السبت، 23 مايو 2009

INEOS Olefins & Polymers to up prices of HDPE pipe grades



INEOS Olefins & Polymers Europe announced plans to increase prices for high-density polyethylene (HDPE) pipe grades by EUR 70/ton, in addition to movements in monthly ethylene pricing. New prices for PE80, PE100 and PEX grades will come into effect on June 1, 2009. The increase in prices for HDPE pipe grades are due to increasing costs of raw materials in Europe, the company said

source:
http://www.plastemart.com/plasticnews_desc.asp?news_id=15314

Fantastic Plastic Changes Color When It’s Stretched to the Breaking Point



Wouldn’t it be useful if an aging, weakening bridge started to turn red as a warning to structural engineers? That’s the potential inherent in a new invention from a team of chemists and materials scientists, who created a plastic that turns red when it’s exposed to stress. Ultimately, such color-changing polymers could be used as coatings on everything from bridges to airplane wings, alerting engineers when vital structures are near failure [ScienceNOW Daily News].

To make the red-alert plastics, researchers placed small ring-shaped molecules that they call “mechanophores” in the center of polymer chains. In response to mechanical force, these rings break, changing the color of the polymer [ScienceNOW Daily News].

In the study, published in Nature, lead researcher Nancy Sottos tested the stretchy plastic material her team had created, which stretched about as much as a Stretch Armstrong doll, by pulling on it until it broke. The bright red color appeared a few seconds before the material snapped, suggesting the molecules acted as an early warning sign that the material had incurred damage. In another test, the researchers mimicked repetitive stress by repeatedly stretching and relaxing the soft polymer. “After a few cycles of that, we got this brilliant color change in the material, without it breaking,” Sottos says [Science News]. But the color change was not permanent, and exposure to light or heat can interfere with the reaction.

Researchers say this was a proof of concept experiment that demonstrates how far they have to go before the technology can be used in practical applications. However, they can’t help speculating on how such a material could be used: Sottos says the material could eventually be used to make solid objects including rollerblade wheels, thin films such as coats of paint, or even thin fibers that could turn red when tiny deformations develop [Science News]. Those fibers could potentially be woven into climbing ropes and parachute cords, two lifelines that can snap unexpectedly.

Beyond sensing stress, researchers say that a mechanoresponsive material would have many applications beyond being a simple force sensor. One can imagine a polymer that provides structural reinforcement once it experiences too much stress, or a material that can release a drug when it suffers a certain level of pressure [Ars Technica]. Sottos is also interested in triggering self-healing reactions in plastics.


What is a polymer


What is a polymer?

A polymer is simply a plastic. Polymers (plastics) are used a lot in our modern lifestyle and is made from one main raw material crude oil.

How polymers are made?

Polymers are simply large molecules in a chain made from many small molecules called monomers (Poly - Many, Mono - One). These monomers make the polymers by joining together in a process called polymerisation. Many of the polymers that we use in our everyday life are made from alkenes.

Why Alkenes?

Alkenes are used to make polymers because the double bond in alkenes can be broken and that bond can be used to join the molecule to another alkene molecule.

The process

When the alkene (In this example ethene) is heated at high pressures and heat in the presence of a catalyst, the molecules in ethene react with each other to form poly(ethene).

High density and low density polymers?

Depending on how the alkene was heated the plastic made will be high density (Strong plastic) or low density (flexible plastic). If ethene is

Heated: 200°C

Pressure: 2000 atm

Catalyst:trace of oxygen

A low density poly(ethene) is formed. It is low density because the molecules are loosely packed because the molecules in the chains are more branched.

If ethene is

Heated: 60°C

Pressure: 2 atm

Catalyst:Ziegler-Natta

A high density poly(ethene) is formed. It is high density because the molecules are tightly packed together and the polymer branches are more compact making the plastic more rigid.

The uses of the low density poly(ethene) is to make plastic bags and cling film as the polymer made is flexible and soft.

The uses of the high density poly(ethene) is to make buckets, bins and bottles(anything upright and strong) because the properties of the high density poly(ethene) is that it is harder and stiffer than low density poly(ethene)


source: http://www.scienceray.com/Chemistry/Explanation-of-Polymers.695573


الاثنين، 11 مايو 2009

colorants plastics



Colorants for plastics can be grouped into two broad categories: pigments and
dyes. Pigments are organic or inorganic colored, white, or black materials. They
are nearly insoluble in plastic. Dyes are intended to dissolve or go into solution
in a given polymer. Physical forms for dyes and pigments can range from dry
prills or powder to liquids. These forms can be used as is or can be preincorporated
into compatible dispersions.



A concentrate supplier usually adds additional
value-added steps such as additive packages and color matching.
The main considerations when selecting colorants usually include dispersion,
migration resistance, heat stability, light stability, and cost. All are dynamic and
change with concentration of the colorant, processing conditions, part thickness,
and additives.




photos curusy:
http://catalogs.indiamart.com/products/masterbatches.html
http://plastoneme.com/aboutus.html

subject source: Encyclopedia of Polymer Science and Technology.

