DuPont (Thailand) Limited Plastics Overview Plastics Overview Plastics Overview Plastics Overview

DuPont (Thailand) Limited

Plastics OverviewPlastics OverviewPlastics OverviewPlastics Overview

September 4th, 2006

Plastics OverviewPlastics OverviewWhy use plastics?

Structure of Polymers

Thermoplastic vs. Thermoset

Thermoplastic, amorphous & crystalline

Polymer additives

Definition of Engineering Polymers

Why Use Plastics?Why Use Plastics?

Why Use PlasticsWhy Use Plastics

• High strength/weight ratio

• Design flexibility through molding

• Easy to fabricate into intricate shapes

• Colorable

• Can be transparent

Why Use PlasticsWhy Use Plastics

•Corrosion resistant

•Light weight

•Economical versus metals

•Good thermal & electrical insulators

•Accepts wide range of modifiers

Structure of PolymersStructure of Polymers


Carbon chains: the backbone ofmost polymer molecules (carbonatoms have a high chemical affinity or one another)

Structure of Polymers-ElementsStructure of Polymers-Elements

Hydrogen

Nitrogen

Oxygen

Fluorine

Silicon

Sulfur

Chlorine

Bromine


Monomers: Pre-fabricated groups of atoms or “chemical compounds” thatcan undergo polymerization

Polymer: A long molecule consisting of many monomer units joined end to end


Homopolymer: A polymer constructed from identical monomer units

Copolymer: A polymer constructed from two or more different monomer units

Linear Homopolymer: A – A – A – A – A – A

Diblock Copolymer: A – A – A – A – B – B – B – B

Triblock Copolymer: A – A – A – B –B –B - A – A – A

Random Copolymer: A – B – B – A – B – A – A – B

Structure of Polymers – Chain TypesStructure of Polymers – Chain Types

Linear: A polymer backbone without side branches or crosslinks

Polyamides (nylon), polyethylene terephthalate (PET),Polyoxymethylene (acetals) and High DensityPolyethylenes are examples

Structure of Polymers – Chain typesStructure of Polymers – Chain types

Branched: The occasional propagation ofa polymer chain off the main backboneof a polymer

Low Density Polyethylene is an example of a polymer with a branched structure which is typically formed under heat & pressure in the presence of a suitable polymerization inhibitor

Structure of Polymers – Chain TypesStructure of Polymers – Chain Types

Crosslinked (networked): Polymer chains that are chemically bonded to each other at various tie points

Typical crosslinked materials include vulcanizedrubber, thermosetting polyesters, epoxies & phenolics.

Structure of Polymers – Building BlocksStructure of Polymers – Building BlocksSimple Molecules:

Simplest Organic Compounds are Multiples of the CH2 Group

Gas Methane 16 g/molGas Ethane C2H6 30 g/molGas Propane C3H8 44 g/molGas Butane C4H10 58 g/molLiquid Pentane C5H12 72 g/molLiquid Octane C8H18 114 g/molLiquid Kerosine C17H36 240 g/molSolid Paraffin C18H38 254 g/molSolid Hard Wax C50H102 702 g/molSolid LMW(PE) C100H202 1402 g/mol

CH4

Structure of Polymers – Chain SizeStructure of Polymers – Chain Size

Ethylene Monomer:

C2 H4 MW = 28 g/mol

3500 Ethylene Monomers:

MW = 100000 g/mol

Actual Size:

0.00004 inches

Size of Polymer Chains

Thermoplastics vs. ThermosetsThermoplastics vs. Thermosets


Thermoplastics Thermosets

Characteristics CharacteristicsSoftens when heated,hardens on cooling,can be re-softened,limited upper servicetemperature

Hardens when heated,crosslinks, cannot be re-softened, generallyhas higher servicetemperature


Thermoplastics

Polyacetals (Poly-oxymethylene : POM)

Polycarbonates

Polyesters (PET, PBT)

Polyolefin (PP, PE)

Polyamide(Nylon)

