5x10
ASTM
D257-54T
660
ASTM
D149-55T
2.0
ASTM
D150-54T
0.0002-0.0003
ASTM
D150-54T
Dielectric strength
(volts/mil)
ness
step
by
step,
V&" thick-
650
ness
constant
Dielectric
(10
cycles)
Dissipation
(power)
is its
that
more
units of
any given
size
means
it
its
important from a
is
pound
light
of other thermoplastics. In
many
applications the
Figure 2.1
is
of material in a
pound
of plastic.
is
also of
If
superior to
many
it is
it is
others.
it
will
2.3,
which shows
is
is
Of
better
all
when
the
combination of
considered.
particular application. It
is
stillest
material
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183
Polypropylene
CELLULOSE ACETATE
ACETATE - BUTYRATE
AND PRO PI NAT E
NYLON
POLYSTYRENE
POLYET
LINEAR
YLENE
1
LOW DENS
ITY
POLY PROPYLENE
22
26
30
CUBIC INCHES PER
Figure
2.1.
of
POUND
common thermoplastics.
LOW DENSITY
POLYETHYLENE
IMPACT STYRENE
HIGH DENSITY
POLYETHYLENE
CELLULOSE
ACETATE-BUTYRATE
POLYPROPYLENE
CELLULOSE ACETATE
STYRENE
NYLON
2
TENSILE STRENGTH
Figure
2.2.
Tensile strength of
10
1000
PS
common thermoplastics.
Properties of Polypropylene
ST
RENE
PACT STYRENE
CELL ULOSE
ACETATE-BUTYRATE
LINEAR
IM
POLYETHYLENE
POLYPROPYLENE
NYLON
LOW DENS
ITY
POLYETHYLENE
200
PERCENT
Figure
that
is
Ultimate elongation of
2.3.
400
ELONGATION
common
thermoplastics.
propylene
As with
is
tensile strength
and elongation,
it is
Some
necessary to
of the
com-
LOW DENS
ITY
RATE
NYLON
200
FLEXURAL MODULUS
Figure
specimens.
in Figure 2.5.
POLYPROPYLENE
IMPACT STYRENE
STYREN
test
compared
~1
POLYETHYL ENE
LINEAR
POLYETHYLENE
CELLULOSE
ACETATE
CELLULOSE
ACETATE- BUT
is
2.4.
Stiffness of
400
lOOOPS
common thermoplastics.
The
20
Polypropylene
HIGH
DENSITY
POLYETHYLENE
GEL LULOSE
ACETATE
IMPACT STYRENE
POLYPROPYLENE
POL YSTYRE NE
10
12
2.5.
Strength in flexure of
Surface hardness
is
common thermoplastics.
very important in
many
applications.
common
thermoplastics.
nylon
is
higher. It
is
among
point of polypropylene
is
field
at
previously closed
LOW DENSITY
POLYETHYLEN E
DENSITY
POLYETHYLENE
HIGH
CELLULOSE
ACETATE-BUTYRATE
POLYPROPYLENE
STYRENE AND
IMPACT STYRENE
NYLON
40
80
120
ROCKWELL HARDNESS
Figure
2.6.
Rockwell hardness of
(R)
Properties of Polypropylene
to thermoplastic materials. Figure 2.7
21
plastics has
POLYETHYLEN
CELLULOSE
ACETATE -BUTYRATE
IMPACT STYRENE
STYRENE
CELLULOSE
AC ETATE
POL
YPROPYLENE
NYLON
200
300
DISTORTION TEMP F
100
HEAT
Figure
2.7.
Heat-distortion temperature of
to definite applications.
The
common thermoplastics.
relate
some
specific properties
propylene.
of polypropylene, as
22
Polypropylene
and how
will react
it
propylene.
In
plastics will
all
phases,
is
its
behavior relates to
its
similar
curve
is
given
for
high-density
its
is
not, to
polyethylene.
most people, a
use polypropylene
is
the
it
more
ffexible.
As
the temperature
23
Properties of Polypropylene
It
w30
LI
NCA
is
not as
is
possible in
POLYETHYLENE
20
POLYPROP YLENE
IOF
-300
-150
150
TEMPt RATURE
Figure
2.8.
linear polyethylene at
various temperatures.
now on
stiffer
is
appreciably
it
to
be
less stiff.
24
Polypropylene
more
two materials
until, at a
is
The
exhibited by polypropylene
referred to as
many people
this
is
entirely useless at
stiffer
polypropylene retains a
this region
much more
shown
The problem
good
useful degree
i.e.,
the
impact strength versus temperature relationship of highdensity polyethylene, polypropylene, and polystyrene. Poly-
propylene
will
is
much
be noted that
tougher above
at
room
low temperature
it
temperature, but
it
its
level
but
it
seems
likely,
there, that
if
25
Properties of Polypropylene
U.7
POLYPROP
o5
LENE
1-2
o
<
LINEAR POLYETHYLENE
POLYSTYRENE
Figure 2.9.
100
100
200
TEMPERATURE
The change
"F
thermoplastic materials.
From
this
we can
makes
most
peratures
and
temperatures.
adequate
for
many
applications
at
low
26
Polypropylene
is
ON
STRENGTH
Any
material can hold, for a short time, a load that will eventually
break
it,
We
applied loads.
of long duration.
shall
Much
by Bryce Maxwell
now
consider
how
it
withstands loads
work done
at the
ratory.
This
known
as creep, but
is
is
and
stiff
to short-term loads
would show
less
creep on long-
is
by no means
true.
The
The
properties of poly-
them.
It
is
a good deal
when
more
a load
is
resistant to
applied over
same deformation.
it
is
in a short time
by applying a dynamic
be learned
27
Properties of Polypropylene
lost in the material
high
0.01
0.1
Figure 2.10.
10
1.0
CYCLES
The change of
PER
SECOND
with frequency of load
loss factor
have a low
and long-term
is
tests
many
oif.
would show
that
it
characteristics.
High-density polyethylene
is
sort.
28
Polypropylene
high-density polyethylene really had less long-term loadcarrying ability than the soft, weak, low-density material.
This fact could readily have been predicted from dynamic test
data. Figure 2.10 shows the change in loss factor with fre-
quency
at
10C.
30
TEMP
Figure 2.11.
The change
50
OQ
in loss factor at
120
The sharp
rise
frequency end
shown by
is different, as can
be seen in Figure 2.10, lower curve, which shows a very
moderate increase in loss factor between 100 and 0.01 cycles.
This indicates that polypropylene will resist long-term loads
is
obvious. Polypropylene
well.
29
Properties of Polypropylene
loses
its
resiliency.
which
100 cps against
temperature. The lower curve gives the same data for polyThis
is
shows
propylene.
POLYPROPYLENE
LINEAR
POLYETHYLENE
UJ200
0.1
Figure 2.12.
The change of
in
100
10
1.0
CYCLES
PER SECOND
It is
surprising
how moderate
10C
is
for polypropylene.
figure
At room temperature
factor of polypropylene
is
frequency decreases.
is
no
rise
as
30
Polypropylene
1500-
POLYPROPYLENE
60O0
20.5
GPS
0.1000-
500-
STRAIN
Figure 2.13.
0.001 IN
PER IN
and
its
resilience
at only a little
an intermittent load
is
gives promise of
good long-term
strength,
whereas a larger
Properties of Polypropylene
31
is
will
make
it can be considered
under severe conditions
other plastic,
life
ON
STRENGTH
EFFECT
OF ENVIRONMENT
Environment includes factors other than those so far considered, one of the most important of these being the effect of
various materials with which the plastic is in contact. Almost
every application involves contact with materials that
is
well
known
its
may
ability to
a property
which is characterized
by failure at relatively low but complex stresses in the presence of certain stress-crack-inducing agents. This has been
an important limitation of polyethylene in many applications,
and it is only in recent years, after nearly 20 years of intensive work on the problem, that some polyethylene manufacturers have succeeded in making polyethylene that is substantially free from this weakness.
Polypropylene has shown no sign of this defect, either with
called environmental stress cracking,
32
Polypropylene
Polyethylene
Liquid
Low
density
Turpentine
-30.7
-37.7
Chloroform
-100%
Xylene
Hexane
Commercial bleach
1%
hydrogen peroxide
The use
such agents
56
-12.8
-15.6
-5.3
-1.0
-16.3
6.0
7.9
0.8
2.0
9.3
23.5
-22.8
-13.9
-18.2
-32.7
-6.3
-24.2
-14.8
-20.9
-7.2
is
63
8.6
tact with
with
Linear
must be
in con-
from the
availability of polypropylene
many
is
superior to that of
The data
in Tables 2.5
results of a series
it is dangerous to
Other grades and
sources of both polyethylene and polypropylene might give
better or worse results; however, the samples used were
representative of some of the most widely used materials.
The contact liquids used were ones that were known or
propylene.
It
generalize
Properties of Polypropylene
33
The most
were tested
As a
Polyethylene
Liquid
Low
Water
1.8
Isopropyl alcohol
1.1
Primol
Methylethylketone
2.6
-8.1
-6.5
-5.6
Dioctyl phthalate
Corn
oil
oil
Methanol
-100
63
-1.1
-7.1
10.1
13.8
3.2
9.8
13.2
-2.3
-60.5
-50.5
5.9
16.0
2.5
2.3
2.2
"Igepal" *
*
-7.1
-78.0
-11.0
-42.7
-14.0
-6.5
-8.1
-1.5
-5.2
-1.6
Silicone oil
Linseed
Linear
density
1.1
-100
9.8
56
-8.6
-11.3
-20.0
-7.1
-6.0
-4.5
-9.1
-4.7
-3.6
-3.4
-19.8
-7.2
-1.8
matter of
fact,
weakened
it is
density polyethylene
its
use.
is
The lowdifferently
It
may
still
it
34
Polypropylene
strength,
The situation as regards permeability is even more comMost published literature leads one to believe that the
plex.
Figure 2.14.
is
which shows the water permeability of lowdensity polyethylene to be quite high, that of the linear considerably lower, and that of polypropylene a little lower still.
in Figure 2.14,
all
when we
consider other
35
Properties of Polypropylene
First, there is
activity.
such materials
is
shown
in Figures 2.15
through 2.19.
/
/pOLYETHVLENE
NEAR
LI
:2oo
LESS CRYSTALLINE
POLY PROP YLJ^WT
^^ 9QViy^VtHZ
100
^^^^.^-^^^^^^HIGHLY
Z^
^^^^^^^
CRYSTALLINE
POLYPROPYLENE
80
120
DAYS
Figure 2.15.
polyethylene
and
and
Methylethylketone
permeability
of
polypropylene.
As can be seen
polypropylene
much
resisted
oil,
common
polish
by low-density polyethylene
some
cases.
36
Polypropylene
300-
:200
tflOO-
Figure 2.16.
600-
LIN
= 200POLY PROPYLENE
LOW DENSITY
Figure 2.17.
POLYETHYLENE
polypropylene.
Properties of Polypropylene
37
DAYS
Pigure 2.18.
400-
:200
Figure 2.19.
Polypropylene
38
With substances of
more
this sort,
polypropylene
is
would
article
S300
=200
I*'
100
10
DAYS
Figure 2.20.
20
In the case of chloroform (Figure 2.18), low-density polyethylene shows the greatest permeability and high-density
There are also substances to which low-density polyis the most resistant. Isopropyl alcohol (Figure 2.19)
is an example. In such a case the low-density polyethylene
would be the preferred material from a permeability standethylene
point.
39
Properties of Polypropylene
There
is
also a
pylene more readily than they do other poly olefins. The most
striking of these
the
is
same behavior
an important
factor,
Where
permeability
is
these materials.
^300
150-
20
DAYS
Figure 2.21.
30
40
oS
Hydrogen peroxide,
Similarly,
meates
(Figure 2.22).
It
differ
it
40
is
Polypropylene
is
better.
all
case.
300
:200.
100-
Figure 2.22.
amorphous
as
is
discussed. Permeation
is
fraction.
Table
2.7.
Material
7o
crystallinity at
Low-crystallinity polypropylene
56
High-crystallinity polypropylene
63
Low-density polyethyelne
Linear polyethylene
91
61
25C
was
41
Properties of Polypropylene
possible to
It is
a crystallinity
it
will then
critical.
common
polypropylene
This
is
Very
80
POLYPROPYLENE
tn
-1
WITHOUT
STABI
LI
ZER
UJ
E20
WITH
STABtLI
50
HOU RS
Figure 2.23.
100
EX PCS
ZER^/^
150
RE
from
light exposure.
42
Polypropylene
light
when
in
they are
an exposure
cabinet.
color
is
POLY PROPYLENE
250
oc
UJ
a.
o
o
40
230
1-
o
^20
<
z
^/
LINEAR
POLYETHYLENE^^"^
iii
o
100
HOURS
Figure 2.24.
AT
250
150
200F
OXIDATION OF POLYPROPYLENE
susceptibility
it
is
for
pylene oxidizes rapidly at relatively low temperature. Figure 2.24 compares oxygen uptake at 200F for unstabilized
is
products will
all
be
stabilized.
how
greatly
43
Properties of Polypropylene
50-
40-
UNSTABI
LI
ZED
STA
Bl L
IZE
20
60
40
20
In service, polypropylene
is
really
much more
heat-stable
compared
to
two
110C,
tensile properties of
polyethylene resin.
30 days at 110C the linear polyand elongation; the mediumdensity polyethylene, while retaining its strength, no longer
It will
be seen that
all
after
strength
44
Polypropylene
and the two polypropylene samples are, if anyand more flexible than at the outset.
One very important fact about the oxidative breakdown
of polypropylene is that it becomes more fluid as oxidation
progresses. This can be shown in a variety of ways. Figure 2.26 shows the effect on melt index and of increased time
elongates;
thing, stronger
Table
2.8.
Tensile Strength
(psi)
Polypropylene
Polyethylene
Time
at
(days)
110C
Medium
density
Linear
2,330
4,550
4,630
4,990
2,830
4,840
4,870
5,070
14
2,890
4,890
4,750
5,090
30
2,220
180
4,870
5,000
Elongation
(%)
275
110
45
105
155
190
14
150
90
75
85
75
65
110
30
75
Polyethylene tends to
stiffen
and become
less fluid
under
decomposed polymer
to
in
the flow in an extrusion die. Problems related to this characteristic constitute a fairly large
processing.
it
decomposes,
will
45
Properties of Polypropylene
becoming more
fluid as it
who has had experiwith
polystyrene
polyethylene
ence
both
and
is well aware of
the increased carbonization problems encountered with the
is
0.57
I90OC
0.55
0.64
0.53
0.52
10
HEATI N&
Figure 2.26.
20
15
Tl
ME
25
Ml N
increases with time
190C.
latter material.
"Injection
Chapter
4.
Up
eral,
to this point
as
compared
we have
to
other plastics,
46
Polypropylene
has been mentioned that polypropylene
is an extremely
can be made in many modifications.
It is essential to the understanding of the material that a few
simple standard tests should be made to show what can be
expected from a particular sample. Chapter 3 will discuss
It
but here
ical properties,
we
The
earliest
terizing polypropylene
laboratories.
