Applied Plastics Engineering Handbook

Applied Plastics Engineering Handbook: Processing, Sustainability, Materials, and Applications, Third Edition presents the fundamentals of plastics engineering, helping bring readers up-to-speed on new plastics, materials, processing and technology. This revised and expanded edition includes the latest developments in plastics, including areas such as biodegradable and biobased plastics, plastic waste, smart polymers, and 3D printing. Sections cover traditional plastics, elastomeric materials, bio-based materials, additives, colorants, fillers and plastics processing, including various key technologies, plastic recycling and waste. The final part of the book examines design and applications, with substantial updates made to reflect advancements in technology, regulations, and commercialization.

Throughout the handbook, the focus is on engineering aspects of producing and using plastics. Properties of plastics are explained, along with techniques for testing, measuring, enhancing, and analyzing them. Practical introductions to both core topics and new developments make this work equally valuable for newly qualified plastics engineers seeking the practical rules-of-thumb they don't teach you in school and experienced practitioners evaluating new technologies or getting up-to-speed in a new field.

Cover image
Title page
Table of Contents
Copyright
Dedication
List of Contributors
About the Editor
Preface to the Third Edition
Preface to the Second Edition
Preface to the First Edition
Part I: Plastics, Elastomeric and Biobased Materials
1. Engineering Thermoplastics—Materials, Properties, Trends
Abstract
1.1 Introduction
1.2 Aliphatic polyamides
1.3 Aromatic polyamides, aramids
1.4 Semiaromatic polyamides
1.5 Polyacetals
1.6 Polycarbonates
1.7 Poly (phenylene ether)
1.8 Polysulfones
1.9 High-temperature sulfone polymers
1.10 Thermoplastic polyesters
1.11 Liquid crystalline polymers (polyesters)
1.12 Poly(phenylene sulfide)
1.13 Polyetherimide
1.14 Polyimides
1.15 Polyamide imides
1.16 Aromatic polyketones
1.17 Polyarylates
1.18 Aliphatic polyketones
1.19 Syndiotactic polystyrene
1.20 Self-reinforcing polyphenylene
1.21 Poly(p-xylylene)
1.22 Polybenzimidazole
1.23 Comparison of physical properties
1.24 Trends in engineering thermoplastics
1.25 Processing
1.26 Conclusions
References
2. Polyolefins: Plastics Engineering Encyclopedia—Elsevier
Abstract
2.1 Industrial processes for polyolefin production
2.2 Classes of polyolefins
2.3 Catalysts for olefin polymerization
2.4 Industrial reactors
2.5 Polyolefine properties
2.6 Applications
2.7 Polyolefin composites
3. Introduction to Fluoropolymers
Abstract
3.1 Introduction
3.2 Fluoropolymer classification
3.3 Fluoropolymer products
3.4 Monomer synthesis
3.5 Monomer properties
3.6 Polymerization and finishing
3.7 Structure–property relationship of PE to PTFE
3.8 Polymer properties of PTFE
3.9 Fabrication techniques
3.10 Applications
3.11 Safety
3.12 Polymerization surfactant
3.13 Economics
3.14 Summary
References
Further reading
4. Polyvinyl Chloride
Abstract
4.1 Introduction
4.2 Synthesis of vinyl chloride
4.3 PVC compounds, processing, and applications
4.4 Vinyl chloride and health sidebar
4.5 Dioxin sidebar
Further reading
5. Thermoplastic Elastomers
Abstract
5.1 Introduction
5.2 Classification and structure
5.3 Production
5.4 Structure–property relationships
5.5 Applications
5.6 Economic aspects and trade names
References
6. Thermoset Elastomers
Abstract
6.1 Introduction
6.2 Some experimental details
6.3 Typical stress–strain behavior
6.4 Control of network structure
6.5 Networks at very high deformations
6.6 Multimodal chain-length distributions
6.7 Other types of deformation
6.8 Filler-reinforced elastomers and elastomer-modified ceramics
6.9 Current problems and future trends
References
7. Biodegradable and Biobased Polymers
Abstract
7.1 Introduction
7.2 Naturally occurring polymers
7.3 Biodegradable polymers derived from renewable resources
7.4 Biodegradable polymers derived from petroleum
7.5 Poly(caprolactone)
7.6 Biobased polymers derived from plant oil
7.7 Conclusion remarks
References
8. Polymeric Biomaterials
Abstract
8.1 Introduction
8.2 Polymeric biomaterials in ophthalmology
8.3 Polymeric biomaterials in orthopedics
8.4 Polymeric biomaterials in cardiovascular
8.5 Polymeric biomaterials for wound closure
8.6 Polymeric biomaterials in extracorporeal artificial organs
8.7 Polymeric biomaterials for nerve regeneration
8.8 Conclusions and future outlook
References