Polystyrene

ABS

PVC

Thermosets

Rubber

Phenolics

Unsaturated Polyesters

Polyurethane

Melamine

Epoxy (Crosslinkable)

Examples

ThermoplasticsAmorphous vs. Crystalline

& Semi-Crystalline

ThermoplasticsAmorphous vs. Crystalline

& Semi-Crystalline

Thermoplastic Polymer TypesThermoplastic Polymer Types

Crystalline Structure

A polymer characterized by ordered arrangement of the chains allowingclose packing of the polymer chains


Amorphous Structure

A polymer characterized by randomentanglement of the individual polymer chains


Semi-Crystalline

A polymer structure characterized by thecombination of amorphous & crystalline arrangements

Amorphous PolymersAmorphous Polymers

Random alignment of polymer chains

Bulky side groups do not allow snug packing of polymer chains

Large spaces between polymer chains allows light to pass easily (transparent)

Large spacing allows chemicals to penetrate (solvent sensitive)

Distinguishing Characteristics:

Crystalline PolymersCrystalline Polymers

Orderly alignment of polymer chains

Molecular attraction pull chains close resulting in higher shrinkage

Absence of bulky side groups allows close packing of polymer chains

Tight packing does not allow light to pass (opaque)

Distinguishing Characteristics:

Heat of Fusion – Crystalline vs. AmorphousHeat of Fusion – Crystalline vs. Amorphous

Delrin® vs. Polystyrene

Crystalline vs. AmorphousCrystalline vs. Amorphous

Plastic CrystallineMold Shrinkage

%

Acetal Yes 2.0

Nylon 66 Yes 1.5

Polypropylene Yes 1.0 - 2.5

Polycarbonate No 0.6 - 0.8

Polystyrene No 0.4

Semi-Crystalline ( Crystalline) ThermoplasticsSemi-Crystalline ( Crystalline) ThermoplasticsPolyester (PET or PBT)

Polyamide (PA), nylon

Polyoxymethylene (POM), acetal

Polyphenylene Sulfide (PPS)

Polyethylene (PE)

Polypropylene (PP)

Polytetrafluoroethylene (PTFE), Teflon

Amorphous ThermoplasticsAmorphous ThermoplasticsPolycarbonate (PC)

Polyphenylene Oxide (PPO)

Acrylonitrile Butadiene Styrene (ABS)

Polysulfone (PSU)

Polyetherimide (PEI)

Polystyrene (PS)

Polymethyl Methacrylate (PMMA)

Polyvinyl Chloride (PVC)

Amorphous vs. CrystallineAmorphous vs. Crystalline

Definition of anEngineering Polymer

Definition of anEngineering Polymer

Definition of “Engineering Polymers”Definition of “Engineering Polymers”

- Combines strength, stiffness & toughness with light weight.

- Exhibits these characteristics

• Under load

• For extended periods of time

• At temperature extremes

• In hostile chemical environments

- Provides predictable performance based on classical design techniques & formulae

What Are They?

Resin FamiliesResin Families

Commodity Engineering Specialty

PVCPEPSPPABS

AcetalPolyesterPolycarbonateModified PPONylon

PolysulfonePEIPPSTPEPolyketonesLCP

Typical Polymer Supply ChainsTypical Polymer Supply ChainsTypical Polymer Supply ChainsTypical Polymer Supply Chains

Oil

Nat. Gas

Intermediates(Polymer Feedstock)

>200,000 ton plantsHMD, AA, Capro, PTA, BDO, MeOH, etc

Crude Oil Crackers>>$Billion

Multi-step chemical process

Polymerization

Key Factor in cost & supply

reliability

Key Factor in tailoring and

leadtime

Polymer

Compounding

From 1000 T AutoclavesTo >50,000 T CPs

ExtrudersFrom <$1MillionTo Mega units

Tailored Products•Glass Reinforced•Mineral Reinforced•Low warpage•Toughened•High Flow•Hydrolysis Resistance•Dozens of additivesProduct lines range from 10->1700

Finished Products

Unmodified Products

Finished Products

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