The
What
will
Index
this
be considered
heptane. This
in
many ways
is
is
insoluble in boiling n-
properties of polyethylene.
Much
is
When
47
Properties of Polypropylene
will refer to
under a load of 22
for polyethylene.
lb.
This
is
190C
is
to
means
directly comparable.
5000
J
1/
y
'h
'
1\
J
7S
4000
In 7
2
>-
Ten
//
3500
)0
90
100
Figure 2.27.
below
1.)
{Courtesy
48
Polypropylene
Yield Strength
effect of
is
on the
left.
Note
from below
110
100
/'
90
80
/'
//
/
/
100
90
Isotactic index
Figure 2.28.
(%)
(Rockwell R) with
5; bottom: grade
isotactic
below
1.)
{Courtesy Montecatini)
is
directly
where
easier flow
means a more
yielding resin.
The reasons
Hardness
Rockwell hardness also increases with increased
isotactic
is
the harder.
49
Properties of Polypropylene
Stiffness
The
tic
stiffness of
polypropylene
is
much
the
is,
same way
as are yield
The data on
resin.
220,000
180,000
160,000
140,000
120.000
100,000
90
Isotactic index
Figure 2.29.
Variation in stiffness
isotactic
(flexural
elastic
modulus) with
this relationship
They
100
(%)
is
50
Polypropylene
whereas
at
material
is stiffer.
lower isotactic-index
levels, the
high-melt index
melt index
Lower
strength lower.
The
less
is
is
is
high.
a great deal
At high
rates
and
will
Shear Stress
In polypropylenes of high isotactic index, shear
off
stress falls
400
5000
\^
^ 360
^
5500
\^
p
S
4500
J^
280
-0.4
Figure 2.30.
0.8
0.4
O.i
2
Mel
og grade
20
grade
inde X
51
Properties of Polypropylene
Impact Strength
The
pact strength
is
somewhat complex,
as
shown
to im-
in Figure 2.31.
when
is
relatively low.
^100
I
50
80
00
60
40
\V
^^
^^
20
S
_E
20
10
100
90
80
Isotactic index
(%)
Softening Temperatures
The
52
Polypropylene
100
y^
y^
^
^^
80
//
y
'/
90
100
Isotactic index
Figure 2.32.
(%)
5;
{Courtesy Montecatini)
Low-Temperature
One
its
Brittleness
is
same
plastics,
but
it
is
by no means the
brittle
ASTM
D746)
when
makes
brittle
it
is
high
(left
curve)
point
is
The previous
many good
many
applica-
is.
It
53
Properties of Polypropylene
20
/,'
^,0
i
^
y
,/
810
100
Grade
Figure 2.33.
(ASTM:D
erties
and
POLYPROPYLENE-FILM PROPERTIES
The polypropylene-film
be assumed that the
film
industry
now
is
so
new
that
it
cannot
propylene
film,
and many
polypropylene film
made by
However,
54
Polypropylene
little
wide market.
It
whose
properties,
when not
so oriented, are
uses, even
when not
and vinyl
losics
It is
films
index.
The lower-melt-index
film retains
its
strength at
much
film.
Poor low-temperature properties are often cited as a weakness of polypropylene film, and the higher-melt-index film
should not be recommended for applications such as frozenfood wrapping where low-temperature resistance is needed.
The lower-melt-index
such purposes.
film,
however,
is
c
4,400-18,000
18-20
15-45
150-200
4,400-8,100
3,400-3,600
29-30
2,800-3,100
29-31
2,400-2,600
29-31
2,800-4,400
3.5-6.8
0.4
5-10
10-300
29-30
1-3
0.05
0.25
125
580
0.7
280
990
100-125
1,000-2,000
50-70
1,500-3,500
300-375
45-50
1,500-2,000
2-3
0.65
200-250
100-115
350-450
2-3
0.65
a
'o
Ph
5-10
75-225
11
97
280
1a
97
280
sq
10^)
F)
75
(g/100
100F)
psi)
cc/100
at
X
(psi
F,
(NTP
permeability
at
hr/mil
(psi)
(75
103
hr/mil
(%)
modulus
impact
permeability
strength
vapor
factor
(%)
in./atm./24
in./24
Elongation
Spencer
Tensile
CO,
Tensile
Water
Area
Haze
sq
o.,
Gas
56
Polypropylene
by the
is
difference
rial. It
modulus, is much greater in the type-1 matecan be seen in the table that the type-2 polypropylene
film
in the
is
tensile
same
stiffness
polypropylene is more
on a par with high-density polyethylene or cellophane.
Present markets show that both stiffness ranges have wide
areas of usefulness. This is one example of the great versatility
of polypropylene resins, which will make it possible to adapt
them to almost any application.
Although the main reason why these films differ is the
difference in isotactic index between the two base resins, this
ethylene film, whereas the type-1
nearly
The
film.
The
stiff
cello-
The area
factor
stiff
is
film will
the
number
polyethylene film
is
pound
price.
it
is
very
significant.
57
Properties of Polypropylene
so, the type-1 material
accompanies
The
rela-
it
quate speed.
many
ture-vapor
purposes.
Cellophane
uncoated form
transmission.
To
it
has a
a better gas
is
much
higher mois-
equal polypropylene
in
this
would be
needed.
table,
polypropylene film
Film
film.
58
Polypropylene
both directions
so
much
Table
in the
2.10.
this
biaxially oriented,
is
is
two
it
directions.
Film
Tensile strength
Room
temperature
300F
Along sheet
Across sheet
15,000 psi
60,000 psi
4,000 psi
8,800 psi
35%
200%
ture)
Oxygen, 25 C, 1 atm
Carbon dioxide 25 C,
12g
13g
37 psi
0.28g/10C sq in./24 hr
atm
Yield
61,000 sq in./lb
Along sheet
Shrinkage
None
200F
250F
300F
Across sheet
None
5%
8%
12%
28%
Much
depends on the relative costs of oriented and unIt was about ten years from the time biaxially
oriented polystyrene film was first introduced until it could be
oriented films.
produced
at a price that
may
making such
be possible to produce
it
By now,
it
may
The
no valid judgment
differences
in
On
for
present,
and
with the
is
possible.
Properties of Polypropylene
the various temperatures used
variations. It
them
greatly.
is
and
in part
59
probably to resin
Note
also that
film,
2.1
I.
Film properties
Values
Specific gravity
0.885-0.895
30,900-31,300
0.45-1.10
300F
softening
Machine
7,600
direction
4,600
Transverse direction
Elongation (average) (%)
Machine
741
730
direction
Transverse direction
Machine
82
426
direction
Transverse direction
O2 transmission (cc/100
sq in./l mil/
180-260
atm)
CO2
transmission
(cc/100
sq
in./l
586-870
mil/atm)
Clarity, haze, gloss
Dimensional
Excellent
stability
up
to
max.
use
temp.
Printability
Equivalent to polyethylene
Resistance to acids
Excellent
Resistance to alkalies
Excellent
Resistance to organics
Variable
60
Polypropylene
that
shown
in
film in
Table 2.10.
or not.
The
strength
in Table 2.9.
Like
all
Some
polypropylene has
Power factor
by the preparation
also very
low but
of the resin.
Power
is
strongly influenced
Resistivity,
dielectric strength
is
Table
Power
2.12.
factor
30C
150C
0.0011
0.0063
2.11
Volume
4.9
resistivity
(ohm-cm)
1.86
IQi*
1.4
3.6
10i5
10^2
ohms
740 volts/mil
Properties of Polypropylene
tion-wire insulation.
Many
now
people
61
believe that
its
rela-
Table
2.13.
ASTM
Property
The
Value
770-820 volts/mil
Dissipation factor
Volume
method
D149
D150
D150
D257
resistivity
2.0-2.1
0.0002-0.0003
1016
ohm-cm
From
it is
The
first
criterion of a pipe
is its
performance of
rigid
is
PVC
lines, the
pipe.
upper
is
very rapid.
rate of decrease
The
line
is
shown
62
Polypropylene
7100
2840 i
200
40
20
60
80
100
120
Temperature (C)
Change of burst
Figure 2.34.
as dotted
it is
Lines
and
having
peratures
is
is
PVC,
the decrease of
mod-
63
Properties of Polypropylene
up
100C. This
to
may make
it
its
water systems.
The bottom
not only
This
much lower
starts
loss of
its
strength
strength. This
may
crystallization
beyond a certain
The use
but
may
provement
is
of very high-
problem, as
this
it
introduces
worth.
Polypropylene pipe for hot water would have the additional advantage (besides those of corrosion resistance, lack
of taste
and odor,
etc.)
that
it
Since piping
tinuous stress,
is
much
less
is
expected to
it
is
is
the
than that
At 120F
is
life
stress
One
of
64
Polypropylene
i
Polypropylene
3000
120F
~^
2000
1000
900
800
__^
iq4F
~"
Special
700 ^..^
00
500
400
300
-^
Polypropylene
'
__
__
inear Polyethylene
^..^.,_^
194 F
~^
200
100
HOURS TO FAILURE
Figure 2.35.
Hoop
material; however, at
of strength with
is
not
recommended
194F.
as
It
3.
CHEMISTRY OF POLYPROPYLENE
NEW WORDS FOR NEW POLYMERS
No
is
number
of
new
and
first
Tacticity
The
first
"tactic" with
its
the adjective
is
some
may be
is
very simple or
is
essential
It is
is
also
65
66
Polypropylene
we must
and
sions,
as a prefix "stereo-."
This
is
is
more
general synonym.
is
is
tion in space,
steric regularity
can be
said to be stereoregulated.
Atactic Polymer
To
tacticity,
is
"atactic."
Isotactie
The
Polymer
really important
is
one
whose basic building blocks are unsymmetrical, and in which
the building blocks are so arranged that, if one passes along
the chain from one block to the next, it will be found to be
"isotactie."
in the
To
same
is
we
shall
a carbon atom
will, if possible,
is
The
that the 4
bonds of
arrange themselves as
if
they
we imagine
that
we
from
ing
us.
at.
each other.
The other
line
one
line
which goes
straight
we
away
are look-
Chemistry of Polypropylene
apexes, however, does not he in this plane
upward toward us
slants
It is
very convenient,
67
but each line
shghtly.
when
bond
lines
shift
of the
ABC
Figure
3.1.
Bond
from the paper at a certain angle, and the other goes down
away from the paper at the same angle. If we look directly
at the plane now, the bonds above and below the paper
would be directly over each other, so, to get a projection
that we can visualize, we can shift our point of view down to
get Figure 3.1b.
If
we now
we
The
bond
from
and 3 are in the plane of the paper. The line
from the center to 2 comes up toward us from the paper, and
the line from the center to 4 goes down away from us at the
same angle. Figure 3.1c is a very convenient way of representing how a carbon atom in a long molecule is arranged in
space. If we take the bonds represented by 1 and 3 in Figure 3.1c to be the ones that go to the main chain of the
molecule, we can then represent this chain by a zigzag line
lines
through
the center to
its
apexes,
lines
68
Polypropylene
atom
in the
down.
Figure
3.2.
bond
directions.
We now
have a means of putting down on paper a repwhat isotactic means. The first part of the
definition is that the molecular building block must be unsymmetrical. Now, the main chain bonds are necessarily the
same. Therefore, to get an unsymmetrical building block it is
necessary for the atoms attached to the other two bonds of
our carbon atom to be different.
Keeping to the simplest case and avoiding, for the present,
any discussion of the many fascinating ways in which giant
resentation of
molecules
may be
built
Figure
3.3.
is
ethylene. If
we make
Chemistry of Polypropylene
69
the
bond angles
When
the double
make
with others to
The
simplest
monomer
is
it
can be
entirely symmetrical.
that can
^"3
Figure. 3.4.
is
propylene.
If
we
double bond
represent propylene as
we
is
we
did ethylene in
When
this
methyl
is
If
the unsymmetrical
chain carbon
is
70
Polypropylene
on the bond
is
extending down. Therefore, they always have the same relative position in space.
If
we had
methyls
k^1^
1
T^
"3
Figure
sometimes up
3.5.
>^^^
1
H
1
in
random
T
""3
"
'z
Diagram of part of an
'"z
isotactic
'z
polypropylene molecule.
Syndiotactic Polymer
ever, misleading
if
we
at that historic
meeting
at
Bad Nauheim.
We
Chemistry of Polypropylene
while
it
resists
distortion of the
71
flexibility,
it
will
rotation
be seen
sible.
is
this
main chain
in
units.
behavior of polypropylene.
Figure 3.6 shows a diagram of the two possible spiral
the
crystals,
the
two enantiomorphous
spirals
are
up
direction,
refer to the
monomer
units.
Each monomer
is
one
is
and
outside.
unit consists of
Each monomer
rotated 120 deg from the next one, so that the fourth
first.
is
72
Polypropylene
least interference.
handed
helices tend to
crystallize in pairs, as
Figure
3.6.
fit
together
shown
is
apparent.
They always
in the illustration.
Diagram of the
Stereoblock Polymers
In addition to isotactic, syndiotactic, and atactic polymers,
it is
tic
also possible to
and then,
make polymers
to very long.
Chemistry of Polypropylene
73
elastomeric properties.
Generally, infrequent inversion in a long chain causes
only a slight lowering of the melting point and a slight increase in elastic elongation. Tensile strength and yield point
will
essentially
the
same
high-molecular-weight
as
isotactic
polymers.
do not
When
enough to produce
some new and interest-
The
The
canized rubbers.
appears
when
the material
is
of the crystals.
The
Polymers of
more
tic
readily
this
made by
74
Polypropylene
catalysts,
under operating conditions most suitable for ecoof isotactic, atactic, and
not
difficult to
thus producing a
isotactic
raw polymer
consisting of a mixture of
many
many
advantages.
When
olefins
Optical Activity
Although
it
is
not a
new
well
known
that
the prop-
beam
of
beam
of light to the
name
75
Chemistry of Polypropylene
of
forms
lized
Some
be discussed
later.
show
rials
little
it
active.
is
a hundred times as
ON
POLYMER PROPERTIES
Crystallinity
and Tacticity
was mentioned
It
the
in
discussion
of
isotactic
poly-
it
two
left
hand.
One
of each
was shown
two
right
hand and
Such
in Figure 3.6.
chains to form a crystal, whereas any lack of regularity interferes with crystal formation.
line,
isotactic
its
there
is
is
not intended to
mean
that
Crystallinity
is
affected
by many
into
low
becomes so high
way
crystallinity percentage.
76
Polypropylene
Also,
a relatively
makes
short chain
it
for the
easier
Therefore,
sample,
of
isotactic
is
polypropylene samples are sometimes described with reference to percentage of isotactic polymer and sometimes with
reference to per cent crystallinity.
They
by extraction with
is
on material so
makes a quite reliable
and atactic polypropylene. The
extracted have
shown
is
entirely
on the properties
It is,
on the
crystallinity,
and
if
samples that
maximum
possible
other
measure of percentage of
isotactic
polymer.
77
Chemistry of Polypropylene
if
is
kept in
mind.
The
The degree
As with
is
its
is
permeability to liquids.
