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&
APPLICATIONS
ALOK KUMAR
CENTRAL INSTITUTE OF PLASTICS ENGINEERING
& TECHNOLOGY,
USAGE OF PLASTICS IN MODERN
CARS
PVC
PE 17%
36%
0.26%
s
PC
Acrylics 2% PS/ SAN/ ABS
1% Nylon 6 & 66
15%
1%
PE Acetal PP PBT
PET PVC EPS PS/SAN/ABS
Nylon 6 & 66 PC Acrylics
LL/LLDPE
PVC 17%
20%
HDPE
14%
GP-HIPS
PP 8%
ABS/SAN
24% PC EPS PET
6%
2% 3% 4%
Other ETPs
2%
Area %
Health
Consumption
2% Defence &
Telecom/el other Consumer Defense & others 2.0
ec. 2% 5%
16%
Consumer 5.0
Transport
6%
Durables
Transport 6.0
Packageing Packaging 23.0
23%
Infrastructur
e
24%
Plasticultur Plasticulture 22.0
e
22%
Infrastructure 24.0
Telecom/ 16.0
Electronics
Health & 2.0
Medicare
PLASTICS-THE MATERIAL
OF CHOICE
• User Friendly
• Versatility
• Light-weight
• Energy Efficient
• Non-corrosive
• Aesthetic
• Abundant
• Recyclable
PLASTICS – Emerging Material
to meet
Engineering Application Demands
• Density
• MFI (Melt flow Index)
• Mechanical Properties
• Impact Strength
• Stiffness
• Toughness
• Creep Resistance
• Abrasion Resistance
• Tear Resistance
Optical Properties
Gloss Clarity & Opacity
PLASTICS – Emerging Material
to meet
Engineering Application Demands
Environmental Stress Cracking Resistance
• Chemical Resistance
Acid Resistance
Alkali Resistance
Hazardous Chem. Resistance
( Pesticide / Insecticide)
Barrier Properties
Water Vapour Transmission Rate
Oxygen Transmission Rate
Aroma Transmission Rate
PLASTICS – Emerging Material
to meet
Engineering Application Demands
• Easy Processibility
Printability
Sealing Property
Seal Strength
Cost Effectiveness
Product Design Flexibility
CALASSIFICATION OF PLASTICS
PLASTICS
THERMO-PLASTICS THERMO-SETTING
COMMODITY ENGINEERING
SPECIALITY
DEFINATION
COMMODITY THERMOPLASTICS
Very High Volume, Low cost,Low
strength, Low Heat Distortion Temp.
ENGINEERING PLASTICS
High strength, High HDT, Low Volume,
High Cost
SPECIALITY THERMOPLASTICS
Very Low Volume, Very High Cost,
Excels in Specific Performance
Requirements.
MAJOR COMMODITY PLASTICS
300
250
200
150
100
50
0
PC POM PSU PET PEI PES PPS PEEK
CRITERIA FOR PERFORMANCE
High Performance
PEI
PSU LCP
Engineering PES
PEEK
Temperature
PPS
PC TPU
PA 11 PA 6/6 HI
PA 6/12 PBT
POM TPE
PA 6 PPO
PA 6/10 PCA – PC/ABS
PA 6/6
Commodity PA 12
ABS
SAN
PS
HDPE
PP
Characteristics of Polyamides
• Semi-crystalline material
• Polar in nature
• Resistant to hydrocarbon solvents, grease, lubricants
• Hygroscopic
• High to medium rigidity – improved by glass fibre filling
• Good electrical insulation – adversely affected by moisture
absorption.
• Good abrasion resistance and low coefficient of friction
• Flame retardant versions are difficult process.
• Dimensions affected by humidity.
• Not good temp. resistance under load – improved by glass
fibre filling.
POLYAMIDES
APPLICATIONS OF POLYAMIDE
•Airbus
•Injection
moulding
Extrusion
Processing
Technology
Blow Molding
Processing
Technology
Air-duct design offers the best combination of the demanding requirements for:
high temperature air ducts.
· higher cold impact than other similar materials
· higher stiffness at high temperatures (150°C) allowing thinner walls
to be designed.
· high melt strength and a low melt viscosity for optimum Production
PA in AUTOMOTIVE, AIR/FUEL MANAGEMENT
Injection
Molding
Ford UK
PA6: The material of choice for
air inlet manifolds
• ‘Fuel economy’ & ‘weight reduction’
• Single molding and replacing aluminium and steel by
plastics
• Provides the chemical, temperature and vibration
resistance required to survive the expected life of
vehicles.
• lower system costs compared to metals through part
and function integration,
• Easier assembly and longer tool life.
• Temperature resistance and a higher burst pressure
resistance after welding.
• Providing safer solutions or more design freedom,
as well as lower system costs as a result of an easier
• Processibility and better surface appearance.
POLY CARBONATE
POLYCARBONATE
CHARACTERISTICS :
• Highest impact strength
• High rigidity
• High dimensional stability
• High heat distortion temp
• Usability in the temperature range of -50 deg. To 135 deg.
• Flame retardancy and low combustibility
• High optical clarity
• Good electrical insulation properties
• Good strain resistance
• Low water absorption
• Food grades available.
• Good low temp. impact strength
POLY CARBONATE
APPLICATIONS:
• AUTOMOTIVE HEADLAMPS, REFLECTORS AND LENSES
• INDICATORS AND BLINKERS
• DASH BOARD COMPONENTS
• CRASH HELMETS
• TELECOM CONNECTORS
• DOMESTIC ELECTRICAL SWITCHES
• TRAFFIC SIGNAL LENSES
• SIGNAL HOUSINGS
• TELEGRAPHIC POLE INSULATOR
• TERMINAL BLOCKS
• LIGHT DIFFUSER
• STREET LAMP CANOPIES
• BUSINESS MACHINE COMPONENTS
POLY CARBONATE
APPLICATIONS
• BABY FEEDING BOTTLES, MIXIE JARS
• BLOOD OXYGENATORS
• I.V. CANNUELA
• FACTORY ROOFINGS
• RAILWAYS PLATFORMS FOOFINGS/BUS STOPS
• SAFETY GLAZINGS
• TELEPHONE BOOTHS
• OFFICE AND FACTORY PARTITIONS
• COMPACT DISKS AND OPTICAL DATA STORAGE DISKS
• RETURNABLE WATER AND MILK BOTTLES.
PC in AUTOMOTIVE, AUTO LIGHTING
Application: Head lamp bezel
Material: PC-unfilled
Injection
molding.
Audi
Injection
Molding
Philips
• Crystalline in nature
• Based mainly on polybutylene
terephthalate. A few grades based on
polyethylene and polycyclohexane
dimethanol terephalate are also available
• The base resins are commercially
manufactured by Esterification reaction of
Terephthalic Acid and appropriate diols.
THERMO PLASTIC POLYESTER
(PET & PBT)
CHARACTERISTICS
• High Mechanical Strength
• Excellent chemical resistance
• High temperature resistance in glass filled grades
• High dimensional stability
• Excellent Electrical tracking resistance
• Can be made flame retardant
• Effect of humidity minimal
• Excellent flow
THERMOPLASTIC POLYESTER
(PET & PBT)
APPLICATIONS:
• Connectors
• TV Components
• Industrial Switches/plug’s
• Business machine components
• Keyboard buttons
• Steam irons
• Cookers
• Air vents
• Plumbing
• Auto ignition systems
• Under bonnet connectors
• Head lamp reflectors
PBT IN AUTOMOTIVE
Application: Actuator, Gear housing window Lift
Material: PBT-GF20