Introduction

Organic materials:
Materials obtained directly from carbon and chemically combined with oxygen, hydrogen and other nonmetallic components

Natural organic materials Wood, coal, petroleum Synthetic organic materials Plastics, synthetic rubbers

POLYMERS
Poly many
Mers parts Polymer- several repeating units

Monomer -Single unit

Resin- liquid form of plastic Acrylic resin, polyethylene resin, amino resin

Polymerization
Polymerization is the process of linking thousands of

monomers to form a large molecule Addition polymerization similar monomers are added chemically No catalyst is used No by products Condensation polymerization Dissimilar monomers are added Elimination of smaller molecules occurs Water or ammonic is formed as by products

Additives
A no of additives are normally used with plastic materials to modify their behaviour, improve properties or reduce the overall cost thereby increasing the range of application of plastic. Types: Plasticizers: these are mixed with plastic to improve their flow characteristics & decrease their brittleness. Flame retardants: these are added to plastic to reduce the flammability of plastic by preventing oxygen reaction Reinforcing agent: these are the materials that are specifically added to plastic materials to raise their mechanical properties. Stabilizers: are used to stabilize the properties of the plastic throughout its useful life

 Lubricants: reduce friction Initiators: initiate the reaction

Dyes and pigments: impart desired colour

Modifiers: improve mechanical properties Catalyst: promote faster and complete polymerization Fillers: improve strength and stability mica, asbestos

Plastic materials
Polymeric materials

plastics

elastomers

thermoplastic

thermosetting

Commodity plastics Polyethylene Polypropylene Polystyrene,PVC

Engineering plastics polyamides acetals cellulosics

Commodity plastic phenolics unsaturated polyester ureas

Engineering plastics silicones urethanes melamines

Thermosetting plastics
Thermosetting materials: Hardened by heat effecting non-reversible chemical change Cannot be reworked Condensation polymerization Time consumption is more Thermosetting resins: Phenol formaldehyde Polyster resin Melamines Phenol furfural Epoxy resins Silicones Urea formaldehyde Alkyds polyurethanes

Thermosetting resins
Phenol formaldehyde
Bakelite Dark colour High strength, stability, rigidity

Uses: plugs, bottle caps Polyster resin Variety of colours Low moisture and good electrical resistance High cost Uses: TV parts, car bodies Melamines Melmac, catlin, melantine,plaskon good electrical and heat resistance Uses: telephone sets, switch pannels

.
Phenol furfural
Good flowability Good resistance to moisture & electricity Uses: brake linings, electrical parts

Epoxy resins
Araldite Good chemical & electrical resistance High cost

Uses:tools and dies, electrical parts

Silicones
Good resistance to heat upto 260 degree C Uses:laminates, coatings

Urea formaldehyde Up to 77 degree C

Uses:toilet seats, buttons

 Alkyds
Oil-modified polyesters Good resistance to heat& electricity Uses:automobile ignition parts

Polyurethanes
Uses: cushions in transportation seats, packing material

Thermoplastics
Thermoplastics:
Separate long & large seized molecules Softens on heating & hardens on cooling Can be reworked Melting temperature varies

Types of Thermoplastics Cellulose derivatives Synthetic resins

Types of Thermoplastics
Cellulose derivatives Cellulose nitrate Cellulose acetate Ethyl cellulose Cellulose butyrate Cellophane Cellulose propionate Synthetic resins
Polyethylenes Polystyrenes Acrylic resins

Vinyles
Polytetra fluoro ethyelene Polyamide Methyl methacrylate

Cellulose derivatives
Cellulose nitrate

Cellulose + nitric+sulphuric acid High toughness, good resistance to moisture Uses: spectacle frames,table tennis balls Cellulose acetate Cellulose +acetic acid High stability & mechanical strength Uses:toys ,tubes, rods Ethyl cellulose Cellulose +ethylene Good electrical properties Uses: dies, nozzles

 Cellulose butyrate

Cellulose +butoric acid Stable against light and heat Uses: radio cabinets, steering wheels Cellophane Attractive appearance Resistance to moisture Uses:curtains, packaging Cellulose propionate Temp upto 93degree C Resistance to moisture Uses: fountain pens, telephones

Synthetic resins
Polyethylenes
Good insulators Uses: pipes, trays

Polystyrenes
Different colours, Crack under load Uses: battery boxes, radio parts

Acrylic resins
High transperancy Resistance to moisture Uses: tubes, plates

Vinyles
PVC Electrical & temperature resistance Uses: raincoats, insulation

 Polytetra fluoro ethyelene

Teflon Temperature up to 288 degree C Uses:electrical insulators, chemical containers

Polyamide
Nylon High strength and resistance to wear Uses: bearings and couplings, wire insulation

Methyl methacrylate
Lucite and plexiglass Light transmission capacity Uses: transparent bowls, contact lenses

Moulding of thermoplastics
Injection moulding
Plunger type Screw type

Blow molding Rotational molding Film blowing Sheet forming process Extrusion process Vacuum forming

Screw type injection moulding

Ram or plunger type injection moulding

Blow molding

Rotational molding

Film blowing

Extrusion process

Sheet forming process

Vacuum forming

Processing of thermosetting
Compression moulding

Transfer moulding
Compression moulding

Transfer moulding

Bonding of thermoplastics
Bonded by lamination High pressure laminates

7MPa & 150 degree C Asbestos, cotton fibres

Low pressure laminates

Paper, glass fibers are used

Fusion & solvent methods

Hot gas welding Nitrogen, hydrogen

Hot tool welding

Ultrasonic welding

Induction welding

Other processing methods

Solvent welding Solvent is applied PVC pipe joints Reaction injection moulding monomers are injected into mould Chemical reaction melts the monomers under pressure Cold forming raw material is pressed in mould at room temperature Cured in oven 14MPa to 84MPa

 Solid state forming Stretching, bending, deep drawing Food packaging tubes, containers Thermoplastic stamping polymer sheet is pressed in dies spring back is minimum