Figure
3.7.
n-heptane permeability.
on
Polypropylene
78
30C
Figure
3.8.
on
toluene permeability.
Figure
3.9.
on
Chemistry of Polypropylene
ship between solvent penetration
and
crystallinity
The degree
79
The
is
shown
solvents used
rapidly.
although the results are not quite the same with the
ence between
and
is
is
true.
The
Many
As we have seen
lar configuration
shown
as
before, solubility
is
a function of molecu-
in Figure 3.10.
22 hr
at
75F with
toluene.
The
crystallinity
soluble fraction of
range
is
quite small.
influenced by crystallinity.
strong,
soft,
and
The
polymer is stiff,
amorphous polymer is
crystalline
Any
practical
polymer which
is
on the per-
The polymer
is
80
Polypropylene
is
The
in
Chapter
2, reflect,
among
and
steric
con-
crystallinity.
<6
50
PERCENT
Figure 3.10.
60
RYSTALLI NUT
on toluene
extractables
in polypropylene.
STEREOSPECIFIC CATALYSTS
The
made
was the
monomer
have the
ability to
add a
Chemistry of Polypropylene
vast
number
81
Both
Many
of these catalysts
ethylene also
olefins in
It
some
made
isotactic
much
may
also
make
linear poly-
of catalysts
82
Polypropylene
inally discovered
many
an
alkali
an oxide of Group
The purpose of
other combinations.
nickel, cobalt,
and other
much
there to be a very
One
suggestion
is
good theory
as follows:
as to
how
triethyl as
C2H5
C2H5
= CHR
+
C2H5--Al
1
C2H5
CH2
>
-f
C2H5--Al
-c = CHR
Chemistry of Polypropylene
The presence
83
aluminum activates the olefin as inis then complexed with the alkyl. This
complex is stabilized by the shift of an ethyl with its electron
pair, and the process can start over. If the olefin is unsymdicated,
metrical,
of the
and the
it is
olefin
itself in
in order to react.
It is interesting
number of Ziegler-type
makes it possible
to
polymer.
It
is
is atactic.
may be
that
it is
not a single
relatively large
number
of molecules.
Natta has shown that there are catalytic complexes containing transition metals
alone do not polymerize the alpha olefins and are not stereospecific catalysts
but
become
highly
stereospecific
on
certain
substances,
crystalline
supports.
He
reported
polymerization
carried
out
with
triethyl
CoCL
support raised
35 to 45 per cent.
When
84
Polypropylene
pended upon the crystal structure of the TiCls. This compound exists in three crystalline forms. The two that are of
interest here are the alpha, or violet form, and the beta, or
brown form. When the violet form was used as catalyst support, the polymer was 80 to 90 per cent isotactic. With the
brown form the polymer was only 40 to 50 per cent isotactic.
in that
specific
and
known
of
is
only in-
of great theoret-
catalysts.
When
may be
double bond
it is
which are
diolefins
polymerize,
the
second
cis
and
trans.
way
the chains.
its
1,4 position.
form
is
to the double
is
bond
joining the
as a side
polymer was not known before the discovery of the stereospecific catalysts. Figure 3.11 also shows vinyl polybutadiene.
This kind of butadiene can be formed in isotactic configura-
85
Chemistry of Polypropylene
tion,
form
if
we remember
isoprene,
is
rubber to match
failure of synthetic
^C=C
/C=c
CIS
TRANS
CHj
CHj CH2
VINYL
ISOTACTIC
"2
Sh,
"2
i^
en*
"2
U^
OH,
Sh
ij
VINYL
S
YN DIOTACTI
"2
Figure 3.11.
uct
was due
duplicate this
to
the
Sh,
"2
"2
"2
l^
Four-ordered polybutadienes.
natural structure.
The use
of stereospecific
polyisoprene.
High-cis
polybutadiene
has
pure
tendency
cis-
to
crystallize at
The vinyl dienes are still too new to deterThey produce rubbers of interesting but not
of other properties.
mine
their uses.
86
Polypropylene
production of
Much work
of other polymers.
the
many
possibilities indicated
on the
plastic
and
CHEMICAL REACTIONS
atom
is
differs
whereas linear
Oxidation
It is
well
known
to a tertiary carbon
other carbons, as
more
it
that a
which
One
polypropylene
At 200F
is
much
is
that the
oxygen uptake of
in
polypropylene.
This
subject
is
discussed
87
Chemistry of Polypropylene
Sulfochlorination
made
vul-
some
industrial applications.
and form an elastomer, polypropylene can be made subamorphous to begin with, if atactic polymer is used.
This means that a small amount of sulfur (less than 1 per
cent) and only enough chlorine to produce the equivalent
sulfochlorination are needed to make the polymer vulcanizture
stantially
able.
amount
of chlorine introduced,
it is
much
lighter.
known
in such
still
changed to
fit
the
new
have
88
Polypropylene
J.
R. Chiang,
Mw,
to the
(?y)
(^)=
1.04
X 10-4 MwO.80
135C, "Decalin"
Mw
Determining
difficult,
from an equation of
shown
its
Determining the
in Figure 3.12
made
As
time consuming,
different
concentrations.
common
this
is
solution
^y
fj
is
solution.
at
it
is
i-yr-]
in
f]r is
the rela-
solvent
one determination made on a solution of a very low concenused is low enough, there is no
substantial difference
intrinsic viscosity.
is
in
grams per
deciliter at the
made up
at
temperature of
room temperature,
the
is
carried
Chemistry of Polypropylene
on
in
89
obtained.
It
ary
must be kept in mind that viscosity is, at best, a secondmethod of determining molecular weight and must be
0.2
0.3
0.6
INTRINSIC
Figure 3.12.
The
1.0
3.0
2.0
VISCOSITY
calibrated
by reference
to
as
As
if
90
Polypropylene
Molecular-Weight Distribution
Any sample
many
different lengths.
if
the sizes
rial
with a
material of the
molecular-weight distribution are very important in determining the properties of the polymer.
The
fractionation of polypropylene
is
its
its
tacticity.
is
more
active
tacticity.
and the
isotactic
all
how
may be
pylene than
understanding of these
effects.
on many properties.
It
may have an
over-
91
Chemistry of Polypropylene
erties are to
weight,
higher-molecular-weight
the
having
materials
the
better properties.
The
control of
properties in polyethylene.
Polypropylene has a
150
disc about
which
and 50
crystallite
in diameter
roughly a circular
is
to
60
thick.
The
This size
erally
is
accepted
for
low-density
gen-
and much
polyethylene,
quite free
crystallite size.
found
samples
which
after
may have
will
The
than
maximum
relatively
long
crystallite
grow with
age,
annealing.
Typical
film
crystallites
gamma
this
is
particularly
92
Polypropylene
marked
Spherulites in Polypropylene
form
relatively
plastics,
polypropylene crystals
spherulites. These
by means of polarized Ught because they
large
aggregates
called
polypropylene forms
which
differ
at least
birefringence.
same spherulite.
work has been done on this problem by
great deal of
spherulite.
Two
the
most
common
in polypropylene
sist
type,
occurs,
it
though
all
generally
known what
applies
surrounding
to
When
this
form
crystallites
are
normal.
It
it
is
is
not
mostly
When this is done, cracks begin to appear between the spherulites, and also within them. The dark areas
between spherulites were first believed to be amorphous
polymer, but it has now been found that they are mostly
voids, and very large spherulites can be separated from one
another with little effort. This clearly shows the great imporlarge sizes.
Chemistry of Polypropylene
tance of controlling spherulite growth
if
strength
93
is
be
to
maintained.
If
a sample of polypropylene
is
partially crystallized
is
and
ob-
extremely
fine,
it
Once
growth
it
is
may
it is
it
is
measured,
g/mil.
PRODUCTION OF POLYPROPYLENE
4.
PROPYLENE PRODUCTION
The
first
is
to
monomer, propylene.
Over 90 per cent of the propylene consumed today is
polymerized to high-octane gasoline. This demand is satisfied
by propane-propylene mixtures easily separated from refinery
obtain a supply of
its
Polypropylene
off-gases.
requires
pure
substantially
pro-
is
off-gases;
the
rest
are
by-products
of
ethylene
production.
is
used in a
PROPANE-PROPYLENE SEPARATION
distillation.
series,
94
stages,
Production of Polypropylene
will isolate a
mixture with
less
95
C3 range.
Separating propane from propylene
than
most
volatility
commercial
data
given
distillation
Figure 4.1
in
is
very low.
is
rather
more
separations.
indicate
It is
that
difficult
Relativeat
300
convenient to op-
cooling water.
.10
1.20
1.30
Figure
4.1.
96
Polypropylene
The use
relative volatility
dling
is
is
more, generally,
make
The
propane
may
the distillation
column
is
operated at 300
where the
relative volatility
is
more
favorable.
it
POLYMERIZATION OF PROPYLENE
The manufacture
manufacturer
ess,
and there
is still
is
of polypropylene
is
so
new
that each
from the
literature.
97
Production of Polypropylene
The
first
monomer
purification of the
it is
is
the
When
is
dry.
the gas
is
formed
is
constituents. In a
vessel. It
may be
subject to
to
some
it
is
made
as required,
salts
that
is
polypropylene
butyl.
is
Catalysts
Chapter
triiso-
3.
The second
preformed catalysts because they are made outside the reaction vessel at some earlier time. These are the Phillips-type
(chromium oxide on silica alumina) and the Standard Oil
catalysts (molybdenum oxide, cobalt molybdate, and other
molybdates on a variety of refractory bases). The activity of
98
Polypropylene
calcium hydride,
in
Chapter
This
etc.
is
also discussed in
3.
now
being used
form
The process
of three steps
of
making polypropylene
consists essentially
the catalysts and solvents from the polymer, and the pelletizing of the polymer to
make
conversion equipment.
made
in
polymer as
it is
to cause the
is
generally
soft,
determining
developed that
operation.
is
will
It is also
a catalyst
may be
atactic
may
develop
atactic content.
known
at this time.
form of the
In addition to
is
very
may
catalyst
after
it
Production of Polypropylene
is
this property.
may
also
99
have an influence on
is
moment
of use.
Gas composition
on polymer
must be quite pure, but
controlled amounts of other gases may be deliberately added
to change polymer properties. Hydrogen, for instance, is
added to reduce molecular weight, and thus improve the flow
properties. Other unsaturated gases may also be added to
propylene to produce copolymers of many types.
properties. It
also
is
a strong influence
is
atm
is
added
monomer
at a pressure
reaction temperature
is
The
in suspension
by the
agitator. This
can be
duction
is
on a continuous
basis.
may be
impurities.
From
remove the
is
filter
to
diluent.
the solvent phase, and the solid matter wiU be mostly isotactic.
The
solvent
is
then
distilled to separate
it
is
100
Polypropylene
instance
is
exposed to
The
extractant
is
air,
hence
in a completely
filter.
The polymer
is
steam-distilled to
remove
dried, ex-
of
HCl and
chlorine containing
essential to
equipment.
it
is
uses, such as
more convenient
which demand the best electrical properties require complete removal of all residues, and film
grades which must have the greatest possible clarity must
be free from all extraneous material. This method of catalyst
removal is evidently effective only in the case of Ziegler-type
catalysts, whose residues are entirely acid-soluble. When
catalysts on a refractory-type substrate are used, it is necessary to dissolve the polymer in a solvent at elevated temperature (xylene at 130C, for instance) and centrifuge or filter
the hot solution to remove catalyst residues.
Electrical grades
It
is
may
silica gel,
also necessary to
add
or
anti-
101
Production of Polypropylene
antioxidant-protected solution
is
cooled to
room temperature
solution.
remove.
a series of
solvent re-
moval
extruders
at the
same
is
steps.
it
is
labor cost.
Once
method
of operation are
special high-pressure
this
process
uses
engineer.
The
reactor
in detail,
will differ
is
usually
may be
and
filters
inert
102
Polypropylene
The
first
removing
solvent recovery
must have
all
MONOMER
MONOMER
CATALYST
REACTO
RECYCLE
STORAGE
SOLV ENT
FLASH DRUM
RECYCLE
FILTER
A^A CTTC
AND LOW POLYMER
I
AGITATOR
EXTRACTANT
FILTER
RECOVERY
Fl
CAT ALYST
RESIDUE
WATER
AGITATOR
LTER
WATER AND
TaTALYST RESIDUE
^ATER
STEAM STILL
ANTI 0X1
STILL
DANX
DECOLORIZER
DISSOLVER ]
RECOVERY
ST0RA6E~|
SOLVENT
FILTER
CL
CATAL YST
COOLER
RESI DUE
FILTER
^RECOVErTIaTAC TIC
POLYMER
EXTRACTION
RECOVERY
SOLVENT
STO RAGE
SHI
Figure
The
may
4.2.
Flow
PPING
all.
The screw
is
103
Production of Polypropylene
is
it
When
the solvent.
the polymer
all
is
useful for
many
propylene
is
quite new,
The
it
polypropylene
stabilized
its
art of stabilizing
all
purposes
has
poly olefins.
Many
Many
is
The
years
been
for
polypro-
104
Polypropylene
pylene. In
serious
its
novelty,
stabilizing polypropylene,
much
and
this is
an important part of
must be added
it
is
subjected to any
Uzer for
some
specific purpose,
may
also be
added in a subse-
quent operation.
COLORING OF POLYPROPYLENE
Colors can be incorporated into polypropylene by any of
two-roll
Economic
factors,
this
process the
is
then
method
of coloring
injection-molding industry.
Some
is
difficulty
has been
common
practice
in
the injection-molding
but
all
serve the
Production of Polypropylene
105
Many
of polypropylene.
erties of
markedly
The previous
polypropylene makes
would be the
case.
and
in poly-
easy to understand
it
why
this
is
walls,
easily
bling or turbulence.
The
The
first,
more
become even
even
to
mix
and
its
operating principle
is
just
changing
change
is
small hole.
in. in
in.
106
Polypropylene
With dispersion
^-plEce TO BE
THIS
IKI
TU;o
secTioMs- HALVED
OKI
DIA.SPHEI2.E
-N^ 63(.029D1A )
DRILU THRU
Figure
4.3.
it
is
with polypropylene.
It
must be kept
in
mind
many
mold
at
will
PROCESSING OF POLYPROPYLENE
5.
The processing
of polypropylene closely
resembles the
its
it
processing
it
be discussed in detail
mention of the basic process
as
essential to
is
Where
reference
is
made
from the
first
book
modifications.
in this series.
EXTRUSION OF POLYPROPYLENE
Although the greatest present use of polypropylene is in
market research and the history of other
injection molding,
thermoplastic materials
make
it
General Considerations
Polypropylene
will
is
to
extrude polyethylene.
As with
An L/D
107
ratio of
20:1
is
good
08
Polypropylene
from 16:1
to 24:1.
recommended,
minimum.