Part II: Environmental Issues
9. Recycling of Plastics
Abstract
9.1 Introduction
9.2 Technology to recycle plastics
9.3 Challenges
9.4 Industries and industry organizations
9.5 Products
9.6 Conclusions
Acknowledgement
References
10. Plastics Waste to Carbon-Based Nanomaterials for Water Treatment and Supercapacitor Applications
Abstract
10.1 Introduction
10.2 Conversion of plastics into CBNs
10.3 Waste-derived CBNs for water treatment
10.4 Waste plastic-derived CBNs for supercapacitor
10.5 Future outlook for CBNs
10.6 Conclusions
Acknowledgments
References
11. Energy Management
Abstract
11.1 Introduction
11.2 Site internal benchmarking
11.3 Site external benchmarking
11.4 Machine external benchmarking
11.5 Summary and conclusions
12. Sustainability Management
Abstract
12.1 Introduction
12.2 Management systems
12.3 Design
12.4 Raw materials
12.5 Manufacturing
12.6 Energy management
12.7 Water management
12.8 The water management program
12.9 Waste minimization
12.10 Use and end-of-life
12.11 Social responsibility and sustainability
12.12 Reporting sustainability
Part III: Plastics Processing
13. Injection Molding Technology
Abstract
13.1 The injection molding screw
14. Microcellular Injection Molding
Abstract
14.1 Introduction
14.2 General discussion of foam processing
14.3 General discussion of microcellular processing
14.4 General discussion of microcellular injection molding technologies
14.5 Process monitoring and control methods for microcellular injection molding
14.6 Equipment requirements for microcellular foam injection molding
14.7 Trexel’s MuCell technology
14.8 Other physical foaming techniques
14.9 Typical objectives of microcellular injection molding
14.10 Limitations of microcellular injection molding
14.11 Best target applications
14.12 More challenging situations
14.13 Commercial examples
14.14 Future trends
References
15. Extrusion Processes
Abstract
15.1 Introduction
15.2 Single-screw extruders
15.3 Single-screw extruder mechanisms
15.4 Twin-screw extruder equipment
15.5 Planetary roller extruders: principle components and operating principles
15.6 Shaping and drawing and extrusion applications
15.7 Extrusion laminations and coatings
15.8 Solidification and cooling
References
Further reading
16. Blow Molding
Abstract
16.1 Introduction
16.2 The process
16.3 Formulas for blow molding
16.4 Troubleshooting
Acknowledgments
17. Compression Molding
Abstract
17.1 Basics of processing by compression molding
17.2 Molding force and pressure
17.3 Typical presses
17.4 Compression molds and associated tooling
17.5 Commonly used resins
17.6 Resin charge characteristics
17.7 Processing parameters for granules, powders, and preforms
17.8 Resin matrix modifiers
17.9 Engineered fiber-reinforced molding compounds
17.10 Comparisons with transfer molding and injection molding
17.11 Similar processes
17.12 Modeling the fluid dynamics and heat transfer of mold filling
17.13 Ensuring part quality and process efficiency
Acknowledgments
References
18. Rotational Molding
Abstract
18.1 Introduction
18.2 Rotational molding process
18.3 Materials for rotational molding
18.4 Molds for rotational molding
18.5 Machinery for rotational molding
18.6 Design for rotational molding
References
19. Thermoforming
Abstract
19.1 Introduction
19.2 Thermoforming characteristics
19.3 Thermoformed product characteristics
19.4 The thermoforming concept
19.5 Thermoforming machinery
19.6 Thin-gauge thermoforming
19.7 Thick-gauge thermoforming
19.8 Other thermoforming technologies
19.9 Heaters
19.10 Thermoforming mold materials
19.11 Operational aspects of thermoforming
References
20. Process Monitoring and Process Control: An Overview
Abstract
20.1 Introduction
20.2 Historical factors affecting the development of process monitoring and controls
20.3 Basic concepts: open-loop and closed-loop controls
20.4 Transducers used in plastics processes
20.5 Data acquisition systems
20.6 General control strategies: extrusion versus injection molding
20.7 Process control applications overview: extrusion
20.8 Process control applications overview: injection molding
20.9 Process development tools
20.10 Conclusions
References
21. Polymer Stabilization
Abstract
21.1 Introduction
21.2 Degradation chemistry
21.3 Stabilizers
21.4 Performance of stabilizers
21.5 Other factors determining the choice of stabilizers
Appendix 21.1 Chemical structure, CAS number, and several trade names of several stabilizers
References
Part IV: Modification and Joining Techniques
22. Surface Modification of Plastics: Atomic Layer Deposition