الأحد، 10 مايو 2009

Plastic pallets :reuse and cost reduction








Low-cost wood is still dominantly used for pallets, but reusability of plastics is a growing attraction among manufacturers looking for sustainable material-handling options. Wood pallet remains a strong force globally for transportation, distribution and storage of manufactured products. Its pre-eminence has been dictated largely by cost, but plastic pallets continue to make inroads because of their durability, reusability and light weight. Plastic pallets made by injection molding, structural foam, thermoforming, rotational molding and compression molding are gaining acceptance in a range of markets including foods, beverages, pharmaceuticals, groceries, automotive and the US Postal Service. The difficulty and cost of wood pallet disposal has always been a concern, but recent focus on the environment is fueling a renewed interest in plastics as an alternative. Reusability is a major attraction making them more economically feasible on a cost-per-trip basis, but the one major hurdle is rising resin prices.

Though introduced in 1960s, it was only in the 1980s, that the automotive market pioneered the use of reusable plastic pallets to minimize handling costs and eliminate disposable packaging issues. Because they cost more than wood, plastic pallets have always had their niche in managed pools or captive closed-loop systems for work-in-process or distribution. Several plastic pallet makers have capitalized by introducing low-cost versions that compete favorably with wood. One method of containing costs is to use recycled resin and scrap regrind. Another factor favoring plastics are international regulations that require treatment of wood to reduce pest migration in export pallets. In future, plastic pallets are expected to play an even larger role as companies adopt greater levels of automation in their warehouses. Greater automation requires repeatability and reliability, and plastics' tailored designs and consistent dimensions and weights offer a distinct advantage over wood pallets, which are vulnerable to splintering off shards and pulling apart as nails loosen.
Currently, wood has more than 90% share of the US pallet market, while plastics account for 2-5%. There are about 2 billion pallets in use every day and approximately 700 million are made and repaired each year. Pallet & Container Research Lab at Virginia Polytechnic Institute and State University estimates that although wood pallets dominate, the plastic pallet market has doubled over the last 10 years. A recent study by the Freedonia Group shows that plastic pallets will have highest growth rate, advancing 2.4% annually to over 130 million pallets by 2012, though their market share will still be under 10%. Meanwhile, demand for wood pallets is projected to increase at a rate just below that of the market average, partly due to growth of pallet refurbishing services. Overall, US pallet demand is forecast to grow 1% pa through 2012 to 1.5 billion pallets valued at $16.8 billion.
















There are no firm statistics on plastic pallet manufacturing, but it is generally believed that injection molding and thermoforming are the dominant processing methods. Each of the five main processes used to make pallets has its own advantages in terms of productivity, performance and end-use application. Injection molding uses high pressure to produce more engineered parts with complex geometries, ribs and tight tolerances. It is a high-output process but tooling can be very costly. Structural foam uses low pressure and less costly aluminum tools. The pallet has an integral skin and a cellular core with a high strength-to-weight ratio.
Single- or twin-sheet thermoformed pallets provide light weight and modest tooling cost for low to medium-volume production. Thermoformed pallets are nestable and are used by the US Postal Service and grocery distributors, providing attractive space savings for truckers and retailers. Rotomolding is typically used for large, custom, heavy-duty pallets for conveyor systems, food processing, and warehouse storage. It offers low-cost tooling but cycle times are longer. Compression molding has emerged as an attractive method that can handle the variable processing characteristics of recycled resins. To combat stable wood prices and increased resin costs, processors of injection and compression molded pallets have turned to using more regrind and recycled plastics. Even in structural foam, the key to better economics is the use of recycled materials. Compression molding is also well positioned in the pallet market because it handles the process variations of recycled materials.