Double-screw as well
is
desirable.
as single-screw
Back pressure
by
way
to
An
many
is
plastics.
when
It
109
Processing of Polypropylene
trusion economics will be completely upset
is
when
the abihty
thoroughly understood.
except for
so,
The
is still
great
benefits
is
POLYPROPYLENE-FILM PRODUCTION
The
to
greatest
is
expected
new
material
is
produce film
first on equipment
and polypropylene has
been no exception.
to
When
now
avail-
on the kind of equipment used to make polyethylene blown tubing, it is not difficult to obtain film, but it
able are run
is
It
or clarity equal to polyethylene blown tubing, except at thicknesses below 0.3 mil (0.0003 in.), and
are not
much
its
physical properties
processing
is
of
Although
method
extrusion method.
lies in its
adaptability to the
110
Polypropylene
Extrusion of Polypropylene Film
Chill-roll
die,
two general
falls into
ment
is
is
is
is
classes
The
first
of these
STRIPPER ROLL
TO
Wl
01 E
NDER
A( R
KNIFE
igure 5.1
method.
this,
web
the
with the
is
chill roll
extruded straight
contact
upon
it,
or by removing
ft
in diameter,
Figure 5.1
is
the film
makes no
The
is
not essential, as
to a mirror
arrangement. For
a diagram of this
and
clarity,
on an
Processing of Polypropylene
condition,
where the
roll
surface
immaterial
is
111
on
if
has no
it
and
linear speed
film
Thicknesses
it.
economical production
commonly used
may be
and
single chill
stripper roll
The
chill roll,
ing. It is
rates.
in this arrangement.
roll
used in coat-
been on the
it.
film.
Some
chill roll
It is also
roll,
or
it
chill
about
necessary to
will
become
and
it
dry before
it
then squeegeeing
roll,
film of water
roll,
it
as in printing.
roller cool. In
of
roller
polypropylene
the
film,
but
it
and
allows considerably higher operating speeds. Depending on
the film and use, it may sometimes be advantageous. As
shown in Figure 5.1, an air knife may also be used to assure
contact of film and roll.
stabilizes
On
the die
roll as
operation,
it
is
desirable to bring
when
it
the
film,
surface
if
possible
it
should be
less
112
Polypropylene
or less
is
with the
not generally
will
make
contact
speeds. Thin film run at high speed will not really contact the
roll at all,
an
air film, as
previously mentioned.
is
One
all
reason
necessary
is
the
way on
why
a short
to prevent the
more severe with polypropylene than with polyits low melt viscosity. Not only does the
narrow excessively, but, under some conditions, the width
This effect
is
ethylene, because of
film
is
stability.
is essential to have a
and chill roll is that the
clarity and gloss of the film are dependent upon extremely
rapid chilling of the melt from extrusion temperature to some
temperature below the crystaUization point. If the film is
drawn through the air for any considerable distance before
contacting the roll, it cools too gradually, and large crystals
form which make it dull and cloudy.
The
it
lip
The best film resins, run at recommended temdrawn down to 0.1 mil without tearing off,
high as 500 fpm. Most of the factors that limit
peratures, can be
at speeds as
much
higher. Poly-
chill-roll
temperatures
which give more rapid chilling of the film, and this pushes
the limitation on speed up to higher levels as well. The lower
heat content of polypropylene also serves to reduce the time
required to chill the film to handling consistency.
Horizontal Extrusion. The other general type of equipfor chill-roll extrusion is a development from
ment used
Processing of Polypropylene
113
is
or more, where
it
is
Equipment
it
picked up by
of this
shown
chill rolls in
is
little less. It
in Figure 5.2.
KNIFE
DIE
CASTING^
ROLLS
^TO
>-< r^
Wi NDER
Figure
5.2.
method.
and
roll up, as
rolls assures
it is
rolled up.
in. to 1 ft in
it
may make
It
better film.
up
many
114
Polypropylene
web speeds
for
film.
Die Design
Although
slot or
which
is
adapted from a
W. Egan and
Figure
5.3.
flat
115
Processing of Polypropylene
Co., shows one
way
in
obtained.
( 1 )
approach
to roll
surface.
(2)
(3)
this
side
impossible.
provided
it
it
is
An
made
is
a source
time.
surfaces highly; a
Control of
With
Web
by Air Flow
either type of
stream of
equipment
it
is
desirable to provide a
it
velocity
Polypropylene
116
with a set of adjustable
lips
jet
Figure
5.4.
Commercial
with
mer
no considerable
knife
is
Much
roll.
skill is
is
web
will
not
small,
if
the
result.
many
The
and should
111
Processing of Polypropylene
contact the
web
die.
place. It
with the
this is
is
chill-roll
unit with
air
knife
in
air knife if
it
film,
and
and
is
surface.
One advantage
development of an
up
is
side of the
web
it
chill
possible without
on the
that
between the
air film
to considerably higher
is
it.
to thinner
If the roll is
highly
Puckering of Film
Good
common
is
effective in pre-
known
as
puckering or seersuckering.
In extreme cases the appearance closely resembles that of
seersucker cloth. There will be longitudinal strips in the film
flat,
effect
appears to be due to
differ-
Although the air knife will not prevent the formamarks under all conditions, it does appreciably
extend the range of operating conditions over which flat film
can be made.
It should be noted that the linear speeds at which these
defects appear are considerably higher for polypropylene
chill roll.
tion of these
118
Polypropylene
there
would be no puckers
was
One
propylene in
is
rial
on the
serious
die lips,
at very
uneven
roll
deposits build
If
the extrusion
is
uninter-
of operation
is
more
down
to a less viscous,
may be
down
between cleanings.
The same
streamlined, or
if
is
roughened
in
any
off,
this.
119
Processing of Polypropylene
Gels in Film
It is
not possible at
this
On
it
From
Flat Film
method has
slit
made by
extruding molten
it
poor
results,
to polypropylene
especially as to appearance.
water tank
This
and several
have closed down; however,
is
carefully baffled
and
rigidly
if
the
supported to pre-
then be brought up very close to the die opening, and this will
produce clear film. The distance between die lip and water
surface required to get this effect is about Va in. Figure 5.5
shows a water bath with necessary baffles in place.
The water carry-over problem that limits the speed of
water-bath polyethylene film appears to be easily controUed
120
Polypropylene
as high as those
Figure
5.5.
to prevent
yet been built that will exceed the ability of the resin to ex-
trude and
draw down.
Processing of Polypropylene
121
rates.
restricted screen
polypropylene
film,
nor does
it
extruder.
is
than
it
will, say,
above 20:1, however, quite often the output of polypropylene will be greater than that of polyethylene.
eter
is
is
compen-
ter 2.
is
usually
from 525 to 575 F. Below this the film is not clear, and
above 600 F the resin degrades. Table 5.1 shows typical
conditions. One of the most common problems encountered
in
polypropylene-film
extrusion
is
generally
described
as
and can
it
is
The normal reaction of those familiar with extruders is to slow down or to put in a heavier screen pack.
These expedients usually make the situation worse, since this
extruded.
do with other
plastics,
itself,
due
to the low melt viscosity of the material, which does not allow
122
Polypropylene
Corrective action
is
Table
5.1.
Resins
melt index
High
melt
index
Die temperature
Stock temperature
Chill-roll temperature
450-550F
525-550F
550-575F
40-100F
450-550F
500-550F
525-550F
40-100F
Screen pack
None
None
Cylinder temperature
finer
than
100 mesh
finer than
100 mesh
20/1 min
15-25
20/1 min
15-25
V2 to
1 in.
V2 to
1 in.
1/2
Va to
1/2
1/4
to
polypropylene
film.
123
Processing of Polypropylene
across the web, because, while the film as a whole
firm contact with the chill
when
temperature
remain
and the
in place,
linear-expansion
It
in
5.2.
Ultimate
stretching
the chill-roll
if
it
of
coefficient
stretch appreciable.
Table
film
they touch
As
above 160F.
is
makes no
roll,
(%)
strength
None
tensile
(psi)
Elongation
8,400
500
250
14,000
115
22,400
23,800
40
40
5,600
200
400
600
900
web
(%)
tension. If the
temperature
is
guide.
found
It
common
"clip
papers, arranged
tracks.
from the
die or
roll.
The
it
The
emerges
tracks diverge
in
angle of
amount
an oven
124
Polypropylene
device
is
SHEET EXTRUSION
made
equipment commonly used
Polypropylene can be
the
into
to
make impact
styrene sheet.
Extrusion temperature will vary with the kind of polypropylene, but most current resins would require 420 to
may be used
to obtain
Die
lip settings
cent
is
permissible.
up
in the nip.
build-up in the
The polypropylene
same
finish as
is
con-
surface;
i.e.,
duller
the roll
if
if
is
cool,
125
Processing of Polypropylene
PIPE
monly used
is
differ
supported, which, of
Two
the core
first,
is
sup-
which are
rigidly fastened to the die body. In recent years it has been
more usual to use an offset die in which the pin goes right
through the die body, while the plastic enters on the side,
and turns at right angles. The most important practical difference between the two dies is that the offset die is particu-
it
own
and
it
pipe extrusion
is
is
its
to support
shape.
when
it
leaves
soft
is
weight or maintaining
front of
base,
larly well
of sizing
its
die
its
in
at this point.
pin holds
in
and at the same time finally fixes its internal diamis most easily done with the offset-type die, because
this permits water lines to be run through the die core to
the mandrel, without excessive difficulty. This method is very
difficult to operate with heavy-walled polypropylene pipe and
the pipe,
eter.
This
126
Polypropylene
is
By drawing
drawn up
vacuum on
Many
it
pipe
method
is
fixes
to the point
common.
Polypropylene resin makes
initial
satisfactory
the pipe
sizing,
pipe by
is
either
carried under
it
completely.
In small
sizes,
polyethylene pipe
it
must be cut
into
as stock
A vacuum of
vacuum
die.
probably produce
slightly smaller
more on cooling
to
room
temperature.
much
it
is
generally
127
Processing of Polypropylene
must be remembered that polypropylene is a considerably stiff er material and sets up more rapidly than polyIt
150
Polyethylene
/
Polyethylene
High density
^^^/
Low density^,''
100
/l
,''
yAv
Polypropylene
50
'^'^''^\
1
TEMPERATURE
Figure
5.6.
Specific heat
v^'.
compared.
ethylene. This
means
when
it
will not
128
Polypropylene
cooler water
is
its
is
adequate.
less cooling
than poly-
means
lower
is
that cooling
from
capacity
are
is
generally higher
much
As
cooling
higher.
with polypropylene
in
some
cases,
(en-
much
period
solid.
but
it still
point where
it
becomes
it
to the
self-supporting.
EXTRUSION COATING
The
mend
When
it
as
The opposite
transition
is
and
high pressure.
Processing of Polypropylene
129
extension
The thermal
ture regulation
sensitivity of
somewhat more
critical.
The usual
relation
625
is
ob-
If
to
melt temperature,
etc., all
no top temperature can be quoted, but, ordinarily, temperatures of from 575 to 600F will give adequate adhesion
without excessive loss of polymer properties.
Any
until
it
heating the an: gap, heating the paper, and the afore-mentioned extended die Hps. In
some
cases,
merely speeding up
As
it
economical operation
at
ommendations
machine design
as to
for fihn
making apply
MONOFILAMENT PRODUCTION
Extruded polypropylene monofilament comprises the seclargest market for the material in this country at the pres-
ond
number
of producers
is
is
not large,
130
Polypropylene
following information
is
Figure
5.7.
Heumann
Extrusion die
E
F
B Quench tank
First
Godet
unit
Orientation oven
Second Godet
Spooling unit
The
die
is
opening
is
openings.
flat
not a continuous
The
die openings
slit
commonly
It
downward.
run through a quench
face
it is
Processing of Polypropylene
131
its
set of
temperature can
drawing
rolls
it
up
to
This step
is
is
is
wound on
from 0.003
denier.
The
0.012
to
denier
grams, of 9,000
from
is
in.
it
may not
wound
a separate spool.
fibers
with a diameter
is
40
to
1000
to 15.
may
may
vary
The
5 lb of fiber /hr.
made from
now
very successful in
can be expected.
available produce
all
become
To
available, considerable
improvement
132
Polypropylene
as high as
350F
it is
is
increased until
then slowed
down
until the fibers are clear again. This gives the point of maxi-
air gap between the die and the surface of the water
quench tank appears to have Kttle effect on the fiber
properties.
Polypropylene
monofilaments,
made
as
recommended
above, show very sharp spots in an X-ray diffraction pattern, which means they have a high degree of axial orientation.
They show a low elongation and little shrinkage below the
The
yarn
is
difference
multifilament
1
so
much
finer, 1.5 to
The
6 denier against 40 to
133
Processing of Polypropylene
to be
much
than for
down
means
of inert-gas blanketing
rapidly.
is
is
essential,
of oxygen by
and special stabili-
also needed.
used for
ment. This
is
different poly-
may be
produce
maximum
strength
after
solvent removal.
134
Polypropylene
the
name
multifilament.
Multifilament
change
it is
its
characteristics
its
handling characteristics.
is
for injec-
tion
molding, this
is
to a considerable extent.
The
way
in
some degree
Polypropylene
is
is
of stiffness,
a useful
way
and the
to classify a
purpose polystyrene
polystyrene is slightly
is
much more
more
rigid.
rigid,
This
is
whereas impact
the
135
Processing of Polypropylene
relatively expensive
The
acetate plastics.
it
over most of
its
the
is
it
same
much
is
same range
is
more
stiffness.
stiffer
It
than high-
frequently compared,
rarely a
molding
resin,
major considera-
but polypropylene
more than
of poly-
stiffness
to replace
is
similar to or slightly
The
poly-
striking.
The
is
more than
"R"
some
cases this
The
slight resiUence of
it
One
is
tures.
Only nylon
is
better.
glossy
visible.
much more
often so
more
is
It is
clearly
exceeds
all
means
is
very
that polypropy-
136
Polypropylene
make
to a relatively
density that
pound
low
it is
would
price
initial price,
was discussed
it is
its
in a practical
way,
to polyethylene,
all
made
molders,
the dis-
because of
that,
resistance,
which allows
trary
its
it
greater stiffness
it had been
and temperature
mold
hotter,
it
that,
Therefore,
put into
It
it
relatively
to raise
it
great
amount
of
heat has to be
might be expected that polypropylene with its very reguwould exhibit a similar need for a great amount
lar structure
137
Processing of Polypropylene
of heat in
its
propylene, because of
its
its
less
it
true.
Poly-
molding temperature
polyethylene,
all
temperature with
not at
is
is
it
this
does have a
It
polyethylene,
it
in cycle, however,
is
time.
capacity,
often possible to
it is
450F
the
linear polyethylene
show a
concerting to those
useful
when
who
may be somewhat
the temperature
is
it.
It is
just right.
dis-
actually very
The main
flow
138
Polypropylene
is
in the low-viscosity
still
just as the
mold
fills.
Under
these
tendency to
flash,
but
fills
the
mold
easily
and
reliably.
450
500
CYLINDER TEMPERATURE "F
Figure
5.8.
Flow
vs.
This also makes polypropylene very responsive to temperature changes in this region; however,
sensitive,
it
is
not excessively
is
rising to
139
Processing of Polypropylene
of the resin
characteristics
make
necessary.
when
is
it is
viscosity
Most
haps
it
its
it
plastics
have
merits a
this
little
its
becomes.