Abstract
22.1 Introduction
22.2 History of atomic layer deposition
22.3 Fundamentals of atomic layer deposition
22.4 Atomic layer deposition on polymers
22.5 Industrial atomic layer deposition equipment
References
23. Plastics Additives
Abstract
23.1 Introduction
23.2 Overview
23.3 Thermal stabilizers
23.4 Nucleating agents
23.5 Antioxidants
23.6 Flame retardants
23.7 Color and colorants
23.8 Fillers
23.9 Reinforcements
23.10 Impact modifiers and impact modification
23.11 Miscellaneous
24. Dispersants and Coupling Agents
Abstract
24.1 Introduction
24.2 Dispersants
24.3 Practical use considerations
24.4 Types of dispersants
24.5 Property effects
24.6 Coupling agents
24.7 Conclusions
Further reading
25. Functional Fillers for Plastics
Abstract
25.1 Introduction
25.2 The basics
25.3 Thermal and electrical properties
25.4 Hardness, friction, scratch resistance, and wear
25.5 Barrier properties
25.6 Optical properties
25.7 Processing
25.8 Extra phase effects
25.9 Popular fillers
25.10 Specialty fillers
References
26. Plasticizers
Abstract
26.1 Introduction
26.2 Mechanism of plasticization
26.3 Types of plasticizers
26.4 Phthalate esters
26.5 Terephthalate esters
26.6 Dibasic acid esters
26.7 Epoxy plasticizers
26.8 Trimellitate esters
26.9 Benzoate esters
26.10 Cyclohexanoate esters
26.11 Polymeric plasticizers
26.12 Phosphate esters
26.13 Citrate esters
26.14 Other plasticizers
26.15 Plasticizer characteristics and performance of flexible PVC
26.16 Plasticizer selections for specific applications
26.17 Plasticizers for other polymers
26.18 Human health aspects of plasticizers
26.19 Future of plasticizers
References
27. Plastics Joining
Abstract
27.1 Introduction
27.2 Mechanical joining
27.3 Adhesive bonding
27.4 Welding
References
Part V: Design and Applications
28. Design of Plastic Parts
Abstract
28.1 Introduction
28.2 Material selection
28.3 Process selection
28.4 Structural design
28.5 Design for manufacturing and assembly
28.6 Environmental impact and recycling
28.7 Conclusions
Acknowledgments
References
29. Three-Dimensional Printing of Plastics
Abstract
29.1 Introduction
29.2 3D printing processes
29.3 Design with 3D printing
29.4 Manufacturing strategy
29.5 Future outlook
29.6 Conclusions
Acknowledgments
References
30. Plastics in Buildings and Construction
Abstract
30.1 Introduction
30.2 Applications
30.3 Plastics recycling
30.4 Plastic applications in green building design
30.5 Future trends
30.6 Conclusions
References
31. A Perspective on the Evolution of Plastics and Composites in the Automotive Industry
Abstract
31.1 Introduction
31.2 Applications of plastics and composites
31.3 Automotive applications of plastics—exterior components
31.4 Automotive applications of plastics—interior components
31.5 Automotive applications of plastics—under-the-hood components
31.6 Future outlook
31.7 Conclusions
References
32. Infrastructure Applications of Fiber-Reinforced Polymer Composites
Abstract
32.1 Introduction
32.2 FRP composites for highway structures
32.3 Applications for waterway structures
32.4 Other infrastructural applications
32.5 Recent innovative FRP applications
32.6 Durability of polymer composites
32.7 Recycling of composites
32.8 New opportunities for composites
32.9 Summary
References
33. The Plastic Piping Industry in North America
Abstract
33.1 Introduction
33.2 Thermoplastic piping materials
33.3 Pipeline and piping rehabilitation technologies
33.4 PEX pipe manufacturing
33.5 Fiberglass-reinforced thermosetting pipe manufacturing
33.6 Long-term strength testing of reinforced thermosetting resin pipe
33.7 Test methods for calculating the long-term hydrostatic strength
33.8 The hydrostatic design basis and the pressure design basis
33.9 Validation of polyethylene pipe materials
33.10 Popelar shift function calculations for PE pipe materials
33.11 Application of shift functions to PE piping materials
33.12 Ductile to brittle transition and failure mechanisms
33.13 Long-term strength testing of reinforced thermosetting piping
33.14 Design of plastic piping systems
33.15 Regulatory
33.16 Applications of thermoplastic and reinforced composite piping
33.17 Critical factors influencing the growth of plastic piping
34. PET Use in Blow Molded Rigid Packaging
Abstract
34.1 Introduction
References
Index

Life Sciences

Physical Sciences & Engineering

Social Sciences & Humanities

Health

Applied Plastics Engineering Handbook

Processing, Sustainability, Materials, and Applications

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Myer Kutz