The International Standard for Phytosanitary Measures 15 (ISPM 15) requires all solid wood packaging like pallets to be heat treated or fumigated with methyl bromide, both of which add cost. Shippers of time-sensitive products are reportedly opting for competitively-priced plastic pallets to avoid potential delays in certification of wood pallets. As a result, the export market has grown significantly in the last 5 years. One of the greatest threats to wood pallets is the start of the first pooling system using RFID-enabled plastic pallets. Pallet pools allow users to rent pallets and return them for inspection and reuse. The IGPS system enables plastic pallets to go beyond typical closed-loop systems and maximizes their reusability. And the innovative RFID technology ensures that the expensive pallets are tracked.
New structural designs to lower cost and weight are being developed. Injection molded and structural-foam pallets are appearing in more complex one and two-piece designs joined with snap-fits and metal fasteners and incorporating steel or nylon reinforcements to provide edge-racking capability. While most injection molded pallets are made of HDPE, at least one company is using PP for greater stiffness. Rehrig Pacific, a leading pallet supplier to beverage companies like Pepsi and Anheuser-Busch, uses PP impact copolymer to achieve higher flex modulus than HDPE. In structural foam, there is growing use of bigger machines with multi-nozzle technology for greater output.
Rotomolded pallets have their niche in heavy-duty, odd-size, custom applications. They are characterized by low-cost tooling, long cycle times, and one of the highest finished part costs among plastic pallet-making processes. Rotomolding produces durable, high-strength, one-piece parts with an average life of 15 yr. Rotomolding has found a home in large industrial transport pallets that carry heavy loads.
An innovative development in single-sheet thermoforming is the new 6.6-lb Air Ride pallet from Novo Foam Products LLC, Westlake , Ohio . It's one of the industry's lightest plastic pallets. Most single-sheet thermoformed pallets weigh in at 6-7 Kg. The Air Ride consists of HIPS bonded to a shape-molded EPS foam core. A patented bonding method is incorporated in the thermoforming process. Dynamic load capacity of 700 Kg is higher than for standard single-sheet pallets. It is for limited air-freight shipments (one or two trips), primarily those originating from Asia.
A non-traditional method of making pallets is a unique vibrational molding process for low production volumes (typically 500 parts or fewer). The Unifuse VIM process developed by Unifuse LLC sinters thermoplastic powders using vibration plus low heat (below the resin melting point) and no pressure. VIM can produce large parts like pallets upto 16 ft long with thick and thin wall sections, deep draws with zero draft, undercuts, and embedded reinforcements. The process generates no waste or molded-in stress. A pallet from two LLDPE pieces that are first molded separately and then fused together has been produced. Low-cost machinery and tooling (aluminum and wood) reportedly make VIM more economical than traditional processes like injection molding, thermoforming, and rotomolding.
Blow molding has found limited commercial success due to technical obstacles. Blow molded pallets require a lot of moving mold sections and a complex layflat involving a large parison. The pallet's square or rectangular shape requires rather tight radius corners and there is a tendency to form thin wall sections and excessive top flash. In Europe , an Italian manufacturer is using extrusion blow molding to make 1000-L IBC containers and 17 Kg pallets for the same containers.

photos curtsy: : www.libertyindustries.net

Article (Source: www.ptonline.com)

Dry vs. Conditioned Polyamide (Nylon)

By: Ben Howe who is a content manager for IDES Inc.

Recently a number of people have been asking about the difference between dry and conditioned data for polyamide (nylon) materials. In a nutshell, "dry" refers to data that is obtained from a sample of material with equivalent moisture content as when it was molded (typically <0.2%). "Conditioned" on the other hand, refers to data obtained from a sample of material that has absorbed some environmental moisture at 50% relative humidity prior to testing. The vast majority of dry and conditioned data is seen with polyamide (Nylon) materials. To understand the need for two sets of data it's important to understand a little about the structure of Polyamide.

Polyamide is classified as a crystalline polymer, but it is only mostly crystalline; some amorphous regions do exist. The crystalline regions form because of the amide group of the polymer being polar. The electrons shared between some atoms aren't shared equally resulting in regions of slight positive and slight negative charges in the polymer chain. These charged regions are attracted to one another causing the polymer chain to fold over itself again and again. These crystalline regions are illustrated in Figure 1.



Figure 1. Polyamide Crystalline Regions

It is from these crystalline regions that polyamide receives much of its strength. These crystalline regions resist being pulled apart. Add more polymer chains to the mix, and you have a lot of semi-crystalline polymer chains attracted to one another. Although these regions haven't technically experienced cross-linking, the result is similar, higher strength and higher stiffness.


The polar nature of the amide group in the polymer is not only polyamide's strength, but is a weakness as well. Water is also a polar molecule, and water is everywhere. As mentioned previously some atoms don't share electrons equally. In this case the selfish atoms are Oxygen and Nitrogen. When a water molecule comes into contact with polyamide, weak bonds form between the two (see Figure 2). As this process continues, the water molecules diffuse though the material seeking out any charged areas and forcing polymer chains apart along the way. This is why polyamide parts swell after being exposed to moisture. The separation of the polymer chains reduces the polar attraction between chains and allows for increased chain mobility, resulting in diminished mechanical properties. It is within the amorphous regions that the water bonds to the polymer chain. Luckily the crystalline regions of polyamide resist being pulled apart by the water because the bonds between the amide groups are stronger than the attraction to water. Were this not the case polyamide would dissolve in water. Instead, water acts as a plasticizer rather than an out right solvent.

Polyamide Interaction with Water


Figure 2. Polyamide Interaction with Water

Plasticizers cause a polymer to swell and soften. Both of these effects are exhibited by polyamides when they are exposed to moisture and must be taken into account when designing a part. This is why both dry and conditioned data for polyamides are given. The tensile strength and stiffness of the material will diminish, while the flexibility and impact toughness will increase with moisture absorption. The extent to which the different properties change depends a great deal on the chemistry of the polymer itself. Polyamide 12, for example, doesn't absorb as much moisture as Polyamide 6, so Polyamide 12's properties don't fluctuate as much with moisture.