It
it
known
that
respond to increases in pressure with more than proportional flow increases. It has also been well understood
plastics
that this
is
a very useful
Acetate formulations
have been modified to increase this property, and such increase has been a major goal in the development of polyethylene resins.
It is
is
flow (shear stress). Figure 5.9 shows such a curve for poly-
phenomenon
is
cavity,
melt tends to
up even before
tends to be
the fluidity
Although
mold
stiffen
more
is
this
design,
its
does
make
less
the
it is
moving
rapidly,
cools at
where
It is clear that
all.
Also,
it
mold where
wider openings.
an excuse for poor
fluid in
as
more evenly
it.
140
Polypropylene
PRESSURE
Figure
5.9.
maximum
benefit
signed to obtain
is
maximum
mold.
Melt-Compression Techniques
These techniques are called by various names such as
molding, sequential-impact molding, and
precompression
others.
The
molding methods
is
that a
valve
is
mold
itself.
The
when
forward and remain closed until full ram pressure has built
up on the plastic behind the valve. The valve is then opened,
allowing the plastic to spurt into the mold under full pressure.
Processing of Polypropylene
In the form called valve gating, the valve
itself.
141
is
in the
mold
maximum
plastic
again.
Plunger
10,000
psi
10 cu in/sec
Granular Region
408, 11.7 cu in.
AVp
Figure 5.10.
AVg
Melt Region
50 Cu in
AVm
+ AVs
plastics other
makes
them so valuable,
worth
it is
To understand what
happens during the injection stroke of an ordinary injectionmolding machine. Figure 5.10 should be referred to. Consider a plunger which can produce 10,000 psi at a speed of
10 cu in./sec. Pushing the loose plastic granules in the
feed section of the machine forces them ahead to create
pressure on melted material farther forward, which then flows
die.
its
The
loosely
In addition to
this,
packed ma-
remove the
is
142
Polypropylene
quite compressible
so that
much
plunger motion
is
used
plastic.
have
to displace
material
is
12 cu
in.
or more. During
mold under
make
this time,
all
As we have
is
very poor.
we move
the
will also
When
its
opened, material
maximum
will
add
maximum
its
starts to
pressure. If flow
travel, de-
viscosity.
filling. In one test reported, the effecwas six times as fast from the precompressed
melt as it was from the same machine used in the conventional manner. This makes possible the filling of thin-wall
sections that would be impossible by older techniques, because the melt would set up before filling was complete. Core
shifting is reduced because the melt viscosity remains so low
that no pressure gradients develop around the core, and weld
Of course
very
much
by the use of
pumps, producing more rapid plunger
larger
Processing of Polypropylene
travel,
this
143
activated by a small
is
movement
of the valve
from full shut to full open is very small and takes something
on the order of 2 milliseconds (msec). The time of opening
can be very accurately controlled, and this gives very precise
control of the
When
amount
it is generally unnecessary to
have temperature variation within the mold to control the
flow; maximum coohng can be used to give minimum cycles.
is
especially suited to
is
If
melt tempera-
is
Shrinkage of Moldings
of polypropylene
is
less
The
but
relatively
quite
is 1
or 2 per cent
a considerable control of
is
144
Polypropylene
plastics,
trolled cooling.
Moldability Area
very informative
way
of
comparing the
relative
mold-
method. The
Cycles (sec)
40
50 60 70
Figure 5.11.
30
40
50
60
Polypropylene
70
30
40
50
60
Low-density polythene
Montecatini)
styrene, polypropylene,
the
shaded area represents the range of time-temperature conditions over which satisfactory moldings can be made. The
upper line represents the maximum temperature which can
be used without overheating and decomposing the plastic.
The lower line is the lowest temperature at which the mold
145
Processing of Polypropylene
is
completely
filled.
The
is
the
shortest cycle at
the area
is
size of the
be seen
is
much wider
for poly-
propylene.
this
tical
when
it
is
are practical
Mold Design
Good mold
all
design
is
worth while
it
is
not at
two and
mold
in polypropylene, as with
as to type of
all critical
all
conventional kinds of
gated.
In multiple-cavity molding
it
is
particularly important to
mold
is
unbalanced,
the parts affording the freest flow will receive a disproportionate share of the flow, even
most other
down
more
so than
is
plastics.
stepped
146
surfaces
Polypropylene
may be marred
if
cooled material
slips
In small multiple-cavity
work 0.040-
to 0.060-in.
gates
Jump
commonly used
bottom
by
to prevent jetting
known
it
cessful.
It should be kept in mind that it is most advantageous to
mold polypropylene at the highest pressure possible. This
means that mold construction should be very solid to with-
Generally,
when
is
a molder tries a
with polypropylene.
Processing of Polypropylene
147
Fluidization on Heating
There
is
One
as that
when
which
is
en-
been
tendency to
its
POLYSTYRENE
MINUTES
Figure 5.12.
Change
IN
INJECTION
CYLINDER
cylinder.
kept in mind
It
it is by no
means the new or special problem that people have implied.
The ability of polyethylene to withstand prolonged heating
without increase of fluidity is seldom required and it is, at
stance,
best,
somewhat
but
respect
much
time at 550F.
It is
148
Polypropylene
history)
is
decompose
until
it
it
When
off and
molding polypro-
more
hence
fluid,
it
is
surfaces
more
easily
is
much
its
makes
the
ticular
guidance.
pends on the
in
mind
that,
any other
plastic.
sizes.
is
The
be molded.
It
it
would of a denser
plastic.
U.2
o
oo
B
'(
<N
c^
<D
g
o
-2
"^
>
CJ
6
>
o
u
>
o
Ul
>
o
S-i
"S
Oh
o
o
ti
5tt
(U
(U
(U
'^
CO
5 ^
O
en
d)
o
i
Cin
."
Q,
Oh o
VO
s
.2
^ 2 o
r^
-r
+:j
3
5 ^
.Si
>
o
t^
> ^
p a
a^
<U
-5
<
150
Polypropylene
The
by
fast injection
makes
it
also
The
resin
this
is
right to left
pump
The
as follows:
From
right.
it
from
is
mechanism
The heater
is
encircled
by
electrical
band
The
is
located to the
left
relatively
is
forced
of the heater,
The duration
the plastic
is
sufficiently,
injected into
the
mold
it.
When
the
is
opened and
is
controlled by
is
con-
trolled
Processing of Polypropylene
151
THERMOFORMING OF POLYPROPYLENE
This
is
ing techniques.
Thermoforming
ess
is
contact with a
mold
to
is
to describe
any proc-
produce a shaped
article.
It is
dis-
which
is
starts
with a tube
usually hot.
Vacuum Forming
Most important of these is the complex of related techvacuum forming, where the heated sheet is
niques called
drawn
into a female
is
satisfactory
When
deeper
where
drawn over a male form of the proper shape,
final shaping being assured by vacuum. A hybrid of these is
called drape-assist or plug-assist vacuum forming, in which
the sheet is first stretched into approximate shape by a male
draws are desired,
the sheet
is
it
is
152
Polypropylene
form and then drawn from the male form into contact with
by vacuum.
This group of techniques is extremely versatile and can
make a wide variety of thin-walled shapes. Rapid improvements in equipment for vacuum forming have shortened the
cycles and allowed automatic operation to the point where
a female die
this
method
is
now
way
of
making a given
piece.
of
vacuum forming
is
based mainly
its
ability to
The
field.
make
much
it
takes too
perature.
improvement
in this respect.
The
is
a great
Table
5.4.
Heater temp
(F)
Polyethylene
(60 mil)
Polypropylene
Polyethylene
(125 mil)
1200-1125
1100-1025
0.30
0.25
0.32
0.27
0.40
0.33
0.40
0.32
Polypropylene takes
5 to
20 per cent
less
Polypropylene
time to heat to
similar
Processing of Polypropylene
time saving will also be
made
153
Figure 5.13.
Pressure Forming
is
is
pressure forming,
154
Polypropylene
vacuum can
exert
more than
atm of
is
no
and
up
in
to the point
may
This sag
where
it
it is
its
own
weight.
The use
sheet
when
it is
of pressure
slightly stiffer
heaters.
Skin Packaging
polypropylene application
is
skin packaging.
may be printed for brand identificaand other information. This assembly is then placed on
a perforated plate which can be evacuated from underneath.
A softened plastic sheet is placed over the assembly, and
sheet of cardboard, which
tion
vacuum
articles to
155
Processing of Polypropylene
method usually
heating time
enough
is
BLOW MOLDING
Development
of Blovs^
Molding
bottle
is
the application
many
employed
in other ways.
Linear polyethylene
quickly
showed
it
itself
to
be
well
propylene
resilience
is
and stress-crack
linear polyethylene in
resistance,
many
it
will
probably replace
applications.
For a long time the development of a blow-molding induswas hampered by a patent condition which
gave a very few relatively large firms an almost monopolistic
control of the industry. These firms were interested only in
making containers and so prevented recognition of the fact
that blow molding is an excellent and economical method
try in this country
Influence of European
all
kinds.
Equipment
Blow-molding equipment imported from Europe has estabblow-molding industry in this country, and
recent cross-licensing agreements have freed the industry
from the patent difficulties that have heretofore hampered it.
It appears, therefore, that blow molding will account for
much more material in the coming years than previously.
lished a thriving
156
Polypropylene
The thermal
properties of
How Blow
Molding Works
AU
Main
DiflFerences
The
extrusion
is
is
that
is
an intermittent one. The multitude of variations in blowmolding machines results from the different approaches used
to correlate the continuous extrusion with the intermittent
blowing.
and
start
the
are as foUows:
Some companies
The
first,
most
but
and
still
When
it
mold
closes,
157
Processing of Polypropylene
mold.
is
mold.
is
mold
parison.
In another
common method
fold leading to a
number
valving
the
die
its
ejecting in
air
plastic flow
is
only possible
through the
die,
either
before use.
158
Polypropylene
When
forms
mold
the
the pin
is
it
bottle
The
conflicting
but
this is the
only
Any machines
perform
just as well
pylene will
that
it
may be
fields
now
held by metal
Blow Molding
Articles
159
Processing of Polypropylene
to bottlemaking but
articles of
many
is
a versatile
kinds.
Many
method
articles
for
making hollow
now made by
injection
best
way
to
make
rigid thermoplastics.
together
metal-plate fabrication.
enough
to
make
them
in
After the pieces are cut and bent to the proper size and
shape, they are clamped in jigs to hold the edges together
firmly,
consists of a device
which heats a
60
Polypropylene
about Vs
It
may be
either elec-
welding rod
diameter
made
of polypropylene
both the
rod and the edges of the joint are being heated by the torch.
A butt weld can also be made by heating the two edges of
in. in
is
the joint
Table
5.5.
Type weld
1/8
l^
Double-V 5 beads
Double-V 5 beads
Double-V 2 beads
Double-V 2 beads
l^
Heated-tool butt
95-100
95-100
85-96
70-85
80-100
V4
1/8
their
Machining Polypropylene
machined by regular metalworking
equipment. Tools must be very sharp, and overheating must
Polypropylene
is
easily
is
number
will
less severe
a very convenient
than
way
of
be required.
Pov^der Techniques
Processing of Polypropylene
161
propylene.
Flame Spraying.
pylene
is
it.
bond
it
is
needed
to
Generally, one or
more base
with a
little
coat. It
and
it
is
also advantageous to
must be
with bonding.
this
is
is
blown up
in a
it
may be
shape
boat
is
is
a very versatile
articles,
method
particularly
for
mak-
those whose
have to be
as fine
light
metal mold
is
filled
heated oven.
It is
162
Polypropylene
The mold
is
dumped
propylene powder
is
is
desirable for
useful in these
6.
PACKAGING APPLICATIONS
POLYPROPYLENE-FILM APPLICATIONS
vinced that
who
market
this
still
in their
in
Film
clarity
many
critical
problem
it.
much more
and
this
means
that
163
64
A
is
Polypropylene
and
this certainly is
factor.
Many
6.1.
in Packaging
(Millions of Pounds)
End
use
Tobacco
0.5
Candy
4.5
Baked goods
Meat and poultry
3.0
5.5
Snacks
1.5
Frozen foods
Dairy products
Fresh produce
Other foods
6.5
5.5
68.0
5.0
Textiles
12.0
Drugs
1.0
Garment and
shirt
bags
30.0
All others
37.0
180.0
two
thirds of the
polypropylene
film.
market that
It is
part of
this, it
does
it
is
What chance
Cellophane users are characterized by a surprising willingness to pay extra money for a better package. A large proportion of the cellophane market is in special premium grades,
which cost more than ordinary cellophane but have better
165
Packaging Applications
properties. It
is
cellophane
it
will replace
Cellophane holds
its
it.
and modify
their
mate-
is
bewildering,
naive.
On
are
cellophane, and
articles
much
its
advantages
superior to that of
greatest advantage in
better.
Polypropylene film
is
many
much
is
greater.
in having
had high-speed
it
is
rapidly
As
displace cellophane
from
its
pound premium
will not
field,
it
tended to
mean
propylene
film.
first
66
Polypropylene
undoubtedly
many
The
to
market,
it
will
be largely carved
where
clarity
fall to
and
stiffness
polypropylene.
etc.,
field.
properties.
Let us
now
consider in a
little
more
do
this,
detail exactly
cellophane
is
where
readily. In order to
it
holds over
in order.
Dried Products
Perhaps the greatest weakness of cellophane is its moisture
Although moisture proofing improves its moisture
resistance, it is still true that cellophane must have a moisture
content within narrow limits for optimum properties. A wide
sensitivity.
cellophane, causing
it
to embrittle
167
Packaging Applications
example
Dried milk
Flour products
Cake,
Rice
biscuit, roll
Dessert powders
Noodles
Powdered starch
Spaghetti
Cellophane
age, to
also limited,
is
packages weighing
packaged
less
by
mix
its
than 3
lb.
Materials ordinarily
be
dis-
Baked goods
Dairy products
Miscellaneous food items
Fresh produce
Frozen foods
Textile products
Tobacco products
Confectionery
Paper products
significant
is
particularly true
compared
It also
to poly-
of cellophane-
is
many packaging
The problem
applications.
168
Polypropylene
and conveniently
easy to
also well
is
make polypropylene
on
its
way
to solution. It
film in such a
way
is
quite
as to offer
the "built-in tear tape" feature that has been highly publicized
film,
ethylene. In general,
much more
embedded
in
view, however,
many
polypropylene
films
of
them
From
because of their
inherently
superior
properties.
Baked Goods
The baking
industry
is
propylene
remainder are
Since
it
still
waxed-paper wrapped.
169
Packaging Applications
it
amount
as a replacement for
is
by no means the
main consideration
wrapper, and price
superiority
is
used.
is
will
The advantages
the
of
the
The
polyolefin
(4)
A package
by twisting or folding
opened loaves.
preserving flavor and
(6)
brittle.
Can be
In regard to
this,
much
It is
brittle at
low tem-
70
Polypropylene
made
flexibility
even
at deep-freeze
temperatures.
now
machines, are
At
present
it
satisfied that
is
same
more
the wrapper.
If
is
found,
it
will
be
it
effects.
This
is
Other Baked Goods. Although bread wrapping is the largwrapping baked goods, more than
packaging of cake,
now used
rolls,
crackers, biscuits,
and miscellaneous
items.
The importance
made
the
transparent
market
is
largely served
polypropylene film
To
is
no penetration of polyolefin
in
large
part to the wide variety
due
films in
purpose,
and
the lack of any single
of equipment used for the
not, as yet, been
It
has
large target, such as bread wrap.
date, there
this field.
is
practically
This
is
Packaging Applications
111
The problems
are
fact,
speeds,
in
and
their solution is
The advantages
erally slower
and
are even
life
such
more
because the
oils, fats,
The
The
its
and
clarity of
acceptance. Polypropylene
no such problem.
is
particularly
operates on a
it
much
industries.
showed
that,
is
most
recent survey by Modern Packaging magazine
among
is
true in
selling price. It
should
make
this industry
move very
however, to develop
this
172
Polypropylene
be needed to match
will
producers to retain
Poultry stuffing
Fruit cake
Pretzels
Iced cakes
Ice
cream cones
Marshmallow-topped
Cookies
Saltines,
soda crackers
Doughnuts
Sugar wafers
Melba
Zweiback
toast
Fresh Produce
is currently the largest market for polyconsumes about 75 miUion pounds a year,
growing rapidly. In certain applications such
Fresh produce
ethylene film.
and
It
this total is
Industry practice
is
these commodities,
comparative
at a
is
firmly entrenched.
and
difficulty of
this
is
it
ever,
may be
is
make
make
it
polyethylene
now
used.
now
A partial
list
follows.
Asparagus
Chicory
Cabbage
Escarole
Broccoli
Cherries
Cauliflower
Sweet corn
Green beans
Green peas
Grapes
Kale
Mustard greens
Celery
Packaging Applications
173
from the usual bag. Irregular shape and size, for instance, is
much more easily compensated for by an overwrap package.
For overwrap, the superior stiffness of polypropylene film will
have a great advantage. Cellophane is hardly a contender in
this field
because of
its
moisture sensitivity.
Table
Average
annual
supply
thousands
Crop
6.2.
Estimated
Estimated
Estimated
potential for
per cent
per cent
pkg
pkg
of lbs
1960
1965
polypropylene
thousands
of pounds
3,379
35
35
4.5
Beans, snap
542
50
2.6
Beets
137
20
50
0.4
Carrots
1,250
90
50
3.9
Celery
1,435
20
40
5.0
Corn
1,339
10
25
2.4
Grapefruit
Apples
1,732
20
20
1.3
Grapes
846
Lemons
589
20
20
20
0.4
10.0
1.3
3,280
50
26
15
20
0.2
Onions, dry
1,785
35
35
2.5
Oranges
4,796
20
20
3.5
parsnips
65
35
35
0.1
Peas, green
66
25
0.8
Potatoes, white
17,158
55
25
7.8
Potatoes, sweet
1,306
30
1.2
Radishes
Tangerines
236
337
75
0.8
30
20
0.5
Turnips
393
50
30
0.5
Lettuce
Limes
Total
Retail level packaging and items not listed
Liners
49.5
5.0
5.0
59^5
174
Polypropylene
The bag
costs
is
than at the
retail level.
minimum
ability
perform the
to
As
the
sig-
operation with a
of special equipment.
labor becomes
is
usually
distinct
in
more
advantage because
it
such equipment.
In order to
make
made by D. R.
Frozen Foods
Before discussing frozen-food markets for polypropylene
film,
it
is
toughness
down
resin
is
its
to deep-freeze temperatures,
flexibility
if
and
the proper
includes about
,000
differ-
Packaging Applications
ent items with a yearly
If
we exclude
volume of 6 or 7
175
billion packages.
changes which are not in the immediate offing, the frozenfood retail-packaging market will shape up approximately as
follows
Billions of
packages annually
Produce
1.5
0.5
Frozen foods
1.5
2.0
packaged
in a paper-
buying, but
it is
and does
The
already started a
movement toward
a polyethylene-bag pack,
made
in continuous sealing
flat film.
and
Machines of
many
filling
this
of
ma-
type are
With equipment of
and gloss of polypropylene film
should
make
it
a strong contender.
It costs
Its
considerably
less.
176
(
Polypropylene
3)
The
rolls of film
take up
much
less
further storage.
now common,
others are
item.
ing,
The
and storing in
and quality
tion of flavor
is
The
savings
The
boilable
cates for
some
as
package and
many advo-
its
ample
and
it is
Two
One
is
the
rolls.
This
is
film,
but poly-
already
There
is
its
condensation of moisture
The
on
is
essential to prevent
is
Packaging Applications
111
polypropylene.
At
all
is
to increase prepackaging.
prepackaged meat
field
needed strength. "Pliofilm" is also used to a considerable extent in fresh-meat packaging, in spite of its high cost and low oxygen transmission.
tective characteristics but lacking the
It is difficult to
market
depends on the development of films with the desired transmission properties at practicable thicknesses, and also of
better
versatility
its
present form
it
does not
The
potential market
is
year.
some
such as
and "Cry-o-vac." These films have a particularly good ability to conform to the contour of the poultry,
making a very neat and attractive package. Polyethylene film
"Pliofilm," saran,
is
its
178
cause
Polypropylene
it
this form-fitting
without
much
it
seems
likely
could be developed
trouble.
Confectionery
Almost 3
billion
in the
United States
its
can be an obstacle.
The
superior
gloss
and
make
it
of
clarity
this
polypropylene
film
amount
in a short time.
on high-speed machinery, so
it
179
Packaging Applications
manufacturers.
cellophane a year
manner
this
involved.
list
of products
wrapped
in
shown below.
is
Caramels
Lozenges
Chewing gum
Marshmallows
Chocolates
Mints
Hard candy
Jellies
Lollipops
Gum
Hygroscopic types
(butter mints, etc.)
Candy-coated nuts
Peanut brittle
Candy-coated popcorn
Candy sticks and canes
drops
Dairy Products
In
Polyethylene
is
its
is
generally
is
The only other major use for plastic film in this industry
in window tops for containers of cottage cheese, ice cream,
now
is
largely filled
lower cost.
The
million
Miscellaneous
Food Items
classes should
180
Polypropylene
packaging. Without going into detail on each one, the following partial
list is
Dried
flakes,
etc.)]
Chocolate (cooking)
Cocoa
Coffee (beans)
gelatin,
ice-cream
fruits
dates,
figs,
(apples,
apricots,
pears,
peaches,
Tea
dings)
Dog
food
(dry
and
biscuits
pellets)
all
food packaging
it
limitations.
Textile Products
Some
of the
from
soiling,
article
(4)
to
low
help selection,
cost,
many
appearance.
Until a few years ago cellophane dominated this market,
Packaging Applications
it
its
but
of
181
short shelf
this
field
in
success.
Polyethylene film
is
It is also
used
is
much
available.
of the sheet-
and pillowcase-pack-
when no
aware
seems
many
years ago,
of. the
likely that
films,
and
it
is
be when
it is
available in
wrapping machinery.
Considering the advantages of polypropylene film in
this
list
182
Polypropylene
some
gives
textile
propylene film:
Bandages
Hosiery
Blankets
Infants'
Shirts
wear
Shoelaces
Bolt goods
Linens
Sweaters
Children's wear
Tablecloths
Draperies
Napkins
Pajamas
Gauze
Pillowcases
Underwear
Gloves
Handkerchiefs
Pillows
Washcloths
Yarns
Towels
Sheets
Tobacco Products
Cigarettes are by far the most important tobacco product,
and the 40 million pounds of cellophane used yearly to
package cigarettes is a natural market for any new film.
At
this time,
cellophane
is
wrapping machines
this film.
machine-handling characteristics
should
make
Its excellent
it
easy
to
boxes.
should be less
field,
The problem
difficult
is
not
is
moisture-resistant
enough
such as aluminum
foil,
to
make
unnecessary.
183
Packaging Applications
to 3
or 4 milUon pounds in
5 years.
Paper Products
The number
many
annually totals
The major
billions.
item,
is toilet tissue.
packaged
which amounts
In general, these
premium grades
are
its
wrapping.
Polyethylene film
kins.
Annual
used to wrap quite a few paper nappaper napkins amount to about 500
is
sales of
for
some
time, purely
on a
A potential market up
cost basis.
The
unrealistic in 5 years.
Confetti
Napkins
Cups
Plates
Toilet tissue
Doilies
Sandwich bags
Envelopes
Garbage bags
Sanitary napkins
Towels
Typing paper
Shelf paper
Writing tablets
Gift wraps
Stationery
Tissues
Miscellaneous Items
In addition to the categories discussed above, there are
wrapped
in polypropylene film.
Many
of these are
now
cello-
184
Polypropylene
in
paperboard
Some
at
still sold in bulk or packaged in paper. These products should benefit greatly from
film.
Friction tape
Rubber goods
Candles
Clay (modeling)
Decalcomanias
Games and
Sanitary items
Glassware
Golf balls
Leather goods
Matches
Deodorants
(unscented)
puzzles
Moth
repellents
Slide fasteners
Soap
Sponges
String and twine
Thread
Plastic articles
Tire patches
Flowers, bulbs
Play balls
Tire wrapping
Powder
Wood
puffs
products
volume and must be considered experimental, so present consumption figures would be meaningless even if they were
available. Our estimates, therefore, are based on potential
markets and the known properties of polypropylene film,
compared to competitive materials. The timing of the development of these markets depends, to a great extent, on
factors that cannot be assessed accurately at this time. Merely
to give an idea of the magnitude of the market that can reasonably be expected, however, a summary of the previous
discussion
is
POLYPROPYLENE BOTTLES
When
linear polyethylene
pected that
it
Packaging Applications
for the squeeze-bottle business.
The
stiff er
185
resin should
make
It
may be
enough, but
stiff
Table
6.3.
it
when
squeezed.
1965
1970
Baked goods
Fresh produce
Frozen foods
Meat and poultry
Confectionery
Dairy products
80
50
20
20
250
200
10
Textile products
20
40
30
30
80
40
50
200
265
1,020
Tobacco
Paper products
Other
15
Total
We
80
60
it
by the blowing
this
The
feature
is
many have
some commercial
not
essential.
unbreakable gives
it
Where
cost
is
it
many
of these
186
Polypropylene
make
it
will process
enough
faster
Where
needed
strength
is
enough
is
a factor, the
less
amount of polypropylene
it
an
advantage.
:^^-^
Figure
6.1.
Powder Co. )
(Courtesy Hercules
Packaging Applications
187
The
makes
it
to
the
first
use of poly-
Only 7 years
and perfumes were nonexistent, but in
1959 they accounted for 77 per cent of the entire fragrance
market. In terms of the aerosol market, colognes and perfumes accounted for only about 8 to 9 per cent of the total
propylene arerosol bottles in the perfume
field.
aerosol containers produced, but, because of the luxury nature of the trade, they constitute about
One
this
field is
more
perfume
bottle
is
test
field
by
188
lar,
Polypropylene
but, as experience
is
built up,
should be possible to
it
many
aerosol
applications.
POLYPROPYLENE BOTTLES
Polypropylene
field.
It
AND CLOSURES
is
a highly competitive
is
by the
field,
availability of inexpensive
field,
shapes.
complete freedom to
and
ornament
to
it
in
is
also a
by molding
in exceptionally short
cycles.
The
light
it
is
it
on a price
is
make
basis.
It
superior to poly-
styrene,
189
Packaging Applications
sistance are also superior to polyethylene,
resilience so that
of requiring, at most, a
Polypropylene
thermoplastics in
is
and
it
has enough
it
minimum
of gasketing.
its
resistance to solvents
stress
INJECTION-MOLDED CONTAINERS
The
fast
ness
make
it
containers.
It has already had some success in this field. An injectionmolded ointment or cosmetic jar is currently in production.
This is molded with double walls, so that it closely resembles
the heavy milk-glass jar that has been standard in this field
for many years. It weighs only a small fraction of what the
glass jar weighs, thus saving shipping costs. Its light weight
190
Polypropylene
They
in popularity for
some
years.
This
is
and the
and the
In
is
now
of the sales
and hobby
field
where
many
like.
There
is
manufacturers in
this field,
and
may
in-
SKIN
The
rapidly.
display
plastic skin
AND
BUBBLE PACKS
excellent
the mer-
tirely clear,
drawback
make polypropylene
in the
is
films en-
a serious
lies
an
appreciable distance below the film, and where the film has to
Packaging Applications
is
films
is
ance.
is
191
lies directly
The
fact that
it
some advantage.
APPLICATIONS OF POLYPROPYLENE
IN THE DURABLE-GOODS
INDUSTRIES
The
fact that
we can even
of
significant
strides
plastic
is,
in itself, evidence
materials
shown
in
recent years
have made
wide vari-
that with
the
proper part and design, and under the right conditions, plastics
can be more
and longer
reliable
made
this material
can ben-
The producer durables consist of industrial-plant machinThey present some of the severest re-
of reliability
highest.
amount
The
192
and chemi-
recommend
it
as a
193
must be
attack.
The use
great impetus in
II,
and
this
and a disadvantage
is
both an advantage
new
material seeking to
to polypropylene.
The disadvantage
is
that
it
is
The advantage
is
worked
out,
is
could be
adverse environments
respect.
One
of the
equipment
is
main
very
significant
one,
because
it
The
difference
withstands
chemicals.
The
is
really a
service
makes
many
it
temuse-
corrosive
and resistance to stress cracking often make it possible to produce a vessel for some particular service with
considerably less polypropylene than any of the competitive
sistance,
194
Polypropylene
plastics.
For
this
may be
ap-
preciably cheaper.
polypropylene
tanks.
is
available.
Figure 7.1
made
of
in-
Figure
in the
7.1.
manufacture of chemical
specialties.
In addition to
and
is
fume hoods
available.
The use
some
practice for
rapidly.
is
much
is
Figure
7.2.
common
would be corroded
end construction
195
polypropylene liner in a
to allow for expansion.
many tempera-
Corp.)
up
liner
made
to
%
it
or
1 in.
The high
entirely practical to
is
196
Polypropylene
POLYPROPYLENE VALVES,
The use
PIPES,
AND
FITTINGS
carries with
them.
supply
Figure
is
7.3.
valve
made
enough
heat
chloride.
resistance
is
no
better
197
where temperature
some advantage
is
made
is
at a
pound, but
in cost per
is
its
specific gravity
higher. It
an
also
is
stability of the
means
its
that
complex shapes on
density,
is
is
low
Polypropylene Pipe
The
liquid service
is
starting,
and
it
it
will
polymers in
and lower
The
this service,
on the
largest
polyethylene.
volume of thermoplastic
This
is
used
chemical resistance
its
cost.
is
in
pipe,
however,
and similar
it
is
and farm-water
applications where
irrigation
is
the fact
198
Polypropylene
vantage in
this respect,
because
is
something of a disad-
at
a good deal
it is
stiffer
and
clamp-type
fittings
in the
molded
fittings
fittings.
it
limit
all
much
it
this time,
maintenance should be
less serious
polypropylene
is
at
polyethylene pipe.
It
must be kept
in
mind
that the
problem
it
to
is
itself.
not so
much
Devotion to
amount
of scrap
and
off-grade resin. This has resulted in poor pipe which has given
199
Figure
7.4..
{Courtesy
200
Polypropylene
same way
however,
this
manner, and
in this
The
as
metal pipe,
it is
its
unlike
polyethylene
pipe;
way.
industrial use
5^
2|
There
>5K
is,
in
as
plumbing
When
happens, polypropylene
for
many
is
known
this
candidate
of the components.
The growth
of
will
all sorts
AND
made
it
necessary
201
is
Figure 7.5.
warm
Fluor
Products Co. )
is
etc.
industrial cooling
it
202
Polypropylene
of the tower
critical,
is
The problem
of the outside
because
this really is
is
very
a packing which
which have shown better
styrene. This
is
where
and eventually
may
soften
This will warp polystyrene grids but will not affect polypropylene.
As long
as polypropylene
than polystyrene
it
will
is
more expensive
appreciably
is
industrial uses
is
where
its
chemical resistance
is
to
many
203
is
entirely
is
Figure
7.6.
made
of polypropylene.
{Courtesy Montecatini)
204
Polypropylene
The
an
installation that
its
cost
is
expected to
new
last a
insulation
long
ma-
go through long testing periods before being approved. These factors have delayed rapid acceptance in this
field, in spite of the fact that polypropylene is for many purterial to
Polyethylene
owed
its
original
and
is
of
no consequence.
used for two main purposes the transmission of electricity for light and power, and for commuInsulated wire
is
nications.
is
still
quite varied,
and,
and
heavy duty. Light-duty wiring includes all domestic wiring
and those circuits in commercial and industrial installations
which feed electric light and small loads such as for office
machinery. Such wire is now largely insulated with polyvinyl chloride-based insulations. Voltage used is small, genfor purposes of discussion, can be divided into light
205
220
erally
60
volts or less,
first
make
The
is
cheaper.
it
half mil of
Two
The
coatings.
stallations
first is
much
volts.
heavier
ing abrades
them heavily
at corners.
and
resistance,
slips
when
make
using poly-
propylene.
The
to cut
tions
is
where
it
is
under
strain.
when
the wire
is
and softening
is
it
is
that
gradually
a combination of simple
chloride. This factor also permits the use of thinner insulations with polypropylene, without increased danger of failure.
Polypropylene
is
somewhat more
stiff
if
and
less
the same
would be
thickstiffer
206
Polypropylene
is
This
is
now
some rubber
also used.
would
still
be
stiffer.
Since flexibility
it is
is
however,
the
cord
a major requirement
This
main
is
lines.
is
an
entirely different
mat-
These
lines are
It is
pos-
marginal applications of
thermoplastic will take
it
this type,
but
it is
be used in certain
doubtful that any
over altogether.
Communications Wire
Communications wire
is
207
and telegraph
polyethylene.
It
industries
cable sheath-
is,
at present,
this,
wall
thicknesses
rather
are
heavy,
form.
is
is,
at present,
The advantage
is
of
that
a thinner insulation.
mined
either
strength.
by
its
The
insulation thickness
electrical resistance or
by
is
its
not deter-
mechanical
is
in-
insulation
to
208
Polypropylene
advantage
is
a change for
small, however,
this
solid insulation.
because of
its
this
is
make
this
an
actuality,
but
going on.
has been
is
used for a number of electrical applications where temperature is not a problem, such as switch plates, appUance plugs,
etc.
Polypropylene
much
is
and price
is
first
being
is
made
of
of secondary importance.
Equipment
Polypropylene
sockets,
pletely
fabric-
ance
is
make
and economically.
Figure 7.6,
coil
The
injection-mold-
these
209
I
Electrical Applications of Polypropylene
Film
their
earliest
applications in the electrical field. In this field, superior properties will justfy the relatively
is no exception
and a considerable amount of polypropylene film has been used, mostly in the form of tapes, for a
variety of electrical applications. These include capacitor dielectrics, cable-barrier tape, layer insulation, and the taping
of coils and foil-wound transformers. The high dielectric
strength of thin films, excellent heat resistance, low dissipation factor, and good winding characteristics have made it
initial
to this tendency,
in such applications
field,
but
it
is
small com-
does represent a
CONSUMER DURABLES
The consumer durables
people term the American
we
of
life.
They
what
way
we
in this field
is
not only
a source of pride for the industry but a real promise of growis already making a contribution
and there is every reason to believe that it
soon be one of the most important plastics for such
applications.
210
Polypropylene
its
appliance industry
is
use
is
Figure
7.7.
parts.
(Courtesy Montecatini)
left,
a hair dryer;
111
one-piece polypropylene
more
scraped
colored
line of dishwashers.
Not only
is this
less expensive;
be cut or
is
no coating
The polypropylene
the way through.
is
to
it
plastisol.
off.
all
new
is
possible to
make many
many
its
superior
physical properties.
The vacuum-cleaner
shown
in Fig-
The
makes
it
possible to use
an application where there are potentially such high temperashows clearly how far superior polypropylene is to other
tures
Polypropylene
212
'
^.__.
Figure
7.8.
Vacuum
m^^M
parts.
(Courtesy Montecatini)
213
its
styrene,
aluminum, high-impact
Figure 7.9.
Montecatini)
The
entire blade
one time.
it
Its light
can reach
full
at
less
bearing load.
214
and
Polypropylene
is
much
less
dangerous
made
if
grill,
makes imbalance
less of a
it
to the best
aerodynamic prin-
is
and other
is accom-
in a polypro-
itself
to
be particularly well
arm
main
out of polypropylene.
tion
and for
its
It
was chosen
for
its
is quite permeable to
one of the solvents involved, but this is no
this application. Many of the weaknesses of poly-
obstacle to
made
ease of fabrica-
215
The
and
its
purpose
mand
now
is
available, but
its
is
much
too exten-
differences in tension.
ciently
its
extensibility
to obtain
material
is
it
appears to
Its
stiffness
and strength
characteristics
are
now commonly
more
used, and
much
ment
it
resistant to moisture
that
now
such
film.
In addition,
it
As
with so
many
it.
long, because
is
is
many
This
216
Polypropylene
gelatin
is
well bonded.
The
It
on any
large scale.
the greatest
is
only steel parts could meet these standards. Very few plastics
are able to withstand the severe service requirements.
The automotive
all its
emphasis on modernity,
style.
The main
European car
shown
that the
American
111
to
Figure 7.10.
parts.
on one part
from
one
plastic
part
molded
in
single
to
adopt
operation.
own manufac-
in point.
Many
other func-
218
Polypropylene
The actual motor parts are probably out of reach of polypropylene for reasons of high temperature; and parts in direct
contact with gasoHne, such as fuel lines, pumps, carburetors,
etc.,
made
are better
is
is,
is
members
will
be
steel for
plastics, especially
arm
rests,
etc.
The
much
molded
The
in
real
economy
will
come when
all
can be molded in, thus eliminating the present tangle underneath the dashboard. This archaic and wasteful construction is long overdue for a sweeping redesign,
electrical wiring
made
of plas-
its
219
use even on
body panels.
as
lamp
fuse blocks,
horns,
It is
pounds
Polypropylene Furniture
Many
furniture field,
and
this
viewpoint
is
being strengthened by
One
of the
first
furniture-like
keep
initial
pected that
is
applications
up
this will
jection
molding today
manner
be ex-
may be
very
is
commonly handled
in
few years.
In addition to the molded pieces mentioned above, polypropylene is appearing as webbing, woven from monofilament. This webbing forms the back and seating of metal
outdoor furniture. Polypropylene monofilaments have weather
this
in a
monofilament and
its
resist-
ance to cold flow keeps polypropylene webbing from deteriorating with time.
220
Polypropylene
very ingenious polypropylene assembly clip for holding
the
8.
APPLICATIONS OF POLYPROPYLENE
IN THE SOFT-GOODS INDUSTRIES
all
the
many
things
we
we use up
Although the requirements for many of these
applications are quite severe and entail very special properties, they are rarely as extreme as in the hard-goods field.
and wear
It is
the things
out.
it
many
cheaper.
It also
more salesmanship
takes
to sell
200 miUion
starts
with a discussion of
fibers.
Many
people
expect this to be the largest single application for polypropylene, yet, except for a rather small
the material
is
practically
unknown on
POLYPROPYLENE FIBERS
In marked contrast to the rapid growth of the plastics
industry, the textile-industry growth has not even kept
up with
consumption in the
United States has averaged 6 billion pounds a year since
World War II, with rather wide fluctuations but no net
the population
increase.
Textile-fiber
growth.
221
222
Polypropylene
product in
It is
this industry.
new
synthetic
it is
In spite of
this,
an
official of
little
pylene
fiber.
essential.
shows that it
ducers to be
is
fiber
is
as strong as
good abrasion
223
pound
of polypropylene
is
facturing costs,
rayon
is
it
be
will eventually
in the general
manu-
range of
pylene fiber
is its
versatility.
market
production in
second largest
It is
taking over
is
for marine
facilitates
it
to float
if
accidentally lost
224
Polypropylene
Figure
overboard.
8.1.
It also dries
its
it
when
make
poly-
it
resistance to oil
and grease.
225
The
line.
stresses,
but
lene line
it
will
still
as
is
and
appreciably cheaper.
Table
8.1.
Comparison of Ropes
Breaking
Inches
around
Fiber type
Manila
same
strength (lb)
Weight per
ft
(lb)
Cost per
ft
(dollars)
12
105,000
4.36
2.57
Polyester
103,000
2.07
7.90
Polypropylene
81/2
106,000
1.70
3.91
it is
much
much
is
clearly
why
polypropylene
recent development
is
Somewhat higher
is
is
rope
made up
of fibers as fine
tenacities
may
it
it
as
well.
Polypropylene monofilament also has applications in chemresistant filter cloths and other heavy-duty fabric
which needs strength and chemical resistance.
ically
226
Polypropylene
highly probable that polypropylene monofilament will
It is
many
of the uses
now
served by
webbing,
etc. Its
much
furniture upholstery,
to
its
resins
on a
make
it
possible
price basis,
and
April,
1957,
Milan
Montecatini
exhibited
polypropylene
These consisted of pure polypropylene, and polypropylene-wool blends; they were indistinguishable in texture, hand, and appearance from pure natural
woolens. Figure 8.2 shows wool-like polypropylene fabrics.
The blanket in the upper left is pure polypropylene, and so
are the hound's-tooth check below it and the modified plaid
at the upper right. The glen plaid in the center is a polypropylene-wool blend.
Everyone who has had an opportunity to handle these
fabrics at the
fabrics
is
Fair.
There appears
to
Even
and
is
excellent.
wool
Figure
8.2.
Polypropylene
fiber fabrics.
its
227
(Courtesy Montecatini)
wide variety of fibers, and in the form of staple, multifilament, and monofilament yarns suitable for every textileto a
manufacturing operation.
228
Polypropylene
Silk-like
The
Polypropylene Fibers
multifilament yarns
produce fabrics
silk.
Although
are
very
similar
to
silk
and
this
market
is
it
still
readily take
it
should
polypropylene
fiber.
The latest development in polypropylene fibers was introduced by Montecatini in 1959. This consists of polypropylene fabrics, and blends of polypropylene and viscose, that
closely resemble cotton and linen. The synthetics have heretofore kept away from this market, in spite of the fact that
cotton is still the most widely used fiber. This is because price
competition from cotton has made it unattractive. The
ultimate cost of polypropylene fiber should be low enough to
make it possible to compete in this field, and considerable
penetration of the market should be possible even at a considerably higher price.
strength
The polypropylene
much more
resistance,
and
it
should be
static
charges.
all
floral print in
Figure
8.3.
229
the upper left corner and the period print at the lower right
are
viscose.
cent
cent
polypropylene.
crisp,
hand
characteristics of
230
Polypropylene
By
it
appears
compete in any
textile
market.
As with
fiber,
and Monte-
catini
no
essentially
different
carbon
resin,
for dyeing.
One
sites
monomer
is
necessary
to copoly-
containing an active
is
It is
probable that
this is the
way polypropylene
available.
Some
actively investigating,
At
this
will follow
and
fibers.
Rayon Corp.
is
the only
Amer-
polypropylene
trial
fiber.
Since this
applications, they
may
company
feel
specializes in indus-
sufficient
The
231
NONWOVEN
NETTING
made
available in the
it
It is
is
used
many
applications for
for instance.
filter
support
its
corrosion
and containers of all sorts. When made from thin sheetwebbing is quite flexible and has possibilities for
conveyor belts, hammocks, and outdoor furniture.
bins,
ing, this
cover on the
wooden
heels of
232
Polypropylene
other
and impact
plastic
styrene.
market
will
it
appears very
this
country.
Although
it
on treating it as if it
wood. They nail it to the shoe and also nail
a lift to the bottom of it. They even insist on using a
curious blunt-pointed nail that was very reliable on wooden
is
were
still
made
of
heels.
It
give
them some
all
these re-
makes
its
resistance
to creep helps
it
and
233
Uke
entrenched that
it is
to
wooden
heel,
and
is
is
so firmly
The
solvents
weaken most
Polypropylene
is
ex-
around the top. These rapid changes in cross secand the presence of the steel insert, create problems
with flow marks, sink marks, splitting around the insert, and
others. The combination of free flow and good physical
properties makes polypropylene one of the easiest plastics
thin edge
tion,
heels
It
now
tually
shoe-heel
Some shoe
leather.
made
of polyethylene
vulnerable.
234
Polypropylene
What
is
vulnerable, however,
antiquated industry.
It is
is
this
entire
musty and
happens, and
of flexibility
is still
in the future.
When
will not
<;
(I)
"I
purpose.
how
the injection-
is
for house-
wares.
injection molded.
The
largest
235
indication of
shown
that
glass,
it
and
will con-
what
is
to
come.
Drinking Glasses
Plastic drinking "glasses" are already quite familiar.
Many
soft,
it
is
almost
and nearly as tough as polyethylene. In addition, it has ample heat resistance for any
temperature likely to be used, and is very abrasion-resistant.
In addition to glasses of normal design, polypropylene is
being used in some ingenious double-walled glasses designed
to keep hot drinks hot and cold drinks cold. Since this glass
is made of two molded pieces that must fit into each other
as
hard and
stiff
as polystyrene,
parts
is
make
reproducible
valuable.
Dinnerware
One
field that
has seen
little
practically
It is
236
Polypropylene
by
institutional users
it
many
where breakage
some
markets, especially
is
an important cost
Figure
8.4.
Polypropylene picnic
setting.
(Courtesy Spencer
Chemical Co.)
substitute,
Polypropylene
The
its
entirely.
already
been
made
dinnerware,
it
however,
has
by
to
fast-cycle,
237
and
designs,
stolid
is
free
from such
limita-
porcelain
because
teacup
it
is
little
too
flexible,
but
moderate thicknesses. The freeflowing properties of polypropylene make the molding of the
most complex shapes quite easy. Polypropylene should continue its growth in this field. Figure 8.4 shows a complete
adequately
it is
stiff
at very
Kitchenware
Polypropylene
is
many kitchenware
items.
At
pres-
ware item
is
better,
if
expensive, in polypropylene. Mixing bowls, pitchers, dishpans, measuring spoons, funnels, pails, water bottles, colanders,
many more
all sorts
line
also
they will
come
in contact.
it
possible to fasten
238
Polypropylene
article, either
by molding them
in
may
Figure
8.5.
At
ings,
to
present,
it
make
etc.,
are difficult
steri-
hzation.
SANITARY PRODUCTS
Hospital and sickroom equipment that must be steriHzable
in this field,
ful.
In spite
Figure
it
is
8.6.
239
Polypropylene
articles
can be pro-
240
Polypropylene
makes
even
it
better.
sterilization.
One
of the
made out
It will
in attractive colors.
oldest plastic
It is
the
applications,
toothbrush
It
seems quite
likely that
this
made of polypropylene.
A related item made in this country is a carafe and tumbler
set for hospital use. The carafe has a disposable plastic-film
toothbrushes
liner
sterilization.
When
at all times
without daily
One
was
of the
first
American applications
of polypropylene
shown that there were many applicawhere the plastic is better than glass. The superior heat
resistance and strength of polypropylene obviously extend
laboratory ware had
tions
this
The
first
is
unsuitable, such
attack glassware.
Many
it
is
less
fragile.
done
in poly-
Polypropylene
will overheat;
is
so
241
be poured into polypropylene beakers, and exothermic reactions resulting in boiling-water temperatures
can be safely
Most
made
WW ^
^
i
Figure
8.7.
ical funnels
sizes.
filter
is
quite
if
accidentally
accordance with federal specifications. In addition to unbreakabihty, these cyUnders have the advantage that the
liquid level can be read
more
easily
than in
glass,
because
is
perfectly
shown
flat.
Typical examples of
in Figures 8.7
and
8.8.
242
Polypropylene
recommended
and photographic
chemicals.
Figure
8.8.
POLYPROPYLENE TOYS
The toy
first
to use plastics in
article for
many
243
Polyethylene,
cellulosics
styrene
vinyls,
copolymers,
and even
this trend.
Formed polypropylene
sheet
etc.,
is
tricycles,
bicycles, etc.
The
great
volume
The high
in plastic toys
is
in injection-molded
molds tends
to retard changes
Using polystyrene or polyethylene molds with
polypropylene increases the cost of the article, because no
advantage can be gained from the superior strength of the
articles.
cost of
in this field.
Some
kits, is
kits is
home
volume
is
in the inflatables,
propylene competition.
some
is
not
to poly-
244
The
Polypropylene
largest
Polypropylene
its
is
now
much
of
some
make
applications where
it
superior to other
typical
example
is
advantage in
fits
this trouble.
is
one great
this field.
INTEGRAL-HINGE APPLICATIONS
may be used for a variety of applifrom luggage to notebooks, it seems worth while to
make special mention of the one-piece molding with a narrow
Since hinged articles
cations,
as
a hinge.
life
of the hinge
is
it
has more
The
it
makes
good abrasion
resistance.
its
appearance retention
is
essential,
life
245
with good
should be in demand.
It
Up
made
in this
way.
FUTURE DEVELOPMENTS
9.
polypropylene.
New
We
will start
COMMERCIAL DEVELOPMENT
Development
It
of the Industry
seems very
methods and
company making
selling this
resin
by mass-production
raw material
to a host of small
finished or
geographical area,
who make
it,
case of polyethylene.
had grown in size and comwhere the limited financial and technical
resources of the film-extrusion industry could no longer keep
The
polyethylene-film market
246
Future Developments
up with
it.
The
247
staffs and great development laborawhich had no other purpose than furnishing technical support for their customers. The processor was no longer
able to afford the technical staff essential for him to remain
in business.
meant
that they
were
it,
it,
Most
all
who
integrate
backward and
start
prob-
will, in all
making
resin,
as has
film will
and AviSun
is
following
it.
The
fiber
similar
lines.
At
is
and
resin.
least
difficult to achieve.
The molding
its
own
shown a
248
Polypropylene
The vacuum-forming industry is similarly characby captive shops operated by the consuming in-
ing shops.
terized
dustries.
the large
volume
is all
production
who
now
in near prospect. It
from
it,
is
resources.
The
perhaps for a
little
Any
fails
to
much
not so
was
consuming industries lacked the technical and financial resources to develop them at anything like the speed necessary
to use the resin production capacity.
There
make
will
is
little
be
and the
built at the
same time
The small
it.
plastic processor
who
has
filled
thousands of
249
Future Developments
has served his purpose in
lifting plastics
from a
tiny special
He must now
gristmill.
The
is
list
section as having
announced plans
way
E.
Petroleum Corp.
Many
others are
known
to
be
active,
is
an
signs of developing as
field,
pylene
fiber.
This material
is
trade
250
Polypropylene
New
Castle, Delaware,
is
start
making polypropylene
fiber
in
pounds of
staple fiber
a year.
who can
supply
it,
make
and
resin.
Capacity Prospects
Future Developments
it
251
is
problem indicated
by the polypropylene producers that give any hope that polypropylene will be able to achieve the goals set for
it.
Market Prospects
It is
1959.
It
is
10 million
Some people
in the industry
mid
60's. It
seems quite
is
grown
another matter.
at
It is
at
252
Polypropylene
it
after polyethylene
and polypropylene
servative,
eventually; however,
its
it
will
is
probably exceed
achievement
A possible
1960
1961
100,000,000 lb
1963
1968
1,000,000,000 lb
30,000,000 lb
250,000,000 lb
propylene
is
such that
it
may be
possible.
Price Prospects
The
markets
is
shown by
market development. At
mass
even
present, poly-
last
253
Future Developments
As noted
is
really of little
impor-
produced
will
The important
resin.
be
advantage, puts
price
it
its
fiber
may be much
The
ultimate
lower.
TECHNICAL DEVELOPMENTS
The
most
interesting of
all.
possibilities
be considered
nology.
stiff
is
simply in degree of
all
concerned with
resin that
capable of
tacticity. It
many markets
rubbers.
254
Polypropylene
high-value
applications
the
can be
processing, difficulties
overcome.
This
is
plastic
this caliber.
Stereoblock Polymers. The stereoblock polymers mentioned in the section on polypropylene chemistry will certainly
if
promise of giving resins that behave lik6 a vulcanized elastomer, without the need for the time-consuming vulcanizing
step, this
Copolymers. In addition
to these variations
this field.
which
The
made
in co-
many
relate to
great
it is
number
of these
able polypropylene
comonomer
may be produced by
the inclusion of a
is
be made of a copolymer. Some other physicalproperty variation may be more readily made by copolymerization; permeability is an example. Specific resistance to
specific permeants may be made possible by certain copoly-
may
also
merizations.
255
Future Developments
rubber in
many
fields.
monomer
It is,
base
may
of the rubber
clearly defined
that,
whatever the
will
have
first
be used,
by virtue
demonstrated
with polypropylene.
High-pressure Polypropylene. There have been recent rumors that a high-pressure process, similar to that used to
make
difiicult
many
This
"^--that
more
is
only one of
cluding in our
that
may be
considerations
expected.
we
first
other plastics
of
this
type
sterically
Mono-
256
Polypropylene
than propylene can be polymerized into steriordered polymers of valuable properties. Somewhat
olefins higher
cally
surprisingly,
tenacity can be
monomers.
is already being produced in pilot-plant quanby Montecatini in Ferrara, Italy. Its usefulness for many
of the applications mentioned in this book for polypropylene
has been demonstrated. Petro-Tex Chemical is building a
pilot plant in Houston, Texas, to produce this polymer, and
many others are also interested. PetroTTex has been studying this polymer since 1955, and they feel that it has great
possibilities in pipe and film. Especially for the latter use,
superior tear strength recommends it over polypropylene.
Many of the traditional monomers such as styrene and the
Polybutene-1
tities
ferent properties
mers. Certainly
from those of
many
their ordinary
random
poly-
The
interest
257
Future Developments
As was
the
when
more
ization or in other
means of
molecule.
The use
of reinforcing
dimensional
stability of
development;
also,
fillers
to
polypropylene
a highly probable
is
It is
possible to
foam
and
its
probable that
It is
all
utility.
propylene more exactly to specific applications will be explored in the near future, as well as
perhaps
now unknown.
DEVELOPMENTS
IN
PROCESSING TECHNOLOGY
Two
lighted
first is
developments in processing technology which high1959 have great implications for polypropylene. The
the growth surge in blow molding. This process, which
some
was no mean
feat,
may make
it
off
on an
ma-
acceler-
molding. Polypropylene
is
and
this appli-
Many
other
258
Polypropylene
applications
now
able to competition
technology develops.
The
much
have been
may be more
as this
which
pylene.
Germany is a
The great gain
in
biaxial orientation
means
gets
from
Company may
well
film.
They
is
which heat-seals
temperatures of 250
the seal can be
This makes
it
to
at well
makes
it
made without
on machinery which
The
film
is,
at present,
259
Future Developments
It is
will
polypropylene.
Cold Stamping
Another processing development that has seen only small
may well assume major dimen-
is
its
makes
than
with
traditional
to large-scale
methods.
hot-forming
This
mass production.
Polypropylene Paper
entirely
new
fields
that
may be
film,
is
many
applications
for
that, in the
260
light,
Polypropylene
polypropylene
is
much more
drying out and becoming brittle nor being attacked by dampness and microorganisms. It could well
become
the writing
is
its
is
nec-
Polypropylene Waxes
Low-molecular-weight isotactic polypropylene waxes have
a great deal of promise.
points, great
low melt viscosity. Possible applications are polishing waxes and modifiers for other plastics,
coatings, etc. These waxes may be polymerized directly under
some conditions but are more conveniently made by thermal
surface hardness, and a
oils
and greases.
It
may
also
bonding polypropylene.
PROGRESS
IN APPLICATION
logical
Future Developments
261
Examples of industries are machinery, appliance, autoetc. These fields have already begun to use some
plastic parts but are still largely oriented toward the metal
trades from which they originated. To a great extent they
have been discouraged from considering plastic parts because
the independent plastic processor did not have the financial
resources to furnish the volume of parts required, or the technical resources to make them with the necessary control and
precision. This situation is rapidly changing, and these industries will soon either have suitably financed and technically competent suppliers, or they themselves will build
ucts.
motive,
processing
facilities.
The economic
the 60's.
become
The consumer
better bargain.
is
and
traditional metals
get,
trades
facing mounting costs, the only recourse will be an increasing use of plastics.
The
in the
same
direction.
Up
primary advantage
struction
is
The
now
building industry
is
The
this stage
262
Polypropylene
was an
portion of the
of
built
are
more or
less
fac-
plastics.
The
building,
building practices,
is
to
in
many
communities that require the use of certain specific tradiAlthough it would be foolish to expect this
obstacle to evaporate quickly, more and more communities
tional materials.
There has also been an increasing trend toward the conand unification of building codes which decreases
the number of authorities that have to be convinced of the
solidation
who
will
making a
troduce
look
living.
new
few
at
This will
make
it
is
fol-
lowing pages.
The use
newly de-
Future Developments
may broaden
that
263
this
called
is
which
is
is
is
captured by the
enough
The discharge of
up electro-
plastic, setting
The
plastic
is
then softened
deform the
beam
nearer.
is
in progress to determine
now
if
poly-
going on between
it
is
its
and there
is
some question
264
Polypropylene
make
not possible
known
to
it is
it
is
resistance, will
be developed
The
The
point of view,
is
quite
amazing
if
long
it.
pre-
are the
most primitive
possible, going
together, the
We
way
still
Romans
largely plant
and animal
dawn
end of
back
could
to the
make con-
hairs twisted
of civilization.
this
dependence on
it
is
one of the
first
life
all
of the great
this transformation.
new
make
INDEX
14, 16
Creep, 26
Crystallinity,
75
Crystallite size, 91
AviSun Corp., 7
Crystal structure, 71
122,
258
Density, 13, 16
Bottles, 184
Boxes, 190
Brittle point, 53
Dinnerware, 235
Diolefin polymers, 84
Bulk resistivity, 12
Burning rate, 13
Burst strength, 62
Dow
Chemical Co., 7
Closures, 188
modulus, 13, 16
204
Electronic components, 208
Coating, 128
Elastic
Electrical uses,
Coloring, 104
16
12, 14, 16
265
12, 14,
266
Index
Extractables, 80
Extraction, 100
Kitchenware, 237
6, 54,
163
Flame
Linear polyethylene,
spraying, 161
Machining, 160
Magnetic tape, 215
Flexural strength, 20
vs.
temperature, 138
Modulus of
Gas permeability, 58
Heat
Mold
Mold
design, 145
59
Industrial
Montecatini,
4, 6,
12
"Moplen," 12
44
scalability, 57,
Immersion,
variables, 149
21
resistance,
effect of,
Rayon
32
Corp., 8
Natta, Professor, 2,
Nonwoven
netting,
3,
88
83
231
Optical activity, 74
Ordered dienes,
58
Overwrap packages, 167
Oxidation, 42, 86
Oxidation stabilizers, 43
Oriented
Oxygen
film,
transmission, 58
In phase modulus, 29
Intrinsic viscosity,
16
Molecular weight, 87
Monofilament extrusion, 129
Monofilament uses, 223
16,
elasticity, 13,
Molding
Heat
Heat
22
Loss factor, 27
Flow
1, 5,
Packaging, 163
267
Index
dairy products, 179
Resistivity, 11, 17
Rockwell hardness,
Rope, 225
12, 20,
48
180
textile products,
tobacco, 182
Shear
rate,
Paper, 259
Shoe
parts,
hexane. 38
hydrogen peroxide, 39
methyl-ethyl ketone, 35
silicone oil, 36
volume,
12, 18
7,
16
Stabilizers, light, 41
215
film,
197, 258
Polymerization, 96
Sulfochlorination, 87
"Poly-Pro," 16
Surface
Powder, 161
resistivity,
60
Syndiotactic polymer, 70
factor, 12, 17
wire;
Specific
Spherulites, 92
water, 34
Power
Power
'"^
isopropyl alcohol, 37
methyl alcohol, 36
Photographic
228
"Clorox," 40
6,
231
to
chloroform. 37
Pipe,
Shear strength, 50
Sheet extrusion, 124
Permeability. 77
resistance
Synthetic rubber,
204
3,
84
Tacticity, 65
Production, 94
Tanks, 194
Tensile modulus,
"Pro-Fax," 10
10, 16
Puckering of
film.
117
volatility,
pylene, 95
propane-pro-
Torsion modulus, 23
268
Index
Trays, 190
Vacuum
Weld
Toys, 243
Valve
13
1
19
values, 160
Wool-like fabrics, 226
forming, 151
gating, 141
Valves, 196
Viscosity, intrinsic, 88
Volume
60
Yield
47
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